Installation and Operating Instructions Weishaupt Gas Burners Sizes 1 To 11

Installation and operating instructions 83050302 – 1/98
Weishaupt gas burners

Sizes 1 to 11
Contents
Title Page
1. General instructions 3
2. Burner installation 5
3. Burner fuel system 7
4. Description of valve trains 8
4.1 Solenoid valves 8
00 85 4.2 Pressure regulator type FRS

4.3 Valve proving VPS 504
4.4 Valve proving type W-DK 3/01
10
11
14
5. Installation of valve trains 15
Conformity certification 5.1 Safety information 15
5.2 Installation example 16
We hereby confirm that Weishaupt gas and dual fuel
burners conform to the basic requirements of the 6. Soundness test of valve trains 18
following EC guidelines: 7. Sequence test of operation 18
– 90/396/EEC Gas Equipment Guideline 8. Preparation for first commissioning 19
– 89/336/EEC Electromagnetic Compatibility 8.1 Testing gas supply pressure 19
– 73/23/EEC Low Voltage Guideline 8.2 Venting gas line 19
9. Commissioning 19
Therefore the burner carries the CE/0085 Label. 9.1 Checks prior to first commissioning 19
9.2 Flame monitoring 19
The product conforms to the type test 9.3 Adjusting gas part 20
0085 of the Notified Body. 9.4 Set gas pressure switch 22
9.5 Set air pressure switch 22
Extensive quality assurance is guaranteed by a certified 9.6 Combustion test 23
Quality Management System to DIN EN ISO 9001. 9.7 Setting pressure and minimum
connection pressure 24
Max Weishaupt GmbH 10. Setting the mixing head 29
Burner and Heating Systems
D-88475 Schwendi 11. Capacity graphs 30
12. Setting ignition electrodes 33
13. Fan wheel attachment 33
14. Sequence of operation 34
14.1 Pre-requisite for burner start 35
14.2 Symbols on the fault position indicator 35
14.3 Basic wiring diagram for LFL 1.../LGK16... 36
14.4 Switching times 37
14.5 Sensor line between LGK 16... and
QRA 53 / QRA 55 or sensor electrode 38
14.6 Technical data 39
15. Cam setting of limit and auxiliary
switches in the servo-motor 40
15.1 Gas burners, two stage 40
15.2 Gas burners, sliding two stage
and modulating 41
16. Throughput determination, conversion
from normal to operating condition 42
17. Fault conditions and procedures 44
2
1. General instructions
Abbreviated instructions Safety
To ensure safe burner operation, the burner has to be
The following table gives an overview of the procedures for installed and commissioned by qualified personnel
installation and commissioning. and all guidelines in these operating instructions have
to be followed.
To ensure safe installation and commissioning Special attention should be paid to the relevant
all instructions given in these installation and installation and safety guidelines given (i.e. local
operating instructions must be followed. Codes of Practice).
DANGER
Flame monitoring devices, limit controls, correcting
elements and all other safety devices must be
commissioned, and may only be replaced by, the
manufacturer or the authorised agent.
Step Action Chapter
Failure to comply can lead to serious injury or death
1 Burner installation 2 and can cause considerable damage to the plant.
2 Installation of gas valve trains 5 Qualified personnel according to this operating
manual are persons who are familiar with the
3 Soundness test of valve train 6 installation, mounting, setting and commissioning of
the product and which have the necessary
4 Testing gas supply pressure 8.1 qualifications such as:-
5 Purging the gas supply line 8.2 – Training, instruction or authorisation to switch
electrical circuits and electrical devices on and off, to
6 Testing sequence of operation 7 earth them and to mark them in accordance with the
safety standards.
7 Testing the mixing head 10
– Training, instruction or authorisation to carry out
8 Testing the plant 9.1 installation, alteration and maintenance work on gas
installations in buildings and on site.
9 Commissioning 9.3
Operating instructions
The installation and operating instructions included with
each burner must be displayed clearly in the plant room.
We refer to DIN 4755, point 5. The address of the nearest
service centre must be entered on the reverse of the
instructions.
Instruction of personnel
Problems are often caused by incorrect burner operation.
The operating staff should be thoroughly instructed with
regard to the operation of the burner. With frequently
occurring burner faults, the nearest service centre must be
notified.
Electrical wiring
Each burner is supplied with a wiring diagram and burner
connection diagram as standard.
Maintenance and service

In accordance with DIN 4756, the whole installation
including the burner should be inspected by a qualified
engineer of the supplier at least once a year. The
combustion figures should be checked after each service
and each time an error has been rectified.
If, during maintenance, control seal joints have to be

opened, these have to be thoroughly cleaned and new
seals fitted when re-assembling.
Installation conditions
Material, construction and type of protection of the burners
and gas valve trains in their standard version are designed
for use indoors. Permitted ambient temperature is - 15°C
to + 40°C.
3
Electrical installation Soundness test
When installing the electrical connection cables ensure Brush connection points with foam forming agents or
that these are long enough to allow the burner and boiler similar, non-corroding materials.
door to be hinged open.
Gas types
Control circuits, which are taken from one of the supply The burner must only be operated with the type of gas
phases, must only be connected with an earthed neutral stipulated on its name plate. When converting to other
conductor. types of gas re-commissioning is required. A conversion kit
may also be needed.
On a mains supply which is not earthed the control voltage
must be supplied via an isolating transformer. Valve train installation
The valve train must be fixed and supported securely.
The pole of the transformer, which is to be used as the Standard connection is from the right.
neutral conductor must be earthed.
Gas meter
The control circuit phase and neutral conductors must The siting, size and type of gas meter are the responsibility
be connected correctly. of the gas supplier. Only those meters, which have been
approved, should be used. If no gas meter is fitted, as for
Ensure the correct fuse ratings are not exceeded. Earthing instance on liquid petroleum gas installations, the operator
and neutral conductors must conform to local regulations. has to be made aware that the burner can not be set to its
optimum, because basic testing is not possible without a
General information for gas operation meter installation.
When installing a gas combustion system, local
regulations and guidelines must be observed. Plant room regulations
Local regulations regarding the design of plant rooms must
The subcontractor responsible for the installation or be observed and the installation of an emergency switch
changes of the gas system must inform the gas supplier of and a mains gas shut off system should be considered.
the type and extent of the installation planned and the Attention should also be paid that sufficient ventilation is
intended work. The subcontractor must ascertain that an available in the plant room. Any shortcoming should be
adequate gas supply to the installation is ensured. noted in the commissioning report.
Installation, alteration and maintenance work on gas The commissioning report must be completed by the
systems in buildings and on process sites, must only be service engineer and signed by the plant operator or his
carried out by installers who have a contract with the gas authorised agent. The operator should be instructed in the
supplier. correct operation of the burner and control panel. The
operating instructions included with each burner must be
Gas characteristics displayed clearly in the plant room.
The following information must be obtained from the gas
supplier: Thermal / manual shut off system
Type of gas, calorific value in kWh/m3, max. CO2 content of If a thermal / manual shut off system is required, this should
flue gas, gas supply pressure. be fitted in front of the burner fuel isolation valve(s). This
installation must conform to local regulations.
Gas line
The gas pipework must be subject to a preliminary and
main test or the combined loading test and soundness
test, according to the pressure range intended. The air or
purge gas required for the test must be expelled from the
pipework.
The determination of the pipework diameter usually gives a

diameter, which is at least one diameter larger than the size
of the burner valve train.
Gas valve train

Observe the sequence and flow direction. The distance
between burner and DMV valve should be as small as
possible in order to guarantee trouble free start.
Pipe thread connection

Only tested and approved sealing material should be used.
Please observe individual user instructions!
4
2. Burner Mounting
Mounting to the heat exchanger Drilling dimensions of the burner plate
Size 1 to 10 Size 11
Installation example for heat exchanger with refractory
d5 d5
60
°
30°
d4 d4
The gap between combustion head
and refractory must be filled with d3 d3
flexible insulating material . Do not
make solid.
Size Combustion Dimensions in mm

head type l1 d1 d2 d3 d4 d5
1 G1/2a 112 130 160 160-170 135 M8

3 G3/1a 157 160 190 186 165 M10
5 G5/1a 200 200 240 235 210 M10
7 G7/1a 230 250 290 298 270 M12

8 G7/2a 230 265 300 298 270 M12
9-10 UG2/1a 233 325 360 330 305 M12

11 UG3/1a 280 380 420 400 385/360* M12
* The burner can only be removed with the boiler plate
Hinging the burner Transport weight

Remove gas butterfly rod
Burner type Weight
Electrical connection (without valve train)
A wiring diagram is enclosed with each burner delivery.
G1 39 kg
Interlock switch
The interlock switch is arranged in such a manner that the G3 43 kg
circuit is closed in the burner closed position. In the burner
open position, the circuit is interrupted by the release of G5 55 kg
the tripping pin in the interlock switch.
G7 76 kg
G8 85 kg
G9 130 kg
G10 131 kg
G11 157 kg
5
Combustion head extension
Combustion head extensions are required on appliances For easy removal of the burner internal head assembly,
with very thick doors and boilers with a flame reversal fire particularly those with head extensions, it is important, that
tube. the burner body is able to swing through approx. 90°.
To enable installation and service work to be carried out,

the refractory should not be longer than dimension l1. Only
valid for standard boiler arrangements, not for special
combustion chambers, ovens etc.
Installation example
Refractory Flexible insulating material
Burner plate Combustion head
Flange gasket
Burner flange
Extension
Burner Extension Dimension in mm

size mm l1 d1 d2 d3
1 100 212 120 130 170

1 200 312 120 130 170
1 300 412 120 130 170
3 100 257 140 160 200

3 200 357 140 160 200
3 300 457 140 160 200
5 100 300 180 200 240

5 200 400 180 200 240
5 300 500 180 200 240
7 100 330 220 250 290

7 200 430 220 250 290
7 300 530 220 250 290
8 200 430 220 265 305

8 300 530 220 265 305
9-10 200 433 280 325 365

9-10 300 533 280 325 365
11 200 480 325 380 420

11 300 580 325 380 420
6
3. Burner fuel system for gas
Valve trains
7 5b 9 In accordance with EN 676 burners must be fitted with
Group A solenoid valves.
Weishaupt gas and dual fuel burners are supplied as
standard with two solenoid valves (on DN 150 with two
single solenoid valves).
Weishaupt also recommend the use of a valve proving

system. In accordance with EN 676 the use of a valve
proving system is required for installations from 1,200 kW.
This and other valve train components, such as gas filter
P P
and gas governor can be found in the Weishaupt
accessories list.
1 2 3 4a 4 8 5 6 Legend
With DMV valve and valve proving system VPS
1 Ball valve
Bilder aus 429
2 Gas filter
7 10 11 5b 9 3 Pressure regulator
4 Gas pressure switch, min.
4a Gas pressure switch, max. (to TRD/IM30)
5 Double Solenoid valve (DMV)
5a Single solenoid valve
5b Ignition gas solenoid valve
6 Gas butterfly valve
7 Pressure gauge with push button valve
8 VPS valve proving
9 Burner
10 Valve leakage indicator
P P P 11 Vent valve
12 Gas pressure switch for valve proving W-DK 3/01
1 2 3 4a 4 12 5a 6
With 2 solenoid valves and valve proving system W-DK 3/01
7
4. Description of valve trains
4.1 Solenoid valves
Function Technical data
DMV-D/11 Max. operating pressure 500 mbar

