Weishaupt WL30/1-C Z-1LN-A User guide

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A 83325802 1/2022-01

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
83325802 1/2022-01 La 2-112
1 User instructions.............................................................................................................. 5
1.1  Target group.................................................................................................................. 5
1.2  Symbols.......................................................................................................................... 5
1.3  Guarantee and Liability............................................................................................... 6
2 Safety ..................................................................................................................................... 7
2.1  Designated application............................................................................................... 7
2.2  Safety measures........................................................................................................... 7
2.2.1  Personal protective equipment (PPE) ..............................................................7
2.2.2  Normal operation...................................................................................................7
2.2.3  Electrical work........................................................................................................7
2.3  Alterations to the construction of the equipment ................................................. 8
2.4  Noise emission ............................................................................................................. 8
2.5  Disposal ......................................................................................................................... 8
3 Product description ........................................................................................................ 9
3.1  Type key ......................................................................................................................... 9
3.2  Type and serial number .............................................................................................. 9
3.3  Function........................................................................................................................10
3.3.1  Air supply ............................................................................................................. 10
3.3.2  Oil supply............................................................................................................. 11
3.3.3  Electrical components....................................................................................... 12
3.3.4  Program sequence............................................................................................. 12
3.3.5  Inputs and outputs............................................................................................. 14
3.4  Technical data.............................................................................................................15
3.4.1  Approval data...................................................................................................... 15
3.4.2  Electrical data ..................................................................................................... 15
3.4.3  Ambient conditions............................................................................................ 15
3.4.4  Fuels...................................................................................................................... 15
3.4.5  Emissions............................................................................................................. 16
3.4.6  Rating.................................................................................................................... 17
3.4.7  Dimensions.......................................................................................................... 18
3.4.8  Weight.................................................................................................................. 18
4 Installation ........................................................................................................................ 19
4.1  Installation requirements...........................................................................................19
4.2  Selecting a nozzle......................................................................................................20
4.3  Burner installation ......................................................................................................22
4.3.1  Rotate burner by 180° (optional).................................................................... 23
5 Installation ........................................................................................................................ 24
5.1  Oil supply.....................................................................................................................24
5.2  Electrical connection.................................................................................................26
6 Operation .......................................................................................................................... 28
6.1  Operating panel..........................................................................................................28
6.2  Display..........................................................................................................................30
6.2.1  Info level ............................................................................................................... 31
6.2.2  Service level ........................................................................................................ 32
6.2.3  Parameter level ................................................................................................... 33

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
83325802 1/2022-01 La 3-112
6.2.4  Access level ........................................................................................................ 35
7 Commissioning.............................................................................................................. 36
7.1  Prerequisite .................................................................................................................36
7.1.1  Connect measuring devices............................................................................ 37
7.1.2  Set minimum oil pressure switch (optional)................................................. 39
7.1.3  Setting values...................................................................................................... 40
7.2  Adjusting the burner..................................................................................................42
7.2.1  Burner without variable speed drive .............................................................. 42
7.2.2  Burner with variable speed drive (optional) ................................................. 48
7.3  Set air pressure switch (optional) ..........................................................................57
7.4  Concluding work........................................................................................................58
7.5  Check combustion.....................................................................................................59
7.6  Subsequent optimisation of operating points .....................................................60
8 Shutdown.......................................................................................................................... 61
9 Servicing............................................................................................................................ 62
9.1  Notes on servicing.....................................................................................................62
9.2  Service plan.................................................................................................................64
9.3  Hinge open the burner..............................................................................................65
9.4  Replace nozzle............................................................................................................66
9.5  Removing and refitting nozzle shut off ..................................................................67
9.6  Set ignition electrodes..............................................................................................67
9.7  Removing the mixing head.......................................................................................68
9.8  Set mixing head..........................................................................................................69
9.9  Service position..........................................................................................................70
9.10  Removing and refitting oil pump ..........................................................................71
9.11  Removing and refitting fan wheel ........................................................................72
9.12  Remove burner motor.............................................................................................72
9.13  Removing and refitting oil pump filter .................................................................73
9.14  Removing and refitting air damper actuator......................................................74
9.15  Removing and refitting angle drive......................................................................75
9.16  Replacing the combustion manager ...................................................................76
9.17  Replacing the fuse ..................................................................................................79
9.18  Set flame senor RAR9 (optional).........................................................................79
10 Troubleshooting ............................................................................................................ 80
10.1  Procedures for fault conditions............................................................................80
10.1.1  Display off.......................................................................................................... 80
10.1.2  Display OFF ...................................................................................................... 80
10.1.3  Display flashes ................................................................................................. 81
10.1.4  Detailed fault codes ........................................................................................ 82
10.2  Rectifying faults........................................................................................................83
10.3  Operating problems................................................................................................87
11 Technical documentation......................................................................................... 88
11.1  Program sequence..................................................................................................88
11.2  Conversion table unit of pressure........................................................................89

