Oil_burner_WL5-PB-H_purflam_BR2019-03

Installation and operating instruction
Oil burner WL5-PB-H purflam® 83242002 1/2019-03

Oil burner WL5-PB-H purflam®
1 User instructions .............................................................................................................. 4

1.1 Target group .................................................................................................................. 4
1.2 Symbols .......................................................................................................................... 4
1.3 Guarantee and Liability ............................................................................................... 5
2 Safety ..................................................................................................................................... 6
2.1 Designated application ............................................................................................... 6
2.2 Safety measures ........................................................................................................... 6
2.2.1 Normal operation ................................................................................................... 6
2.2.2 Electrical connection ............................................................................................ 6
2.3 Electrical work .............................................................................................................. 6
2.4 Alterations to the construction of the equipment ................................................. 6
2.5 Noise emission ............................................................................................................. 7
2.6 Disposal ......................................................................................................................... 7
3 Product description ........................................................................................................ 8

3.1 Type key ......................................................................................................................... 8
3.2 Serial number ................................................................................................................ 9
3.3 Function ........................................................................................................................ 10
3.3.1 Air supply ............................................................................................................. 10
3.3.2 Oil supply ............................................................................................................. 10
3.3.3 Electrical components ....................................................................................... 11
3.3.4 Program sequence ............................................................................................. 12
3.4 Technical data ............................................................................................................. 14
3.4.1 Approval data ...................................................................................................... 14
3.4.2 Electrical data ..................................................................................................... 14
3.4.3 Ambient conditions ............................................................................................ 14
3.4.4 Fuels ...................................................................................................................... 14
3.4.5 Emissions ............................................................................................................. 15
3.4.6 Rating .................................................................................................................... 16
3.4.7 Dimensions .......................................................................................................... 17
3.4.8 Weight .................................................................................................................. 17
4 Installation ........................................................................................................................ 18
4.1 Installation conditions ................................................................................................ 18
4.2 Check rating ................................................................................................................ 19
4.3 Burner installation ...................................................................................................... 20
5 Installation ........................................................................................................................ 22
5.1 Oil supply ..................................................................................................................... 22
5.2 Electrical connection ................................................................................................. 24
6 Operation .......................................................................................................................... 25
6.1 Operating panel .......................................................................................................... 25
6.2 Display .......................................................................................................................... 25
7 Commissioning .............................................................................................................. 26
7.1 Prerequisite ................................................................................................................. 26
7.1.1 Connect measuring devices ............................................................................ 27
7.1.2 Setting values ...................................................................................................... 29
7.1.3 Preset air pressure switch ................................................................................ 29
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7.2 Adjusting the burner .................................................................................................. 30

7.3 Concluding work ........................................................................................................ 32
7.4 Check combustion ..................................................................................................... 32
8 Shutdown .......................................................................................................................... 33
9 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 air nozzle ............................................................................ 38
9.5.1 Mixing head 1.19 … 1.24 ................................................................................ 38
9.5.2 Mixing head 2.24 … 2.25 ................................................................................ 39
9.6 Removing and refitting nozzle shut off .................................................................. 40
9.7 Set ignition electrodes .............................................................................................. 41
9.8 Removing and refitting ignition electrodes ........................................................... 42
9.9 Removing heat exchanger and temperature switch ........................................... 43
9.10 Set mixing head ....................................................................................................... 44
9.11 Set recirculation aperture ...................................................................................... 45
9.12 Removing the fan ..................................................................................................... 46
9.13 Removing and refitting oil pump .......................................................................... 47
9.14 Remove pump motor .............................................................................................. 48
9.15 Removing and refitting oil pump filter ................................................................. 49
9.16 Replacing the fuse .................................................................................................. 50
9.17 Optimise start behaviour (optional) ..................................................................... 51
10 Troubleshooting ............................................................................................................ 52
10.1 Procedures for fault conditions ............................................................................ 52
10.1.1 Illuminated push button off ............................................................................ 52
10.1.2 Illuminated push button red ........................................................................... 53
10.1.3 Illuminated push button flashes .................................................................... 56
10.2 Operating problems ................................................................................................ 57
11 Technical documentation ......................................................................................... 58

11.1 Wiring diagram ......................................................................................................... 58
11.2 Conversion table unit of pressure ........................................................................ 60
12 Project planning ............................................................................................................. 62

12.1 Oil supply .................................................................................................................. 62
13 Spares ................................................................................................................................. 64
14 Notes ................................................................................................................................... 72
15 Key word index .............................................................................................................. 73
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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.
operating instructions
1.1 Target group

The manual is intended for the operator and qualified personnel. They should be
observed by all personnel working with the unit.
Work on the unit must only be carried out by personnel who have the relevant train-
ing and instruction.
Persons with limited physical, sensory or mental capabilities may only work on the
unit if they are supervised or have been trained by an authorised person.
Children must not play with the unit.
1.2 Symbols
Immediate danger with high risk.
Non observance can lead to serious injury or death.
DANGER
Danger with medium risk.
Non observance can lead to environmental damage,
serious injury or death.
WARNING
Danger with low risk.
Non observance can cause damage to the equip-
ment and injury to personnel.
CAUTION
Important information
Requires direct action

Result after an action
Itemisation
… Range of values
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1 User instructions
1.3 Guarantee and Liability

Guarantee and liability claims for personal and equipment damage are excluded, if
they can be attributed to one or more of the following causes:
non approved application,
non-observance of the manual,
operation with faulty safety equipment,
continual operation despite a fault,
improper installation, commissioning, operation and service,
repairs, which have been carried out incorrectly,
the use of non original Weishaupt parts,
force majeure,
unauthorised modifications made to the unit,
the installation of additional components, which have not been tested with the
unit,
the installation of combustion chamber inserts, which impede full flame forma-
tion,
unsuitable fuels,
defects in the inlet lines.
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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
assessment of combustion and flame stability during individual process conditions
and of the shutdown limits of the combustion plant has to be carried out and docu-
mented.
The combustion air must be free from aggressive compounds (e.g. Halogens). If the
combustion air in the boiler room is contaminated, increased cleaning and servicing
will be required. In this case ducted air intake is recommended.
The burner should only be used in enclosed rooms.
Improper use could:
endanger the health and safety of the user or third parties,
cause damage to the unit or other material assets.
2.2 Safety measures

Safety relevant fault conditions must be eliminated immediately.
Components, which show increased wear and tear or whose design lifespan is or
will be exceeded prior to the next service should be replaced as a precaution.
The design lifespan of the components is listed in the service plan [ch. 9.2].
2.2.1 Normal operation

All labels on the unit must be kept in a legible condition.
Stipulated settings, service and inspection work should be carried out at regular
intervals.
Only operate the unit with its cover closed.
2.2.2 Electrical connection

For work carried out on live components:
Observe the accident prevention instructions DGUV Regulation 3 and adhere to
local directives,
tools in accordance with EN 60900 should be used.
2.3 Electrical work
2.4 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.
Use only original Weishaupt replacement parts.
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2 Safety
2.5 Noise emission

The noise emissions are determined by the acoustic behaviour of all components
fitted to the combustion system.
Prolonged exposure to high noise levels can lead to loss of hearing. Provide oper-
ating personnel with protective equipment.
Noise emissions can further be reduced with a sound attenuator.
2.6 Disposal
Dispose of all materials and components in a safe and environmentally friendly way
at an authorised location. Observe local regulations.
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3 Product description
3.1 Type key

Example WL5-PB-H 1.19
W Type: W burner
L Fuel: Oil EL
5 Size
P Burner type: purflam (Blue flame burner)
B Construction
H Version: Nozzle assembly with oil preheating
1. Mixing head size
19 Air nozzle size
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3.2 Serial number

The serial number on the name plate identifies the product. This is required by
Weishaupt's customer service department.
1 Name plate
Ser.No.
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3.3 Function
3.3.1 Air supply
Fan with variable speed drive