Two single solenoid valves normally closed, fast opening, Voltage/frequency ~(AC) 230 V - 15 %...
fast closing, manual limiting of gas throughput is possible to 240 V + 10 % 50/60 Hz
by adjusting main flow at valve 1 (V1). or ~(AC) 110 V 50/60 Hz
Ambient temperature -15 °C ... +60 °C
Installation Horizontal or vertical
Pressure test point Electrical connection

DMV-D 507/11 - 520/11 1 2 3
L1 N L2
V1 V2
2 1 3
1 2 3
4 5 1 2
Legend N L1
2 1 Pressure into V1
33
1 3 2 Pressure between V1 and V2
3 Pressure after V2
4 Inlet flange connection L2 V1 V2
5 Outlet flange connection
DMV-D 5040/11 - 5125/11 1 2 3

4
5 DMV and GW plug
4
6 7
V1 V2 m
4 2c
4
6 7 1 2 3 5 1
Legend
3 4 1, 2 Pressure into V1
2 5 3 Pressure between V1 and V2 2
1 4 Ignition gas outlet 4 3
5 Pressure after V2
6 Inlet flange connection
7 Outlet flange connection
MVD 507/5 MV 5150/5-S
R 3/4"
DN 3/4” with DN150 with

R 1/4” both sides socket connection R1/4” both sides flange connection
DIN 2633 PN16
8
Changing solenoid valve DMV
A
1. Switch off and isolate installation
B
2. Remove connection plug
3. Remove paint seal from screw A
4. Remove counter sunk screw A
C
5. Remove cheese head screw B
6. Remove cap (C) and metal plate (D)
D 7. Change solenoid, checking new unit is correct
type/voltage
8. Refit metal plate (D) and cap (C)
9. Refit screws A and B
E
10. Do a gas tightness test at test point 2 and 3:
pmin = 100 - 150 mbar
11. Carry out function test
12. Switch on supplies and test burner
Gas throughput adjustment

DMV 507-5125 DMV 507 - 520/11 Throughput adjustment on V1 via
covered adjusting screw.
One turn = 0.5 mm stroke
adjustment, anti-clockwise to
max min increase flow , and vice-versa.
V1
DMV 5040 - 5125 Throughput adjustment on V1 via
covered adjusting screw.
One turn = 1 mm stroke
adjustment, anti-clockwise to
increase flow , and vice-versa.
Factory pre-set: maximum stroke
Connection of gas pressure switch to DMV
Gas pressure switch on DMV - flanged version
9
Gas pressure switch on DMV - Gas pressure switch with intermediate flange on DMV -
screwed version screwed version
4.2 Pressure regulator type FRS
Outlet pressure adjustment (set value) 1. Remove cap A

2. To increase outlet pressure (set value), turn screw B
clockwise.
A
or
B 3. To reduce outlet pressure (set value), turn screw B anti-
clockwise.
4. Prove the adjustment is correct.
5. Replace cap A
Changing the spring 1. Remove cap A. Turn screw B totally anti-clockwise.

2. Remove spring retainer C, and remove the spring D.
3. Fit new spring D.
A 4. Re-fit spring retainer C, and by turning screw B set the
required outlet pressure.
B 5 Prove adjustment is correct and re-fit cap A, and new
C range label.
D
Type of spring / colour Outlet pressure range

mbar
orange 5… 20
blue 10… 30
red 25… 55
yellow 30… 70
black 60… 110
pink 100… 150
10
4.3 Valve proving system VPS 504
III III
III II
I
III
III
III
III
III III III
Series 04
Operation
The valve proving system type VPS 504 operates to the The VPS 504 carries out a self-test during the switching
pressure build up principle. The progr. is activated at heat sequence. If a fault occur release is prohibited and an error
request. Valve proving is carried out after every burner start. message is displayed.
Technical data
Max. operating pressure 500 mbar Fusing fitted to

Test volume ≤ 4,0 l housing T6,3 L 250 V
Pressure increase via Switching current operating output max. 1A
motor pump ≈ 20 mbar lockout output max. 1A
Voltage/frequency ~(AC) 230 V - 15 %... Release time ≈ 10… 26 s
to 240 V + 10 % / 50 Hz max. number of test cycles 20 /h
or ~(AC) 110 V / 50 Hz Ambient temperature -15 °C ... +60 °C
Type of protection/switching duration Installation vertical or horizontal
Series 04 IP 54 / 100 % Ed
Pre-fusing (by others) 10 A F or 6,3 A T
Pressure reduction
1 Connection pe, p1
DMV-. …
2 Connection pa, p2 1 MB- … 2
3, 4 Test points
p1 p2
pe pa
pa
p2 2 p1 p2
pe VPS 504 pa 3
pe
p1 1 pe
p1
pa
p2
3 4
11
Sequence of operation
p p p p p
e e p + 20 mbar e e e
e
V1 V2 V1 V2 V1 V2
p1 p2 A=Programmer p1 p2 p1 p2
pe A pa pe A pa pe A pa
VPS 504 VPS 504 VPS 504
p1 p2 p1 p2 p1 p2
pe pa pe pa pe pa
Shutdown Pressure build-up Operation
Shut down condition: Valve 1 and valve 2 are closed. Programme sequence
Pressure build-up: The internal motor pump increases the Regulator

504 "DICHT"
VPS "Sound" Vtest =V0.3
Prüfl = 0,3 l
gas pressure in the test section by approx. 20 mbar when Pump motor
Solenoid valve
compared to the pressure pe on the inlet side of valve 1. Diff. pres. switch
Release signal
During the test phase the inbuilt differential pressure
switch checks the test section for soundness. Once the Regulator
VPS "Sound" Vtest =V4.0
504 "DICHT" Prüfl = 4,0 l
test pressure has been reached the motor pump is Pump motor
Solenoid valve
switched off (end of test phase). The release time (10 to Diff. pressure switch
Release signal
26 secs) depends on the test volume (max. 4.0 l).
VPS "Not Sound"
If the test section is sound, the contact to the burner Regulator
504 "UNDICHT"
control is released after max. 26 secs. The yellow signalling Pump motor
Solenoid valve
lamp is illuminated. Diff. pressure switch
Release signal
If the test section is not sound or if the pressure increase of Lockout signal
+ 20 mbar is not reached during the test phase (max

26secs.), the VPS 504 goes to lockout. The red signalling
lamp is illuminated as long as contact is made by the 0 5 10 15 20 25 30 [s]
regulator (heat request).
An automatic restart is carried out following short term
voltage loss during the test phase or during burner
operation.
Installation
Remove closing
plug
VPS on DMV screwed VPS on DMV flanged
Note:
– Remove closing plug prior to installation
– Properly tighten cover screw and connecting screw,
avoiding over-tightening!
– Protect flange surface. Tighten screws in diagonally
opposite sequence.
– The unit must not be used as a lever.
– When work in on the VPS 504 is complete carry out
valve proving and function test.
– Ensure tight sealing when changing parts.
12
Electrical connection VPS 504 series 04
With cable gland PG 13.5 and connection to screw VPS 504

VPS 04 504
Series
Serie 04
terminals.
intern
internal
V3
Potential free relay contacts must only be used for notundicht
sound
signalling and never for burner control circuit! P
sound
dicht
Release time tF
Time required by the VPS 504 to carry out a complete test
cycle. The release time of the VPS 504 depends on the 1 2 3 4 5 6 7 8
Operating
Freigabe-
spannung
NC COM NO B L1 N
test volume and inlet pressure:
Betriebs-
}
Release
Neutral
voltage
signal
signal
cond.
leiter
Null-
Erde
Earth
Potential free lockout signal
V test < 1.5 l V test > 1.5 l potentialfreies Störsignal
(Leitwartensignal) Operating voltage
Betriebsspannung ~(AC) 230 V 50 Hz
pe > 20 - 500 mbar pe > 20 mbar
tF ≈ 10 s tF > 10 s
Interchangeable
tF max / VPS 504 ≈ 26 s fuses:
T 6.3 L 230V
Test time Pt to ICE 127 2/III
(DIN 41662)
Pump time of the motor pump. D5 x 20
Test volume V test

Volume between V1 on the outlet side and V2 on the
inlet side.
V test max. / VPS 504 = 4 l. t F [s]

30
Test volume of the multiple settings units 28
26
Type Rp/DN Test volume Application range
Anwendungsbereich
24
22 r
ba
DMV-D(LE) 503/11 Rp 3/8 0.09 l 20 0 m ar
5 0 mb
DMV-D(LE) 507/11 Rp 3/4 0.09 l 18
=
p e 300
=
DMV-D(LE) 512/11 Rp 1 1/4 0.25 l 16
pe
DMV-D(LE) 520/11 Rp 2 0.25 l 14 mb

ar
100
DMV-D(LE) 5040/11 DN 40 0.36 l 12 p e=
20
mb
ar
DMV-D(LE) 5050/11 DN 50 0.36 l p e=

10
DMV-D(LE) 5065/11 DN 65 0.60 l 8
tF
DMV-D(LE) 5080/11 DN 80 1.70 l 6 ≈ 10 s
DMV-D(LE) 5100/11 DN 100 2.30 l 4 V
VPrüf
DMV-D(LE) 5125/11 DN 125 3.75 l 2
test.
≤ 1,5
1,5 ll
1 2 3 4 VV Prüf
test [l]
Installation dimensions S04/S04
126,5
Sicherung eingebaut, auswechselbar
Fuse built into housing, exchangeable
Fusibile integré dans la couvercle du boîtier
interchangeable
Typ/Type/Type/Tipo T 6,3 L 250 V

Betriebsanleitung beachten!
Please comply with the operating instructions!
Suivre les instructions de la notice d'utilisation!
Additional
Zusätzlich cable Seguire le istruzioni!
100
Kabeldurchführung
entry
PG 11 möglich
147
PG11
VPS 504 Series 04
150
Standard:
Standard
Kabeldurch- pa
cable entry
führung
22
PG 13.5
PG 13,5 pe
pa pe
13
4,3
5
Ø9
53,7
72
Vor dem Öffnen ist das Gerät stromlos zu schalten
Suction connection
Prima di apire l'aparecchio togliere la corrente
Fonctionamento
Funziamento
Dérangement
pe
Störung
Betrieb
Lockout
Blocco
pe
Run
(gas inlet) (Gaseingang)

Before opening switch off power supply
Achtung, Warning, Attention, Attentione
test point
Meßstutzen Sauganschluß
Ouverture uniquement hors tension
Pressure connection
Typ: VPS 504
Schaltstrom Imax. 4A
-15°C T 60°C………
pa
Serie 04
219 881
-15°C T 70°C……
~(AC) 50 Hz 230 V
~(AC) 50 Hz 240 V
pmax. = 500 mbar
pa
CE-0085AP0168
test point (to the test section)

Druckanschluß (zur Prüfstrecke)
Meßstutzen
ID-No.
IP54
Ersatzsicherung
Replacement fuse
13
4.4 Valve proving system type W-DK 3/01
Construction Gas valve train with Weishaupt valve proving system W-DK 3/01
The valve proving system W-DK 3/01 consists of four main 1 Solenoid valve 1
parts: 2 Solenoid valve 2
● Programmer fitted into the control panel of plant 3 Leakage indicator unit
● Gas pressure switch fitted to the test section between 4 Vent valve
the solenoid valves 5 Gas pressure switch 3 1 4 2 5 6
0,2 … 0,5 m
● Vent valve (normally open) fitted into the vent line 6 Programmer fitted in
control panel
● Leakage-indicator unit fitted into the vent line
Function
The tightness of the solenoid valves in the gas valve train is
checked prior to each burner start.
Operation
1.Test phase: During pre-purge all three solenoid valves
are closed. If pressure builds up due to possibly leaking
first valve, the pressure increase is detected by the gas P
pressure switch.
2. Test phase: If the first solenoid valve is gas-tight, it is

opened momentarily , but the vent valve remains closed.
Gas pressure is now in the section between the three Test result
solenoid valves. It is tested for a reduction in pressure in If a pressure increase (phase 1) or pressure decrease (phase
test section. The test is carried out by the programmer. 2) is detected, the burner start is inhibited. Otherwise the
solenoid valves are tight and the burner starts.
Pressure switch setting

