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Installation and operating instructions

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 Conformity Certification Content
to ISO/IEC Guide 22 Title Page
Confirmed by: Max Weishaupt GmbH
1. General instructions 3
Address: Max Weishaupt Straße
2. Burner installation 4
D-88475 Schwendi
3. Oil supply 6
Product: Oil burner with fan
Type: RL30
4. Pump assemblies for M + S 8
RL40
RL50
5. Oil hose installation instructions
RL60
for metal hoses (oil S) 9
RL70
6. Oil preheater system 12
The products described above conform to
7. Pumps for oil EL, M and S 14
Document No.: EN 267
EN 292
8. Fan wheel attachment 15
EN 50 081-2
EN 50 082-2
9. Burner fuel system 16
EN 60 335
10. Regulating systems 18
In accordance with the guidelines
10.1 Regulating system RL30 18
10.2 Regulating system RL40 to RL70 19
89/336/EC Electromagnetic Compatibility
10.3 Regulating system RMS30 to RMS50 20
Directive
10.4 Regulating system RMS60 to RMS70 21
73/23/EC Low Voltage Directive
10.5 Oil regulator 22
98/37/EC Machinery Directive
10.6 Nozzle heads 23
these products are labelled as follows
11. Nozzle circulation 24
11.1 Nozzle circulation on
MS burners, vers. Z 24
11.2 Nozzle circulation on
RMS30 to RMS70 25

12. Capacity graphs 27

Schwendi 24.03.1999
13. Nozzle selection 30
13.1 Two and three stage burners 30
13.2 Regulating burners 32
ppa. ppa.
Dr. Lück Denkinger
14. Setting the combustion head 34

15. Setting the ignition electrodes 37

16. Air regulation, burners

two and three stage 38
The burners were type tested at an independent testing
17. Oil/air compound regulation, regulating burners40
station (TÜV Bau und Betriebstechnik, Munich) and
certified by DIN CERTCO.
18. Cam setting of limit and
auxiliary switches in the servomotor 42
Registration No.:RL30/2 5G332/99
RL40/1 5G789/97
19. Commissioning 43
RL40/2 5G584/2000
19.1 Tests prior to first commissioning 43
RL50/1 5G790/97
19.2 Adjustment 43
RL50/2 5G585/2000
RL60/2 5G587/2000
20. Sequence of operation 45
RL70/1 5G588/2000
20.1 Pre-requisite for burner start 46
RL70/2 5G589/2000
20.2 Symbols on the fault position indicator 46
20.3 Basic wiring diagram for
Comprehensive Quality Assurance is ensured by a
burner control LAL2.../LOK16... 47
certified Quality Management System to DIN ISO 9001.
20.4 Switching times 48
20.5 Technical data 49

21. Fault conditions and procedures 50

2
1. General
Safety Installation
To ensure safe burner operation, the burner has to be The installation of oil fired equipment must be carried out
installed and commissioned by qualified personnel to extensive guidelines and regulations. It is the duty of the
and all guidelines in these operating instructions have installer to familiarise himself with all regulations.
to be followed. Installation, commissioning and maintenance must be
carried out with care. Fuel oils to DIN 51 603 should be
Special attention should be paid to the relevant used.
installation and safety guidelines given (i.e. local
Codes of Practice). Wiring diagram
A wiring and connection diagram must be included with
Flame monitoring devices, limit controls, correcting every burner delivered.
elements and all other safety devices must be
commissioned, and may only be replaced by, the Maintenance and service
manufacturer or the authorised agent. The burners should be inspected at least once a year by
the supplier or their appointed agent. The combustion
Failure to comply can lead to serious injury or death quality should be checked after each service or repair.
and can cause considerable damage to the plant.
Installation conditions
Qualified personnel Material, construction and type of protection of the
Qualified personnel according to this operating burners in their standard version are designed for use
manual are persons who are familiar with the indoors. Permitted ambient temperature (when using
installation, mounting, setting and commissioning of relevantly treated oil) is - 15° C to + 40° C.
the product and which have the necessary
qualifications such as:- Electrical installation
When installing the electrical connection cables ensure
– Training, instruction or authorisation to switch that these are long enough to allow the burner and boiler
electrical circuits and electrical devices on and off, to door to be hinged open.
earth them and to mark them in accordance with the
safety standards. Control circuits, which are taken directly from one of the
supply phases, must only be connected with an earthed
Operating instructions neutral conductor.
The installation and operating instructions included with
each burner must be displayed clearly in the plant-room. On a mains supply which is not earthed the control voltage
The address of the nearest service centre must be entered must be supplied via an isolating transformer.
on the reverse of the instructions.
The pole of the transformer, which is to be used as the
Instruction of personnel neutral conductor must be earthed.
Problems are often caused by incorrect burner operation.
The operating staff should be thoroughly instructed with The control circuit phase and neutral conductors must
regard to the operation of the burner. With frequently be connected correctly.
occurring burner faults, the nearest service centre must be
notified. Ensure the correct fuse ratings are not exceeded. Earthing
and neutral conductors must conform to local regulations.

3
2. Burner installation
Installation example for standard combustion head Installation example for combustion head with extension

Size Size
30 to 50 60 and 70

The gap between combustion head and refractory must be filled with flexible
insulating material. Do not make solid.

The drawing shows a refractory for heating appliances 1 Burner flange

without cooled front. The depth of the refractory must not 2 Flange gasket
project past the front edge of the combustion head 3 Extension
(dimension l1 or l3). Alternatively the refractory may take a 4 Refractory
conical form (≥ 60°C). 5 Flexible insulating material, do not make solid
6 Combustion head
Refractory may not be required on boilers with water
cooled fronts, depending on the boiler manufacturer's
instructions.

The mounting plate on the heat exchanger should be sized

to the dimensions given below.

Dimensions in mm

Burner Combustion head

size type l1 l2 l3 d1 d2 d3 d4 d5 d6

L30.../2-A, MS30Z/2-A
R...30/2-A M30/2 302 150 452 250 M12 285 360 290 260
L40.../1-B, MS40Z/1-B
R...40/1-B M30/2 302 300 602 250 M12 285 360 290 260

RL40/2-A M40/1 332 150 482 296 M12 325 400 330 300
RMS40/2-A M40/2 362 150 512 290 M12 325 400 330 300
R...50/1-B M40/2 362 300 662 290 M12 325 400 330 300

L50T/2-A M50/1 357 150 507 280 M16 390 480 390 360
M50/1 357 300 657 280 M16 390 480 390 360

R...50/2-A M50/2 390 150 540 350 M16 390 480 390 360
M50/2 390 300 690 350 M16 390 480 390 360

R...60/2-A M60/2 407 150 557 400 M16 435 470 440 410
M60/2 407 300 707 400 M16 435 470 440 410

R...70/1-A M70/1A 417 150 567 480 M16 500 550 520 450
R...70/2-A M70/1A 417 300 717 480 M16 500 550 520 450

4
Hinging open the burner Transport
On size 60 and 70 open closing lid on housing and To simplify installation of the burner to the appliance,
remove regulating rod. burners sizes 50 to 70 are fitted with lifting rings.
On size 30 to 50 open housing cover and remove
regulating rod. Burner type Weight kg

Electrical wiring L30Z, L30T 90

Each burner is supplied with a wiring diagram and burner MS30Z 135
connection diagram as standard. RL30 100
RMS30 140
Interlock switch
The interlock switch is arranged in such a manner that the L40Z, L40T 135
circuit is closed in the burner closed position. In the burner MS40Z 160
open position, the circuit is interrupted by the release of RL40 145
the tripping pin in the interlock switch. RMS40 165

L50T 200
RL50 210
RMS50 250

RL60, RMS60 255

RL70, RMS70 355

5
3. Oil supply
Reliable operation to a large extent depends on the oil Oil supply to burner
supply. The pipe system and sizing can be obtained from Oil supply line to the burner termination of the oil supply
out technical worksheets. pipes must allow tension free connection of the flexible oil
hoses. Both oil and electrical connections must allow the
Ring main system burner to swing open.
The use of a ring main oil system is recommended and
often essential. Pressure regulating valve in the ring main.

Note Setting for distillate oil EL

The installation dependent ring main pressure increases Ring main pressure 1 ... 1.5 bar.
the factory pre-set burner pump pressure.
Setting for oil S
Single pipe installation on request. To avoid vaporisation of water in the fuel oil, the minimum
ring main pressure, including a safety margin, must be set
Suction lift operation according to the following table. It is based on the
Suction lift operation is possible for individual burners pressure, which is measured at the burner pump inlet (ring
operating on distillate oil EL. For installation and functional main pressure).
diagrams for ring main and suction lift operation, see
technical work sheet 5... Oil temperature on Ring main pressure
burner °C up to bar
Ring main pump with oil filter
Large installations (industrial or district heating) should, if 125 2.5
at all possible, be operated without interruptions. We 130 2.7
therefore recommend the use of a duplex-pump unit, 135 3.2
which can operate with one or the other pump. Both
pumps are fitted with oil filters, so that it is possible to 140 3.8
clean one pump or it's filter during burner operation. The 145 4.4
supply quantity must be at least twice the nozzle capacity 150 5.0
of all burners connected to the ring main. Pre-requisite is
the installation of a gas / air separator or circulation tank. Note
With residual oil installations, filters, pumps and oil Isolating devices in the return flow line must be
lines must be equipped with line heating. protected from unintentional closure (e.g. ball valves
with mechanical connection or burner interlock
Strainer switch).
A strainer is fitted in the burner oil pipe work (flow), to
prevent debris, such as loosened particles from the Shut off combination into the burner
welded joints for example from reaching the solenoid Ball valves are generally only closed during prolonged
valves. The filter should be cleaned periodically, service work or shutdown periods. They are mechanically
particularly at the early stage of operation. connected and are fitted with an interlock switch. This
interlock switch prevents burner operation when the ball
Air/gas separator valves are shut.
Weishaupt air/gas separator should be fitted at the point
at which the burner is connected to the ring main system. Attention!
The air/gas separator should be fitted as close to the If the shut off combination is used to test the operation
burner as possible (see technical work sheets). It is of the end position switch, the manual lever may only
particularly important to use a separator on residual fuel oil be closed until the end position switch has responded.
installations. When installing the air/gas separators, The combination can only be shut completely when
please observe the instruction label of the unit. the burner pump has shut off. Otherwise pressure
surges and cavitation can damage the pump.
Filter
A fine mesh filter between the ring main and burner pump The installation of non return valves is not permitted
connection must be fitted. This filter prevents dirt particles on burners with return flow nozzles.
from the oil and pipework from reaching the burner.
Operating without filter can have the following Residual oil installation must have adequate heating of
consequences: the pipework.
■ Seizing of pump gearing
■ Blocking of solenoid valves and nozzle. The gas/air separators should be fitted as close as
possible to the burner. Single pipe installation on
request.

6
Line heating of oil supply pipes with tracer cable. Example of line heating
Avoid winding the tracer cable in spirals round the pipe but Insulating sleeve, pipe insulation
lay parallel along the pipe axis (see illustration). The tracer of heat resistant material
cable loading is approximately 30 Watt per metre.
Operating voltage is 220 or 380 Volt. The tracer cable is Aluminium foil
laid back and forth on the pipe (see illustration), so that
both cable ends finish in the same place. It is important Cable tie
that the cable is laid closely to the pipe in order to
guarantee good heat transfer. The cable is connected with Tracing cable
so-called cold ends. The pipe insulation must be suitable
for a temperature of more than 100° C.

