Weishaupt WL40/1-A Z-1LN-A User guide

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A 83319702 1/2020-10

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
83319702 1/2020-10 La 2-116
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  Serial number..............................................................................................................10
3.3  Function........................................................................................................................11
3.3.1  Air supply ............................................................................................................. 11
3.3.2  Oil supply............................................................................................................. 12
3.3.3  Electrical components....................................................................................... 13
3.3.4  Program sequence............................................................................................. 14
3.3.5  Inputs and outputs............................................................................................. 16
3.4  Technical data.............................................................................................................17
3.4.1  Approval data...................................................................................................... 17
3.4.2  Electrical data ..................................................................................................... 17
3.4.3  Ambient conditions............................................................................................ 17
3.4.4  Fuels...................................................................................................................... 17
3.4.5  Emissions............................................................................................................. 18
3.4.6  Rating.................................................................................................................... 19
3.4.7  Dimensions.......................................................................................................... 20
3.4.8  Weight.................................................................................................................. 20
4 Installation ........................................................................................................................ 21
4.1  Installation conditions................................................................................................21
4.2  Selecting a nozzle......................................................................................................22
4.3  Burner installation ......................................................................................................24
4.3.1  Rotate burner by 180° (optional).................................................................... 25
5 Installation ........................................................................................................................ 26
5.1  Oil supply.....................................................................................................................26
5.2  Electrical connection.................................................................................................28
6 Operation .......................................................................................................................... 30
6.1  Operating panel..........................................................................................................30
6.2  Display..........................................................................................................................32
6.2.1  Info level ............................................................................................................... 33
6.2.2  Service level ........................................................................................................ 34
6.2.3  Parameter level ................................................................................................... 35

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
83319702 1/2020-10 La 3-116
6.2.4  Access level ........................................................................................................ 37
7 Commissioning.............................................................................................................. 38
7.1  Prerequisite .................................................................................................................38
7.1.1  Connect measuring devices............................................................................ 39
7.1.2  Set minimum oil pressure switch (optional)................................................. 41
7.1.3  Setting values...................................................................................................... 42
7.2  Adjusting the burner..................................................................................................44
7.2.1  Burner without variable speed drive .............................................................. 44
7.2.2  Burner with variable speed drive (optional) ................................................. 50
7.3  Set air pressure switch (optional) ..........................................................................59
7.4  Concluding work........................................................................................................60
7.5  Check combustion.....................................................................................................61
7.6  Subsequent optimisation of operating points .....................................................62
8 Shutdown.......................................................................................................................... 63
9 Servicing............................................................................................................................ 64
9.1  Notes on servicing.....................................................................................................64
9.2  Service plan.................................................................................................................66
9.3  Hinge open the burner..............................................................................................67
9.4  Replace nozzle............................................................................................................68
9.5  Removing and refitting nozzle shut off ..................................................................69
9.6  Set ignition electrodes..............................................................................................70
9.7  Removing the mixing head.......................................................................................71
9.8  Set mixing head..........................................................................................................72
9.9  Service position..........................................................................................................73
9.10  Removing and refitting oil pump ..........................................................................74
9.11  Removing and refitting fan wheel ........................................................................75
9.12  Remove burner motor.............................................................................................76
9.13  Removing and refitting oil pump filter .................................................................77
9.14  Removing and refitting air damper actuator......................................................78
9.15  Removing and refitting angle drive......................................................................79
9.16  Replacing the combustion manager ...................................................................80
9.17  Replacing the fuse ..................................................................................................83
9.18  Set flame senor RAR9 (optional).........................................................................83
10 Troubleshooting ............................................................................................................ 84
10.1  Procedures for fault conditions............................................................................84
10.1.1  Display off.......................................................................................................... 84
10.1.2  Display OFF ...................................................................................................... 84
10.1.3  Display flashes ................................................................................................. 85
10.1.4  Detailed fault codes ........................................................................................ 86
10.2  Rectifying faults........................................................................................................87
10.3  Operating problems................................................................................................91
11 Technical documentation......................................................................................... 92
11.1  Program sequence..................................................................................................92
11.2  Conversion table unit of pressure........................................................................93