1/2 flow pressure
Technical data
Weishaupt valve proving systemTypeW-DK 3/01 Typ W-DK 3/01
Mains voltage/Frequency V / Hz 220 ± 15% / 50 or 60
Fusing A in accordance with the
pre-fusing of the burner
control
Perm. ambient temperature °C – 10…+ 60

Programmer Test times
– Pressure switch test
with/without pressure secs. 8
– Fill test section secs. 2
– Test time with test pressure secs. 9
Type of protection IP 40
Consumption VA approx. 4
Installation as required
Weight kg 0,734
Pressure switch GW50 A4 Setting range mbar 2,5…50
Pressure switch GW150 A4 Setting range mbar 30…150
Vent valve LGV 507/5 Nominal diameter R 3/4”
Leakage indicator
(without glycerine) Nominal diameter R 3/4”
Programmer
Plug-in unit
133
Sub- base
23
Cable
entry
150 75
Fitting dimension
II 5 5
II 100
14
5. Installation of valve trains
5.1 Safety notice
Risk of explosion!
If the valve trains are not installed correctly,
their soundness and strength cannot be
DANGER guaranteed.
To avoid deadly accidents, the following safety

instructions must be observed during
installation:
● Observe the maximum permitted gas pressure in the

valve train. Contact your local gas supplier to obtain the
connection pressure of the gas mains.
The connection pressure must not exceed the maximum
pressure recorded on the name plate.
● Valve trains must be installed securely to avoid vibration

during operation.
Suitable supports should be used (available as
Weishaupt accessory).
The supports must be fitted to the specific site require-
ments when mounting the valve trains.
● Valve trains must be installed tension free. Never

compensate for mistakes made during installation by
over tightening the flange screws.
● Flange screws should be tightened diagonally opposite.
● Ensure flange gaskets are clean and fitted correctly.
● Only gas board approved sealing material should be

used. If a connection needs to be loosened often, flange
connections with inlaid gasket should be used.
Other installation information:

On installations, which are subject to special regulations
for steam boilers, the valve trains can be vented with a test
burner. The first solenoid is fitted with a connection point
for this test burner.
To allow the boiler door to be hinged open, a flange

connection point, if possible at door level, should be fitted
(compensator see drawings, chapter 5.2).
To achieve better start conditions, the distance between

burner and solenoid valves (ignition and mains gas) should
be as small as possible.
Observe sequence and flow direction of valve train.
If a thermal shut off device TAE is required, this must be

fitted in front of the ball valve.
15
5.2 Installation example
High pressure supply with DMV flanged
1 2a 3 4 5a 6 7 8
11 10 9
Low pressure supply with DMV flanged
1 2a 3 4 5b 6 7 8
11 10 9
16
Low pressure supply with DMV screwed
1 2a 3 4 5b 6 7 8
11 10
Low pressure supply with single valves (only for nominal diameter DN 150)
1 2b 2b 3 4 5b 6 7 8
12 10 9
1 Solenoid valve for ignition gas 7 Pressure gauge with push button valve
2a Double solenoid valve DMV 8 Ball valve
2b Single valve 9 Compensator
3 Test burner 10 Gas pressure switch, min.
4 Gas pressure switch, max. (to TRD/IM30) 11 Valve proving system VPS
5a High pressure regulator 12 Pressure switch for valve proving system W-DK 3/01
5b Low pressure regulator
6 Filter
17
6. Soundness test of valve trains
Soundness test of the gas train must be carried out with
the main isolating cock and DMV valves closed. Proceed
as follows:
1. Test phase: ball cock up to 1st valve seat (V1) V2

V1
The test assembly is connected to the gas filter and DMV
inlet. During pressure testing, the test point 2 between
DMV valve seats V1 and V2 has to be open.
2. Test phase: volume between 1st and 2nd valve seat
The test assembly is fitted to the DMV test point 2. 1
Test pressure in the valve train should be between 100 and 2

150 mbar.
Wait 5 minutes for pressure equalisation.

3
The valve train is not leaking if the pressure drop is no First test phase Second test phase
more than 1 mbar after the test period of 5 minutes has
elapsed 1 Rubber hose with T piece
2 Aspirator
3. Test phase: Valve train connection parts and gas 3 U-tube manometer or electronic manometer
butterfly valve
The third test phase can only be carried out during

operation and by using a leak detection solution.
Results of the pressure test must be recorded on the

service/commissioning report.
Attention!
After all maintenance and commissioning work on gas
supplying components a soundness test must be
carried out.
7. Sequence test of operation

Wiring connection check – Gas pressure switch shuts down the burner.
Check that the wiring to all parts, especially the valve train, – Gas solenoid valves are closed.
is carried out in accordance with the wiring diagram
supplied with the burner. If the gas pressure switch does not shut down the after the
safety time of 2 seconds has elapsed, then the burner
Testing the burner control locks out.
Check the rotation of burner motor.
Version with two solenoid valves and valve proving
Sequence test gas operation (without gas) system W-DK 3/01
The ball valve must be closed and the selector switch on – Burner motor starts.
dual fuel burners set to gas operation. Air is pumped into – The servomotor opens the air damper in approx. 40 (20)
the valve train by means of the hand pump still connected seconds.
from the soundness test. The pressure must be at least as – The full load pre-purge period is 30 seconds.
high as the subsequent gas operating pressure. – Valve proving is carried out in accordance with the
sequence of operation (see chapter 24).
The burner is switched on and the following programme – The servomotor closes the air damper to the ignition
should take place: position in approx. 35 (17) seconds.
– The pre-purge time of approx. 4 seconds begins.
Versions with DMV and valve proving system VPS – Gas solenoid valves are opened.
– Burner motor starts following successful valve proving. – Pressure in the valve train falls.
– The servomotor opens the air damper in approx. 40 (20) – Gas pressure switch shuts down the burner.
seconds. – Gas solenoid valves are closed.
– The full load pre-purge period is 30 seconds.
– The servomotor closes the air damper to the ignition If a fault occurs during the sequence of operation see
position in approx. 35 (17) seconds. description of burner control LFL1... and the additional
– The pre-purge time of approx. 4 seconds begins. information.
– Gas solenoid valves are opened.
– Pressure in the valve train falls.
18
8. Preparation for first commissioning
8.1 Testing the gas supply pressure
Risk of explosion! 1. Connect pressure test unit to filter.

The mains gas pressure must not exceed the 2. Slowly open the ball valve monitoring the pressure test
max. permitted pressure of the valve trains listed unit at all times.
DANGER on the burner name plate. The mains gas 3. Close the ball valve immediately if the mains gas
pressure must be checked prior to first pressure exceed the max. permitted pressure of the
commissioning. valve train. The burner must not be started.
4. Contact your nearest Weishaupt branch office.
8.2 Purging the gas supply line
Purging If a test burner is installed, this must be used to ensure

The valve train must be purged prior to first that no air is present in the equipment.
commissioning.
Any air or inert gas in the distribution lines must also
A hose leading into the open is connected to the test point be expelled form the pipework. This work is usually
on the gas solenoid valve to discharge the air. carried out by the local gas authority.
After purging, the test manometer or gauge is When work on the valve train involves changing
reconnected at the test point on the solenoid valve. components, the valve train must be purged and
undergo a valve proving test before the burner is
switched on again.
9. Commissioning
9.1 Checks prior to first commissioning
The whole installation must be checked prior to the ● Have temperature switch, pressure switch and safety
first commissioning. limiting systems been set to operation?
● Is sufficient load available?
● Has the heat exchanger been installed ready for ● Has the low water safety interlock been adjusted correctly?
operation? ● Have all fuel carrying parts been vented (free of air)?
● Are heat exchanger and system filled sufficiently with ● Check rotation of burner motor.
heating medium? ● Has the valve proving of the valve train been carried
● Are movable exploding flaps fitted? out?
● Is the flue gas damper open? ● Is the gas supply pressure correct?
● Are the flue gas ways free?
● Are the ventilators of air heaters operating correctly? It is possible that other site-specific tests will have to be
● Is the ventilation to the plant sufficient? carried out. Refer to the operating instructions of individual
● Has the whole installation been wired correctly? site components.
9.2 Flame monitoring
Ionisation detector on LFL... and LGK... UV detector QRA2 on LFL

22 24 22 23
Microammeter
Microammeter (range 0 ... 600 µA
(range 0... 150 µA) or 0 ... 1 mA)
Minimum required sensor current in µA Test for flame sensor

min. required ionisation UV cell QRA2 Ionisation electrode: By separating the plug connections
ionisation current 6 70 in the vicinity of the terminal strip.
UV cell: By withdrawal from the holder on the burner
values normally >15 >120 flange.
obtained
Note: With the LGK 16... burner control and UV sensor
QRA 53/55, it is only possible to measure the sensor
current by means of the special sensor current measuring
instrument type KF8832.
19
9.3 Adjusting
Switch on procedure Butterfly valve pre-setting

– Open ball valve.
– Release gas pressure regulating spring
(see chapter 4.2).
Version Z:
– Set selector switch in control panel to “stage 1” or
“partial load”.
Version ZM:
– Set selector switch in control panel to “stop”
– Reset installation.
– Switch on burner operating switch.
Ignition
After the pre-purge time has elapsed, wait for flame Disengaging servomotor SQM
formation. If ignition problems occur check the pre-setting
of the gas butterfly valve (nominal approx. 5 - 10° “Open”
on the gas butterfly scale), as well as the position of the
ignition load switch in the servomotor (ZM: No. IV, Z: No.V)
and if necessary increase slightly. Check sensor current
with microammeter.
Intermediate testing (partial load to full load):

After approx. 20 secs. the servomotor runs from ignition to
partial load position.
Set gas pressure to table in chapter 9.7 (Setting pressure

into solenoid valve).
Carry out CO test.
Disengaging servomotor 1055/80
Version Z:
– Switch off servomotor with toggle switch
– Adjust regulating cam step by step with servomotor
dis-eneaged
– Re-engage servomotor.
– Carry out CO tests at each cam setting up to
full load setting.