The fan supplies the air from the air inlet via the intake connection to the mixing
head. The fan speed is set using a potentiometer. This matches the air quantity to
the mixing pressure required for combustion.
Air damper with nozzle solenoid (optional)

When the fan starts, the nozzle solenoid opens the air damper. At burner shutdown
the air damper closes automatically. At burner shutdown the air dampers close
automatically.
Air pressure switch

The air pressure switch monitors the fan pressure. If the fan pressure is insufficient,
the combustion manager initiates a lockout.
An additional air pressure switch is not required for ducted air intake.
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.
A solenoid valve opens and closes the oil supply to the nozzle. The pressure regu-
lating valve and solenoid valve are integrated into the pump.
Nozzle head with nozzle shut off

The nozzle shut off is integrated in the nozzle head. It prevents oil leaks after shut-
down.
Heat exchanger
The heat exchanger in the nozzle assembly heats the oil. At an oil temperature of
approx. 45 °C the temperature switch releases the burner start.
Sequence diagram
1 2 3
1 Oil pump on burner

2 Solenoid valve on the oil pump
3 Nozzle head with nozzle shut off and nozzle
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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.
Pump motor
The pump motor drives the oil pump.
Ignition unit
The electronic ignition unit creates a spark at the electrode, which ignites the fuel/
air mixture.
Flame sensor
The combustion manager monitors the flame signal via the flame sensor.
If the flame signal becomes too weak, the combustion manager carries out a con-
trolled shutdown.
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3.3.4 Program sequence
Oil preheating
At heat demand and after the initialisation time (TI) has elapsed, the heat exchanger
heats the oil in the nozzle assembly (TH).
The temperature switch closes at a temperature of approx. 45 °C.
Pre-purge
The pump motor and the fan start. The fan runs at 95 % of the operating speed
(TZ). The burner is now in the pre-purge (TV) and pre-ignition phase (TVZ).
Ignition
The air pressure switch is activated during the pre-purge phase (TV).
Ignition starts.
Fuel release
Following the pre-purge time (TV) the solenoid valve (K11) opens and releases the
fuel.
Safety time
With fuel release, safety time (TS) and post-ignition time (TNZ) start.
The flame signal must be present within the safety time (TS).
Ignition is switched of once the post-ignition phase (TNZ) has elapsed.
Operation
The combustion manager monitors the flame signal via the flame sensor.
Post-purge
If there is no longer a heat demand, the solenoid valve (K11) closes and stops the
fuel supply.
Post-purge time (TN) begins.
Following the post-purge phase (TN) the fan switches off.
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W-FM 05
L N T1 T2 6 12 2 3 11 4 5 13 B4
P P P
F2 B15 S22 B10
B1
M M
1 1
E1 M2 M1 Y17 T1 K11 P11
L N
TI
TH
TV
TV Z
TZ
TS
TNZ
TN
B1 Flame sensor TH Heating time heat exchanger

B10 Air pressure switch TI Initialisation time: 1 s
B15 Temperature or pressure regulator TN Post-purge time: 1.2 s
E1 Heat exchanger TNZ Post-purge time: 15 s
F2 Temperature or pressure limiter TS Safety time: 4.6 s
K11 Solenoid valve TV Pre-purge time: 16 s
M1 Fan TVZ Pre-ignition time: approx. 15 s
M2 Pump motor TZ During this time the motor operates at 95 % oper-
ating speed.
P11 Control lamp operation (optional) Voltage is applied
S22 Temperature switch Flame signal present
T1 Ignition unit Current path
Y17 Air damper actuation (optional) START (orange)
Ignition phase (flashing orange)
Burner operation (green)
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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 231 W
Consumption during operation max 181 W
Power consumption max 1.1 A
Internal unit fuse T6.3H, IEC 127-2/5
External fuse max 16 AB
3.4.3 Ambient conditions

Temperature in operation –10(1 … +40 °C
Temperature during transport / storage –20 … +70 °C
relative humidity max 80 %, no dew point
(1
with the relevant suitable fuel oil and layout of oil supply.
3.4.4 Fuels
Fuel oil EL to DIN 51603-1
Fuel oil EL A Bio 10 to DIN 51603-6
Fuel oil EL to ÖNORM-C1109 (Austria)
Fuel oil EL to SN 181 160-2 (Switzerland)
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3.4.5 Emissions
Flue gas
To EN 267 the burner complies with emission class 3.
The NOx values are influenced by:
combustion chamber dimensions
flue gas system
fuel
combustion air (temperature and humidity)
medium temperature
Sound levels
Dual number noise emission values
WL5-PB-H WL5-PB-H WL5-PB-H WL5-PB-H WL5-PB-H
1.19 1.21 1.22 1.23 1.24
Measured sound power level LWA 57 dB(A)(1 57 dB(A)(1 58 dB(A)(1 58 dB(A)(1 59 dB(A)(1
(re 1 pW) 4 dB(A) 4 dB(A) 4 dB(A) 4 dB(A) 4 dB(A)
Uncertainty value KWA
Measured sound pressure level LpA 51 dB(A)(2 51 dB(A)(2 52 dB(A)(2 52 dB(A)(2 53 dB(A)(2
(re 20 μPa) 4 dB(A) 4 dB(A) 4 dB(A) 4 dB(A) 4 dB(A)
Uncertainty value KpA
WL5-PB-H WL5-PB-H
2.24 2.25
Measured sound power level LWA 59 dB(A)(1 59 dB(A)(1
(re 1 pW) 4 dB(A) 4 dB(A)
Uncertainty value KWA
Measured sound pressure level LpA 54 dB(A)(2 54 dB(A)(2
(re 20 μPa) 4 dB(A) 4 dB(A)
Uncertainty value KpA
(1
Determined to ISO 9614-2.
(2
Determined at 1 metre distance from the front of the burner.
The measured noise levels plus uncertainty values form the upper
limit value, which could occur when measuring.
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3.4.6 Rating
Combustion heat rating

The ratings range depends on:
Size of mixing head (1. or 2.)
Diameter of air nozzle (19 … 25 mm)
Mixing head Combustion heat rating Oil throughput [kg/h]
[kW]
ME 1.19 16.5 … 20.0 1.4 … 1.7
ME 1.21 20.0 … 24.0 1.7 … 2.0
ME 1.22 23.0 … 26.5 1.9 … 2.2
ME 1.23 26.0 … 29.0 2.1 … 2.4
ME 1.24 28.0 … 32.0 2.3 … 2.7
ME 2.24 31.0 … 35.0 2.6 … 2.9
ME 2.25 34.0 … 40.0 2.9 … 3.4
1.3
1.2 2.25
1.1 2.24
1.0 1.24
1.23
0.9 1.22
1.21
0.8 1.19
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
-0.1
2 -0.2
-0.3
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4
1 Combustion heat rating [kW] or [kg/h]

2 Combustion chamber pressure [mbar]
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3.4.7 Dimensions
Burner
155 mm
- weishaupt -
292 mm
216 mm
1
0 ... 90 mm 286 mm
240 mm 4
3
143 mm
1 2 3 4
ME 1.10 … 1.24 80 mm 100 mm 200 … 290 mm 338 mm
ME 2.24/2.25 90 mm 105 mm 240 … 330 mm 378 mm
3.4.8 Weight
approx. 13 kg
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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],
sufficient combustion air is available, if necessary install ducted air intake,
Prepare heat exchanger

The refractory 3 must not protrude beyond the recirculation aperture 5. It can,
however, take a conical shape (min 60°).
The distance from flame tube front edge to the rear wall of the combustion chamber
must be a minimum of 100 … 150 mm to ensure sufficient flame burn-out.
If necessary, undo locknut 2 on the sliding flange to adjust the installation depth of
the burner [ch. 4.3].
Following installation, the aperture 4 between adapter pipe 1 and refractory
should be filled with flame-proof, resilient material. Do not make solid.
3 4 5
0 ... 90 mm
2
60° M8
1
45°
110 mm
110 mm
130 ... 150
1 Adapter pipe
2 Locknut on sliding flange
3 Refractory
4 Aperture
5 Recirculation aperture
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4 Installation
4.2 Check rating