Attention!
The cold ends must not be shortened.
Oil supply pipe

Example of an oil supply system for residual oil S (burner size RMS 60/70)
Burner Burner

All oil supply lines are to be fitted with line heating. The For the inlet and outlet fittings for the media pre-
isolating valves in the supply and return lines must be heater see separate oil pre-heater leaflet.
mechanically connected.

Legend
1 Storage tank with outflow heater. 11 Pump
2 Quick action shut off valve (mechanically 12 Pressure gauge 0 to 40 bar
connected) with limit switch 13 Adjustable pressure regulating valve
3 Filter (pump station)
4 Ball valve 14 Oil pre-heater (electric)
5 Compound gauge - 1 to + 5 bar 15 Oil pre-heater (media)
6 Oil ring main pump (reserve pump) 16 Oil pre-heater (media or electric)
7 Pressure gauge 0 to 10 bar 17 Thermometer 0 to 160° C
8 Non return valve 18 Adjustable pressure regulating valve (ring main)
9 Air/ as separator 19 Line heating (media)
10 Ball valve (mechanically connected) with limit 20 Line heating (electric)
switch 21 Relief valve

7
4. Pump station for residual oils M + S
Pump capacity Pump - Tech. Data
for burner Capacity at Speed Motor at
sizes 60 + 70 150 mm2/s 450 mm2/s Single pump Duplex pump
approx. kg/h l/h rpm [kW] type type

230 - 350 860 2900 1,5 SPF 10 / 38 SPZ 10 / 38

350 - 650 1740 2900 2,2 SPF 20 / 38 SPZ 20 / 38

650 – 940 2310 2900 4,0 SPF 20 / 46 SPZ 20 / 46

Pump Filter
Spindle screw pumps are used, fitted with a relief valve. High capacity filters are used, which are integrated into
This valve is set at the factory to 37 bar and protects the the pump body. On duplex units one filter is connected to
motor against overloading. This valve does not usually each pump. Frequency of cleaning depends on the
require further adjustment. The actual working pressure is amount of contamination of the fuel oil. For residual oil S
set by the pressure regulating valve in the pump station. the oil filters must be fitted with line heating.
It is recommended that the pump station is placed on an
absorption base. Setting the pressure regulating valve.
The cover nut ➄ is removed and the required pump
Technical information: pressure set with the adjusting screw.
Max supply pressure: _______________________ 5,0 bar
Max permissible vacuum: ____________________ 0,5 bar Clockwise rotation = pressure increase
Max atomising pressure: _____________________ 30 bar Anti clockwise rotation= pressure reduction
Oil supply temperature: _______________________ 90° C
Max oil-pump viscosity____________________ 450 mm2/s The setting can be checked on the pressure gauge. The
pressure gauge isolating valves must be closed after
Note for commissioning adjustments have been carried out
When commissioning it must be ensured that pump(s)
never run dry. During commissioning, the filter, pipelines Ball valves on the pump station
and pumps must be pre-filled with fuel oil and vented. The ball valves are only closed when the pumps are being
repaired. Also with duplex units the ball valves remain open
The direction of rotation of the motor should checked. on the idle pump. The fuel oil is prevented from flowing
back by the non return valve. When switching over from
one pump to the other it is only necessary to actuate the
selector switch on the control panel.

Isolating combination shut off valves on burner

connection.
The ball valves are generally only closed in cases of
prolonged service work or shutdown. They are
mechanically connected and have an interlock switch.
Burner operation is inhibited by this interlock switch when
the valves are closed.

8
Single Pump station type SPF

Dimensions for pump station SPF

SPF 10/38 20/38 20/46 40/38

d1 33.7 33.7 42.4 48.3

d2 26.9 26.9 33.7 42.4

Duplex Pump station type SPZ

Dimensions for pump station SPZ

SPZ 10/38 20/38 20/46 40/38

d1 33.7 33.7 42.4 48.3

d2 26.9 26.9 33.7 42.4

➀ = Fuel oil inlet (suction side) ➃ = Burner return (to be provided on site)
➁ = Fuel oil outlet (pressure line to burner) ➄ = Cover nut for pressure adjusting screw
➂ = Fuel oil return (pump return) ➅ = Filter heating

5. Oil hose installation instructions for metal hoses (oil S)

RMS40/RMS50 - example

Burner
size h l b1* b2 b3 DNConnection

30/40 690 80 200 8 470 20 M 30 x 1.5

50 780 80 200 8 470 25 M 38 x 1.5

* Dimension depends on the sizing and version of the shut

off combination (see worksheet print No. 745).

9
RMS60/RMS70 - example
Burner Return Supply Supply Return
size h l l1 b1* b2 b3 b4 r DN Connection

60 655 570 235 1000 130 620 170 240 16 M 26 x 1.5

70 835 570 260 1000 130 675 170 240 20 M 30 x 2

* Dimension depends on the sizing and version of the shut off

combination (see worksheet print No. 745)

l1

Oil hoses to
Oil hoses to be be
supported b4 supported

General
The oil hoses and pressure hoses used are made of
corrugated high-grade steel with a high grade woven wire
sleeve cover.

The oil hoses and pressure hoses are well suited for
residual oil operation if the following application rules are
observed. Resistance against the chemical effects and
temperature of the fuel oil is designed for long term
service.

The TRD 411, DIN 4787 standard specifies metallic hoses

for residual oil installations.

Oil and pressure hoses must be protected from external

mechanical damage.

When installing care must be taken to ensure that the

hoses are not twisted. They must not receive torsion strain
either during installation or during later movement. It is
important that both hose ends and movement lie in
one plane.
In order to ensure torsion free installation the hose should
first be only loosely fixed at one end, then moved through
the required hose movement 2 to 3 times, so that the hose
can align without distortion, and then tighten in position.
A second spanner should be used for counter holding.

Particular care must be taken to ensure that the hoses do

not foul each other or other equipment (burner, oil line or
boiler) during operation.
Specification and technical data
Adequate curve radii and minimum hose lengths must be
adhered to during installation. In most cases the hoses Oil hoses in oil supply installations (supply and return
should be supported when installed horizontally. lines)
On residual oil (S) installations, the hoses must be suitable
The hose connections can be fitted in either swivel for an operating pressure of 10 bar and an operating
direction. temperature of 160°C. Allowing for the temperature factor
for the high grade steel, the following applies for these
Example hoses.
Connect hoses without twisting. On threaded swivel
connections, a second spanner should be used for Nominal pressure ______________________ PN = 16 bar
counter holding. Test pressure __________________________ PP = 21 bar

When installing the oil hoses in the supply and return

(between pump and rigid pipe installation) the product
related technical drawings should be observed.

10
Oil hoses to DIN 4798 Part 1 pressure class A are Pressure hoses (between pump and nozzle)
supplied for distillate oil. Maximum hose length to DIN
4755 = 1.5 m. For this application the pressure hoses should be suitable
for an operating pressure of 30 bar and an operating
Heated oil hoses for residual oil operation on request, temperature of 160° C.
electric rating 80 Watt.
Under consideration of the temperature factor the
Technical data: following applies:
Nominal pressure _______________________ PN = 10 bar
Test pressure __________________________ PP = 15 bar Nominal pressure ______________________ PN = 64 bar
Operating temperature __________________ TB = 70° C Test pressure __________________________ PP = 82 bar

Oil hose connection to burner type

Oil hoses Oil hoses

DN/length mm Connection Conn. DN/length mm Connection Conn.

nipple nipple nipple nipple
Supply Return pump install. Supply Return pump install.
side side side side

L30Z/2-A 13 1000 1000 G 1/2 G 1/2 L50T/2-A 20 1000 1000 M30x1.5 G 1/2
L30T/2-A 13 1000 1000 G 1/2 G 1/2
RL30/2-A 20 1000 1000 M30x1.5 G1 RL50/1-B 25 1300 1300 M38 x 1.5 G1
RL50/2-A 25 1300 1300 M38 x 1.5 G1
RMS30/2-A 20 1300 1000 M30x1.5 G1 RMS50/1-B 25 1500 1150 M38 x 1.5 G1
MS30Z/2-A 20 1300 1000 M30x1.5 G1 RMS50/2-A 25 1500 1150 M38 x 1.5 G1

RL60/2-A 25 1300 1300 M38 x 1.5 G 1

L40Z/1-B 13 1000 1000 G 1/2 G 1/2 RMS60/2-A 16 1150 1500 M26 x 1.5 (18L) G 1/2
L40T/1-B 13 1000 1000 G 1/2 G 1/2
RL40/1-B 20 1300 1300 M30x1.5 G1 RL70/1-A 25 1300 1300 M38 x 1.5 G 1
RL40/2-A 20 1300 1300 M30x1.5 G1 RL70/2-A 25 1300 1300 M38 x 1.5 G 1
RMS70/1-A 20 1150 1500 M32 x 2 (22L) G 3/4
RMS40/1-B 20 1300 1000 M30x1.5 G1 RMS70/2-A 20 1150 1500 M32 x 2 (22L) G 3/4
RMS40/2-A 20 1300 1000 M30x1.5 G1
MS40Z/1-B 20 1300 1000 M30x1.5 G1

11
6. Oil preheater system
Caution hot! The ball valve fitted between the media and electric pre-
Hot surfaces. heater (see technical description of electrical and media
Do not touch. pre-heaters) is closed when the heating medium is
Touching an oil preheater during operation available. The valve must only be open during start up on a
DANGER can lead to serious skins burns. cold plant and remain open until the final working
temperature or pressure of the installation is reached.
For burners using medium and residual fuel oil, the oil must During this period only the electric pre-heater heats the oil
be preheated to the temperature required for atomisation. and the throughput of the burner must be adapted to the
pre-heat capacity of the electric pre-heater during the
The oil can be heated electrically or with a heating starting time of the cold plant.
medium, or by a combination of both electrical and media
pre-heater. Hot water, low pressure steam, high pressure On downward firing burners, media pre-heaters are
steam and thermal fluid can be used as heating media. rotated 90° C. The oil pre-heaters MV9 and MV10 can
only be fitted with the media outlet on top for liquid
On installations with media pre-heater and without media or below when using steam. If the burner is
electrical pre-heater, the following minimum pressures and ordered for downward firing, this is already allowed
temperatures are required for heating the residual oil S: for. If the burner is to be changed to downward firing at
a later stage, then extra brackets are required to fix the
High pressure steam over 7.5 bar media pre-heater.
Hot water from 180 - 200° C
Thermal fluid from 200 - 300° C Nozzle head heating
A heating cartridge with a capacity of 100 Watt is fitted in
These temperatures and pressures must always be the nozzle body. An electronic P type controller controls
available so that the oil can be heated to the temperature the nozzle temperature. An NTC sensor is fitted to
and viscosity required for atomisation. determine the temperature. The ROB control can be set
between temperatures of 65 and 130°C according to the
The pre-heater combination consists of a media pre-heater fuel quality.
station and an electric pre-heater station, which have to be
connected on site. The oil outlet of the media pre-heater The temperature release switch in the regulating control is
station should be connected to the oil inlet of the electric connected in series with the oil pre-heater release
pre-heater station. thermostat and only allows burner start after the selected
nozzle head temperature and minimum oil pre-heater
temperature has been reached.