– Make the necessary corrections to the
pressure settings.
Version ZM:
– Disengage servomotor
– Turn gas regulating cam step by step by hand
and re-engage servomotor.
– Carry out CO tests at each cam setting up to full load Setting combustion air
setting.
– Make the necessary corrections to the
pressure settings.
Full load setting

Drive up servomotor electrically towards full load:
Version Z:
– Set toggle switch in the servomotor to “On”.
– Set selector switch in control panel to full load.
Version ZM:
– Disengage servomotor
– Turn gas regulating cam to intermediate position and
re-engage servomotor.
– Set selector switch in the control panel to full load.
The required amount of gas for full load must be set and
measured at the gas meter (the gas pressures given in the
table chapter 9.7 are only an aid for setting and adjusting).
20
Combustion test: Completing commissioning
Regulate the amount of gas by adjusting the gas setting Check ignition load setting once burner has been
pressure. Regulate the combustion values by adjusting the commissioned, if needed adjust at the auxiliary switch in
curve band of the air regulating cam and positioning of the the servomotor (Z: No.V,ZM:No.IV). The ignition load
regulating sleeve so that best possible values and good setting needs to be reliable and free of ignition ‘impact’,
flame stability are achieved with fully opened air damper. regard must be taken of local requirements covering
ignition firing rate limitations. An ignition test needs to be
The gas pressure set for full load must not be altered. made with the gas pipework downstream of the safety
valve and the head of the burner devoid of gas. The
Intermediate check (“full load to partial load”). required measurements can be made by holding the
Version Z: burner in the start gas phase (Z: toggle switch in
As the burner rating changes between full and partial servomotor, ZM: interrupt servomotor neutral at ignition
load (high and low fire) occur quickly, it is only load position).
necessary to do spot checks at the intermediate
ratings for CO. Check the CO limit by setting burner from low fire (partial
load) to high fire (full load) and high fire to low fire.
Start cams step by step electrically, (trip switch off,
selector switch stage 1), start points with trip switch. With the installation operating test the function and setting
of safety equipment, i.e. gas and air pressure switches,
Version ZM: plant temperature/pressure limit switches, interlocks.
As the operating range of the burner is used at
intermediate levels as well as the max. and min. levels, Documentation:
combustion tests are required at each cam setting. The following setting values have to be noted on the
Adjust cams step by step (selector switch “Stop”, commissioning report.
disengage servomotor, adjust, re-engage
servomotor). At ignition load: At full and partial load:
Gas throughput Gas throughput
Adjust combustion values by adjusting the air curve band. Sensor current Gas pressure into ball valve
CO Gas pressure after ball valve
Ensure the curve bands have an even profile. CO2
With liquid petroleum gas: CO
Partial load setting take smoke measurements Exhaust gas temperature
Set selector switch on control panel to “Stage 1” or Fan pressure
“Partial load”. Set the required gas volume (throughput) by Suction/pressure in
means of the auxiliary switch in the servomotor (Z: No 11, combustion chamber
ZM: No.V1) and measure volume at the gas meter. Sensor current
Pay attention to the minimum limits of the capacity graphs,

flue gas temperatures and instructions of the boiler
manufacturer.
21
9.4 Set gas pressure switch
Gas pressure switch, min. Gas pressure switch type GW50A2

To set a pressure switch for gas, a manometer has to be
fitted to test point 1 of the DMV and the microammeter for
measuring of the ionisation current. When determining the
switch point, pay attention that this is not below half the
regulated pressure, that the ionisation current is a
minimum of 5 µA and that combustion is CO < 1000 ppm
(CO increase due to excess air).
25 20
30
Setting is carried out in the following manner:
15
40 35
1. Burner is operating
GW
10 5
50 A
2
45
2. Gradually close ball valve so that the pressure at the 50 mbar
2,5
pressure test unit slowly decreases.

3. Setting pressure has been reached when
– CO increases
– sensor current is only 5 µA
– or when half the regulated gas pressure has been
reached.
4. Slowly turn the setting cam of the gas pressure switch
to the right until the burner carries out a controlled
shutdown.
5. Control - the burner is restarted with open ball valve. If
the ball valve is closed again, the shut down pressure
can be tested. The burner control must not go to
lockout.
Gas pressure switch, max.

must be set to 1.3 x pa max.
9.5 Set air pressure switch
Size 1 to 3 Pressure switch for air type LGW50A2

Fan pressure is measured at full load. Switch point is set to
> 80% of the pressure measured at full load.
Size 5 to 11
The air pressure switch is pre-set. The switch point
must be checked and adjusted during commissioning.
For this a differential pressure measurement between 30
25 20
15
points ➀ and ➁ is required. Pressure behaviour is

40 35
10 5
monitored throughout the set range of the burner by the

45
2,5
50 mba
pressure test unit (i.e. U tube). The lowest differential

pressure value is used for the determination of switch
point.
The switch point is set to > 80% of this value. To do this,

the protective cap of the LGW is removed and the
calculated value is set at the setting wheel.
Example:
Reduced differential 20 mbar
Switch point air pressure switch 20 x 0.8 = 16 mbar Differential pressure test (on sizes 5 to 11)
Installation dependant influences, such as flue gas

recirculation, heat exchanger, installation or air supply, on
the air pressure switch and the settings may result in ➁
adjustments having to be made.
22
9.6 Combustion test
Calorific value of various types of gases and CO2 max.

Gas type Calorific value Hi CO2 max.
MJ/m3 kWh/m3
First gas family
Group A (Towns Gas) 15,12…17,64 4,20…4,90 12…13
Group B (Grid Gas) 15,91…18,83 4,42…5,23 10
Second gas family
Group LL (Natural Gas) 28,48…36,40 7,91…10,11 11,5…11,7
Group E (Natural Gas) 33,91…42,70 9,42…11,86 11,8…12,5
Third gas family
Propane P 93,21 25,99 13,8
Butane B 123,81 34,30 14,1
To ensure efficient and problem free operation of the Flue gas temperature for partial load is the result of
installation, flue gas measurements must be taken. the control range adjustment.
The different maximum CO2 contents can be obtained The instructions of the manufacturer are to be
from the local gas board (guide values see table). followed closely on hot water boiler installations.
Normally a partial load of 50 - 65% of the nominal load
Excess air should not exceed 10-20% at full load and is set (some of the data may be on the boiler rating
30% at partial load. plate).
Excess air λ ≈ CO2 max. On air heater installations the partial load is normally
CO2 measured
even higher. Again, the instructions of the
The CO content must not be more than 0.005 vol.% manufacturer should be closely followed.
(50ppm).
The flue gas installation should also be set out to
Flue gas temperature for full load (nominal load) is the protect against damage through condensation
result of burner setting at nominal loading. (excluding acid proof chimneys).
23
9.7 Setting pressure and minimum connection pressure
The results of the following tables have been calculated on With low pressure supplies with double solenoid valves
flame tubes under idealised conditions. The values are (DMV) pressure regulators to EN 88 with safety
therefore guidelines for basic settings. Small variations diaphragm are used. Maximum permissible connection
may occur when commissioning depending on individual pressure into isolating valve is 300 mbar on low pressure
installations. installations.
* The data given for DN40 is also valid for 1 1/2” and With high pressure supplies HP regulators to DIN 3380
those for DN50 for 2” valve trains. are selected from the technical brochure “Pressure
regulating and safety assemblies for Weishaupt gas and
The combustion chamber pressure in mbar must be added dual fuel burners”.
to the minimum gas pressure determined.
HP regulators for connection pressure up to 4 bar are
Selection of nominal diameter for valve trains for towns gas detailed in this brochure.
see separate worksheet, print No. 900.
Max. supply pressure see burner name plate.
The data given for calorific value Hi relate to 0°C and

1013.25 mbar.
Size 1
Burner Low pressure supply (gas pressure in mbar High pressure supply (setting pressure in mbar
rating into isolating valve, pe.max = 300 mbar) into double solenoid valve)
kW Nominal diameter of valve trains Nominal diameter of valve trains
3/4” 1” 40* 50* 65 3/4” 1” 40 50 65
Nominal diameter of gas butterfly valve Nominal diameter of gas butterfly valve
25 25 25 25 25 25 25 25 25 25
Natural Gas E, Hi = 37.26 MJ/m3 (10.35 kWh/m3), d = 0.606

150 14 – – – – 7 – – – –
200 21 10 – – – 11 – – – –
220 25 11 – – – 13 – – – –
250 31 13 8 – – 16 6 – – –
280 37 15 9 8 – 20 7 5 5 –
300 42 17 10 9 – 23 7 6 6 5
320 47 18 11 9 8 25 8 6 6 5
340 52 20 12 10 9 28 9 7 6 6
Natural Gas LL, Hi = 31.79 MJ/m3 (8.83 kWh/m3), d = 0.641

150 18 9 – – – 9 – – – –
200 28 12 – – – 15 5 – – –
220 33 14 9 – – 18 6 – – –
250 42 16 10 8 – 22 7 5 5 –
280 51 19 11 9 8 27 8 6 6 5
300 58 22 12 10 9 31 9 7 6 6
320 65 24 13 10 9 35 10 7 7 6
340 73 26 14 11 9 39 11 8 7 6
Liquid Petroleum Gas, B/P, Hi = 93.20 MJ/m3 (25.89 kWh/m3), d = 0.555

150 – – – – – – – – – –
200 11 – – – – 6 – – – –
220 13 – – – – 7 – – – –
250 16 8 – – – 8 – – – –
280 18 9 – – – 10 – – – –
300 20 10 – – – 11 – – – –
320 23 11 – – – 12 5 – – –
340 25 12 8 – – 14 6 – – –
* The data given for DN40 is also valid for 1 1/2” and those for DN50 for 2” valve trains.
24
Size 3
3/4” 1” 40* 50* 65 80 3/4” 1” 40 50 65 80
25 25 40 40 40 40 25 25 40 40 40 40

300 41 16 9 – – – 22 6 – – – –
350 54 20 10 8 – – 29 8 5 – – –
400 69 25 12 9 – – 37 10 6 6 – –
450 86 30 14 11 9 – 46 12 7 7 6 5
500 105 36 16 12 9 9 56 14 8 8 6 6
550 126 42 18 13 10 9 68 17 9 9 7 6
600 149 49 21 15 11 10 80 19 10 10 8 7
650 174 56 23 16 12 11 93 22 11 11 9 8

300 57 21 10 8 – – 30 8 – – – –
350 76 26 12 10 – – 40 10 6 6 – –
400 98 33 15 11 9 – 52 13 7 7 6 5
450 123 40 18 13 10 9 65 16 8 8 6 6
500 150 49 20 14 11 9 80 19 10 9 7 6
550 181 58 23 16 12 10 96 22 11 10 8 7
600 214 68 27 18 13 11 114 26 13 12 9 8
650 250 78 30 20 14 12 133 29 14 13 10 9

300 19 9 – – – – 10 – – – – –
350 25 11 – – – – 13 – – – – –
400 32 13 8 – – – 17 6 – – – –
450 39 16 9 – – – 21 7 – – – –
500 47 19 11 9 – – 26 8 6 6 5 –
550 56 21 12 10 8 8 30 40 6 6 6 5
600 66 25 13 11 9 9 36 11 7 7 6 6
650 76 28 14 12 10 9 42 12 8 8 7 7
Size 5
3/4” 1” 40* 50* 65 80 100 3/4” 1” 40* 50* 65 80 100
25 25 40 50 50 50 50 25 25 40 50 50 50 50
3 3
Natural Gas E, Hi = 37.26 MJ/m (10.35 kWh/m ), d = 0.606
500 105 35 16 11 9 – – 56 14 8 7 5 – –
550 126 42 18 12 9 8 – 67 16 9 8 6 5 5
600 149 49 20 14 10 9 8 79 19 10 9 7 6 6
650 174 56 23 15 11 9 9 93 22 11 10 7 6 6
700 201 64 26 17 12 10 9 107 25 12 11 8 7 7
800 261 82 32 20 14 11 10 139 31 15 13 10 8 8
900 – 102 39 24 16 13 12 – 38 18 15 11 9 9
940 – 111 42 25 17 13 12 – 41 19 16 12 10 9

500 150 48 20 13 10 8 – 80 18 9 8 6 5 5
550 180 58 23 15 11 9 8 96 22 11 9 7 6 6
600 214 67 27 17 12 10 9 113 25 12 11 8 7 6
650 250 78 30 19 13 11 10 133 29 14 12 9 7 7
700 289 90 34 21 14 11 10 – 33 16 13 10 8 7
800 – 115 43 25 16 13 12 – 43 19 16 11 9 9
900 – 144 52 30 19 15 13 – 53 23 20 13 11 10
940 – 157 57 33 20 15 13 – 57 25 21 14 11 10