The burner as supplied to the customer is set for a specific burner capacity, see ta-
ble.
Mixing head Burner capacity Nozzle size Pump pressure Load range
[kW](1 [gph](1 [bar] [kW]
ME 1.19 approx. 17.0 0.35 10 … 12(1 … 15 16.5 … 18.0
approx. 18.2 0.40 10 … 11(1 … 15 18.0 … 20.0
ME 1.21 approx. 21.7 0.45 12 … 13(1 … 15 20.0 … 24.0
ME 1.22 approx. 25.8 0.50 12 … 13(1 … 15 23.0 … 26.5
ME 1.23 approx. 27.9 0.55 12 … 13(1 … 15 26.0 … 29.0
ME 1.24 approx. 30.9 0.60 12 … 13(1 … 15 28.0 … 32.0
ME 2.24 approx. 33.1 0.65 13(1 … 16 31.0 … 35.0
ME 2.25 approx. 37.0 0.65 13 … 16(1 34.0 … 40.0
(1
Delivery status
Within the capacity range of the mixing head, the burner capacity can be changed
via the nozzle size and the pump pressure.
If the capacity exceeds this capacity range, a different mixing head has to be fitted
[ch. 9.5].
Recommended nozzles
Size Make Characteristics
ME 1.19 Danfoss 80°SR
ME 1.21 … ME 2.25 Fluidics 80°SF
Danfoss 80°SR
Nozzle selection table

Different load values are possible due to tolerances.
Stage 1 Burner capacity [kW] at pump pressure
Nozzle size [gph] 10 bar 11 bar 12 bar 13 bar 14 bar 15 bar 16 bar
0.35 15.7 16.4 17.0 17.7 18.3 19.0 –
0.40 17.4 18.2 19.0 19.9 20.5 21.3 –
0.45 19.1 19.9 20.8 21.7 22.5 23.4 –
0.50 22.7 23.8 24.8 25.8 26.9 27.9 –
0.55 24.7 25.7 26.8 27.9 28.9 30.0 31.1
0.60 27.3 28.8 29.7 30.9 32.0 33.2 34.4
0.65 – – – 33.1 34.3 35.5 36.7
0.75 – – 37.2 38.6 39.7 40.7 42.1
The capacity values were determined at a test bed, they do not correspond with the Weishaupt slide rule.
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4 Installation
4.3 Burner installation

Remove burner flange 1 from burner housing.
Fit flange gasket 2 and burner flange 1 to the heat exchanger using screws 3.
The aperture between combustion head and refractory should be filled with
flame-proof, resilient insulating material (do not make solid).
3
2
Fix flame tube 2 to adapter pipe 1 using the bayonet principle.
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4 Installation
Fit burner to burner flange 3.

Fix sliding flange 4 using the bayonet principle with the screws 2.
If necessary, undo locknut 1 on the sliding flange and adjust the installation
depth by moving the burner [ch. 4.1].
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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(1
Supply pressure max 2 bar(1
Supply temperature max 60 °C(1
(1
Measured at the pump.
Check conditions for oil hoses

Length 1200 mm
Oil hose connection G⅜
Nominal pressure 10 bar
Thermal load max 100 °C
Connect oil supply
Damage to the oil pump caused by incorrect connection

Mixing up supply and return can damage the oil pump.
Ensure correct connection of oil hoses to the supply and return of the pump.
CAUTION
Fit oil hoses with bracket 4 and grommet 3 to burner.
4 3
1 Return
2 Supply
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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).
If these conditions for connection can not be met:
Adapt oil supply on site.
Purge oil supply and ensure it is tight
Oil pump seized due to running dry

Pump could be damaged.
Fill oil supply with oil and purge.
CAUTION
Ensure oil supply is tight.
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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.
DANGER Safeguard against accidental restart.
The electrical connection must only be carried out by qualified electricians. Ob-
serve local regulations.
Observe wiring diagram [ch. 11.1].
Check polarity and wiring of 7 pole connection plug 1.
Plug in connection plug 1.
With remote reset, install connection line separately. Do not exceed maximum cable
length of 10 metres.
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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.
CAUTION Only lightly press illuminated push button.
The illuminated push button on the combustion manager has the following func-
tions:
display operating condition [ch. 6.2],
display fault codes [ch. 10.1.2],
reset burner lockout [ch. 10.1.2].
Re-starting the burner during burner operation:

Press illuminated push button for 1 second.
6.2 Display
Illuminated push button Operating condition
orange Start phase
Flashing orange Ignition and pre-purge phase
Green Operation
red Fault [ch. 10]
Additional flashing signals can be read off as fault code [ch. 10].
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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,
sufficient combustion air is available, if necessary install ducted air intake
the annulus between flame tube and heat exchanger is filled
the heat exchanger is filled with medium
the regulating, control and safety devices are functioning and set correctly
the flue gas ducts are unimpeded
a measuring point conforming to standards is available to measure the flue
gas
the heat exchanger and flue gas ducting up to the test point are sound (ex-
traneous air influences the test results)
the operating instructions of the heat exchanger are complied with
a heat demand is available
Additional system-related tests could be necessary. Please observe the operating
guidelines for the individual components.
On installations with process equipment, the conditions for safe operation and
commissioning must be met, see worksheet 8-1 (Print No. 831880xx).
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7 Commissioning
7.1.1 Connect measuring devices
Pressure measuring device and ammeter

Pressure measuring device for mixing pressure.
Ammeter for flame signal.
Connect pressure measuring device 2.
Test adapter No. 13 required (Order No. 240 050 12 052).
Unplug plug No. 13.
Plug in test adapter No. 13.
Connect ammeter 1.
Flame Signal
Extraneous light detection from 13 μA
Minimum flame signal 35 μA
Recommended flame signal 70 … 100 μA
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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.
WARNING Remove oil measuring devices once commissioning is complete.
Close fuel shut off devices.

Remove closing plug on the pump.
Connect vacuum gauge 1 and pressure gauge 2.
-1
9
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7 Commissioning
7.1.2 Setting values
Determine mixing pressure

Determine the mixing pressure required for the preset combustion heat rating
from the diagram and note down.
11.0
10.5
24
1.
19
10.0 5
23 2.2
1.
21
22 1.
1.
1. .24
9.5
2
9.0
8.5
8.0
7.5
7.0
6.5
2 6.0
5.5
16 18 20 22 24 26 28 30 32 34 36 38 40 42
1 Combustion heat rating [kW]

2 Mixing pressure [mbar]
Guide values, which may vary depending on combustion chamber resist-
ance.
7.1.3 Preset air pressure switch

The presetting of the air pressure switch is only valid for the initial burner start. Dur-
ing commissioning, the pressure switch must be set correctly.
Preset air pressure switch to approx. 5.5 mbar.
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7 Commissioning
7.2 Adjusting the burner

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],
suction resistance or flow pressure of oil pump [ch. 5.1],
mixing pressure [ch. 7.1.2].
1. Start the burner

Heat demand from the boiler controller required.
Open fuel shut off devices.
Switch on voltage supply.
Illuminated push button lights up red.
Burner starts in accordance with the programme sequence [ch. 3.3.4].
2. Set pump pressure

The pump pressure must be set according to the nozzle selected.
Check pump pressure at pressure gauge.
Set pressure using pressure regulating screw 1:
increase pressure: clockwise rotation,
decrease pressure: anticlockwise rotation.
Check combustion values
3. Determine combustion limit

Read the position of the potentiometer 1 on the scale and note it down.
Determine combustion limit and slowly reduce O2 content using the poten-
tiometer 1 (turn to the left) until the combustion limit determined is reached
(CO content approx. 100 ppm or smoke number approx. 1).
Measure and document O2 content.