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
83319702 1/2020-10 La 4-116
12 Project planning............................................................................................................. 94
12.1  Oil supply ..................................................................................................................94
12.2  Continuous running fan or post-purge...............................................................96
12.3  Additional requirements.........................................................................................97
13 Spares................................................................................................................................. 98
14 Notes .................................................................................................................................112
15 Key word index ............................................................................................................113

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
1 User instructions
83319702 1/2020-10 La 5-116
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 WL40/1-A Z-1LN-A
1 User instructions
83319702 1/2020-10 La 6-116
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 WL40/1-A Z-1LN-A
2 Safety
83319702 1/2020-10 La 7-116
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 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 WL40/1-A Z-1LN-A
2 Safety
83319702 1/2020-10 La 8-116
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 WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 9-116
3 Product description
3.1 Type key
WL40/1-A Z-1LN-A
Type
W Series: Compact burner
L Fuel: Oil EL
40 Size
1 Ratings size
A Construction
Version
Z Type of control: two stage
1LN Mixing head: LowNOX
A Mixing head version

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 10-116
3.2 Serial number
The serial number on the name plate identifies the product. This is required by
Weishaupt's customer service department.
1
1Name plate
Ser.No.

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 11-116
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 WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 12-116
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 the stage1 solenoid valve and the
safety solenoid valve. Stage2 solenoid 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 with oil pressure switch
PP
12543
6
1254 43
6
1Oil pump on burner
2Stage 1 solenoid valve (normally closed) on the oil pump
3Minimum oil pressure switch (optional)
4Safety solenoid valve (normally closed)
5Nozzle head with nozzle shut off and nozzle
6Stage 2 solenoid valve (normally open) on the oil pump

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 13-116
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.

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 14-116
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 valve and the safety valve open. The fuel is released. The safety time begins. The dis-
play shows symbol .
8Post-ignition time starts, this aids flame stabilisation.
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 WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 15-116
B4
P11
P13
W-FM 25
B5
P
P
B15
L
T1
T2
F2
N
L
N
K11
5
K14
1
K13
6
M
M20
T1
4
B1
13
M
1
M1
3
T
I
T
V
T
N
T
S
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
K14 Safety solenoid valve TNPost-purge time: 2 s [ch.6.2.3]
M1 Burner motor TSSafety time: 3 s
M20 Air damper actuator TVPre-purge time: 20s
P11 Control lamp operation (optional) Voltage is applied
P13 Control lamp stage2 (optional) Flame signal present
T1 Ignition unit Current path

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 16-116
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 FU 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 Safety solenoid valve (K14)
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 Stage1 solenoid valve (K11)
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
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 WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 17-116
3.4 Technical data
3.4.1 Approval data
DIN CERTCO 5G820
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901 W
Consumption during operation max801 W
Power consumption max 4.0 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 WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 18-116
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
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
78
4
dB(A)(1
dB(A)
Measured sound pressure level LpA (re 20 μPa)
Uncertainty value KpA
73
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 WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 19-116
3.4.6 Rating
Combustion heat rating
Combustion heat rating 140 … 500 kW
11.8…42 kg/h(1
Combustion head W40/1LN
(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
12,5
15
17, 5
20
22,5
25
2 7, 5
30
32,5
35
37, 5
40
42,5
-2
100
425
450
475
500
525
400
375
350
325
300
275
250
225
200
175
150
125
-1
0
1
2
3
4
5
6
7
2
1
3
4
1Combustion heat rating [kW] or [kg/h]
2Combustion chamber pressure [mbar]
3Capacity graph with flame sensor QRB4 (intermittent operation)
4Capacity graph with flame sensor LFS1/RAR9 (continuous operation)

Installation and operating instruction
Oil burner WL40/1-A Z-1LN-A
3 Product description
83319702 1/2020-10 La 20-116
3.4.7 Dimensions
Burner
450 mm
577 mm
480 mm
151 mm
360 mm
72 mm
245 mm
615 mm
480 mm
570 mm
185
1
1231 mm without combustion head extension
331 mm with combustion head extension (100 mm)
3.4.8 Weight
approx. 37 kg