500 46 18 10 – – – – 25 7 – – – – –
550 55 20 11 8 – – – 29 9 5 5 – – –
600 65 23 12 9 – – – 35 10 6 6 – – –
650 75 27 13 10 8 – – 40 11 7 6 5 – –
700 86 30 15 11 9 8 – 46 13 8 7 6 5 5
800 111 38 17 13 10 9 9 60 16 9 8 7 6 6
900 139 46 21 14 11 10 9 75 19 11 9 8 7 7
940 151 50 22 15 12 10 10 81 20 11 10 8 7 7
25
Size 7
3/4” 1” 40* 50* 65 80 100 125 3/4” 1” 40* 50* 65 80 100 125
40 40 40 50 65 65 65 65 40 40 40 50 65 65 65 65
3 3
800 256 77 30 18 12 9 8 – 134 26 13 11 7 6 5 5
900 – 96 37 22 13 10 9 9 – 32 16 13 9 7 6 6
1000 – 117 44 26 15 12 10 9 – 39 19 16 10 8 7 7
1100 – 141 52 30 17 13 11 10 – 46 22 19 11 9 8 7
1200 – 166 61 34 19 14 12 11 – 55 26 21 13 10 9 8
1400 – 224 81 44 24 17 14 12 – 73 34 28 16 12 10 9
1600 – 290 103 55 29 20 16 14 – 94 43 35 19 14 12 11
1750 – – 122 65 33 22 17 15 – 111 50 40 22 16 13 12

800 – 109 41 24 14 11 9 8 – 36 17 14 9 7 6 6
900 – 136 50 28 16 12 10 9 – 45 21 17 11 8 7 7
1000 – 167 61 34 19 13 11 10 – 54 26 21 12 9 8 7
1100 – 201 72 40 21 15 12 11 – 65 30 24 14 10 9 8
1200 – 237 85 46 24 16 13 12 – 77 35 28 16 11 10 9
1400 – – 113 60 30 20 15 14 – 103 46 37 20 14 12 10
1600 – – 145 76 37 24 18 15 – 133 59 47 25 17 13 12
1750 – – 172 89 43 27 20 17 – – 69 55 28 19 15 13

800 108 35 16 11 8 – – – 57 13 7 7 – – – –
900 136 43 19 13 9 – – – 71 15 9 8 6 – – –
1000 166 52 22 14 10 9 – – 87 18 10 9 6 6 5 5
1100 200 62 26 16 11 9 9 8 105 22 12 10 7 6 6 6
1200 237 72 29 18 12 10 9 9 125 25 14 12 8 7 6 6
1400 – 97 38 23 15 12 10 10 – 33 17 15 10 8 8 7
1600 – 124 48 28 17 13 12 11 – 42 21 18 12 10 9 8
1750 – 147 56 32 19 15 13 12 – 50 25 21 13 11 10 9
Size 8
40* 50* 65 80 100 125 40* 50* 65 80 100 125
40 50 65 65 65 65 40 50 65 65 65 65

1100 51 28 16 11 10 9 21 17 10 8 7 6
1200 60 33 18 13 10 9 25 20 12 8 7 7
1300 69 38 20 14 11 10 28 23 13 9 8 7
1400 79 43 22 15 12 11 32 26 14 10 9 8
1600 101 54 27 18 14 12 41 33 18 12 10 9
1800 127 66 33 21 16 14 51 40 21 14 11 10
2000 154 80 39 24 18 15 62 49 25 16 13 11
2250 193 99 47 28 20 17 77 60 30 19 15 13

1100 71 38 20 14 11 10 29 23 13 9 7 7
1200 83 44 23 15 12 10 34 27 15 10 8 7
1300 97 51 26 17 13 11 39 31 16 11 9 8
1400 111 58 29 18 14 12 45 35 18 12 10 9
1600 143 74 36 22 16 14 57 45 23 15 12 10
1800 179 92 43 25 18 15 71 55 28 17 13 11
2000 220 111 51 30 21 17 86 67 33 20 15 13
2250 276 138 63 35 24 19 107 83 40 24 18 15

1100 25 15 10 8 – – 11 9 6 5 – –
1200 28 17 11 9 8 – 13 11 7 6 5 5
1300 32 20 12 10 9 8 14 12 8 6 6 6
1400 37 22 14 11 9 9 16 14 9 7 6 6
1600 46 27 16 12 10 10 20 17 11 8 7 7
1800 57 32 19 14 12 11 25 20 12 10 8 8
2000 69 38 21 15 13 12 29 24 14 11 9 9
2250 85 47 25 18 14 13 36 29 17 13 11 10
26
Size 9
40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150
50 50 65 80 80 80 80 50 50 65 80 80 80 80
3 3
1600 96 53 27 17 13 11 10 36 32 17 11 9 8 8
1800 120 65 32 20 15 12 11 44 40 20 13 10 9 9
2000 146 79 38 23 16 14 12 54 48 24 15 12 10 10
2200 176 94 44 26 18 15 13 64 57 28 17 13 11 11
2400 208 111 51 29 20 16 14 75 67 33 20 15 13 12
2800 279 147 67 37 25 19 17 100 89 42 24 18 15 14
3200 – 190 84 45 29 22 19 129 114 53 30 21 17 16
3500 – 225 99 52 33 25 21 – 135 62 34 24 19 18

1600 136 73 35 21 15 12 11 49 44 22 14 10 9 8
1800 170 91 42 24 17 14 12 61 55 27 16 12 10 10
2000 208 110 50 28 19 15 13 75 66 32 19 14 11 11
2200 250 132 59 33 22 17 15 89 79 38 21 16 13 12
2400 296 156 69 37 24 19 16 105 93 44 24 17 14 13
2800 – 208 91 47 30 22 19 – 124 57 31 21 17 15
3200 – 269 116 59 36 26 22 – – 72 38 26 20 18
3500 – – 136 68 41 29 24 – – 85 44 29 22 20

1600 44 26 15 11 10 9 8 18 16 10 7 7 6 6
1800 54 32 18 13 11 10 9 21 20 12 9 8 7 7
2000 65 38 21 14 12 11 10 26 23 14 10 8 8 8
2200 77 44 24 16 13 12 11 30 27 16 11 9 9 8
2400 91 51 27 18 14 13 11 35 32 18 12 10 9 9
2800 121 67 34 22 17 15 13 46 41 22 15 12 11 11
3200 156 85 42 26 19 17 15 59 52 28 18 15 13 12
3500 185 100 48 29 21 18 16 69 62 32 20 16 14 14
Size 10
40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150
50 50 65 80 80 80 80 50 50 65 65 65 65 80
3 3
2000 146 78 37 22 16 13 11 53 47 24 14 11 10 9
2200 175 93 43 25 17 14 13 63 56 28 17 13 11 10
2400 207 110 50 28 19 16 14 74 66 32 19 14 12 11
2600 241 127 58 32 21 17 15 86 76 37 21 15 13 12
2800 278 146 66 36 24 18 16 99 88 41 24 17 14 13
3200 – 189 83 44 28 21 18 128 113 52 29 20 16 15
3600 – – 102 53 33 24 20 – – 64 34 24 19 17
3950 – – 121 61 37 27 23 – – 76 40 27 21 19

2000 208 110 50 28 19 15 13 74 66 31 18 13 11 10
2200 250 131 59 32 21 16 14 89 78 37 21 15 12 11
2400 296 155 68 36 23 18 15 105 92 43 24 17 13 12
2600 – 180 79 41 26 20 17 122 107 49 27 19 15 13
2800 – 208 90 46 29 21 18 – 123 56 30 21 16 14
3200 – – 115 58 35 25 21 – – 71 37 25 19 17
3600 – – 142 70 41 29 23 – – 88 45 29 22 19
3950 – – 169 82 47 33 26 – – 104 52 33 24 21

2000 65 37 20 14 11 10 9 25 23 13 9 8 7 7
2200 77 43 23 15 12 11 10 30 27 15 10 9 8 8
2400 90 50 26 17 13 12 11 34 31 17 12 10 9 8
2600 105 58 29 19 15 13 12 40 36 19 13 11 10 9
2800 120 66 33 21 16 14 12 45 41 22 14 12 10 10
3200 155 84 41 25 18 16 14 58 52 27 17 14 12 11
3600 194 104 49 29 21 17 16 71 64 32 20 16 14 13
3950 231 124 58 33 23 19 17 85 75 38 23 18 15 14
27
Size 11
40* 50* 65 80 100 125 150 40* 50* 65 80 100 125 150
65 65 65 80 100 100 100 65 65 65 80 100 100 100
3 3
3200 – 182 82 43 26 20 16 121 106 51 27 19 14 13
3400 – 204 91 47 29 21 17 136 119 57 30 20 16 14
3600 – 228 101 51 31 22 18 – 132 63 33 22 17 15
3800 – – 112 56 33 24 20 – – 69 36 24 18 16
4000 – – 123 61 36 26 21 – – 76 39 25 19 17
4400 – – 146 72 41 29 23 – – 90 46 29 21 19
4800 – – 172 84 47 32 25 – – 106 53 33 24 21
5100 – – 193 93 52 35 27 – – 118 59 36 26 22

3200 – – 113 56 33 23 19 – – 70 36 23 17 15
3400 – – 127 63 36 25 20 – – 78 39 25 18 16
3600 – – 141 69 39 27 21 – – 87 43 27 19 17
3800 – – 156 76 42 29 23 – – 96 47 29 21 18
4000 – – 172 83 46 31 24 – – 105 52 31 22 19
4400 – – 205 98 53 35 27 – – 125 61 36 25 21
4800 – – – 114 61 39 30 – – – 71 41 28 24
5100 – – – 127 67 43 32 – – – 78 45 30 25

3200 151 81 40 24 17 14 12 54 48 25 16 12 11 10
3400 170 90 44 26 18 15 13 61 54 28 17 13 11 11
3600 189 100 48 28 19 16 14 67 59 31 19 14 12 11
3800 210 111 53 30 21 17 15 74 66 34 20 15 13 12
4000 232 122 58 32 22 18 15 82 72 37 22 16 14 13
4400 279 145 68 37 25 20 17 98 86 43 25 18 15 14
4800 – 171 79 43 28 22 19 115 101 50 29 20 17 15
5100 – 192 88 47 30 23 20 129 113 56 31 22 18 16
28
10. Setting the mixing head
Burner Flame tube Perforated Diffuser Diffuser Nozzle Flame tube
type mm diffuser mm mm distances mm distances setting mm
type ø ø outer ø inner ø outer ø inner a b c d e
G1/1-E G1/2a 130 115 80 95 40 15 13 5 8 139 - 154
G3/1-E G3/1a 160 133 90 100 40 15 18 5 8 158 - 178
G5/1-D G5/1a 200 173 100 100(125)* 50(50)* 5 13 8 8 168 - 193
G7/1-D G7/1a 250 213 110 110(135)* 50(50)* 5 23 8 8 193 - 218
G8/1-D G7/2a 265 213 120 120(155)* 50(50)* 5 30 8 8 193 - 218
G9/1-D UG2/1a 325 270 130 130 70 5 33 8 10 217 - 247
G10/1-D UG2/1a 325 270 130 130 70 5 33 8 10 217 - 247
G11/1-D UG3/1a 380 315 155 155 70 5 43 8 10 274 - 304
* Diffuser special version, see spares list
Combustion head dual fuel burners sizes 1 to 3 Combustion head dual fuel burners sizes 5 to 11
Perforated diffuser
Perforated diffuser
Conical diffuser G8 to G11
Diffuser
Nozzle star
Flame tube setting
29
11. Capacity graphs
Size 1 The ratings depending on pressure in the combustion
mbar Burner type G1/1-E
chamber are limit values, which have been measured
Type of combustion head G1/2a 115-95K on idealised test flame tubes to DIN 4788, part 1 or
Rating kW, Natural Gas 60 – 335 EN 267 and DIN 4788, Part 2 or EN 676. All ratings data
Distillate oil EL 60 – 335 given relate to an air temperature of 20° C and an
6 installation elevation of 500 m.
5
4 Modulating burners
3 The modulating burner is based on the sliding two stage
2 burner. The modulating characteristic is obtained with a
1 special regulating controller, which is fitted in the control
0 panel. A servomotor with 42 seconds running time is also
-1 used.
-2
-3
The burner types shown are type tested for the following
fuels:
-4
kW 0 50 100 150 200 250 300 350 400
Natural Gas _______________________________ E and LL
Liquid Petroleum Gas ___________________________ B/P
Size 3
mbar Burner type G3/1-E Burners with speed control or electronic compound
Type of combustion head G3/2a-133-100K regulation
Rating kW, Natural Gas 90 – 630 There is no reduction in the rating when using speed
Distillate oil EL 90 – 630 control or electronic compound regulation, even when
12
combined with O2 regulation. On burners with speed
10 control and electronic compound regulation and FGR as
8 well as with or without O2 regulation a reduction f 5 %
occurs.
6
4 Burners with flue gas recirculation (FGR) and /or O2