Electric pre-heater fitted size 50 Electric pre-heater station

Media pre-heater station

Ball valve

12
Capacity of heated components
Burner Burner Pump Nozzle head Solenoid valve Pressure Oil regulator Valve block
type pump Watt Watt supply/return switch Watt Watt
type Watt Watt

MS30Z/2-A E7 80 100 20 20 – 20

RMS30/2-A TA3 100 100 20 20 20 –

MS40Z/1-B TA2 100 100 20 20 – 20

RMS40/1-B TA3 100 100 20 20 20 –

RMS40/2-A TA3 100 100 20 20 20 –

RMS50/1-B TA4
RMS50/2-A T2 100 100 20 20 20 –

RMS60/2-A SPF 20/38

SPZ 20/38 100 100 20 20 20 –

RMS70/1-A SPF 20/46

SPZ 20/46 100 100 20 20 20 –

RMS70/2-A SPF 20/46

SPZ 20/46 100 100 20 20 20 –

Valve block heating MS30/40 Heated nozzle head

NTC sensor

Heating cartridge

Heating cartridge

Heated pump station Pump TA, heated

Heating sleeve Heating cartridge

13
Heated oil regulator Heated pressure switch

Heating
Heating cartridge cartridge

Heated solenoid valve

Heating cartridge

7. Pumps for fuel oils EL, M and S

Pump J7 / E7 Coupling TA

6
7 8 9 10

1 4 12 2 5 3

Pump TA Coupling T
6 5

7 8 9 10

1 4 12 2 2a 3

Pump T 1 Supply connection

2 Return connection
3 5 6 1
2a Return connection oil regulator
3 Nozzle supply line
4 Pressure adjusting screw
5 Pressure gauge connection
6 Vacuum gauge connection
7 Coupling centre piece
8 Coupling element
9 Socket head screw
10 Pump coupling
11 Pressure regulating valve
12 Pressure adjusting screw
2
11 2a 4 12
14
Pumps type TA and T are suitable for installation in a two The coupling element on the pump should have an axial
pipe system. movement of 1.5 mm.

With a T pump, the pressure regulating valve is fitted Burner Pump fitted
separately. The pipe system is arranged in such a manner
L30Z/2-A J7
that the two pipe system has to be used.
L30T/2-A J7
RL30Z/2-A TA3
Adjustment
RMS30Z/2-A TA3
■ Prior to operation, the oil line on the suction side must
M30Z/2-A E7
be filled with fuel oil and the pump must be vented. If
this is omitted, seizing of the pump may occur due to L40Z/1-B J7 /TA2*
dry operation. L40T/1-B J7 /TA2*
RL40/1-B TA3
■ For testing the vacuum, the supply line pressure or the
RMS40/1-B TA3
ring main system pressure on the suction side of the
RL40/2-A TA3
pump, screw the vacuum gauge or pressure gauge into
MS40Z/1-B E7/TA2**
connection (5 or 6).
RMS40/2-A TA3
■ For pressure adjustment, remove the cap nut (4) and
L50T/2-A TA2
adjust the pump pressure as required.
RL50/1-B TA4
Clockwise rotation = pressure increase
RL50/2-A T2
Anticlockwise rotation = pressure decrease
RMS50/1-B TA4
■ The vacuum at the pump inlet must not exceed 0.4 bar. RMS50/2-A T2

■ Maximum supply pressure RL60/2-A T2

J pump _________________________________ 2,0 bar
RL70/1-A to 600 kg T2
E, TA & T pump __________________________ 5,0 bar
RL70/2-A from 600 kg T3
■ Supply temperature
Pump Pressure Vacuum
J pump _____________________________ max. 70° C
gauge gauge
E, TA & T pump ______________________ max. 90° C
J7, E7 G 1/8 G 1/2
Pump coupling
TA2, 3, 4 G 1/4 G 1/4
There is a fixed coupling fitted between fan and oil pump
T2, 3 G 1/4 G 1/4
(motor shaft). When adjusting the intermediate coupling, it
must be ensured that there is no axial tension on the pump * With throughput above 220 kg/h
drive shaft. ** With throughput above 250 kg/h

8. Fan wheel attachment

Burner size. 30 + 40 Burner size 50/1 Burner size 50/2 Burner size 60/2 Burner size 70/1, 70/2
A self-locking conical shaft transfers the power of the Burner size 60/2
motor to the fan wheel. When refitting, ensure the surface The coupling piece is connected to the fan wheel with two
is clean and undamaged. screws. For security the coupling piece is connected to
the motor shaft by a M10x40 left-hand threaded screw.
Burner size 30/2, 40/1 and 40/2
The coupling piece is fitted to the hub. The fan wheel hub Burner size 70/1 and 70/2
is connected to the motor shaft by a M8x30 screw with The coupling piece is connected to the fan wheel with two
left-hand thread. M6 screws. For additional security the coupling piece is
connected to the motor shaft by three M8 screws.
Burner size 50/1 and 50/2
The coupling piece is connected to the fan wheel with two Removing the fan wheel
pins. For security the coupling piece is connected to the The fan wheel must be removed with an extractor, order
motor shaft by a M10x40 screw with left-hand thread. number 121 362 0013/2 via the two existing tappings.

15
9. Burner fuel systems
RL30 L30Z/2-A
1 5b 4b 19 6b 1 4 4c 19 6

115 V 115 V

115 V 115 V
P M

5b 13 10 4b 20 4c

MS30Z/2-A, MS40Z/1-B L30T/2-A

1 9 2 11 19 16
1 4 4c 19 6a

115 V

115 V

3 13 18 17 20 4c

RL40/1-B, RL40/2-A RMS30/2-A, RMS40/1-B,

RL50/1-B, RL50/2-A, RL60/2-A, RL70/1-A, RMS40/2-A RMS50/1-B,
RL70/2-A RMS50/2-A
1 9 2 19 8 1 9 2 11 14 19 8

115 V 115 V

115 V 115 V
P M
P M

3 13 10 20
3 13 10 20

RMS60/2-A, RMS70/1-A
RMS70/2-A, with separate pump L40Z/1-B
1 11 9 15 12 2 19 8 1 5 4 19 6

ϑ P

115 V

115 V
ϑ P M

7 3 15 13 10 20 4

L40T/1-B
1 5 4 19 6a

4
16
Attention The shut off device in the nozzle head (nozzle shut off
The shut off devices (solenoid valves) 2 and 3, as well as valve) acts as one safety shut off device each in the supply
(4b) and (5b), are electrically connected in series. The and return. Together with the safety shut off devices (2)
solenoid coil voltage is therefore 115V with mains and (3) (solenoid valves) and the safety shut off device in
voltage of 230V AC, 50 Hz. the nozzle head, the requirements to EN 267 for two shut
off devices in both the nozzle supply and return are met.
On the shut off device (solenoid valve) (3, 4b, 5b), the
directional arrow  on the solenoid valve must point
towards the nozzle. This means that the solenoid valve in
the nozzle return is fitted against the flow direction 
(during burner operation).

1 Pump, without solenoid valve fitted 8 Shut off device (nozzle head)
2 Shut off device (solenoid valve) Type MDK 60 RL40/1-B
Coil 20 W, 115 V; 50 Hz 50W, 230V RL40/2-A
Type 321 H 2322, G 3/8 MS30-40 RL50/1-B
RL40-60 RMS30/2-A
RMS40-60 RMS40/1-B
Type 321 H 2522, G 1/2 RL70 RMS40/2-A
RMS70 RMS50/1-B

3 Solenoid valve, normally closed Type MDK 70 RL50/2-A

Coil 20 W, 115 V; 50 Hz 60W, 230V RL60/2-A
Type 121 G 2320, G 3/8 MS30-40 RMS50/2-A
RL40-60 RMS60/2-A
RMS40-60
Type 121 G 2520, G 1/2 RL70 Type MDK 80 RL70
RMS70 85W, 230V RMS70

4 Solenoid valve, normally closed 9 Filter

Coil 19V, 230V; 50 Hz
Type 121 K 2423, G 1/8 L40 10 Oil regulator

4b Solenoid valve, normally closed 11 Oil preheater

Coil 19 W, 115V
Type 121 K 2423, G 1/8 RL30 12 pressure switch 3 to 25 bar
(pre-set to 18 bar)
4c Solenoid valve, normally closed
Coil 9W, 230V; 50 Hz 13 Pressure switch 0 to 10 bar, return
Type 121 C 2323, G 1/8 L30 on EL set to 5 bar
on MS set to 7 bar
5 Solenoid valve, normally closed
Coil 20W, 230V; 50 Hz 14 Temperature switch 60° C
Type 121 K 6220, G 1/4 L40
15 Temperature sensor PT 100
5b Solenoid valve, normally closed
Coil 20W, 115V; 50 Hz 16 Nozzle head M, two stage with
Type 121 K 6220, G 1/4 RL30 shut off device fitted

6 Nozzle head EL, two stage (without 17 Solenoid valve, normally closed
shut off device fitted) L30-40Z Coil 19W, 230V; 50 Hz
Type 121 K 2423, G 1/8 MS30-40
6a Nozzle head EL, three stage (without
shut off device fitted) L30-40T 18 Solenoid valve, normally open
Coil 19W, 230V; 50 Hz
6b Nozzle head R (without shut off Type 122 K 9321, G 1/8 MS30-40
device fitted)
19 Nozzle supply
7 Solenoid valve, normally open
Coil 19W, 230V; 50 Hz 20 Nozzle return
Type 322 H 7306, G 3/8 RMS60-70

Attention!
The 20 Watt solenoid coils must not be mixed up with
19 Watt solenoid coils.

17
10. Regulating systems
10.1 Regulating system RL30 for oil EL

The regulating system has no nozzle shut off. The solenoid Operational diagram 1
valves carry out this function.

Operation
During pre-purge the oil solenoid valves (4b), (4c), (5b)
and (5c) are closed. Oil is supplied at pressure by the oil
pump to the closed valve in the nozzle supply line (5b). The
solenoid valves (4b) and (4c) and solenoid valve (5b) and
(5c) are connected electrically in series.

Operational diagram 1
After pre-purge and fuel release by the burner control, the
oil solenoid valve (4b), (4c), (5b) and (5c) are opened. The
oil flows via the nozzle supply (19) to the nozzle and
through the return (20) to the oil regulator (10). The oil
regulator is in its open position (ignition setting), and due
to the low line resistance only a small volume of oil exists at Operational diagram 2
the nozzle. The greater proportion of oil flows via the nozzle
return (20) to the oil regulator and to the pump return. The
return line oil pressure at partial load setting is approx. 10
bar.

Operational diagram 2
Full load operation is obtained by the metering slot of the
oil regulator reducing due to the rotation of the oil regulator
by the servomotor to the full load position (turning to the
right when looking onto the shaft). This restricts the oil flow
via the return line forcing a higher oil volume to exit via the
nozzle. On burner shut down the oil solenoid valves close,
and the nozzle is isolated from the oil supply.

The pressure switch (13) (set to 5 bar) supervises the

pressure in the return. If pressure rises to above 5 bar the Legend
burner locks out. 1 Oil pump
4b Solenoid valve in nozzle supply
4c Solenoid valve in return (fitted against the flow
direction)
5b Safety solenoid valve in nozzle supply
(second shut off device)
5c Solenoid valve in return (fitted against the flow
direction)
10 Oil regulator
13 Oil pressure switch (set to 5 bar)
19 Nozzle supply
20 Nozzle return

18
10.2 Regulating system RL40 to RL70 for oil EL
Operation
Operational diagram 1 Operational diagram 1

During burner shut down, all shut off devices (2), (3) and
(8) are closed. closed
closed
Oil regulator
The servomotor drives the oil regulator, and by means of a
vee-shaped metering groove it regulates the oil quantity.

Operational diagram 2
closed
During pre-purge, the shut off devices (2), (3) and (8) are
closed. The pump pressure set is present at the shut off
device (2).