Read air number (λ) and note down.
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7 Commissioning
4. Set air pressure switch
To ensure protection against accidental contact with the electrical connections, the
cover must be secured with screw 1.
Undo screw 3.
Slowly turn setting cam 2, until the burner shuts down.
The air pressure switch is now set.
Shutdown limit of the air pressure switch corresponds to the combustion limit.
Re-tighten screw 3.
3 2
5. Set excess air

Set the position of potentiometer 1 previously noted down.
Start the burner.
Check combustion values
Increase air number (λ) previously noted down to ensure sufficient excess air:
by 0.15 … 0.2 (equates to 15 … 20 % excess air),
by more than 0.2 for more difficult conditions, such as:
dirty combustion air,
fluctuating intake temperature,
fluctuating chimney draught.
Example
λ + 0.15 = λ*
Set excess air (air number λ*) via potentiometer 1 whilst observing the mixing
pressure, do not exceed CO content of 50 ppm:
increase O2 content = clockwise rotation,
decrease O2 content = anticlockwise rotation.
Check combustion values [ch. 7.4].
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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.
Check control and safety devices.

Check tightness of oil carrying components.
Enter combustion values and settings in the commissioning record and/or test
sheet.
Mount cover on burner.
Inform the operator about the use of the equipment.
Hand the installation and operating manual to the operator and inform him that
this should be kept with the appliance.
Point out to operator that the installation should be serviced annually.
7.4 Check combustion
Check flue gas temperature

Check flue gas temperature.
Ensure that the flue gas temperature complies with the data provided by the
boiler manufacturer.
If necessary adjust flue gas temperature, e g.:
Increase burner capacity to avoid condensation in the flue gas ducts, except
on condensing units.
Reduce burner capacity to improve efficiency.
Adjust heat exchanger to the data provided by the manufacturer.
Determine flue gas losses

Measure combustion air temperature (tL) near the air damper(s).
Measure oxygen content (O2) and flue gas temperature (tA) at the same time at
one point.
Determine flue gas losses using the following formula:
A2
qA = (tA - tL ) ( )+B
21- O2
qA Flue gas losses [%]

tA Flue gas temperature [°C]
tL Combustion air temperature [°C]
O2 Volumetric content of oxygen in dry flue gas [%]
Fuel factors Fuel oil
A2 0.68
B 0.007
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8 Shutdown
8 Shutdown
For breaks in operation:
Switch off burner.
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9 Servicing
9 Servicing
9.1 Notes on servicing

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.
DANGER Safeguard against accidental restart.
Danger of getting burned on hot components

Hot components can lead to burns.
Allow components to cool.
WARNING
Servicing must only be carried out by qualified personnel. The combustion plant
should be serviced annually. Depending on site conditions more frequent checks
may be required.
Components, which show increased wear and tear or whose design lifespan is or
will be exceeded prior to the next service should be replaced as a precaution.
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.
The following components must only be replaced and must not be repaired:
combustion manager
flame sensor
actuator
oil solenoid valve
pressure switch
Prior to every servicing

Inform the operator about the extent of service work to be carried out.
Switch off mains switch of installation and safeguard against accidental reactiva-
tion.
Remove cover.
Unplug boiler control connection plug from combustion manager.
Following servicing

Touching the ignition device can lead to electric shock.
Do not touch ignition device during the ignition process.
DANGER
Check tightness of oil carrying components.

Check function of:
ignition,
flame monitoring,
oil pump (pump pressure and suction resistance),
control and safety devices.
Check combustion values, if necessary re-adjust the burner.
Enter combustion values and settings in the commissioning record.
Refit cover.
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9 Servicing
9.2 Service plan

Components Criteria / design lifespan(1 Service procedure
Air duct Soiling Clean
Air damper (optional) Soiling Clean
Air pressure switch Switch point Check
250 000 burner starts or 10 years(2 Replace
Ignition cable Damage Replace
Ignition electrode Soiling Clean
Damage/wear Replace
Combustion Manager 250 000 burner starts or 10 years(2 Replace
Flame sensor Soiling Clean
Damage Replace
250 000 burner starts or 10 years(2
Flame tube/mixing head Soiling Clean
Damage Replace
Oil nozzle Soiling/wear Replace
Recommendation: at least every 2 years
Nozzle shut off Soundness Replace
Oil pump filter Soiling Replace
Oil hose Damage/oil escaping Replace
Recommendation: every 5 years
Oil solenoid valve Soundness Replace oil pump
250 000 burner starts or 10 years(2
(1
The specified design lifespan applies for typical use in heating, hot water and steam systems as well as for thermal
process systems to EN 746.
(2
If a criterion is reached, carry out maintenance measures.
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9 Servicing
9.3 Service position

Observe notes on servicing [ch. 9.1].
Open quick release fastener 1.
Service position A and B

Place the burner into the required service position.
A B
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9 Servicing
9.4 Replace nozzle

Do not clean nozzles, always fit new nozzles.
Place burner into service position A [ch. 9.3].

Unplug ignition cable 4.
Undo screws 1 and remove mixing head.
Counter-hold on the nozzle body 3 using a spanner and remove nozzle 2.
Fit new nozzle ensuring it is seated tightly.
Fit mixing head up to stop and secure.
Set nozzle distance [ch. 9.10]
Set ignition electrodes [ch. 9.7]
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9 Servicing
9.5 Removing and refitting air nozzle
9.5.1 Mixing head 1.19 … 1.24

Removing
Remove screws 1 and remove air nozzle.
Refitting
Refit air nozzle in reverse order.
Set mixing head [ch. 9.10]
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9 Servicing
9.5.2 Mixing head 2.24 … 2.25

Removing
Press apart metering ring 5 using the setting gauge and remove.
Remove clip 6 for metering ring.
Remove ignition electrodes [ch. 9.8].
Lightly open retaining clips 4.
Remove HTI refractory 1.
Remove screws 2 and remove air nozzle 3 with retaining clips.
1 2
6 3
5 4
Refitting
Refit air nozzle in reverse order.
Set mixing head [ch. 9.10]
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9 Servicing
9.6 Removing and refitting nozzle shut off

Removing
Remove nozzle [ch. 9.4].
Counter-hold the nozzle assembly 4 using a spanner and remove nozzle holder
1.
Remove valve piston 2 and compression spring 3 using a suitable tool (e. g.
pliers), do not damage valve piston and O ring.
Refitting
Do not refit damaged valve pistons, replace as necessary.
Refit nozzle shut off in reverse order.
Check nozzle distance [ch. 9.10].
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9 Servicing
9.7 Set ignition electrodes

Place burner into service position B [ch. 9.3].
Set ignition electrodes with the help of the setting gauge.
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9 Servicing
9.8 Removing and refitting ignition electrodes

Removing
Unplug ignition cable.
Remove screws 1 and remove ignition electrodes from mixing head.
Refitting
Refit ignition electrodes in reverse order.
Set ignition electrodes.
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9 Servicing
9.9 Removing heat exchanger and temperature switch

Remove nozzle [ch. 9.4].
Unplug plug number 6 and 12.
Undo oil lines 5.
Remove screw 3 and remove nozzle assembly 2.
Remove screw 1 and temperature switch 6.
Remove heat exchanger 4 using a suitable tool (e.g. pliers).
1 2
4
12
6
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9 Servicing
9.10 Set mixing head

Set nozzle distance

Insert setting gauge and check dimension A (2.5 mm).
If the value measured deviates from dimension A:
Undo screw 1 on the guide tube and screw 2 on the mixing head.
Adjust nozzle body until dimension A is reached and ensure that the mixing head
is flush with the guide tube.
Tighten screw 1 and screw 2.
1 2
A
=
2.5
mm
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9 Servicing
9.11 Set recirculation aperture