2 regulation
If a flue gas recirculation system or O2 regulation is
0
provided, then the maximum burner capacity graphs are
-2 reduced by the following values:
-4
kW 0 200 400 600 800 1000 1200
Reduction approx. % System
5% FGR or O2 regulation
Size 5 10 % FGR with O2 regulation
mbar Burner type G5/1-D
Type of combustion head G5/1a 173-100 With flue gas recirculation it must also be noted that the
Rating kW, Natural Gas 175 – 940 combustion chamber resistance increases by the factor
Distillate oil EL 200 – 940
12
1.3. The exact value can be obtained from the planning
documents for flue gas recirculation, print No. 1025.
Destillage oil EL
10 Please also check if combustion head extensions are

8 needed with FGR (see “Special Equipment”). On burners
6
with flue gas recirculation, only sound absorbers of special
execution may be fitted.
4
2 For towns and sewage gas the maximum burner

Natural gas
0
ratings in the graphs must be reduced by 10%.
-2 Range of regulation on oil operation
-4 Dual fuel burners with spill type nozzles have a
kW 0 200 400 600 800 1000 1200 maximum turndown ratio on oil operation of approx. 3 :
1. It should be noted that the lower operating point
must lie within the capacity graph.
Combustion head “Open”

Combustion head “Closed”
(see dimension “e”, chapter 10)
30
Size 7
Type of combustion head G7/2a 213-110
Rating kW, Natural Gas 300 – 1750
16
14
12
10
8
6
4
2
0
-2
-4
kW 0 400 800 1200 1600 2000
Size 8
Type of combustion head G7/2a 213-120
16
14
12
10
8
6
4
2
0
-2
-4
kW 0 400 800 1200 1600 2000
Size 9
Type of combustion head UG2/1a 270-310
16
14
Destillage oil EL
12
10
8
6
4
Natural gas
Natural gas
2
0
-2
-4
kW 0 1000 2000 3000 4000 5000

31
Size 10
Type of combustion head UG2/1a 270-130
Rating kW, Natural Gas 500– 4100
Distillate oil EL 750– 4100
16
14
Destillage oil EL
12
10
8
6
4
Natural gas
2
Natural
0
gas
-2
-4
kW 0 1000 2000 3000 4000 5000
Size 11
Type of combustion head UG 3/1a 3215-155
26
24
22
20
18
16
14
12
10
8
6
4
2
0
-2
-4
-6
kW 0 1000 2000 3000 4000 5000 6000

32
12. Ignition electrode setting
Ignition electrode setting
G8 to G11
A minimum distance of
25 mm must be kept
between ignition and
ionisation electrodes
13. Fan wheel attachment

Burner sizes 1 and 3 Removing the fan
The fan fits onto a cylindrical shaft. Power is transmitted
via a shaft key. The fan is secured by an M8 set screw and Burner sizes 1 and 3
the shaft key. The extractor, Part No. 111 111 00 0122, can be applied
to the two M6 threaded holes and the fan removed.
Burner size 5 Burner sizes 5-8
The fan fits onto a cylindrical shaft. Power is transmitted The extractor, Part No. 111 111 00 01/2, can be applied
via a shaft key. The fan is fixed to the motor shaft by an M6 to the two M6 threaded holes and the fan removed.
x 25 screw with washer.
Burner sizes 9-11
Burner sizes 7-8 To remove the fan the extractor, Part No. 121 362 0013/2
On burner sizes 7-8 the fan fits onto a cylindrical shaft. is applied to the two M10 threaded holes.
Power is transmitted by a shaft key. The fan is fixed to the
motor shaft by an M8 countersunk screw and washer.
Burner sizes 9-11

On burner sizes 9-11 the fan fits onto a self locking cone
shaft which transmits the power from the motor. The
coupling piece is connected to the fan with two cylindrical
pins. An M10 x 40 left hand threaded screw secures the
coupling piece to the motor shaft.
Burner sizes 1 and 3 Burner size 5 Burner sizes 7 and 8 Burner sizes 9 to 11
33
14. Sequence of operation
Gas operation version ZM
Regulator Nominal load Ignition and Ratings Regulator

Sequence diagram for air “On” pre-purge fuel release regulation “Off”
Full load
Partial load
Ignition load
Terminal on LFL/LGK “Closed”
Control circuit
Time sequence diagram

for servomotor
Full load
Sequence diagram for gas
Partial load
Ignition load
“Closed”
Time sequence
diagram for ignition
and fuel release
Position indicator on burner
control
* on size 8 to 11, ** size 1 to 7

The LFL1... burner control units are designed to provide
control and supervision of multistage and modulating
burners. They are only suitable for burners with intermittent
burner operation. The fail safe burner control LGK16... is
used for burners for continuous operation.
34
14.1 Pre-requisite for burner start
– Reset control unit

– Air damper closed. The limit switch for the ‘CLOSED’
position must supply voltage from terminal 11 to
terminal 8.
– The control contacts for the ‘CLOSED’ position of fuel
valves or other contacts between terminal 12 and
“S10” with similar control functions must be closed.
– The normally closed contact of the air pressure monitor
must be closed (LP test), i.e. terminal 4 must be under
voltage.
– The contacts of the gas pressure switch “S11” and the
temperature or pressure switch “F4, F5” must also be
closed.
14.2 Symbols on the fault position indicator
In the event of a fault condition the fuel supply is always If lockout occurs at any other point between start and
interrupted immediately. Simultaneously the sequence pre-ignition, which is not marked by a symbol, there is
switch stops and thus lockout is indicated. The symbol normally a premature and thus faulty flame signal.
appearing above the reading mark indicates the kind of
fault.
➛ No start e.g. because the closed signal has not been

supplied to terminal 8 by the limit switch/auxiliary
switch or because a contact has not been closed
between terminals 12 and 4 or 4 and 5.
Controlled shut down because the open signal has

not been supplied to terminal 8 by the limit switch.
P Lockout because the air pressure signal has not been

received by the start of the air pressure check. Air
pressure failure after this point also causes the a–b Start up sequence
control to go to lockout.
b – b’ With some time variants: ‘idle steps’ of the
■ Lockout due to a fault in the flame supervision circuit. sequence switch up to the self shut down after
burner start up (b = operating position of the
❷ Controlled shutdown because the position signal for sequence switch).
the low flame position has not been supplied to
terminal 8 by the auxiliary switch. b(b’) – a Post purge sequence after controlled shut
down. In start position ‘a’ the sequence switch
1 Lockout because no flame signal has been received on switches itself off automatically or immediately
completion of the first safety time. Any flame signal initiates another burner start, e.g. after a fault
failure after completion of the first safety time also has been corrected.
causes the control to go to lockout.
● Duration of safety time with expanding flame
2 Lockout because no flame signal has been received on burners.
completion of the second safety time (flame signal of ●● Duration of safety time with interrupted pilot
the main flame with interrupted pilot burners). burners.
I Lockout because the flame signal has been lost during

operation or air pressure failure has occurred.
➛ Lockout on completion of control programme

sequence due to extraneous light (e.g. flame not
extinguished, leaking fuel valves) or due to a faulty
flame signal (e.g. aged UV tube, fault in flame
supervision circuit or similar).
35
14.3 Basic wiring diagram for burner control LFL1... / LGK 16...
LGK...
B1
F3 QRA5..
1
UV 2
L
M
5 4 3
S1
N
22 15 24 23
F4
1
F LFL/LGK
B1
br1
a b 22 23 24
I
a b
ar1 ar2 LFL...

uv QRA2
4 12 6 7 +
K1 K1 B1
S10
S11
22 23 24
M1 M1
F5
N N V
5 13 14
FR
fr1 fr3 fr2
a b
XII b a b
XIII a
XI IV
NTC XIV
b a a b
a b
AR VII
a b
ar3
S H
br2 II X VIII VI V III
b a a b a b a b a b
E M
BR M
A SM
3 21 2 16 17 18 19 20 9 11 10 8
F6
1
Y6 III I II IV
M
S3
H6 LK
T1 Y1 Y4 Y2
N N
Legend:
AR Load relay (main relay) with contacts “ar” M1 Fan or burner motor
B1 Flame sensor S Reset key
BR Lockout relay S1 Burner on
F Fuse in burner control S3 Remote reset
F3 Control fuse S10 Air pressure switch
F4 Temperature or pressure switch S11 Gas pressure switch
F5 Temperature or pressure regulator T1 Ignition transformer
F6 Temperature or pressure regulator FULL LOAD Y1 Solenoid valve ignition gas
FR Flame relay Y2 Solenoid valve
H Control lamp Lockout Y4 Solenoid valve
H6 Remote indication for lockout Y6 Servomotor
K1 Motor contactor
LK Air damper
36
LFL1... / LGK16
Control outputs
of contacts:
Positions of lockout indicator
Legend for diagram of sequence switch

t1 Pre purge time t10 Interval to start of air pressure control
t2 Safety time t11 Run time of air damper (Open)
t3 Pre-ignition time t12 Run time of air damper (min.)
t4 Interval between voltage on terminals 18 and 19 t13 Permissible after burn time
t5 Interval between voltage on terminals 19 and 20 t16 Interval up to OPEN command for air damper
t6 Post purge time t20 Interval up to self shut down of the sequence switch
t7 Interval to voltage on terminal 7 (not on all controls)
t8 Duration of start up sequence
t9 Second safety time * * Programme for interrupted pilot burners.
14.4 Switching times

Switching times in seconds * in start up sequence
The figures in brackets apply to burners with interrupted pilot.
LFL 1.122 LFL 1.322 LFL 1.622
LGK 1.122 LGK 1.322 LGK 1.622
t7 Start delay for burner motor 2 2 2

t16 Interval from start up to OPEN command of air damper 4 4 4
t11 Run time of air damper in OPEN position optional optional optional
t10 Interval from start up to comm. of air pressure check 6 8 8
t1 Pre-purge time with air damper open 10 36 66
t12 Run time of air damper to ignition position optional optional optional
t3 Pre-ignition period 4 4 4
t2 First safety period 2 2 2
t4 Interval between start of t2 and release
of valve at terminal 19 6 10 10
–(t9) Second safety period – (2) – (2) – (2)
t5 Interval between end of t4 and release of load
controller or valve at terminal 20 4 10 10
– Duration of start up (without t11 and t12) 30 60 96
t6 Post purge time 10 12 12
t13 Permissible after burn time 10 12 12
* Valid for frequency 50 Hz. For 60 Hz frequency switching times are reduced by approx. 20%.
37
14.5 Sensor line between LGK16... and QRA53 / QPA 55 or sensor electrode
Installation of sensor line Test possibilities of the detector cable