Operational diagram 3
Operational diagram 2
After pre-purge and fuel release by the burner control (the
servomotor is in ignition load position) the burner type RL
closed
opens the shut off devices (2), (3) and (8) simultaneously.
Fuel oil is released for combustion.
closed
The pressure switch (13) (set to 5 bar) regulates the
pressure in the return. If the pressure increases above
the permitted level, the burner locks out. At burner
shut down the shut off devices (2), (3) and (8) close closed
simultaneously.

The switch point of this pressure switch was set prior to

burner delivery and does not need to be adjusted during
burner commissioning.
Operational diagram 3

open

open

open

Legend
1 Pump
2 Shut off device (solenoid valve)
3 Shut off device (solenoid valve)
8 Shut off device (nozzle head)
9 Filter
10 Oil regulator
13 Pressure switch 0 to 10 bar, (return)
(on EL set to 5 bar)
19 Nozzle supply
20 Nozzle return

19
10.3 Regulating system for RMS30 to RMS50

1. Off position 1. Off position RMS30 - 50

During burner shut down the shut off devices (2), (3) and
(8) are closed. The shut off device (3) (fitted against the
flow direction) simultaneously prevents an increase in
closed
pressure in the burner system resulting from heating the
oil.

closed

closed

2. Pre-purge period 2. Pre-purge period RMS30 - 50

When heat is called for the combustion air fan for
chamber pre-purge and the pump are started. Shut off
device (2), (3) and (8) are closed. The oil and air regulator
then run back to the ignition position. However, this closed
operating phase is only started when the temperature
switch (14) reaches the required oil temperature.
closed

closed

3. Start phase 3. Start phase RMS30 - 50

After pre-purge both shut off devices (2) and (3) open in
the ignition position and the oil circulation period begins.
Shut off device (8) opens after this period is complete and
releases the oil for combustion. The pressure switch (13) open
(set to 7 bar) monitors the pressure in the return. If the
pressure exceeds the set values, the burner shuts down.
At burner shut down, shut off devices (2), (3) and (8) open
close simultaneously.

Depending on the temperature at the temperature switch

(14), circulation is carried out as described in the open
sequence diagram (see chapter 11.2).

Legend
1 Pump, without solenoid valve
2 Shut off device (solenoid valve)
3 Shut off device (solenoid valve)
8 Shut off device (nozzle head)
9 Filter
10 Oil regulator
11 Oil pre-heater
13 Pressure switch 0 to 10, (return) (on MS set to 7 bar)
14 Temperature switch
19 Nozzle supply
20 Nozzle return

20
10.4 Regulating system RMS60 to RMS70

1. Off position 1. Off position RMS60/RMS70

During burner shut down the shut off devices (2), (3) and
(8) are closed. The shut off device (3) (fitted against the
flow direction) simultaneously prevents an increase in
pressure in the burner system resulting from heating the closed
oil. The shut off device (7) in the connection line is open.

closed
open closed

2. Pre-purge 2. Pre-purge period RMS60/RMS70

When heat is called for the fan for combustion chamber
pre-purge and the pump are started. Shut off device (2),
(3) and (8) are closed.
closed
After the release thermostats in the CROw controller
(fitted in the control panel) and the ROB controller have
switched over, and prior to the commencement of the pre-
purge period, preheated oil is circulated to the burner
though shut off device (7). The oil temperature is
measured by the temperature sensor PT100 in the supply closed
and when the CSRW controller switch is actuated after open closed
the temperature has been reached, pre-purge
commences. Shut off devices (2), (3) and (8) are closed
during this period.
The oil and air regulator runs back into ignition position.
Shut off devices (2) and (3) are opened, valve (7) is
closed.
During the oil circulation period the oil temperature is 3. Start phase RMS60/RMS70
measured by the temperature sensors PT100 fitted in the
return. If the temperature drops below the set value, the
above sequence is repeated. Once oil circulation is
complete (up to max. 40 secs.) the shut off device (8) in open
the nozzle head opens and releases the oil for
combustion. Once the ratings regulation has been
released, the temperature sensor PT100 in the return is
looped out and only becomes active again at a new burner
start.
open
3. Start phase open
closed
After pre-purge both shut off devices (2) and (3) open in
the ignition position, valve (7) is closed. Shut off device
(8) in the nozzle head opens after the oil circulation period
(up to max. 40 secs.) is complete and releases the oil for
combustion. The pressure switch (12) (set to 18 bar)
monitors the minimum atomising pressure. If the pressure
falls below the set values, i.e. due to wear and tear of
pump, the burner shuts down. The pressure switch (13) Legend
(set to 7 bar) monitors the pressure in the return. The
burner shuts down If the pressure exceeds 7 bar. 2 Shut off device (solenoid valve)
3 Shut off device (solenoid valve)
At burner shut down, shut off devices (2), (3) and (8) 7 Shut off device, (solenoid valve) normally open
close simultaneously and shut off device (7) opens. 8 Shut off device (nozzle head) type MDK 60,
type MDK 70, type MDK 80
9 Filter
10 Oil regulator
12 Pressure switch 3 to 25 bar, (supply) (set to 18 bar)
13 Pressure switch 0 to 10 bar, (return) (on MS set to
7 bar)
15 Temperature switch PT 100
19 Nozzle supply
20 Nozzle return

21
10.5 Oil regulator

The oil regulator is set according to oil throughput Oil regulator

required in order to ensure optimum regulation. Each
regulator has two regulating grooves, which can be
changed over. Each regulator has two code numbers
embossed on the shaft, for example 5 + 6 (see Primary setting
illustration). Code number
Oil regulating cam
Oil regulator Usage
code oil throughput kg/h

1 70… 120
2 121… 280

3 281… 380
4 381… 420

5 421… 700
6 701… 1000

The oil regulating groove selected can be seen from

above in the primary setting cam 1.

Cam
identification Primary setting
regulating cam
cam 1
corresponds to
0° on
servomotor

Adjusting spring

22
10.6 Nozzle heads
Nozzle head RL30 Nozzle head size 50 to 70, type MDK 70/MDK 80

21 22 20 23 24 25
19 26


Reg.-Nr.

20 24 25

19

19 Nozzle supply When changing the solenoid valve the seal cap (21) must
20 Nozzle return be unscrewed.
21 Seal cap
22 Solenoid coil
23 Closing needle
24 Swirl plate
25 Nozzle plate
26 Regulating nozzle

23
11. Nozzle circulation
11.1 Nozzle circulation MS burners, version Z

Nozzle circulation on two stage MS burners

In standby mode, the oil in the oil line system is heated by Nozzle 1
the oil preheater (9) and the heating cartridge (13) in the
nozzle head to the value set in the ROB. The heated oil
passes through the supply pipe, nozzle head and normally
open solenoid valve (3) stage 1 via the solenoid valve (6),
which has been fitted against the flow direction, to the oil
Nozzle 2
pump return line. The whole burner oil system is now filled
with warm oil. During this period the shut off device in the
nozzle head remains closed, and no oil can exit via the
nozzle. 5 6

Once minimum temperature has been detected by the

switch contact in the ROB controller and in the oil
preheater, burner start is released. The two switch
contacts are switched in series. The oil pump circulates
the through the filter and solenoid valve to the oil
preheater. The oil is heated to the required atomising
viscosity.

A heating cartridge also heats several other parts of the

burner (see chapter 6).

After the pre-circulation phase solenoid valve (3) in the 1 Pump without solenoid valve fitted
nozzle return line is energised and closes. Oil pressure in
the return line to the nozzle head increases, and once it 2 Solenoid valve type 121K2423 coil 19 Watt
has reached 10 to 12 bar, the nozzle shut off opens for the (normally closed) G 1/8
start of stage 1.
3 Solenoid valve type 122K9321 coil 19 Watt
A limit switch in the servomotor opens the solenoid valve (normally open) G 1/8
for stage 2.
5 Solenoid valve type 321H2322 coil 20 Watt
The nozzle shut off is opened by the oil pressure and (normally closed) G 3/8
opens stage 2. A tight seal ensures drip free shut off for
nozzles 1 and 2 during burner shut down. 6 Solenoid valve type 121G2320 coil 20 Watt
(normally closed) G 3/8
Nozzle head heating
The heater is fitted integral within the nozzle head and is 7 Nozzle head as shut off device
temperature isolated externally. The heating cartridge has
a capacity of 100 Watt and the assembly is temperature 8 Filter
regulated by an electronic P controller. The temperature
sensor is fitted adjacent to the oil inlet connection. The 9 Oil preheater
ROB controller can be set for temperature release
between 65° C and 130° C dependent on oil quality. 10 Pressure switch 0 - 10 bar (on EL set to 5 bar,
on MS to 7 bar)
When the burner switches off, solenoid valve (3) becomes 11 Temperature switch
de-energised and opens. The oil pressure in the nozzle
head drops immediately and the nozzle shut off device 12 Heat insulation
closes.
13 Heating cartridge Solenoid valve (6) in
Nozzle head maintenance and cleaning return fitted against
Both nozzles can be exchanged without affecting the 14 Nozzle shut off device the flow direction
function of the hydraulic nozzle shut offs.
If nozzle shut off (14) is removed, the shut off devices in
the flow and return must be isolated.

Oil pressure switch

Please refer to manufacturers operating manual.

24
11.2 Nozzle circulation on burner types RMS30 to RMS 50

Nozzle head heating

As with two stage burners, regulating burners for residual
oils are also fitted with temperature controlled nozzle head
heating. This enables the nozzle head to be kept at a
constant temperature. The heating cartridge, whose
thermal output is controlled by the ROB regulating control,
has a capacity of 100 Watts. The ROB control can be set
between temperature control points of 65°C and 130°C.

An NTC sensor is fitted on the heating cartridge support to

measure the temperature.

The temperature release switch in the regulating control is

connected in series with the oil pre-heater release
thermostat and only allows burner start after the selected
nozzle head temperature and minimum oil pre-heater
temperature has been reached.

Cold start with two purge times

Pre-purge
120°

100°
Servomotor [ <) ° ]

80°

60°
Second purge time

40°
First purge time Post heat time
Safety valves Safety valve
20° open closed
Safety valves Burner start
open
0°
Time [s]
40 22,5 30 35 40 5
Start up time approx. 175 secs.

Start in warm condition with oil line temperature in supply > 60°C

Pre-purge
120°

100°
Servomotor [ <) ° ]

80°

60°
Short purge
40°

20°
Burner start

0°
Time [s]
40 22,5 30 5
Start up time approx. 100 secs.