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
83325802 1/2022-01 La 4-112
12 Project planning............................................................................................................. 90
12.1  Oil supply ..................................................................................................................90
12.2  Continuous running fan or post-purge...............................................................92
12.3  Additional requirements.........................................................................................93
13 Spares................................................................................................................................. 94
14 Notes .................................................................................................................................108
15 Key word index ............................................................................................................109

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
1 User instructions
83325802 1/2022-01 La 5-112
1 User instructions
Translation of original
operating instructions
This manual forms part of the equipment and must be kept on site.
Carefully read the manual prior to working on the unit.
1.1 Target group
The manual is intended for the operator and qualified personnel. It should be ob-
served by all personnel working with the unit.
Work on the unit must only be carried out by personnel who have had the relevant
training 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
DANGER
Danger with high risk.
Non observance can lead to serious injury or death.
WARNING
Danger with medium risk.
Non observance can lead to serious injury or death.
CAUTION
Danger with low risk.
Non observance can cause injury to personnel.
NOTICE
!
Non observance can cause damage to the equip-
ment and environmental damage.
Important information
Requires direct action
Result after an action
Itemisation
… Range of values

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
1 User instructions
83325802 1/2022-01 La 6-112
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.

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
2 Safety
83325802 1/2022-01 La 7-112
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 preferably be operated indoors.
If the burner is not operated indoors, weather protection is required to protect from
rain and direct sunlight. The ambient conditions must be adhered to [ch.3.4.3].
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 Personal protective equipment (PPE)
Use the necessary personal protective equipment for all work.
2.2.2 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.
2.2.3 Electrical work
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.
The device contains components, which could be damaged by electrostatic dis-
charge (ESD).
When working on circuit boards and contacts:
do not touch circuit boards or contacts,
if necessary, take ESD protective measures.

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
2 Safety
83325802 1/2022-01 La 8-112
2.3 Alterations to the construction of the equipment
All conversions require written approval from Max Weishaupt GmbH.
No additional components may be fitted, which have not been tested for use
with the equipment.
Do not use combustion chamber inserts, which hinder flame burnout.
Use only original Weishaupt replacement parts.
2.4 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.
2.5 Disposal
Dispose of all materials and components in a safe and environmentally friendly way
at an authorised location. Observe local regulations.

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 9-112
3 Product description
3.1 Type key
WL30/1-C Z-1LN-A
Type
W Series: Compact burner
L Fuel: Oil EL
30 Size
1 Ratings size
C Construction
Version
Z Type of control: two stage
1LN Mixing head: LowNOX
A Mixing head version
3.2 Type and serial number
The type and serial number on the type plate clearly identify the product. They are
required by Weishaupt's customer service department.
1
1Name plate
Type: Ser. No.:

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 10-112
3.3 Function
3.3.1 Air supply
Air damper
The air damper regulates the air quantity required for combustion. The combustion
manager drives the air damper via actuator. At burner shutdown the air damper
closes automatically. This reduces heat loss in the heat exchanger.
Fan wheel
The fan wheel supplies the air from the air intake housing to the combustion head.
Diffuser
The air gap between flame tube and diffuser is adjusted by positioning the diffuser.
This adjusts the mixing pressure and the air quantity required for combustion.
Air pressure switch (optional)
Depending on the burner application, optional equipment may be required for op-
timum operation [ch.12.3].
The air pressure switch monitors the fan pressure. If the fan pressure is insufficient,
the combustion manager initiates a lockout.