● The connections between burner control terminal 23, Due to the capacitance of the detector cable connected to
and UV cell terminal 3, as well as burner control terminal terminal 15 and 23 of the LGK burner control a voltage
15 and UV cell terminal 4, have to be fitted as separate reduction in the sensor circuit occurs due to the
single core coaxial cables with a capacitance of max capacitance loading. To obtain a reading, the voltage can
45pF/m. The coaxial cable used can be of types RG-62 be measured at the connection terminals 22 and 23
A/U or RG-71 B/U. The screening of these coaxial without detector cable connected and subsequently with
cables must be earthed on both cable ends. detector cable connected, providing the line length is
within the stipulated limits. The voltage difference must not
● For the connection between the burner control terminals be higher than 22 VAC. A higher voltage reduction
1, 2, 22 and the matching terminals of the UV cell indicates the danger of unsafe monitoring.
terminals 1, 2 and 5 a normal three core, 1.5mm2 PVC
cable can be used. The line length is unlimited. Sensor line LGK 16 with ionistion monitoring
When fitting a sensor line for ionisation monitoring,
● The coaxial cable and the three core cable may be fitted attention has to be paid to a low capacitance installation.
in the same cable duct as other mains voltage lines The coaxial cable RG-62 A/U or RG-71 B/U as well as the
(control lines and motor lines). much cheaper ignition cable -w- order No. 743 200, are
suitable as a sensor line. Because of the installation of the
low capacitance detector cable to terminal 24 of the
● Maximum line length for the coaxial cable is 60m. The control (especially compared to earthed cable) the normal
connection to the burner terminal rail and the control max. detector cable length of 60 m can be exceeded.
panel terminal rail must be carried out according to the
wiring diagram. It is important that terminal 22 on the
LGK terminal sub-base is earthed.
Wiring diagram
Burner
Burner control Terminal in

control panel Burner connection
LGK... terminal
Terminal
socket
1 Mains cable 3 x 1.5 mm2 1

1 1
2 2
2 2
5 5
22 5
QRA5...
3 3
23 3
4 4
15 4
Cable
Single core coaxial cable
AGM 1
Screening
max. 60 m
38
14.6 Technical data
UV supervision with LFL1 ...

Mains voltage ____________220 V - 15%… 240 V + 10% Supply voltage _______________ operation 330 V ± 10%
Frequency__________________50 Hz - 6%… 60 Hz + 6% test 380 V ± 10%
Consumption ________________________________3,5 VA Min. required sensor current ____________________70 µA
Fuse (inbuilt) ________________M6, 3/250 E semi time lag Max. sensor current _____ operation 630 µA, test 1300 µA
according to DIN41571, sheet 2).
External fuse ______________________________max. 10 A Max. permissible cable length to detector on LFL1 ...
Permissible input current at terminal 1 ____5 A continuous, – normal cable, wired separately ________________100 m
peaks of up to 20A
Permissible load _________________________sup to 20A
of control terminal_______________________total max. 5A
Required switching capacity of switching devices
– between terminals 4 and 5 ______________________1 A
– between terminals 4 and 12 _____________________1 A
– between terminals 4 and 14 1A cont., peaks of up to 20A
Mounting position ___________________________optional
Protection standard ___________________________IP 40
Permissible ambient temperature __-20… + 60°C at 220 V
UV supervision with LGK 16 ...

UV Ionisation
Supply voltage __280V ~ ± 10 % (without sensor current) ___________________________________245 V ~ ± 10%
Max. permitted length see ____________________________________________60 m

Of sensor line (wired separately) ___________chapter 20.5
39
15. Cam setting of limit and auxiliary switches
15.1 Gas burner, two stage (servomotor 1055/80)
Description The diagram is also shown on the servomotor cover.
By disengaging the cam from the drive wheel, the cam can
be moved to check the correct actuation of the limit and Switch for burner adjustment
auxiliary switches by the switch cams. The cam is brought This switch offers the facility of stopping the servomotor
into the basic position (scale position 0°) and then slowly electric operation.
turned clockwise to the right (when viewed from the
direction, servomotor to cam). Switch III must be actuated Therefore, by also disengaging the drive mechanically, the
by the third cam to supply the auxiliary winding ‘open’. After regulating cam can be placed at any position between
some rotational movement, limit switch IV is no longer partial and full load.
actuated by the fourth cam.
After the setting work is complete, the drive mechanism
The switch points of the limit switches ‘open’ and ‘closed’ should be re-engaged and the switch reset to the normal
are set on delivery to a total angle of rotation of 90°. operating position.
Limit switch adjustment

Via an indicator on the drive axis the position of the air
damper is shown on a scale 0° - 90°.
Between the switch and setting cams there is an

adjustment scale. The adjustment of the cam switch is
shown on this scale by a small indicator and gives the
switching point of the appropriate switch in relation to the
actual air damper position. The limit switch and cam
switches are marked on all wiring diagrams with I, II, III, IV,
V and have the function as shown in the connection
diagram.
Servomotor type 1055/80 with inbuilt cam switches I - VI Connection diagram
Bottom of housing
Servomotor
Switch position
Switch indicator
90
identification
Gear wheel (may be 18 0
Control uncoupled for manual
17
cam aid adjustment)
16
Air damper 15
position indicator Control cams: 14 VI
auxiliary switch VI 13
Socket pin (must 12
be removed Auxiliary switch V, V
11
schwarz - black - noir
when changing ignition load
printed circuit 10
board) Auxiliary switch II, 9 II
grün -green - vert
partial load 8
7
Fixing for air I M
grau - grey - gris
6 1
black
damper shaft Auxiliary switch I

5
green
4 III
Terminal rail Limit switch III,
full load 3
grey
Printed circuit 2
IV
board cover Limit switch IV, Closed 1
I – free
II – partial load ~ 50°
III – open 90°
IV – closed 0°
V – ignition load ~ 10°
VI – free
The switch settings must be reset

when commissioning to the
requirements of the installation.
40
15.2 Gas burner, sliding two stage and modulating (servomotor SQM)
Description The outer scale on the end of the cam shaft serves as a
The limit and auxiliary switches are set manually on the position indicator. With the lever fitted on the gearbox the
adjustable cams. The cams have a small pointer, which cam switches can be disengaged from the drive. This
indicates the appropriate switching point on a scale makes it possible, manually, to turn the cam to any position
between the cams. required. When the lever is in the vertical position the drive
is engaged.
The servomotors are supplied with the following standard
switch settings:
I – Open 120°
II – Closed 0°
III – free
IV – Ignition load gas ~ 20°
V – free
VI – Partial load gas ~ 45°
VII – free
The switch settings must be reset when commissioning to
the requirements of the installation.
Setting limit and auxiliary switches Disengaging the servomotor
Connection diagram
21 1 11 22 2 12 23 3 13 24 4 14 25 5 15 26 6 16 27 7 11 a b c
N
M
~ I II III IV V VI VII
I - Limit switch full load

II - Limit switched closed
III* - free
IV - Auxiliary switch ignition load gas
V - free
VI - Auxiliary switch partial load gas
VII - free
41
16. Throughput determination, conversion from normal to operating conditions
To obtain a given burner heat input rate, the gas quantity With other gas pressures and gas temperatures the
must be calculated. conversion factor can be determined according to the
following formula.
Example:
Boiler nominal rating: 5000 kW Po + PG 273
Efficiency (in advance): 92% f = ––––––– · –––––––
1 013 273 + tG
Natural gas LL (calorific value) Hi = 8.83 kWh/m3
The humidity content of the gas is small and is therefore
Boiler loading = not taken into account in the table figures or conversion
factor.
5000
–––––– = 5435 kW
0.92 Average yearly air pressure at various height sectors
Gas throughput: Vn = Average geodetic Average yearly air pressure in

height of supply area mbar at an average temperature at
5435 above sea level sea level of 10°C.
–––––– = 616 m3/h
8.83 Northern Southern
Germany Germany
As the gas volume is altered considerably by pressure and mbar mbar
temperature, the gas quantity must be calculated to the
appropriate operating condition. 0 1015 1017
1… 50 1012 1014
Operating condition for above example: 51…100 1006 1008
101…150 1000 1002
mbar 151…200 994 996
201…250 988 990
Po = Barometer level 960 251…300 982 984
PG = Gas pressure* 500 301…350 976 978
351…400 970 972
Total pressure 1460 401…450 964 966
451…500 958 960
tG = Gas temperature 10°C 501…550 952 954
551…600 946 949
* Read gas pressure and gas temperature from gas meter. 601…650 941 943
651…700 935 937
701…750 929 931
See table: 960 + 500 = 1460 mbar gives the factor 1.391
1)
1 mbar = 0,750 Torr = 10,20 mm VS
In order to obtain the correct loading for the example, the 1 Torr = 1,333 mbar = 13,6 mm VS
gas throughput calculated must be divided by the factor 1 mm VS = 0,0735 Torr = 0,0981 mbar
read off.
Gas throughput in operating conditions:
Vn 616
VB = ––––––– = ––––––– 443 m3/h
f 1.391
Total pressure Po+PG Conversion factor f

in Gas temperature tG in °C
mbar1) Torr 0 5 10 15 20 25
900 675 0.888 0.872 0.857 0.842 0.828 0.813

920 690 0.908 0.892 0.876 0.861 0.846 0.832
940 705 0.928 0.911 0.895 0.880 0.865 0.850
960 720 0.948 0.931 0.915 0.899 0.884 0.868
980 735 0.967 0.950 0.933 0.917 0.901 0.886
1000 750 0.987 0.969 0.952 0.936 0.920 0.904

1020 765 1.007 0.989 0.972 0.955 0.939 0.922
1040 780 1.027 1.009 0.991 0.974 0.957 0.941
1060 795 1.046 1.027 1.009 0.992 0.975 0.958
1080 810 1.066 1.047 1.029 1.011 0.994 0.976
1100 825 1.086 1.066 1.048 1.030 1.012 0.995

1120 840 1.106 1.086 1.067 1.048 1.031 1.013
1140 855 1.125 1.105 1.086 1.067 1.049 1.031
1160 870 1.145 1.124 1.105 1.085 1.067 1.049
1180 885 1.165 1.144 1.124 1.104 1.086 1.067
42
Total pressure Po+PG Conversion factor f
in Gas temperature tG in °C
mbar1) Torr 0 5 10 15 20 25
1200 900 1.185 1.164 1.144 1.123 1.104 1.085
1220 915 1.204 1.182 1.162 1.141 1.122 1.103
1240 930 1.224 1.202 1.181 1.160 1.141 1.121
1260 945 1.244 1.222 1.200 1.179 1.159 1.140
1280 960 1.264 1.241 1.220 1.198 1.178 1.158
1300 975 1.283 1.260 1.238 1.216 1.196 1.175
1320 990 1.303 1.280 1.257 1.235 1.214 1.194
1340 1005 1.323 1.299 1.277 2.254 1.233 1.212
1360 1020 1.343 1.319 1.296 1.273 1.252 1.230
1380 1035 1.362 1.338 1.314 1.291 1.269 1.248
1400 1050 1.382 1.357 1.334 1.310 1.288 1.266
1420 1065 1.402 1.377 1.353 1.329 1.307 1.284
1440 1080 1.422 1.396 1.372 1.348 1.325 1.303
1460 1095 1.441 1.415 1.391 1.366 1.342 1.320
1480 1110 1.461 1.435 1.410 1.385 1.362 1.338
1500 1125 1.481 1.454 1.429 1.404 1.380 1.357
1520 1140 1.500 1.473 1.448 1.422 1.398 1.374
1540 1155 1.520 1.493 1.467 1.441 1.417 1.392
1560 1170 1.540 1.512 1.486 1.460 1.435 1.411
1580 1185 1.560 1.532 1.505 1.479 1.454 1.429
1600 1200 1.579 1.551 1.524 1.497 1.472 1.446
1620 1215 1.599 1.570 1.543 1.516 1.490 1.465
1640 1230 1.619 1.590 1.562 1.535 1.509 1.483
1660 1245 1.639 1.610 1.582 1.554 1.528 1.501
1680 1260 1.658 1.628 1.600 1.572 1.545 1.519
1700 1275 1.678 1.648 1.619 1.591 1.564 1.537