25
Additional start circuits with two purge times approx. 55 to 60°C. If the oil line temperature is more than
Operation: this figure before the boiler regulator switches on, then
After pre-purge has taken place and the ignition position only the short purge time of 5 secs. is used for the
has been reached, the safety valves are opened for 35 subsequent burner start.
secs to enable the burner fuel system components to be
heated. The safety solenoid valves are then closed for The circuit is so designed that there is a ballast effect as
approx. 40 secs. The oil pre-heater will regain heat and far as the switching condition of the thermostat is
can give the maximum temperature after the 40 secs. have concerned. This means that during an existing start up
elapsed. process, any thermostat response will not produce an
After this period, the safety solenoid valves are re-opened alteration in the sequence of operations already started, so
and at the same time a return signal is given to the burner that a cold start or a warm start always clearly takes place
control to continue the start up sequence. An interval of 6 once commenced.
secs., determined by the burner control, produces a
second purge time up to the oil release and the If, depending on oil temperature, a warm start is required,
temperature peak of the oil heater is utilised for the then the start up time of the burner is shortened by up to
moment of ignition. 75 secs. due to the omission of the recirculation tome of
max. 35 secs. and the after-heat time of 40 secs.
So that the cold start process does not take place when
re-starting from a warm condition, or after a short shut The circulation return is always connected into the pump
down period, a thermostat, fitted in the burner fuel line return line.
system between oil pre-heater outlet and distribution
piece, determines whether a cold or warm start with short
purge period is required. The thermostat switching point is

26
12. Capacity graphs
The ratings depending on pressure in the combustion Size 30/2-A
chamber are limit values, which have been measured mbar Burner type RL30/2-A RMS30/2-A
on idealised test flame tubes to DIN 4787, part 1 or EN Type of comb. head M30/2 - 190k x 65 M30/2 - 190k x 65
267. All ratings data given relate to an air temperature Rating kW, 475 - 2440 675 - 2440
kg/h Dist. oil EL40 - 205 –
of 20° C and an installation elevation of 500 m. Res. oil S – 60 - 217
22
The oil throughput information refers to calorific 20
values of 11.91 kWh/kg for distillate oil EL and 11.24 18
kWh/kg for residual oil S. 16
14
12
Modulating burners 10
The modulating burner is based on the sliding two stage 8
burner. The modulating regulating characteristics are 6

Distillate oil EL
4
achieved with a special regulator, which is built into the

Residual
2
control panel. The servomotor with 42 seconds run time is

oil S
0
used. -2
[kW] 0 400 800 1200 1600 2000 2400

Burners with speed control or electronic compound [kg/h] EL 0 50 100 150 200
regulation
There is no reduction in the rating when using speed [kg/h] S 0 50 100 150 200

control or electronic compound regulation, even when

combined with O2 regulation. On burners with speed
control and electronic compound regulation and FGR as
well as with or without O2 regulation a reduction of 5 %
occurs.
mbar Burner type L30Z/2-A, L30T/2-A
Type of comb. head M30/2 - 190k x 65
Rating kW, 475 - 2440
kg/h Dist. oil EL 40 - 205

22
20
18
16
14
12
10
8
6
4
2
0
-2
[kW] 0 400 800 1200 1600 2000 2400

[kg/h] EL 0 50 100 150 200

mbar Burner type M30Z/2-A

Type of comb. head M30/2 - 190 k x 65
Rating kW, 675 - 2440
kg/h Res. oil S 60 - 217

22
20
18
16
14
12
10
8
6
4
2
0
-2
[kW] 0 400 800 1200 1600 2000 2400

[kg/h] S 0 50 100 150 200

27
 Size 40/1-B
mbar Burner type L40Z/1-B mbar Burner type L40T/1-B
Type of comb. head M30/2 - 200 x 50 M30/2 - 175 x 50 Type of comb. head M30/2 - 200 x 50 M30/2 - 175 x 50
Rating kW, 655 - 2560 895 - 2980 Rating kW, 655 - 2560 955 - 3215
kg/h Dist. oil EL 55 - 215 75 - 250 kg/h Dist. oil EL 55 - 215 80 - 270
22 22
20 20
18 18
16 16
14 14
12 12
10 10
8 8
6 6
4 4
2 2
0 0
-2 -2
[kW] 0 1000 2000 3000 4000 [kW] 0 1000 2000 3000 4000

[kg/h] EL 0 50 100 150 200 250 300 [kg/h] EL 0 50 100 150 200 250 300

mbar Burner type RL40/1-B RMS40/1-B mbar Burner type MS40Z/1-B

Type of comb. head M30/2 - 190k x 65 M30/2 - 190k x 65 Type of comb. head M30/2 - 200 x 50 M30/2 - 175 x 50
Rating kW, 475 - 2920 785 - 2920 Rating kW, 1010 - 2560 1010 - 2980
kg/h Dist. oil EL 40 - 245 - kg/h Res. oil S 90 - 228 90 - 265
Res. oil S - 70 - 260
22 22
20 20
18 18
16 16
14 14
12 12
10 10
8 8
6 6
Distillate oil EL

Residual oil S

4 4
2 2
0 0
-2 -2
[kW] 0 500 1000 1500 2000 2500 3000 3500 [kW] 0 500 1000 1500 2000 2500 3000 3500

[kg/h] EL 0 50 100 150 200 250 300 [kg/h] S 0 50 100 150 200 250 300

[kg/h] S 0 50 100 150 200 250 300

Size 40/2-A
Burner type RL40/2-A mbar Burner type RMS40/2-A
Type of comb. head M40/1 - 217k x 35 Type of comb. head M40/2 - 217k x 75
Rating kW, 775 - 3575 Rating kW, 1010 - 3690
kg/h Dist. oil EL 65 - 300 kg/h Res. oil S 90 - 328

22 22
20 20
18 18
16 16
14 14
12 12
10 10
8 8
6 6
4
Distillate oil

4
Distillate

2 2
oil EL

0 0
EL

-2 -2
[kW] 0 1000 2000 3000 4000 [kW] 0 1000 2000 3000 4000

[kg/h] EL 0 50 100 150 200 250 300 [kg/h] S 0 50 100 150 200 250 300 350

28
 Size 50/2-A mbar Burner type RL50/2-A RMS50/2-A
Type of comb. head M50/2-290-185 M50/2-290-185
mbar Burner type L50T/2-A Rating kW, 1130-6170 1460-6170
Type of comb. head M50/1-185 x 50 kg/h Dist. oil EL 95-518 -
Rating kW, 1010-4765 Res. oil S - 130-549
kg/h Dist. oil EL 85-400 22
22 20
20 18
18 16
16 14
14 12
12 10
10 8
8 6

Distillate oil EL
6 4
4

Residual
2
2

oil S
0
0 -2
-2 [kW] 0 1000 2000 3000 4000 5000 6000
[kW] 0 1000 2000 3000 4000 5000
[kg/h] EL 0 50 100 150 200 250 300 350 400 450 500 550
[kg/h] EL 0 50 100 150 200 250 300 350 400 450
[kg/h] S 0 50 100 150 200 250 300 350 400 450 500 550

Size 50/1-B Size 60/2-A

mbar Burner type RL50/1-B RMS50/1-B mbar Burner type RL60/2-A RMS60/2-A
Type of comb. head M40/2-217k x 75 M40/2-217k x 75 Type of comb. head M60/2-345-230 M60/2-345-230
Rating kW, 715-3810 1125-3810 Rating kW, 1310-7265 1800-7265
kg/h Dist. oil EL 60-320 - kg/h Dist. oil EL 110-610 -
Res. oil S - 100-339 Res. oil S - 160-646
22 22
20 20
18 18
16 16
14 14
12 12
10 10
8 8
6 6

Distillate oil EL
Distillate oil EL

Residual oil S
Residual oil S

4 4
2 2
0 0
-2 -2
[kW] 0 500 1000 1500 2000 2500 3000 3500 4000 [kW] 0 1000 2000 3000 4000 5000 6000 7000

[kg/h] EL 0 50 100 150 200 250 300 350 [kg/h] EL 0 100 200 300 400 500 600

[kg/h] S 0 50 100 150 200 250 300 350 [kg/h] S 0 100 200 300 400 500 600

Size70/1-A Size 70/2-A

mbar Burner type RL70/1-A RMS70/1-A mbar Burner type RL70/2-A RMS70/2-A
Type of comb. head M70/1a-425-290 M70/1a-425-290 Type of comb. head M70/1a-425-290 M70/1a-425-290
Rating kW, 1905-8750 2025-8750 Rating kW, 1905-10900 2025-10900
kg/h Dist. oil EL 160-735 - kg/h Dist. oil EL 160-915 -
Res. oil S - 180-778 Res. oil S - 180-970
22 22
20 20
18 18
16 16
14 14
12 12
10 10
8 8
6 6
Distillate oil EL

Distillate oil EL
Residual oil S

Residual oil S

4 4
2 2
0 0
-2 -2
[kW] 0 2000 4000 6000 8000 10000 [kW] 0 2000 4000 6000 8000 10000

[kg/h] EL 0 100 200 300 400 500 600 700 800 900 [kg/h] EL 0 100 200 300 400 500 600 700 800 900

[kg/h] S 0 100 200 300 400 500 600 700 800 900 [kg/h] S 0 100 200 300 400 500 600 700 800 900

29
13. Nozzle selection

13.1 Two and three stage burners Spray characteristic

It is recommended that solid or semi-solid nozzles be used
with a spray angle of 60° and 45° respectively. Due to the
various configurations of combustion zones encountered,
no binding information can be given.

Nozzle spray angles and patterns alter depending on the

atomising pressure. The data marked on the nozzle only Solid spray Semi solid spray
applies at a pressure of 7 bar.
Spray angle
On two stage burners the total burner capacity must be
divided between two nozzles. Usually nozzle 1 is sized to
have sufficient capacity for the basic load at approximately
2/3 of the total load. At peak demands nozzle 2 is added to
the throughput. A different nozzle ratio may be required,
depending upon the heat demand and the appliance flue
gas pressure loss.

On three stage burners the total burner capacity must be

divided between three nozzles. The load is distributed Nozzle cleaning
depending on heat requirement and construction of the Nozzle cleaning is not recommended. A new nozzle should
heat exchanger. be fitted.
The charts are compiled using distillate oil with a viscosity Atomising pressure
of 4 mm2/sec (cSt.) at 20°C. Oil EL __________________________________ 10 - 16 bar
Oil M + S _______________________________ 20 - 25 bar
Removing and replacing nozzles
When removing and replacing the nozzle, the nozzle head Nozzle make Solid spray Semi-solid spray
must be held with a suitable spanner. Before fitting nozzles
ensure that the insert is firmly seated. Monarch – PLP / PLHO

Steinen SS –

30
Nozzle selection diagrams
The diagrams are based on fuel oil to DIN 51 603.
Variations in viscosity and manufacturing tolerances result
in a throughput variation. Atomising viscosity is max.
10 mm2/s.

Because oil pressure is lost via the pre-heater and burner

fuel system, the precise oil throughput can only be
determined by weighing.

Pressure in bar
(at the nozzle)

l/h
Distillate oil γ = 0.84 [ kg/dm3] kg/h

Medium oil γ = 0.93 [ kg/dm3] kg/h

Residual oil γ = 0.97 [ kg/dm3] kg/h

Oil throughput

Pressure in bar
(at the nozzle)

l/h
Distillate oil γ = 0.84 [ kg/dm3] kg/h

Medium oil γ = 0.93 [ kg/dm3] kg/h

Residual oil γ = 0.97 [ kg/dm3] kg/h

Oil throughput

31
13.2 Regulating burners
Nozzle selection diagrams Spill type nozzles
The diagrams show the flow rate of the regulator nozzles
depending on supply pressure. They are based on fuel oil
to DIN 51 603. Variations in viscosity and manufacturing
tolerances result in throughput variations. Atomising
viscosity is max. 10 mm2/s. Because oil pressure is lost via
the pre-heater and burner fuel system, the precise oil Typ WB3/K3 Typ W
throughput can only be determined by weighing.
Nozzle return pressure spill back nozzle WB3/K3 or W
Nozzle selection for residual oil operation series 4
Details of oil throughput listed in the nozzle selection When commissioning the nozzle return pressure must be
diagrams relate to fuel oil EL. Due to the higher viscosity of measured. This must not be less than 5 bar for partial load
residual oil 5% must be deducted from the required oil for WB3/K3 and 8 bar for W series 4.
throughput. Nozzle selection can be made using this
reduced value. Care must be taken that the minimum pump The return pressure is measured at the test point of the oil
pressure does not fall below 20 bar, even at the lowest oil regulator.
regulator position.
For residual burners RMS a pump pressure between Nozzle cleaning
25 and 30 bar should be selected and on RL burners a The nozzle has to be taken apart and each part cleaned in
pump pressure between 20 and 30 bar. petrol or paraffin. The filter sieve must be replaced. If other
parts are defective or worn the nozzle must be replaced.