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 11-112
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.
Solenoid valves
The solenoid valves open and close the oil supply.
For ignition, the combustion manager opens stage 1 solenoid valve. Stage 2 solen-
oid valve opens or closes depending on heat demand.
Minimum oil pressure switch (optional)
Depending on the burner application, optional equipment may be required for op-
timum operation [ch.12.3].
The minimum oil pressure switch monitors the pump pressure in the supply. If the
preset pressure is not achieved, the combustion manager initiates a lockout.
Nozzle head with nozzle shut off
The nozzle shut off is integrated in the nozzle head. It prevents oil leaks after shut-
down.
Sequence diagram
Standard Continuous operation PED (Pressure Equipment Directive)
PPP
1253
6
1254
43
6
1254 47
6
1Oil pump on burner
2Solenoid valve stage1 on the oil pump(1
3Minimum oil pressure switch (optional)
4Additional safety solenoid valve(1
(with min. oil pressure switch, continuous operation or PED)
5Nozzle head with nozzle shut off and nozzle
6Solenoid valve stage2 on the oil pump(2
7Minimum oil pressure switch
(1 normally closed
(2 normally open

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 12-112
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.
Operating panel
The values and parameters of the combustion manager can be displayed and
changed at the operating panel.
Burner motor
The burner motor drives the fan wheel and the oil pump.
With variable speed drive, a frequency converter is connected upstream.
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.
3.3.4 Program sequence
The operating phases for commissioning the burner are shown on the display.
Phase Function
TEST After the power supply has been switched on the combustion manager performs a self-test.
LAt heat demand, the air damper actuator drives to the reference point.
1The combustion manager monitors for extraneous light.
2The air damper actuator drives to pre-purge, to air damper setting stage 2 (operating point P9).
3Ignition and pre-purge is initiated.
4Pre-purge. The remaining pre-purge time is displayed.
5The air damper actuator drives to ignition position (operating point P0).
6Waiting time in ignition position.
7Stage 1 solenoid opens. The fuel is released. The safety time begins. The display shows symbol .
8Stabilisation time
9The air damper actuator drives to air damper setting stage 1 (operating point P1).
10 The burner is in operation. Depending on the regulator demand for stage 2, the stage 2 solenoid valve
opens or closes.
15 If there is no longer a heat demand, the solenoid valves close and stop the fuel supply. Following the
post-purge phase the burner motor switches off. The air damper actuator closes.
OFF Standby, no heat demand.

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 13-112
B4
P11
P13
W-FM 25
B5
P
P
B15
L
T1
T2
F2
N
L
N
K11
1
K13
6
M
M20
T1
4
B1
13
M
1
M1
3
T
S
T
I
T
V
T
N
P
B16
T8 T6T7
1234 5
B1 Flame sensor 1Operating point P0 (ignition position)
B15 Temperature or pressure regulator 2Operating point P1 (stage1)
B16 Temperature or pressure regulator stage2 3Operating point P2 (solenoid valve stage2)
F2 Temperature or pressure limiter 4Operating point P9 (stage2)
K11 Stage1 solenoid valve 5Operating phase
K13 Stage2 solenoid valve TIInitialisation time (Test): 3 s
M1 Burner motor TNPost-purge time: 2 [ch.6.2.3]
M20 Air damper actuator TSSafety time: 3 s
P11 Control lamp operation (optional) TVPre-purge time: 20s
P13 Control lamp stage2 (optional) Voltage is applied
T1 Ignition unit Flame signal present
Current path

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 14-112
3.3.5 Inputs and outputs
Observe wiring diagram supplied.
-weishaupt-
13
3
N
7
3
C
4
1
6
5
14
L
N
T1
T2
S3
B4
B5
T6
T7
T8
GL/A AM FC NA P TWI
8
11
15
12
X6
X7
F7
1
2
TWI TWI interface (VisionBox, accessory)
P O2 sensor (accessory)
NA Speed signal (Namur)
FC Frequency converter
AM Operating panel
L/A Air damper actuator
G Coded plug (black)
1Slot for analogue module EM3/3 or fieldbus module EM3/2
2W-FM cover
1 Stage1 solenoid valve (K11)
3C Burner motor or frequency converter for continuous running fan /
voltage supply flame sensor LFS1 (continuous operation)
3N Burner motor or frequency converter
4 Ignition unit
5 Not used
6 Stage2 solenoid valve (K13)
7 Bridging plug No. 7
8 Oil meter (impulse generator)
11 Air pressure switch
12 Oil pressure switch
13 Flame sensor QRB4
14 Remote rest or
switch contact flame sensor LFS1 (continuous operation)
15 Air pressure switch for ducted air intake (LDW2)
X6 7 pole connection plug
X7 4 pole connection plug
F7 Internal unit fuse (T6.3H, IEC 127-2/5)