1720 1290 1.698 1.667 1.639 1.610 1.583 1.555
1740 1305 1.718 1.687 1.658 1.629 1.601 1.574
1760 1320 1.737 1.706 1.676 1.647 1.619 1.591
1780 1335 1.757 1.725 1.696 1.666 1.638 1.609
1800 1350 1.777 1.745 1.715 1.685 1.656 1.628
1820 1365 1.797 1.765 1.734 1.704 1.675 1.646
1840 1380 1.816 1.783 1.752 1.722 1.693 1.663
1860 1395 1.836 1.803 1.772 1.741 1.711 1.682
1880 1410 1.856 1.823 1.791 1.759 1.730 1.700
1900 1425 1.876 1.842 1.810 1.778 1.748 1.718
1920 1440 1.895 1.861 1.829 1.796 1.766 1.736
1940 1455 1.915 1.881 1.848 1.815 1.785 1.754
1960 1470 1.935 1.900 1.867 1.834 1.803 1.772
1980 1485 1.955 1.920 1.887 1.853 1.822 1.791
2000 1500 1.974 1.938 1.905 1.871 1.840 1.802
2050 1538 2.024 1.988 1.953 1.919 1.886 1.854
2100 1575 2.073 2.036 2.000 1.965 1.932 1.899
2150 1613 2.122 2.084 2.048 2.012 1.978 1.944
2200 1650 2.172 2.133 2.096 2.059 2.024 1.990
2250 1688 2.221 2.181 2.143 2.106 2.070 2.034
2300 1725 2.270 2.229 2.191 2.152 2.116 2.079
2350 1763 2.320 2.278 2.239 2.199 2.162 2.125
2400 1800 2.369 2.326 2.286 2.246 2.208 2.170
2450 1838 2.419 2.375 2.334 2.293 2.255 2.216
2500 1875 2.468 2.424 2.382 2.340 2.300 2.261
2550 1913 2.517 2.472 2.429 2.386 2.346 2.306
2600 1950 2.567 2.521 2.477 2.434 2.392 2.351
2650 1988 2.616 2.569 2.524 2.480 2.438 2.396
2700 2025 2.665 2.617 2.572 2.526 2.448 2.441
2750 2063 2.715 2.666 2.620 2.574 2.530 2.487
2800 2100 2.764 2.714 2.667 2.620 2.576 2.532
2850 2138 2.813 2.762 2.715 2.667 2.662 2.577
2900 2175 2.863 2.812 2.763 2.714 2.668 2.623
2950 2213 2.912 2.860 2.810 2.761 2.714 2.667
3000 2250 2.962 2.909 2.858 2.808 2.761 2.713
3100 2325 3.060 3.005 2.953 2.901 2.852 2.803
3200 2400 3.159 3.102 3.048 2.995 2.944 2.894
3300 2475 3.258 3.199 3.144 3.089 3.036 2.984
3400 2550 3.356 3.296 3.239 3.181 3.128 3.074
3500 2625 3.455 3.393 3.334 3.275 3.220 3.165
3600 2700 3.554 3.490 3.430 3.369 3.312 3.255
3700 2775 3.653 3.587 3.525 3.463 3.405 3.346
3800 2850 3.751 3.684 3.620 3.556 3.496 3.436
3900 2924 3.850 3.781 3.715 3.650 3.588 3.527
4000 3000 3.949 3.878 3.811 3.744 3.680 3.617
43
17. Fault conditions and procedures
If faults occur the basis requirements for correct operation When it is established that the fault is not due to external
must first be examined. conditions, the burner must be tested. Reset the burner
lockout and switch on burner, by careful observation of the
1. Check the electric supply. sequence of operations the cause can be recognised and
2. Check that the gas supply is correct and that manual remedied. When checking, a microammeter and a U tube
valves are open. manometer must be used.
3. Check that all controls e.g. thermostats, pressure

switches, water level interlocks, limit and time switches
are correctly set.
4. Ensure that the burner air or gas settings have not been
altered.
Condition Cause Remedy

General faults
Burner motor does not start No electric supply Close circuit
Fuse blown Replace
Neutral open circuit Repair
Motor faulty Replace
Control circuit open Look for contact break, switch on

or reset regulator or detector
Gas supply interrupted Open isolating valve, inform gas

isolating valve closed authority if no gas for a prolonged
period.
Burner control fault Replace

Lack of air
Burner motor starts, after full Air pressure switch faulty Replace
load pre-purge lockout occurs
Burner motor starts, lockout after Solenoid valve leaking indication Repair leak
approx. 20 secs. (only on versions on valve proving programme if
with valve proving W-DK3/01) burner control in start position
Burner motor starts, lockout Pressure switch contact Set pressure switch correctly,
after 10 secs of full load pre-purge does not switch in operating position if necessary replace
(air pressure too low)
Fan contaminated Clean
Burner motor rotation incorrect Correct rotation
Ignition failure
Burner motor starts, voltage on Ignition electrode gap too wide Adjust setting (see chapter 12)
terminal 16 of burner control,
no ignition, after a short time
lockout occurs Ignition electrodes or ignition line Remove earth connection, replace
have earth connection, insulating damaged electrodes or cables.
body fault
Ignition transformer faulty Replace ignition transformer
No flame establishment
Motor starts, ignition in order, after short Solenoid valve does not open, as Replace solenoid valve correct
time lockout occurs solenoid valve coil is faulty or cables interruption to electric supply,
interrupted. check voltage to terminal 17.
44
Condition Cause Remedy
Lockout after flame establishment
Ignition flame forms. Lockout Blocked filter Clean filtern

occurs when running at normal load
Pressure regulating control sluggish Check breather orifice
Gas meter faulty or Inform gas authority

water in lower lying lines.
Flame monitoring fault on ionisation
Burner motor starts, ignition is audible, Ionisation current fluctuates, too low Alter position of ionisation
normal flame establishment then fault electrode, correct possible high
shutdown resistance in ionisation line and
terminals (tighten terminals).
Gas/air mixture setting not correct Re-adjust (see commissioning)
Ignition spark affected, negative Ignition transformer primary

ionisation current side, change phase and neutral
Flame sensor (UV cell) UV cell dirty Clean (remove oil and
grease traces)
Illumination too weak Check combustion setting
UV cell defective Replace
Regular maintenance saves energy and protects the environment

We recommend regular maintenance of combustion Excellent combustion quality is a pre-requisite for
equipment to all plant operators. It saves fuel and environmentally friendly operation.
ensures constantly good combustion results.
45
Weishaupt products Max Weishaupt GmbH, D-88475 Schwendi
Tel. (0 73 53) 8 30, Fax (0 73 53) 8 33 58
Print No. 503 GB, July 98
and service Printed in Germany. All rights reserved
Oil, gas and dual fuel burners types W and WG/WGL

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

R, G, GL, RGL – up to 10.900 kW
These are used on all types and sizes of central heating
plant. The basic model which has proved successful over
many years is the basis for a variety of versions. These
burners have founded the outstanding reputation of
Weishaupt products.
Oil, gas and dual fuel burners types WK –

up to 17.500 kW
WK types are decidedly industrial burners.
Advantages: Built to the modular system, load dependent
variable combustion head, sliding two stage or modulating
operation, easy to service.
Weishaupt control panels, the proven complement to

Weishaupt burners
Weishaupt burners and Weishaupt control panels form
the ideal unit, a combination which has already proved
successful in hundreds of thousands of combustion
installations. The advantages: Cost saving during planning,
installation, servicing and guarantee work. The responsibility
belongs to one manufacturer.
Weishaupt Thermo Unit / Weishaupt Thermo Gas.

These Units combine the technical innovations and operating
efficiencies developed from over 1 million installations.
Weishaupt Thermo Gas and Weishaupt Thermo Unit
provide the ideals of complete heating centres for houses
and appartments.
Product and service are the complete

Weishaupt achievement
An extensive service organisation guarantees Weishaupt
customers the greatest possible reliability. In addition
our customers are looked after by heating firms who have
been working with Weishaupt for many years.

Installation and Operating Instructions Weishaupt Gas Burners Sizes 1 To 11

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Installation and Operating Instructions Weishaupt Gas Burners Sizes 1 To 11

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Installation and operating instructions 83050302 – 1/98

Weishaupt gas burners

00 85 4.2 Pressure regulator type FRS

Maintenance and service

If, during maintenance, control seal joints have to be

The determination of the pipework diameter usually gives a

Gas valve train

Pipe thread connection

Size Combustion Dimensions in mm

1 G1/2a 112 130 160 160-170 135 M8

7 G7/1a 230 250 290 298 270 M12

9-10 UG2/1a 233 325 360 330 305 M12

* The burner can only be removed with the boiler plate

Hinging the burner Transport weight

To enable installation and service work to be carried out,

Refractory Flexible insulating material

Burner plate Combustion head

Burner Extension Dimension in mm

1 100 212 120 130 170

3 100 257 140 160 200

5 100 300 180 200 240

7 100 330 220 250 290

8 200 430 220 265 305

9-10 200 433 280 325 365

11 200 480 325 380 420

Weishaupt also recommend the use of a valve proving

With 2 solenoid valves and valve proving system W-DK 3/01

Function Technical data

DMV-D/11 Max. operating pressure 500 mbar

Pressure test point Electrical connection

DMV-D 5040/11 - 5125/11 1 2 3

MVD 507/5 MV 5150/5-S

DN 3/4” with DN150 with

Gas throughput adjustment

Factory pre-set: maximum stroke

Connection of gas pressure switch to DMV

Gas pressure switch on DMV - flanged version

4.2 Pressure regulator type FRS

Outlet pressure adjustment (set value) 1. Remove cap A

Changing the spring 1. Remove cap A. Turn screw B totally anti-clockwise.

Type of spring / colour Outlet pressure range

III III III

Max. operating pressure 500 mbar Fusing fitted to

VPS 504 VPS 504 VPS 504

Pressure build-up: The internal motor pump increases the Regulator

+ 20 mbar is not reached during the test phase (max

VPS on DMV screwed VPS on DMV flanged

With cable gland PG 13.5 and connection to screw VPS 504

Test volume V test

V test max. / VPS 504 = 4 l. t F [s]

DMV-D(LE) 520/11 Rp 2 0.25 l 14 mb

DMV-D(LE) 5050/11 DN 50 0.36 l p e=

Installation dimensions S04/S04

Typ/Type/Type/Tipo T 6,3 L 250 V

(gas inlet) (Gaseingang)

pmax. = 500 mbar

test point (to the test section)

2. Test phase: If the first solenoid valve is gas-tight, it is

Pressure switch setting

Perm. ambient temperature °C – 10…+ 60

To avoid deadly accidents, the following safety

● Observe the maximum permitted gas pressure in the