Turn setting screw 1 until the scale on the indicating bolt 2 is equal to the ta-
ble value.
The indicating bolt has been factory preset to show the clearance of the recircula-
tion aperture 3 in mm.
If the indicating bolt has been moved (e. g. during transport):
Remove plug from indicating bolt 2.
Turn indicating bolt until it matches the current recirculation aperture.
Re-fit stopper.
1
+
– 2
–
+
Mixing head Recirculation aperture [mm]

ME 1.19 1.5
ME 1.21 4.0
ME 1.22 4.0
ME 1.23 5.0
ME 1.24 5.0
ME 2.24 2.0
ME 2.25 2.0
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9 Servicing
9.12 Removing the fan

Unplug plug No. 3.
Remove screws 2 from fan and screws 3 from intake connection.
Remove fan.
Remove screws 1, remove intake connection and gasket.
2
3
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9 Servicing
9.13 Removing and refitting oil pump

Removing
Unplug plug 1.
Remove oil hoses 5 and screwed unions 6.
Remove oil line 4.
Undo screws 2 and remove oil pump.
Refitting
Install oil pump in reverse order and:
ensure correct alignment of coupling 3,
ensure correct allocation of flow and return of the oil hoses.

CAUTION
3 2
6
5
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9 Servicing
9.14 Remove pump motor

Remove the oil pump [ch. 9.13].
Unplug plug No. 2.
Remove screws 1 and remove motor.
2
1
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9 Servicing
9.15 Removing and refitting oil pump filter

Removing
Remove bolts 1.
Remove pump cover.
Replace filter 3 and gasket 2.
3
2
Refitting
Refit filter in reverse order ensuring sealing surfaces are clean.
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9 Servicing
9.16 Replacing the fuse

Remove all plugs from the combustion manager.
Remove screws from the combustion manager.
Remove combustion manager.
Replace fuse (T6.3H, IEC 127-2/5).
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9 Servicing
9.17 Optimise start behaviour (optional)

It is possible to optimise the start behaviour by increasing the fan speed.
Burner with air damper fitted.
Increase fan speed via potentiometer until 10 is reached on the scale.
Maximum fan speed has been set.
Undo locknut 2 on nozzle solenoid (left hand thread).
Set excess air using setting screw 1:
increase O2 content = clockwise rotation,
decrease O2 content = anticlockwise rotation.
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10 Troubleshooting
10 Troubleshooting
10.1 Procedures for fault conditions

The combustion manager recognises irregularities of the burner and indicates these
with the illuminated push button.
The following conditions can occur:
illuminated push button off [ch. 10.1.1],
illuminated push button red [ch. 10.1.2],
illuminated push button flashes [ch. 10.1.3].
10.1.1 Illuminated push button off

The following faults may be corrected by the operator:
Fault Cause Rectification
Burner not operating External fuse has tripped(1 Check fuse.
Heating switch is set to Off Switch on heating switch.
Temperature limiter or pressure limiter Reset temperature limiter or pressure
on heat exchanger has triggered(1 limiter on heat exchanger.
Low water safety interlock on heat ex- Top up water.
changer has triggered(1 Reset low water safety interlock on
heat exchanger.
Temperature regulator or pressure regu- Adjust temperature regulator or pres-
lator on heat exchanger has been set in- sure regulator on heat exchanger.
correctly
Boiler or heating circuit control is not Check function and setting of boiler
functioning or has not been set correctly or heating circuit control.
(1
Notify your heating contractor or Weishaupt Customer Service if the problem occurs repeatedly.
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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.
Read error code

Only 5 seconds after a fault occurred can it be been analysed and read.
Press illuminated push button for 5 seconds.
Illuminated push button briefly lights up orange.
Illuminated push button flashes red.
Count between the flashing pauses and flashing signals and note down.
Rectify cause of fault, see table.
Resetting
Damage resulting from incorrect fault repair

Incorrect fault repair can cause damage to the equipment and injure personnel.
Do not carry out more than 2 lockout resets successively.
WARNING Faults must be rectified by qualified personnel.

Red signal extinguishes.
Burner has been reset.
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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 Check oil supply
No flame, Anti siphon valve does not Check valve, if necessary
end of safety time open replace
Shut off device closed Open shut off device
Pre-filter strainer soiled Replace pre-filter strainer
Oil pump defective Replace oil pump
[ch. 9.13]
No oil throughput at the Oil nozzle blocked Replace nozzle
nozzle
No ignition Ignition electrode dirty or Clean ignition electrode
wet
Ignition electrode spark gap Set ignition electrode
too big or short circuited [ch. 9.7]
Ceramic insulator defective Replace ignition elec-
trodes
Ignition cable defective Replace ignition cable
Ignition unit defective Replace ignition unit
Solenoid valve does not Coil defective Replace coil
open
Combustion manager does Flame sensor soiled Clean flame sensor
not detect a flame signal Flame sensor defective Replace flame sensor
Illumination insufficient Check burner setting
Check correct position of
illumination tube.
Pump motor does not run Oil pump seized Replace oil pump
[ch. 9.13]
Capacitor defective Replace capacitor
Pump motor defective Replace pump motor
No flame formation despite Nozzle distance incorrect Check nozzle distance,
ignition and oil supply adjust if necessary
[ch. 9.10]
Recirculation aperture too Reduce recirculation
big aperture [ch. 9.11].
Mixing pressure too high Check mixing pressure
[ch. 7.1.2]
Flashing 3 times Air pressure switch does Air pressure switch set in- Reset air pressure switch
Air pressure switch fault not react correctly
Air pressure switch defect- Check air pressure
ive switch, if necessary re-
place
Setpoint speed of fan is not Fan defective Check fan, if necessary
achieved replace [ch. 9.12]
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10 Troubleshooting

Fault codes Fault Cause Rectification
Flashing 4 times Flame signal prior to or after Extraneous light source Extraneous light detection
Flame simulation/ operation present from 13 μA
extraneous light Find and eliminate ex-
traneous light source
Flame sensor defective Check flame sensor, if
necessary replace
Flame formation during pre- Solenoid valve leaking Replace oil pump
purge [ch. 9.13]
Flashing 7 times Flame has failed Oil supply leaking Check oil supply
Flame failure during opera- Suction resistance in front
tion of pump too high
Oil nozzle soiled Replace oil nozzle
Flame signal insufficient Burner setting incorrect Check burner setting
Check flame signal
[ch. 7.1.1]
Flame sensor soiled Clean flame sensor
Flame sensor defective Check flame sensor, if
necessary replace
Flashing 8 times Temperature switch does Actuator defective Check actuator, replace if
Release contact fault not close necessary
Temperature switch defect- Check temperature
ive switch and heat ex-
changer, if necessary
replace [ch. 9.9]
Flashing 10 times Burner does not start Heat exchanger defective Reset burner [ch. 10.1.2]
Combustion manager fault Combustion manager de- Reset burner [ch. 10.1.2],
fective if fault reoccurs replace
combustion manager
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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

Fault codes Cause Rectification
Flashing green/red Extraneous light prior to heat demand Find and eliminate extraneous light
source
Flashing red/orange with pause Excess voltage Check voltage supply
Flashing orange/red Low voltage Check voltage supply
Internal unit fuse (F7) faulty Replace fuse [ch. 9.16]
Combustion manager fault Replace combustion manager
Flashing green Flame sensor soiled Clean flame sensor
Flame sensor defective Replace flame sensor
Burner operation with weak flame signal Adjust burner whilst observing the re-
(< 45 µA) commended flame signal [ch. 7.1.1]
Glimmering red OCI mode activated (not used) Press illuminated push button for
more than 5 seconds
Combustion manager changes to op-
erating mode
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10 Troubleshooting
10.2 Operating problems