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 15-112
3.4 Technical data
3.4.1 Approval data
DIN CERTCO 5G912
Basic standards EN267:2009 + A1:2011
Additional standards, see EU conformity certifica-
tion.
3.4.2 Electrical data
Mains voltage / mains frequency 230 V/50 Hz
Consumption at start max692 W
Consumption during operation max592 W
Power consumption max 3.1 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
Installation elevation max 2000 m(2
(1 With the relevant suitable fuel oil and layout of oil supply.
(2 Consultation with Weishaupt is required for higher installation elevation.
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)

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 16-112
3.4.5 Emissions
Flue gas
In accordance with EN267, the burner meets the requirements of emission class 3.
The NOx values are influenced by:
combustion chamber dimensions
flue gas system
fuel
combustion air (temperature and humidity)
medium temperature
Combustion chamber dimensions, see Weishaupt Partner Portal / Documents and
Applications / Online Applications / NOX calculation for burners.
Sound levels
Dual number noise emission values
Measured sound power level LWA (re 1 pW)
Uncertainty value KWA
76
4
dB(A)(1
dB(A)
Measured sound pressure level LpA (re 20 μPa)
Uncertainty value KpA
71
4
dB(A)(2
dB(A)
(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.

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 17-112
3.4.6 Rating
Combustion heat rating
Combustion heat rating 72…300 kW
6.1…25.2 kg/h(1
(1 The oil throughput data relates to a calorific value of 11.9 kWh/kg for fuel oil EL.
Capacity graph
Capacity graph to EN267.
The capacity data given relates to an installation elevation of 500m above sea
level. For installation elevations above 500m a capacity reduction of
approx.1%per100m applies.
A limited capacity graph is valid for ducted air intake.
10
12
14
16
18
20
22
24
8
6
-0.5
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
-1.0
60
80
100
120
140
160
180
200
220
240
260
280
300
2
1
1Combustion heat rating [kW] or [kg/h]
2Combustion chamber pressure [mbar]

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
3 Product description
83325802 1/2022-01 La 18-112
3.4.7 Dimensions
Burner
420 mm
480 mm
460 mm
127 mm
342 mm
62 mm
226 mm
620 mm
460 mm
510 mm
158
1
1167 mm without combustion head extension
267 mm with combustion head extension (100 mm)
367 mm with combustion head extension (200 mm)
3.4.8 Weight
approx. 28 kg

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
4 Installation
83325802 1/2022-01 La 19-112
4 Installation
4.1 Installation requirements
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 front edge of the combustion head.
The refractory can take a conical shape (min60°).
Refractory may not be required on boilers with water-cooled front, unless the man-
ufacturer gives other instructions.
Following installation, the aperture 4 between flame tube and refractory should be
filled with flame-proof, resilient insulating material. Do not make solid.
Heat exchangers with deep refractories or thick doors, or heat exchangers with re-
verse flame combustion chambers may require a combustion head extension. Head
extensions of 100 and 200mm are available. Dimension 2 then changes accord-
ing to the head extension used.
45°
60°
170 ... 186 mm
M8
130 mm
140 mm
127 mm
1
4
3
2
1Flange gasket
2167 mm
3Refractory
4Aperture

Installation and operating instruction
Oil burner WL30/1-C Z-1LN-A
4 Installation
83325802 1/2022-01 La 20-112
4.2 Selecting a nozzle
Determine nozzle size.
Load distribution
The load distribution of the burner is made via a pressure change-over on the oil
pump.
Generally, stage1 takes on approx. 65 % of the maximum oil throughput, a different
distribution may be necessary.
Example
Burner capacity required: approx. 230 kW
65 % of burner capacity required: 230 kW × 0.65 = 150 KW
Nozzle size 3.50 gph, see nozzle selection table:
Stage 1: 9 bar (149 kW)
Stage 2: 22 bar (234 kW)
Recommended nozzles
Make Characteristics
Fluidics 45°HF
Fluidics 60°HF(1
(1 Alternative for short combustion chambers of if the flame in unstable.
Pump pressure setting
Stage 1 Stage 2
9 … 11 … 12 bar 17 … 20 … 22 bar
Spray characteristic and spray angle varies depending on pump pressure.