Burner RL30 Burners RL40/1-B, RL40/2-A, RL50/1-B

RMS30/2-A, RMS40/1-B, RMS40/2-A, RMS50/1-B
Nozzle selection diagram type WB3/K3
Regulator nozzle type WB3 to 70 kg/h Nozzle head MDK60
type K3 80 ... 230 kg/h Regulator nozzle type WS4 and WS5V
Spray angle 45°/ 50° Spray angle 50°
230 460 W 460

220 440

210 420 W 420

200 200 400

W 390
190 190
380
180 180
360 W 360
170 170
340
160 160 W 330
320
150 150
300 W 300
140 140
280
130 130 W 275

120 260
120
W 250
110 110 240

W 225
100 100 220

90 90 200 W 200

80 80
Nozzle size relating to 30 bar

180 W 180
Nozzle size relating to 30 bar

70 70
160 W 160
65 65
140 W 140
Oil throughput [kg/h]

60 60
Oil throughput [kg/h]

W 125
120
55 55 W 110
100 W 100
50 50 W 90
80 W 80
45 45 W 70
60 W 60
40 40 W 55
W 50
40 W 45
35 35 W 40

30 30 20
20 25 30 20 25 30
Supply pressure [bar] Supply pressure [bar]

Example nozzle selection, type WB3 Example nozzle selection, type WS4 or WS5V
Oil throughput required: _____________________50 kg/h Oil throughput required: ____________________160 kg/h
Nozzle size to diagram: ___________________________50 Nozzle size to diagram: _______________________W 160
Supply pressure to diagram: ___________________30 bar Supply pressure to diagram: ___________________30 bar
32
Regulator nozzle type 24 or 32 Nozzle needle classification
Swirler plate Nozzle needle
Due to the nozzle sizing it is possible that the required Nr. ø mm
burner rating with closed return may need to be corrected
by increasing the pressure. 24 W7 to 24 W12 2,8
32 W6 to 32 W7 3,8
With MS burners in addition to the density the from 32 W8 4,8
throughput resistance in the oil pre-heater must also
be allowed for. Removing and replacing nozzles
When removing and refitting the nozzle it must be counter
Example: held with a spanner.
Oil throughput required: ____________________300 kg/h
Nozzle specification Nozzle cleaning
to diagram:____________________________24 D 1.7 W9 The nozzle has to be taken apart and each part cleaned in
Supply pressure to diagram: ___________________25 bar petrol or paraffin. If available, compressed air is the most
suitable cleaning agent. Cleaning tools such as steel
Nozzle return pressure needles etc. must not be used.
The nozzle return pressure must be measured when
commissioning. In normal cases at partial load it must not
be set below 12 bar for residual oil and 10 bar for distillate
oil EL. A T piece has been fitted to the oil regulator for
measuring.
Burner RL/RMS50/60 Burner RL70, RMS70
Nozzle head MDK70 Nozzle head MDK80

1050
600

1000

950
24 D 2,3 W13

500
24 D 2,2 W12 900

24 D 2,1 W12

850
24 D 2,1 W11 32 D 3,0 W10/1
Nozzle size
Nozzle size

800
24 D 2,0 W11 400 32 D 3,0 W10

24 D 1,9 W11 750

24 D 1,9 W10 32 D 2,8 W10 700

24 D 1,8 W10
300
24 D 1,8 W9 650
32 D 2,8 W9
24 D 1,7 W9

24 D 1,6 W9 600
Closing pin ø 4,8

32 D 2,6 W9

24 D 1,5 W8
550
24 D 1,4 W7 200 32 D 2,6 W8

24 D 1,4 W6
500
24 D 1,3 W6 32 D 2,4 W8
Oil throughput [kg/h]

Oil throughput [kg/h]

24 D 1,3 W5
24 D 1,3 W4
24 D 1,2 W4
450
Closing pin ø 2,8

24 D 1,1 W3 32 D 2,4 W7
24 D 1,0 W3
100
Closing pin

24 D 0,9 W2 400
32 D 2,2 W7
24 D 0,8 W2
ø 3,8

32 D 2,2 W6 350
20 25 30 20 25 30
Supply pressure [bar] Supply pressure [bar]
33
Spray characteristic regulator nozzle Test point nozzle return pressure

Semi-solid spray Hollow spray

Nozzle type WS5 WB3/K3

WS4
W 24
W 32

14. Setting the combustion head

Size 30/2-A
Burner type a b c d e f g Combustion head type dimensions

L30Z/2-A 90 10 65 250 260 190 40 M 30/2-190 x 65

MS30Z/2-A 90 10 65 250 260 190 40

L30T/2-A 90 10 65 250 260 190 40

RL30/2-A 90 10 65 250 260 190 40

RMS30/2-A 90 10 65 250 260 190 40

L30Z, L30T, MS30

The combustion head is fixed over the complete ratings
range. The nozzle distance can be adjusted with the
movable diffuser. The diffuser distance to the front edge
of the combustion head is set to approx. 90 mm across
the whole ratings range. The integral movable sleeve can
be fixed according to burner rating. On maximum rating
the movable sleeve has to be set for lesser air throughput
to match the mixing velocity. Under "g" the max. opening
of the movable sleeve can be seen.

RL30, RMS30
The combustion head M30/2-190 k x 65 is a single plate
mixing head with a sliding sleeve. This sliding sleeve is
moved axially depending on the load requirement and
changes the opening cross section. The movement of the
sliding sleeve is compound regulated by the servomotor.
The setting dimensions must be checked prior to
commissioning.

34
Size 40/1-B and 40/2-A
L40Z, L40T, MS40 Combustion head type dimensions
The burner has a fixed mixing head. Combustion head and
diffuser are fixed in their position. The two diffuser M30/2 - 190k x 65 M30/2 - 175 x 50
diameters are determined by the oil throughput capacity M40/2 - 217k x 75 M30/2 - 200 x 50
range. This results in a reduction to the air gap in the M40/1 - 217k x 75
combustion head and thus matches the mixing velocity to
the ratings range. The combustion head allocated to the
burner is selected for the maximum oil throughput given.
Combustion head and diffuser are appropriately marked.

RL40/1-B / RMS40
The combustion head M40/2-217 x 75k is a single plate
mixing head with sliding sleeve. This sliding sleeve is
moved axially depending on the load requirement and
changes the opening cross section. The movement of the
sliding sleeve is controlled in compound by the Burner type a b c d e f
servomotor. The setting dimensions must be checked prior
to commissioning. L40Z/1-B 90 0 - 10 50 250 260 175/200

RL40/2-A MS40Z/1-B 90 0 - 10 50 250 260 175/200

The burner has a fixed mixing head. Combustion head and
diffuser are fixed in their position. The combustion head L40T/1-B 90 0 - 10 50 250 260 175/200
allocated to the burner is selected for the maximum oil
throughput given. Combustion head and diffuser are RL40/1-B 90 10 65 250 260 190
appropriately marked.
RL40/2-A 70 10 35 296 300 217

RMS40/1-B 90 10 65 250 266 190

RMS40/2-A 100 10 75 290 300 217

Size 50/1-B and 50/2-A

Combustion head type dimensions Combustion head dimensions
M50/1-185-50 M50/2-290-185

If the burner is operated in the medium to lower The construction of the combustion head for oil EL and S
throughput range, then the air annulus cross section is the same. For pressure side air regulation an external
between diffuser and combustion head can be altered. and internal sleeve is moved axially and alters the opening
cross section (see chapter 17.). This movement is
The combustion head can be adapted to the appropriate controlled in compound by the servomotor. The setting
combustion chamber requirements as follows:- Move the dimensions of the combustion head must be checked
combustion head from the basic position in the direction prior to commissioning the burner.
of the combustion chamber. The combustion head and
diffuser fixing screws need to be loosened to do this and Burner type a b c d e f g
the combustion head or diffuser can be moved
accordingly. This results in a reduction in the air gap and RL50/1-B 100 10 75 290 300 217 -
an alteration of the mixing velocity to suit the lower RL50/2-A 150 6 75 350 360 185 290
capacity range. RMS50/1-B 100 10 75 290 300 217 -
RMS50/2-A 150 6 75 350 360 185 290
The combustion head allocated to the burner is selected
for the maximum oil throughput given. Combustion head The adjustment should be carried out in such a way that
and diffuser are appropriately marked. the oil spray cone does not touch the combustion head,
diffuser or ignition electrodes.
35
Size 60/2-A
The construction of the combustion head for oil EL and S Combustion head dimensions type M60/2-345-230
is the same. For pressure side air regulation an external
and internal sleeve is moved axially and alters the opening
cross section (see chapter 17.). This movement is
controlled in compound by the servomotor. The setting
dimensions of the combustion head must be checked prior
to commissioning the burner.

Burner type a b c d e f g

RL60/2-A 180 ca. 10 70 400 410 230 345

RMS60/2-A 180 ca. 10 70 400 410 230 345

The adjustment should be carried out in such a way that

the oil spray cone does not touch the combustion head,
diffuser or ignition electrodes.

Size 70/1-A and 70/2-A

The construction of the combustion head for oil EL and S Combustion head dimensions type M70/1a-425-290
is the same. For pressure side air regulation an external
and internal sleeve is moved axially and alters the opening
cross section (see chapter 17.). This movement is
controlled in compound by the servomotor. The setting
dimensions of the combustion head must be checked prior
to commissioning the burner.

Burner type a b c d e f g

RL70/1-A 180 ca. 10 120 480 450 290 425

RL70/2-A 180 ca. 10 120 480 450 290 425
RMS70/1-A 180 ca. 10 120 480 450 290 425
RMS70/2-A 180 ca. 10 120 480 450 290 425

The adjustment should be carried out in such a way that

the oil spray cone does not touch the combustion head,
diffuser or ignition electrodes.

36
15. Ignition electrode setting
The distance of the ignition electrodes to the nozzle and
the diffuser should be checked.

The ignition electrodes must not be touched by the

atomised oil spray.
The distance of the ignition electrodes to the diffuser and
the nozzle must always be greater than the spark gap.

Setting the ignition electrodes on regulating burners

6
4…

3,5 … 4

Setting the ignition electrodes on two and three stage burners

3,5 … 4

Nozzle 2 Nozzle 1
Nozzle 3 6
4…

37
16. Air regulation, two and three stage burners
Two and three stage burner size 30 Air regulation for two and three stage burners size 30.
The air inlet cowl is fitted with 2 air dampers.