Observation Cause Rectification
Oil pump makes severe mech- Oil pump sucks air Ensure oil supply is tight
anical noise Suction resistance in oil line too high Clean filter
Check oil supply
Oil nozzle atomisation uneven Nozzle blocked/soiled Replace nozzle [ch. 9.4]
Nozzle worn
Flame tube/air nozzle has heavy Oil nozzle defective Replace nozzle [ch. 9.4]
soot deposit Mixing head set incorrectly Set mixing head [ch. 9.10]
Incorrect combustion air quantity Adjust burner
Boiler room ventilated insufficient Ensure sufficient boiler room ventila-
tion
Wrong oil nozzle Check nozzle type
Recirculation aperture too small Increase recirculation aperture
[ch. 9.11]
Combustion pulsating or burner Mixing head set incorrectly Set mixing head [ch. 9.10]
booming Incorrect combustion air quantity Adjust burner
Wrong oil nozzle Check nozzle type
CO content too high Nozzle distance too big Check nozzle distance, adjust if
necessary [ch. 9.10]
Fan speed too low Increase fan speed
Stability problems Nozzle distance incorrect Check nozzle distance, adjust if
necessary [ch. 9.10]
Recirculation aperture too big Reduce recirculation aperture
[ch. 9.11].
Fan speed too high Reduce fan speed
Burner pulsating at START Combustion chamber resistance too Check installation
high (e. g. condensing boiler) If necessary optimise start behaviour
[ch. 9.17]
Flue gas noise emission too Unsuitable or no flue gas sound ab- Check or fit flue gas sound absorber
high sorber installed
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11 Technical documentation
11.1 Wiring diagram

For special version observe wiring diagram supplied.
K1 W-FM 05
K3 K2
F7
X6 L PE N T1 T2 S3 B4 X3:6 X3:12 X3:2 X3:3
M2 M
~
M
E1 Y14 S22 C1 M1 Y17

F2 B15
P P
P11
S1 P6
F1
L PE N
X6 B15 Temperature or pressure regulator

F7
C1 Motor capacitor
E1 Heat exchanger
X3:
F2 Temperature or pressure limiter
5
F7 Internal unit fuse (T6.3H, IEC 127-2/5)
4
F1 External fuse
6
K11 Solenoid valve
3
2 M1 Fan
12 M2 Pump motor
11 P6 Control lamp operation (optional)
13 P11 Control lamp lockout (optional)
W-FM 05 S1 Operating switch
S22 Temperature switch
Y14 Safety valve (optional)
Y17 Air damper actuation (optional)
83242002 1/2019-03 La 58-76

K3 K2
X3:11 X3:4 X3:5 X3:13
P
h
B10 T1 P11.1 K11 B1
B1 Flame sensor
B10 Air pressure switch
P11.1 Hours counter (optional)
T1 Ignition unit
K11 Solenoid valve
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11.2 Conversion table unit of pressure

Bar Pascal
Pa hPa kPa MPa
0.1 mbar 10 0.1 0.01 0.00001
1 mbar 100 1 0.1 0.0001
10 mbar 1 000 10 1 0.001
100 mbar 10 000 100 10 0.01
1 bar 100 000 1 000 100 0.1
10 bar 1 000 000 10 000 1 000 1
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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.
With oil temperatures < 5 °C, the separation of paraffin can cause oil lines, oil fil-
ters and nozzles to become blocked. Avoid placing oil tanks and pipelines in
areas subject to frost.
The oil supply should be installed in such a way that the oil hoses can be con-
nected free of tension.
Fit oil filter in front of pump, recommended mesh aperture 70 μm.
Suction resistance and supply pressure
Pump damage due to excessive suction resistance

A suction resistance greater than 0.4 bar can damage the pump.
Reduce suction resistance – or – install oil supply pump or suction unit, whilst
CAUTION observing the maximum supply pressure at the oil filter.
The suction resistance depends on:

suction line length and diameter,
pressure loss of oil filter and other components,
lowest oil level in the oil storage tank (max 3.5 m below the oil pump).
If an oil feeder pump is installed:
max 1.5 bar supply pressure at oil filter,
max 0.7 bar supply pressure into automatic de-aerator.
Elevated oil level

If the suction line is leaking the tank can be siphoned dry. An electric anti siphon
valve 1 can prevent this.
Observe manufacturers instructions regarding pressure loss caused by anti si-
phon valve.
The anti siphon valve must close with a delay and show a pressure relief towards
the oil storage tank.
Maintain height differences:
max 4.6 m between oil level and anti siphon valve,
on single pipe system max 8 m between anti siphon valve and automatic de-aer-
ator,
on two pipe system max 20 m between anti siphon valve and oil pump.
1 1
max 4.6 m
max 4.6 m
max 20 m
max 8 m
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12 Project planning
Single pipe system

CAUTION
If the oil is supplied via a single pipe system, and automatic de-aerator must be in-
stalled in front of the oil pump.
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.
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13 Spares
13 Spares
1.05
1.04
1.07
1.01 1.09
1.06
1.11
1.10
1.08
1.02
1.03
1.18
1.17
1.16
1.15
1.14
1.13
1.12
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13 Spares
Pos. Description Order No.

1.01 Cover complete 245 050 01 092
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 Burner housing 245 050 01 012
1.05 View port glass 245 050 01 187
1.06 Lining 245 050 01 147
1.07 Bracket for service position 245 050 01 217
1.08 Spring nut 412 506
1.09 Cover burner housing
– without air inlet 245 050 01 127
– with air inlet 245 050 01 137
1.10 Grommet 241 050 01 177
1.11 Press fitting for quick release fastener 499 310
1.12 Adapter pipe
– D80 (ME 1.xx) 245 050 14 427
– D90 (ME 2.xx) 245 050 14 437
1.13 Sliding flange
– D80 (ME 1.xx) 245 050 01 247
– D90 (ME 2.xx) 245 050 01 267
– Screw M8 x 25 DIN 6921 409 269
– Screw M8 x 25 DIN 921 8.8 402 500
– Hexagonal nut DIN 934 -8 411 401
1.14 Gasket sliding flange
– D80 245 050 01 157
– D90 245 050 01 167
1.15 Adapter ring
– D80 245 050 01 257
– D90 245 050 01 277
1.16 Burner flange 245 050 01 237
1.17 Flange gasket 245 050 01 287
1.18 Flame tube H6
– MB 800 (ME 1.xx) 240 050 14 057
– MB 900 (ME 2.xx) 240 050 14 077
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13 Spares
2.01 2.07
2.05
2.06
2.12
2.08
2.10
2.11 2.09
2.16 2.04
2.13
2.03
2.02
2.14 2.18
2.17
2.15 2.19
2.22
2.21
2.20
2.30
2.29 2.23
2.28
2.31 2.25
2.35
2.24
2.27
2.34
2.33
2.32
2.26
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13 Spares

2.01 Housing cover 245 050 01 032
with quick release fastener cpl.
– Circlip for quick release fastener 499 311
– Pin for quick release fastener 499 312
2.02 Bracket for oil hoses 241 400 01 367
2.03 Cover housing cover 245 050 02 057
2.04 Solenoid for air damper with plug cable 245 050 12 092
2.05 Air damper 245 050 02 017
2.06 Spring for air damper 245 050 02 047
2.07 Shaft for air damper 245 050 02 067
2.08 Cylindrical taper pin 3.0m 6x18mm DIN 7-A1 423 484
2.09 Flame sensor QRC1A 600 588
2.10 Ignition unit type W-ZG01 230V 50VA 603 219
2.11 Bracket for air pressure switch 245 050 24 037
2.12 Setting gauge WL5 purflam 245 050 00 027
2.13 Air pressure switch 691 447
2.14 Hose 4.0 x 1.75 120 mm 241 050 24 017
2.15 Plug cable No.11 air pressure switch 245 050 12 042
2.16 Combustion Manager W-FM 05
– 113 230V PB (TN = 2 s) 600 472
– 114 230V PB for WTU (TN = 25 s) 600 474
2.17 Radial fan complete with EC motor 245 050 08 012
with fixing bracket and O ring
2.18 Plug cable No. 3 EC housing 245 050 12 022
2.19 Gasket intake connection/fan 245 050 01 107
2.20 Intake connection 245 050 01 047
2.21 Mounting bracket for cover 245 050 01 227
2.22 O ring 50 x 2.5 NBR70 ISO 3601 445 526
2.23 Motor ECK02/H-2P 230V 50Hz 75W 652 098
- Capacitor 4.0 µF 420V, AC, DB 713 473
2.24 Plug cable No. 2 pump motor 245 050 12 082
2.25 Plug coupling 652 135
2.26 Pump ALEV 30C 601 857
– Filter set with seal 601 107
2.27 Solenoid coil T80 Suntec 220-240V 50-60Hz 604 495
2.28 Plug cable No. 5 solenoid valve 245 050 12 032
2.29 Oil line flow 245 050 06 018
2.30 Screwed union 24-SX-LL04-ST 452 020
2.31 Pressure hose DN 4 284 mm ( leakage oil)
– Standard 491 247
– diffusion resistant 491 134
2.32 Sealing ring A10 x 14 x 4.0 DIN 7603 Cu 440 037
2.33 Swivel screw R1/8 M10 x 1 241 110 06 057
2.34 Sealing ring A10 x 14 x 1.5 DIN 7603 Cu 440 034
2.35 Oil hose DN 4, 1200 mm
– Standard 491 126
– diffusion resistant 491 131
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13 Spares
3.17
3.16
3.18
3.19
3.20
3.12
3.13
3.07
3.09
3.10 3.08 3.14

3.11
3.15
3.03
3.02
3.05
3.01
3.06
3.04
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13 Spares

3.01 Nozzle body with oil line 245 050 10 162
– Ring 21.1 x 25.4 x 3.8 245 050 10 117
3.02 Nozzle shut off set 240 050 10 012
3.03 Nozzle
– 0.35 gph 80°SF Fluidics 602 747
– 0.40 gph 80°SF Fluidics 602 748
– 0.45 gph 80°SF Fluidics 602 749
– 0.50 gph 80°SF Fluidics 602 750
– 0.55 gph 80°SF Fluidics 602 751
– 0.60 gph 80°SF Fluidics 602 752
– 0.65 gph 80°SF Fluidics 602 753
– 0.75 gph 80°SF Fluidics 602 754
– 0.35 gph 80°SR Danfoss 602 136
– 0.40 gph 80°SR Danfoss 602 130
– 0.45 gph 80°SR Danfoss 602 131
– 0.50 gph 80°SR Danfoss 602 132
– 0.55 gph 80°SR Danfoss 602 133
– 0.60 gph 80°SR Danfoss 602 134
– 0.65 gph 80°SR Danfoss 602 135
– 0.75 gph 80°SR Danfoss 602 137
3.04 Ring 21.1 x 25.4 x 3.8 245 050 10 117
3.05 Temperature switch 245 050 10 192
3.06 Heat exchanger 245 050 10 072
3.07 Guide tube 245 050 10 172
3.08 Adjusting lever top part 241 110 10 077
3.09 Adjusting lever bottom part 241 110 10 067
3.10 Indicating bolt M6 x 90 241 110 10 097
3.11 Plug 5.25 241 110 10 087
3.12 Centering screw
– D80 (ME 1.xx) 245 050 14 102
– D90 (ME 2.xx) 245 050 14 302
3.13 Illuminating tube end piece 245 050 12 057
3.14 Ignition electrode set
– MB 800 (ME 1.xx) 245 050 14 447
– MB 900 (ME 2.xx) 245 050 14 457
3.15 Ignition cable 380 mm 245 050 11 032
3.16 Metering ring
– MB 800 (ME 1.xx) 245 050 14 017
– MB 900 (ME 2.xx) 245 050 14 207
3.17 Clip for metering ring 245 050 14 397
3.18 HTI refractory for air nozzle 2.24 245 050 14 407
3.19 Clip for insulation 245 050 14 417
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13 Spares
3.17
3.16
3.18
3.19
3.20
3.12
3.13
3.07
3.09
3.10 3.08 3.14

3.11
3.15
3.03
3.02
3.05
3.01
3.06
3.04
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13 Spares

3.20 Air nozzle
– D19 MB 819 (ME 1.19) 245 050 14 022
– D21 MB 821 (ME 1.21) 245 050 14 032
– D22 MB 822 (ME 1.22) 245 050 14 042
– D23 MB 823 (ME 1.23) 245 050 14 052
– D24 MB 824 (ME 1.24) 245 050 14 062
– D24 MB 924 (ME 2.24) 245 050 14 212
– D25 MB 925 (ME 2.25) 245 050 14 342
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14 Notes
14 Notes
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15 Key word index
15 Key word index
A Flow pressure .............................................................. 22, 62

Air number .................................................................... 30, 31 Flow temperature ................................................................ 22
Air pressure switch............................................................. 10 Flue gas losses.................................................................... 32
Ambient conditions............................................................. 14 Flue gas temperature ......................................................... 32
Ammeter................................................................................ 27 Fuel......................................................................................... 14
Anti siphon valve ................................................................. 62 Fuel oil ................................................................................... 14
Aperture ........................................................................ 18, 20 Fuel release .......................................................................... 12
Approval data....................................................................... 14 Fuse ....................................................................................... 50
Atomising pressure............................................................. 30 Fusing .................................................................................... 14
B G
Bar .......................................................................................... 60 Guarantee............................................................................... 5
Boiler room ............................................................................. 6
Booming................................................................................ 57 H
Breaks in operation............................................................. 33 Heat exchanger .................................................... 10, 18, 43
Heating element .................................................................. 43
C Hours counter...................................................................... 59
Capacity ................................................................................ 16 hPa ......................................................................................... 60
CO content .......................................................................... 31 Humidity ................................................................................ 14
Combustion air ...................................................................... 6
Combustion chamber pressure ....................................... 16 I
Combustion heat rating ..................................................... 16 Ignition ................................................................................... 12
Combustion manager ................................................ 11, 25 Ignition electrodes .............................................................. 41
Commissioning.................................................................... 26 Ignition unit ........................................................................... 11
Consumption........................................................................ 14 Illuminated push button ...................................... 25, 52, 53
Conversion table ................................................................. 60 Initialisation time .................................................................. 13
Installation............................................................................. 18
D Installation location ............................................................. 18
Design lifespan ............................................................... 6, 34
Dimensions........................................................................... 17 K
Display ................................................................................... 25 kPa.......................................................................................... 60
Disposal .................................................................................. 7
Drilling pattern ..................................................................... 18 L
Ducted air intake ............................................................ 6, 10
Liability..................................................................................... 5
Lifespan............................................................................ 6, 34
E
Lockout................................................................... 52, 54, 56
Electrical connection.......................................................... 24
Electrical data ...................................................................... 14 M
Electrode............................................................................... 41
Emission................................................................................ 15 Mains voltage ....................................................................... 14
Emission class ..................................................................... 15 Maintenance position......................................................... 36
Error code............................................................................. 53 mbar ....................................................................................... 60
Error codes................................................................... 54, 56 Measuring device................................................................ 27
Errors ..................................................................................... 54 Mixing head .................................................................. 16, 45
Excess air.............................................................................. 31 Mixing pressure ........................................................... 27, 29
Extraneous light .................................................................. 27 Monitoring current .............................................................. 27
MPa ........................................................................................ 60
F
N
Fabrication number............................................................... 9
Fan pressure ................................................................ 27, 29 Name plate ............................................................................. 9
Fault ....................................................................................... 52 Noise...................................................................................... 57
Fault history .......................................................................... 53 Nozzle ............................................................................ 19, 37
Faults ..................................................................................... 56 Nozzle distance ................................................................... 44
Filter ............................................................................... 49, 62 Nozzle head.......................................................................... 10
Flame sensor........................................................................ 11 Nozzle selection .................................................................. 19
Flame signal ................................................................. 11, 27 Nozzle selection table ........................................................ 19
Flame tube............................................................................ 18 Nozzle shut off ............................................................. 10, 40
Flashing codes ............................................................ 54, 56
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15 Key word index
O Single pip system................................................................ 63