The two air dampers are connected by a rod, so that they

are operated parallel by the servomotor.
When commissioning the oil fired installation the following
adjustments are required on the mechanical part of the
regulating equipment:

■ Setting for partial load operation (operating with nozzle

I). The adjustment is carried out via cam switch II - partial
load in servomotor.
■ Setting for full load operation (operating with both
nozzles). Via cam switch III - full load in the servomotor, a
pre-setting of the air damper for full load is carried out.
■ Setting the switch point for the switching of solenoid
valve stage 2. This is carried out on cam switch I - ■ Final settings of the cam switches in the servomotor for
solenoid valve 2, in a way that the switch is no longer full load - switch III and partial load - switch II, are carried
de-pressed at approx. 2/3 of the setting range. This out once a flue gas analysis has been carried out.
avoids the flame lifting off the diffuser due to increased
air supply. On burners L30Z (two stage): Servomotor type
1055/23

On burners L30T (three stage): Servomotor type

1055/80
Servomotor type 1055/23

Bottom of housing
Motor
Switch position
Switch indicator
identification
Gear wheel (may be
Control cam uncoupled for manual
setting aid adjustment)

Air damper
position indicator Control cam: auxiliary
switch II partial load

Socket pin Auxiliary switch valve

(printed circuit full load
board securing
pin)
Limit switch Full load

Fixing for air black

damper shaft Limit switch Closed green
Printed circuit
board cover Terminal rail
grey

38
Servomotor type 1055/80

Bottom of housing
Motor Switch identification
Switch position
Switch indicator 90
identification
Gear wheel (may be 18 0
Control cam uncoupled for manual
17
setting aid adjustment)
16
Air damper Control cam: auxiliary 15
position indicator switch VI, valve 14 VI
stage 3 13
Auxiliary switch V, 12 V
Socket pin intermediate 11

schwarz - black - noir

(printed circuit load/partial load
board securing 10
Auxiliary switch II, 9 II
pin)

grün -green - vert

partial load 8
7 I M

grau - grey - gris

Fixing for air Auxiliary switch I, valve 6
damper shaft stage 2 1

black
5

green
4 III
Terminal rail Limit switch III,
full load 3

grey
Printed circuit 2
IV
board cover Limit switch IV, Closed 1

Cam setting of limit and auxiliary switches in servomotor type 1055

The air damper position is indicated on a scale 0° to 90° The limit switches and cam switches are marked in all
by a pointer on the shaft. wiring drawings with I, II, III, IV* and have the function
which is shown in the connection diagram.
There is a setting scale between the cam switches. The
setting knobs on the cam switch indicate with a small The connection diagram is also shown on the cover of the
pointer on this scale and give the switching point of the servomotor.
appropriate switch in relation to the air damper position.

The cam switches are set as follows using the setting

scale:

Cam switches

VI* – Solenoid depending on burner rating,

valve but set above V
Full load

V* – Partial depending on burner rating

load set between I and VI
for air regulation

IV – Closed 0°

III – Full load depending on burner rating

up to 90°

II – Partial load depending on burner rating

between 0° and approx. 50°

I – Solenoid depending on burner rating

valve between partial and
Intermediate intermediate at approx. 10°
load to 40°

* only used for version T

39
17. Regulating burners oil / air compound regulation
Compound regulation setting

Full load (100%)

Ignition load (from 20 - 30%)

Partial load (from 30 - 70%)
Basic setting

Air damper rod with linkage

Nozzle return

Metering slot

Oil regulator

Cam disc

Servomotor drive shaft Adjustable spring band

Air regulation
An adjustable rod connects the bearing to the
External sleeve regulating sleeve. At burner start (ignition load), the
internal sleeve 'A' runs to the closed position up to the
diffuser. There is a spring loaded absorption element
in the drive rod, which has a compensating effect.
After burner start (ignition load), the internal sleeve
starts to open to the partial load position. The
movement of the sleeve continues depending on the
load position requirement. With a reduction in cross
section and increased mixing pressure in the
combustion head, better combustion figures are
obtained. In special cases, i.e. in the smaller load
Internal sleeve range, the movement of the sleeve can be reduced by
the sleeve rod, depending on plant operating
conditions. Each burner has its own sleeve movement
and has holes for fixing the rod. The numbers 1, 2 and
3 are marked on the lever and relate to the actual size
of burner. The movement limit must not be exceeded
■ The cam segment is driven clockwise by the when adjusting the sleeve rod, or the rod will be bent.
servomotor to the full load position. The adjustable
spring band on the cam segment operates the air Regulating sleeve position
damper linkage and the regulating sleeve and opens
the damper for full air prepurge. Burner type Basic position*
■ At the end of the prepurge period, the servomotor Number on Movement
brings the oil regulator, which is on the same axis of drive lever mm
rotation as the cam disc, and the air damper to the
ignition load position. In this position the oil regulator is RL30/2-A - 40
wide open, which means that only a small quantity of RL40/1-B - 40
oil is atomised at the nozzle, the larger proportion RL40/2-A - –
flows back via the return. The air damper is closed so RMS40/1-B - 40
that the air supplied is matched to the atomised oil RMS40/2-A - 55
quantity.
■ The servomotor drives the compound mechanism in a R…50/1-B 3 35
continuous movement from partial load to full load. R…50/2-A 2 50
That means the air damper is opened and the oil R…60/2-A 1 60
regulator closes and less oil flows to the return line. R…70/1-A 2 60
■ Air quantity compound regulation: The external and R…70/2-A 2 60
internal sleeve is fixed on the sleeve device. The sleeve
movement in the combustion head is controlled by the * Maximum sleeve movement with air damper completely
servomotor via an intermediate bearing. open

40
The external and internal sleeves are closed at cam
position 3.5 to 4. This corresponds approximately to the
burner partial load position.
In the ignition load position, the push rod moves into the
spring sleeve.
Driver external and internal sleeve / movement setting External and internal sleeve position

Before hinging burner

open disconnect ball
joint

Disengage the drive Air quantity setting

41
18. Cam settings of limit and auxiliary switches in the servomotor SQM
Description Setting limit and auxiliary switches
The limit and auxiliary switches are set manually on the
adjustable cams. The cams have a small pointer, which
indicates the appropriate switching point on a scale
between the cams.

With the lever fitted on the gear box, the cam switches can
be disengaged from the drive. This makes it possible to
manually turn the cam to any position required. When the
lever is in vertical position the drive is engaged.

The servomotors are supplied with the following standard

switch settings:

RL(MS)40-70 ZMD L40-50TD

I - Full load 120° Full load 90°

II - Closed 0° Closed 0°
III - Ignition load Partial load
IV - free Ignition load
V - free MV Full load
VI - free MV Partial load
VII - Partial load free
Disengaging the drive
When commissioning the switch settings must be
reset to the requirements of the installation.

The outer scale on the end of the cam shaft serves as a

position indicator.

The connection diagram is also shown on the servomotor

cover.

The cam switches are set for the appropriate function

using the setting scale as shown in the connection
diagram.

Connection diagram

21 1 11 22 2 12 23 3 13 24 4 14 25 5 15 26 6 16 27 7 17 a b c
N

M
~
I II III IV V VI VII

42
19. Commissioning the oil part
19.1 Tests prior to initial commissioning

Before commissioning can commence, the entire plant ● Have temperature controller, pressure controller and
must check. safety limit controls been set correctly and place into the
operation position?
● Has the heat exchanger been mounted ready for ● Is load available?
operation? ● Has the low water safety interlock been set correctly?
● Are heat exchanger and system filled sufficiently with ● Have all fuel carrying pipe lines been purged of air?
heating medium? ● Is the rotation of the burner motor correct?
● Are the flue gas passages free from obstruction? ● Is sufficient fuel oil in the tank?
● Are explosion flaps operable? ● Has a soundness test of the oil system been carried out?
● Is the flue gas damper open? ● Are the oil supply pumps (if fitted) switched on?
● Are the ventilators on heat exchangers operating ● Are the oil shut off devices open?
correctly? ● Are oil supply lines and pump filled with oil?
● Is sufficient air supply ensured? ● Is the correct oil nozzle fitted?
● Have the operating instructions of the heat exchanger
been followed? Other installation specific tests may be required. See
● Has the whole installation been wired correctly? operating instructions of individual components.

19.2 Adjusting

Switch on procedure RL (RMS) burners:

Open shut off valve (shut off assemblies) in the oil supply. Set oil throughput by adjusting pump pressure (20 to
Set selector switch in the control panel to "Stage 2" or 30 bar).
"Full load". Reset installation. Set combustion values by adjusting the air curve band
Switch on burner operating switch. and positioning of the flame tube (see Ch. 16 and 17),
so that with fully opened air damper a smoke number
Ignition (only with EL) <1 and CO2> 13 Vol. - % with good
Once pre-purge is complete await flame formation. flame stability can be achieved.

If ignition problems occur: M (MS) (RM) (RMS) burners:

The smoke number of medium and heavy oil burners
L (MS) burners: depends largely on the quality of fuel oil. Therefore no
Check nozzle size of stage 1; if necessary select estimated smoke number can be given.
different nozzle. Check position of auxiliary switch II in
the servomotor, if necessary adjust to match air The pump pressure and the position of flame tube set on
requirement. full load must not be adjusted.

RL (RMS) burners: Intermediate testing ("full load to partial load")

Check position of ignition load switch on the only on regulating burners:
servomotor (No. III), if necessary increase setting. A point by point combustion check is necessary across
the whole regulating range of the burner.
Test sensor current on the microammeter.
Adjust cams manually step by step in the direction of
Full load setting ignition load (selector switch "Stop", disengage
After approx. 11 secs, the servomotor runs from ignition servomotor, adjust, re-engage).
load (partial load) to full load. (Ensure that this run up is Regulate combustion values by adjusting the air curve
carried out with excess air by first reducing the intended bands. Ensure the curve bands have an even profile.
pump pressure.) For full load the required oil throughput
must be set and measured (nozzle selection diagrams are Partial load setting
only an aid for setting and checking). Set selector switch in the control panel to "stage 1" or
"Partial load".
Carry out combustion analysis:
L (MS) burners:
L (MS) Burners: Match excess air to the oil throughput required for the
Set oil throughput by adjusting pump pressure (EL = nozzle selected for partial load with the auxiliary switch
10 - 16 bar, M/MS = 20 to 25 bar), if necessary select (No. II).
different nozzle size. Measure oil throughput, if necessary select a different
Set combustion values by adjusting the servomotor, nozzle. Set the transition switching point for the
limit switch No. III and positioning of the flame tube second nozzles with auxiliary switch No. I so that the
(see Ch. 16 and 17), so that with fully opened air excess air phase, prior to switch over is not too long,
damper a smoke number (only with EL) <1 and CO2> and the flame extinguishes, but on the other hand that
13 Vol. - % with good flame stability can be achieved. any smoke period after switch over is as short as
possible.

43
RL (RMS) burners: Documentation
Set and measure the required oil throughput for partial The following setting values for full and partial load must
load with auxiliary switch No. VII. be recorded on the report sheet or test sheet.
Oil throughput
L (MS) burners; Nozzle type
If changing the nozzle on partial or intermediate load Pump pressure
(two-/three stage burners) the full load setting has to Supply and return pressure (on RGL burners)
be re-checked and if necessary re-adjusted. For partial CO2, O2
load setting, the lower ratings limits of the capacity Smoke number
graphs, the flue gas temperature and instructions from
the boiler manufacturer have to be observed. Flue gas temperature
Fan pressure
Concluding work: Draught or pressure in the combustion chamber
Check ignition load setting when the burner has been Sensor current
commissioned: Room temperature
Atomising temperature (on MS and RMS burners)
Regulating burners: Air damper setting
If necessary correct at auxiliary switch No. III. Cam setting on curve band (on R burners)

Stage burners:
If necessary select new nozzle. Full and partial load
setting will then have to be repeated.
Setting is correct if the burner starts without start
impact.

Check and adjust operation of safety equipment (i.e. air

pressure switch, thermostat, pressure stat. etc.) whilst
installation is in operation.