Oil feeder pump .................................................................. 62 Single pipe system ............................................................. 63
Oil filter .......................................................................... 49, 62 Solenoid valve...................................................................... 10
Oil hose ................................................................................. 22 Soot deposit......................................................................... 57
Oil nozzle ...................................................................... 19, 37 Sound .................................................................................... 15
Oil preheater ........................................................................ 43 Sound power level.............................................................. 15
Oil preheating ...................................................................... 12 Sound power levels............................................................ 15
Oil pressure measuring device ........................................ 28 Sound pressure level ......................................................... 15
Oil pump ................................................. 10, 22, 28, 47, 63 Spares ................................................................................... 65
Oil pump filter ...................................................................... 49 Stability problems ............................................................... 57
Oil supply...................................................................... 22, 62 Standards ............................................................................. 14
Oil temperature.................................................................... 62 Storage.................................................................................. 14
Oil throughput...................................................................... 16 Suction resistance ...................................................... 22, 62
Operating hours counter................................................... 59 Supply.................................................................................... 22
Supply pressure ................................................... 22, 28, 62
Supply temperature ............................................................ 22
P
Pa............................................................................................ 60 T
Pascal .................................................................................... 60
Plug assignment.................................................................. 58 Temperature ......................................................................... 14
Post-purge............................................................................ 12 Temperature switch............................................................ 43
Post-purge time................................................................... 13 Transport............................................................................... 14
Pre-filter................................................................................. 62 Troubleshooting .................................................................. 57
Pre-ignition time .................................................................. 13 Two pipe system ................................................................. 63
Pre-purge.............................................................................. 12 Type key .................................................................................. 8
Pre-purge time..................................................................... 13
Pressure gauge ................................................................... 28 U
Pressure measuring device ...................................... 27, 28 Unit ......................................................................................... 60
Pressure regulating screw ................................................ 30 Unit fuse ................................................................................ 50
Pressure switch................................................................... 10 Unit of pressure................................................................... 60
Program sequence ............................................................. 12
Pulsating ............................................................................... 57 V
Pump........................................................ 10, 22, 28, 47, 63
Pump filter............................................................................. 49 Vacuum ................................................................................. 62
Pump pressure ............................................................ 28, 30 Vacuum gauge..................................................................... 28
Voltage supply ..................................................................... 14
R
W
Recirculation aperture................................................ 45, 57
Recommended nozzles ..................................................... 19 Weight................................................................................... 17
Refractory ............................................................................. 18 Wiring diagram .................................................................... 58
Remote reset........................................................................ 24
Reset...................................................................................... 53
Reset button......................................................................... 25
Return .................................................................................... 22
Ring main operation ........................................................... 63
S
Safety measures.................................................................... 6
Safety time.................................................................... 12, 13
Sequence diagram ..................................................... 10, 12
Serial number......................................................................... 9
Service................................................................................... 34
Service contract .................................................................. 34
Service interval .................................................................... 34
Service plan.......................................................................... 35
Service position................................................................... 36
Setting gauge .............................................................. 41, 44
Shutdown ............................................................................. 33
Shutdown time .................................................................... 33
Signal lamp........................................................................... 25
83242002 1/2019-03 La 74-76

83242002 1/2019-03 La
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 Wall-hung condensing boilers
for gas up to 240 kW
The compact burners, proven millions of times
over, are economical and reliable. Available as The wall-hung condensing boilers WTC-GW
gas, oil and dual fuel burners for domestic and have been developed to meet the highest
commercial applications. demands in ease of operation and efficiency.
The purflam® burner version with special Modulating operation means these units
mixing head gives almost soot-free combustion operate quietly and economically.
of oil with greatly reduced NOx emissions.
monarch® WM Burners Floor-standing condensing boilers

and Industrial Burners up to 11,700 kW for oil and gas up to 1,200 kW
These legendary industrial burners are durable The floor-standing condensing boilers
and versatile. WTC-GB (up to 300 kW) and WTC-OB
Numerous variations of oil, gas and dual fuel (up to 45 kW) are efficient, low in pollutants
burners meet a wide range of applications and and versatile in use.
capacity requirements. Even the largest capacities can be covered by
cascading up to four gas condensing boilers.
WKmono 80 Burners up to 17,000 kW Solar systems
The WKmono 80 burners are the most The stylish flat-plate collectors are the ideal
powerful monoblock burners from Weishaupt. complement for any Weishaupt heating
They are available as oil, gas or dual fuel system. They are suitable for solar water
burners and are designed for tough industrial heating and for combined heating support.
application. With versions for on-roof, in-roof and flat roof
installations, solar energy can be utilised on
almost any roof.
WK Burners up to 32,000 kW Water heaters/Energy storage
These industrial burners of modular The diverse program of potable water and
construction are adaptable, robust and energy storage for various heat sources
powerful. includes storage volumes of 70 to 3,000 litres.
Even on the toughest industrial applications In order to minimize storage losses, potable
these oil, gas and dual fuel burners operate water cylinders from 140 to 500 litres are
reliably. available with highly efficient insulation using
vacuum insulation panels.
MCR Technology / Building Automation Heat pumps up to 180 kW

from Neuberger
The heat pump range offers solutions for the
From control panels to complete building man- utilisation of heat from the air, the soil or
agement systems - at Weishaupt you can find ground water.
the entire spectrum of modern control Some systems are also suitable for cooling
technology. Future orientated, economical and buildings.
flexible.
Service Geothermal probe drilling
Weishaupt customers can be assured that With its daughter company, BauGrund Süd,
specialist knowledge and tools are available Weishaupt also offers geothermal probe and
whenever they are needed. Our service well drilling. With the experience of more than
engineers are fully qualified and have 10,000 systems and more than 2 million meters
extensive product knowledge, be it for burners, of drilling, BauGrund Süd offers a
heat pumps, condensing boilers or solar comprehensive service program.
collectors.
83242002 1/2019-03 La

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Installation and operating instruction

Oil burner WL5-PB-H purflam® 83242002 1/2019-03

1 User instructions .............................................................................................................. 4

3 Product description ........................................................................................................ 8

83242002 1/2019-03 La 2-76

7.2 Adjusting the burner .................................................................................................. 30

11 Technical documentation ......................................................................................... 58

12 Project planning ............................................................................................................. 62

15 Key word index .............................................................................................................. 73

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1.1 Target group

Requires direct action

83242002 1/2019-03 La 4-76

1.3 Guarantee and Liability

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2.1 Designated application

2.2 Safety measures

2.2.1 Normal operation

2.2.2 Electrical connection

2.3 Electrical work

2.4 Alterations to the construction of the equipment

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2.5 Noise emission

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3.1 Type key

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3.2 Serial number

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3.3.1 Air supply

Fan with variable speed drive

Air damper with nozzle solenoid (optional)

Air pressure switch

3.3.2 Oil supply

Nozzle head with nozzle shut off

1 Oil pump on burner

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3.3.3 Electrical components

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3.3.4 Program sequence

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B1 Flame sensor TH Heating time heat exchanger

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3.4 Technical data

3.4.1 Approval data

Basic standards EN 267:2011

3.4.2 Electrical data

3.4.3 Ambient conditions

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Combustion heat rating

1 Combustion heat rating [kW] or [kg/h]

83242002 1/2019-03 La 16-76

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4.1 Installation conditions

Burner type and capacity graph

Prepare heat exchanger

130 ... 150

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4.2 Check rating

Nozzle selection table