44
20. Sequence of operation of burner control LAL 2 ... and LOK 16 ...
Oil burner version ZMD

Regulator Nominal load Ignition and fuel Ratings Regulator

Sequence diagram for air servomotor "On" pre-purge release regulation "Closed"
Full load I I
Switch points I - VII

Partial load
III VII VII III
Ignition load

LAL 2... / LOK 16... "Closed" II

Position indicator P 1
Control circuit 12/4/5
14
8
Time sequence diagram for 9
servomotor 10
11
20
6
Burner fan 7
Sequence for oil

Time sequence diagram for 15

ignition and fuel release 16
18
19

Oil burner version L40 - 50T

Regulator Nominal load Ignition and fuel Ratings Regulator
Sequence diagram for air servomotor "On" pre-purge release regulation "Closed"
Full load I
Switch points I - VII V
Ignition load IV
VI

Partial load III

LAL 2... / LOK 16... "Closed" II
Position indicator P 1
Control circuit 12/4/5
14
8
9
Time sequence diagram 10
for servomotor 11
20
Burner fan 6
7
Sequence for oil
Stage 3

Stage 2
Stage 1

Time sequence diagram for 15

ignition and fuel release 16
18
19

The LAL2... burner control unit is designed to provide

control and supervision of multistage and modulating
burners. They are only suitable for burners with
intermittent burner operation. The self checking burner
control LOK16... is recommended for burners for
continuous operation.

45
20.1 Pre-requisites for burner start 1 Lockout because no flame signal has been received on
completion of the first safety time. Any flame signal
- Reset control unit failure after completion of the first safety time also
- Air damper closed. The limit switch for the 'CLOSED' causes the control to go to lockout.
position must supply voltage from terminal 11 to terminal
8. | Lockout because the flame signal has been lost during
- The control contacts for the 'CLOSED' position of fuel operation or air pressure failure has occurred.
valves or other contacts between terminal 12 and "LP"
must be closed. Terminal 4 must be energised. ➛ Lockout on completion of control programme
sequence due to extraneous light or due to a faulty
flame signal.
20.2 Symbols on the lockout indicator
If lockout occurs at any other point between start and pre-
In the event of a fault condition the fuel supply is always ignition, which is not marked by a symbol, there is normally
interrupted immediately. Simultaneously the sequence a premature and thus faulty flame signal.
switch stops and thus lockout is indicated. The symbol a-b Start up sequence
appearing above the reading mark indicates the kind of b-a Post purge sequence after controlled shut down.
fault. In start position 'a' the sequence switch switches
itself off automatically.
➛No start e.g. because a contact has not been closed
between terminals 12 and 4 or 4 and 5 or because the
closed signal has not been supplied to terminal 8 by
the limit switch/auxiliary switch

▲ Controlled shut down because the open signal has

not been supplied to terminal 8.

P Lockout because the air pressure signal has not been

received by the start of the air pressure check. Air
pressure failure after this point also causes the control
to go to lockout.

■ Lockout due to a fault in the flame supervision circuit.

▼ Controlled shutdown because the position signal for
the low flame position has not been supplied to terminal
8 by the auxiliary switch.

46
20.3 Basic wiring diagram for burner control LAL 2... / LOK 16...

F 10

(3)

Legend

AR Load relay (main relay) with contacts "ar" M1 Fan or burner motor
B1 Flame sensor S Reset key
BR Lockout relay S1 Remote reset
F Fuse in burner control T1 Ignition transformer / ignition unit
F4 Temperature or pressure limit controller Y6 Servomotor
F5 Temperature or pressure controller Y11 Solenoid valve stage 1
F6 Temperature or pressure controller FULL LOAD Y12 Solenoid valve stage 2
F10 Air pressure switch * Wire link
FR Flame relay
H Control lamp Lockout Burner controls are safety devices! Do not open!
H6 Remote indication for lockout Interference can result in unforeseen consequences!
K1 Motor contactor
LK Air damper

47
 Control output
to terminal:
Burner controls are safety
Positions of lockout indicator devices! Do not open!
Interference can result in
unforeseen consequences!

Legend for diagram of sequence switch

t1 Pre purge time t6 Post purge time
t2 Safety time t7 Interval to voltage on terminal 7
t3 Pre-ignition time t8 Duration of start up sequence
t3n Post ignition time t10 Interval to start of air pressure control
t3” Pre-ignition time (long) t11 Run time of air damper (Open)
t4 Interval between voltage on terminals 18 and 19 t12 Run time of air damper (min.)
t5 Interval between voltage on terminals 19 and 20 t13 Permissible after burn time
t16 Interval up to OPEN command for air damper
t20 Interval up to self shut down of the sequence
switch (not on all controls)

20.4 Switching times

Switching times in seconds * in start up sequence LAL 2.14/ LAL 2.25/ LAL 2.65/
LOK 16.140 LOK 16.250 LOK 16.650

t7 Start delay for burner motor M1 2 2,5 2,5

t16 Interval from start up to OPEN command of air damper 4 5 5
t11 Run time of air damper in OPEN position optional optional optional
t10 Interval from start up to commencement of air pressure check 6 10 10
(if intended)
t1 Pre-purge time with air damper open 10 22,5 67,5
t12 Run time of air damper to min. position optional optional optional
t3” Pre-ignition period "long" (on terminal 15) from start from start from start
t3 Pre-ignition period "short" (on terminal 16) 2 2,5 2,5
t2 First safety period t1 4 5 5
t3n Post purge time (on terminal 15) 10 15 15
t4 Interval 8 7,5 7,5
t5 Interval between end of t4 and release of load controller
or valve at terminal 20 4 7,5 7,5
t20 Interval up to self shut down of the sequence switch
(idle steps, i.e. no change in the contact position) 32 35 12,5
- Duration of start up (without t11 and t12) 30 47,5 92,5
t6 Post purge time 10 15 15
t13 Permissible after burn time 10 15 15

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

48
20.5 Technical data Permissible ambient temperature __-20 ... + 60° C at 220V

Mains voltage _____________220V - 15% ... 240V + 10% Flame monitoring with QRB (not on LOK 16...)

Frequency _________________50 Hz - 6% ... 60 Hz + 6% Recommended illumination in Lux __________________40

Consumption _______________________________3,5 VA Average response sensitivity of the amplifier ________8 µA

Fuse (inbuilt)____________________________M6,3/250 E Max. possible sensor current __________________160 µA

(semi time lag according to DIN41571, sheet 2)
Flame failure indication during operation _ p 3 Lux at 2856 K
External fuse ______________________________max. 10A
Max. permissible length of detector cable _________20 m
Permissible input current at terminal 1 ___5 A continuous,
peaks of up to 20A Max. permissible ambient temperature ___ - 20 to + 70° C

Permissible load of control terminals _____4A continuous; Flame monitoring with RAR...
peaks up to 20A,
total max. 5A Min. required sensor current _____________________6µA
Required switching capacity of switching devices
- between terminals 4 & 5 ________________________1A Max. possible sensor current ___________________25 µA
- between terminals 4 & 12 _______________________1A
- between terminals 4 & 14 _____________5A continuous, Permitted length of connection cable - ______30 m RAR 7
peaks of up to 20A
Permitted ambient temperature __________ -20 ... + 60° C
Mounting position __________________________optional
Note:
Protection standard ___________________________IP 40 Flame detector wiring must not be bunched together with
other wiring.

Permitted ambient conditions for electrical components

Temperature Humidity Requirements re.
EMC Low voltage directive

In operation: max. 80% rel. humidity EC guideline 89/333 EEC EC guideline 73/23/EEC
-20 … +40°C EN 50081-2 EN 60335
EN 50082-2
Transport/storage:
-40 … +60°C

49
21. Fault conditions and procedures
If faults occur the basis requirements for correct operation
must first be examined.

1. Check the electric supply.

2. Ensure that an oil supply is available.
3. Check that all controls e.g. thermostats, pressure
switches, water level interlocks, limit and time switches
are set correctly.

When it is established that the fault is not due to external

conditions, the burner must be tested. Reset the burner
lockout and switch on burner, by careful observation of the
sequence of operations the cause can be recognised and
remedied. When checking, a microammeter and a U tube
manometer must be used.

Condition Cause Remedy

1. Ignition
Ignition failure Ignition electrodes shorted out Adjust

Ignition electrode gap too wide Adjust setting

Electrodes soiled Clean and adjust

Insulating body fault Replace

Ignition transformer/ ignition unit faulty Replace

Burner control faulty Replace

Ignition cable charred Replace, find cause and rectify

2. Motor
Does not start Motor defective Replace

Contactor faulty Replace

Loud mechanical noise Bearing faulty Replace

3. Pump
Supplies no oil Gearing damaged Replace

Suction valve leaking Remove and clean or replace

Suction line leaking Seal lines

Shut off valve closed Open

Filter soiled and closed up Clean

Filter leaking Replace

Capacity has decreased Replace pump

Severe mechanical noise Pump sucks air Tighten unions, vent

Vacuum in oil line too highvalves fully Clean filter, open

4. Nozzle
Uneven atomisation Nozzle loose Tighten

Drillings partially blocked Remove and clean

Worn due to extended use Replace

No oil throughput Nozzle blocked Remove and clean

Nozzle leaking Nozzle cut off faulty Replace

50
Condition Cause Remedy

5. Burner control with flame sensor

Does not respond to flame Flame sensor obscured Clean

Fault lamp on Flame failure Locate cause and reset

6. Combustion head
is contaminated with oil or Incorrect setting Correct setting dimensions
has heavy carbon deposits

Wrong combustion head Replace

Nozzle size incorrect Repalce

Combustion air quantity incorrect Readjust burner

Boiler house not adequately ventilated Boiler house ventilation must be via a
permanent opening, the cross section of
which must be at least 50% of all
chimney cross sections belonging to the
plant

7. Solenoid valve
Does not open Coil faulty Replace coil

Does not close tightly Particles on valve seat Dismantle valve, remove particle

8. Oil preheater
Burner does not start Temperature switch for burner Increase oil temperature at the oil release
not close does temperature adjusting screw of the
temperature controller

Temperature switch for Replace

oil release faulty

Temperature switch for oil Tighten

release loose

Temperature switch for oil Replace

release with incorrect temperature
range fitted

Heating element burnt out Replace preheater

Poor combustion Temperature too low Increase temperature at

temperature controller

9. Pressure switch in the return line

Burner does not start Return line pressure too high, Check return line, ring main
setting 5 bar for RL, 7 bar for pressure, shut off devices
RMS must not be increased

10. Cleaning and lubrication regulations

Depending on the degree of contamination of the combustion air, fan rotor, ignition electrodes, flame sensor and air intake
should be cleaned as required.

The moving/rotating burner parts require no lubrication.

Motor bearing damage, which is recognised and remedied quickly, prevents more extensive damage to the burner.
Development of noise in the motor bearing should be investigated immediately.

Regular maintenance saves energy and protects the environment

We recommend regular plant maintenance of all Excellent combustion quality is a pre-requisite for
combustion equipment. It saves fuel and ensures environmentally friendly operation.
constantly good combustion results.
51
Weishaupt products Max Weishaupt GmbH, D-88475 Schwendi
Tel. (0 73 53) 8 30, Fax (0 73 53) 8 33 58
Print No 83042802, october 2000

and service Printed in Germany. We reserve the right to

make changes. All rights reserved.

Weishaupt (U.K.) Ltd.

Stoke Gardens, Slough SL1 3QD
Tel. (01753) 51 23 45
Fax (01753) 51 25 85

Neachells Lane, Willenhall

West Midlands, WV13 3RG
Tel. (01902) 60 98 41
Fax (01902) 63 33 43

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

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

Oil, gas and dual fuel burners types Monarch

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

Oil, gas and dual fuel burners types WK –

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

Weishaupt control panels, the proven complement to

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

Weishaupt Thermo Unit / Weishaupt Thermo Gas.

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

Product and service are the complete

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