Page 1
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
83054802 1/2018-07
Page 2
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
1 User instructions.............................................................................................................. 8
1.1 Target group.................................................................................................................. 8
1.2 Symbols.......................................................................................................................... 8
1.3 Guarantee and Liability............................................................................................... 9
2 Safety .................................................................................................................................. 10
2.1 When gas can be smelled.......................................................................................10
2.2 Safety measures.........................................................................................................10
2.2.1 Normal operation................................................................................................ 10
2.2.2 Electrical connection......................................................................................... 10
2.2.3 Gas supply........................................................................................................... 11
2.3 Alterations to the construction of the equipment ...............................................11
2.4 Noise emission ...........................................................................................................11
2.5 Disposal .......................................................................................................................11
3 Product description ..................................................................................................... 12
3.1 Variations .....................................................................................................................12
3.2 Function........................................................................................................................12
3.2.1 Burner Control.................................................................................................... 12
3.2.2 Low gas programme.......................................................................................... 12
3.2.3 Valve proving....................................................................................................... 13
3.2.4 Load controller.................................................................................................... 14
3.2.5 Variable speed drive.......................................................................................... 14
3.2.6 O2 trim / monitoring .......................................................................................... 14
3.2.7 Program sequence............................................................................................. 15
3.2.7.1 Gas direct ignition....................................................................................... 15
3.2.7.2 Gas with ignition pilot valve ......................................................................16
3.2.7.3 Light oil direct ignition................................................................................ 18
3.2.7.4 Heavy oil direct ignition.............................................................................. 20
3.2.7.5 Heavy oil with gas pilot ignition................................................................ 22
3.3 Inputs ............................................................................................................................24
3.3.1 Voltage supply .................................................................................................... 24
3.3.2 Safety circuit........................................................................................................ 24
3.3.3 Reset..................................................................................................................... 24
3.3.4 Air pressure switch............................................................................................ 24
3.3.5 Fan contactor contact....................................................................................... 25
3.3.6 Fuel selection...................................................................................................... 25
3.3.7 Minimum oil pressure switch ........................................................................... 25
3.3.8 Max. oil pressure switch ................................................................................... 25
3.3.9 Start release Oil.................................................................................................. 26
3.3.10 Heavy oil immediate start............................................................................... 26
3.3.11 Start release Gas............................................................................................. 26
3.3.12 Valve proving gas pressure switch.............................................................. 26
3.3.13 High gas pressure switch.............................................................................. 27
3.3.14 Low gas pressure switch............................................................................... 27
3.3.15 Flame sensor .................................................................................................... 28
3.3.16 External load controller (X5-03)................................................................... 30
3.3.17 External load controller (X62)....................................................................... 31
3.3.18 External load controller (Bus)........................................................................ 31
3.3.19 Setpoint switch-over....................................................................................... 32
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.3.20 Temperature sensor........................................................................................ 33
3.3.21 Speed measurement....................................................................................... 33
3.3.22 Fuel Meter ......................................................................................................... 34
3.3.23 Flue gas temperature sensor ........................................................................ 34
3.3.24 Combustion air sensor / CO resistance circuit board............................ 34
3.3.25 O2 sensor ......................................................................................................... 35
3.4 Outputs ........................................................................................................................36
3.4.1 Alarm..................................................................................................................... 36
3.4.2 Motor..................................................................................................................... 36
3.4.3 Oil pump / magnetic coupling......................................................................... 36
3.4.4 Start signal, pressure switch relief................................................................. 37
3.4.5 Ignition .................................................................................................................. 37
3.4.6 Anti syphon valve................................................................................................ 38
3.4.7 Oil fuel valves...................................................................................................... 39
3.4.8 Fuel valves Gas .................................................................................................. 40
3.4.9 Operational display............................................................................................ 40
3.4.10 Analogue output............................................................................................... 41
3.4.11 Frequency converter ....................................................................................... 41
3.5 Technical data.............................................................................................................42
3.5.1 Electrical data ..................................................................................................... 42
3.5.2 Ambient conditions............................................................................................ 43
3.5.3 Dimensions.......................................................................................................... 44
4 Installation........................................................................................................................ 46
4.1 Installing O2 sensor ..................................................................................................46
5 Installation........................................................................................................................ 48
5.1 Electrical connection.................................................................................................48
6 Operation .......................................................................................................................... 53
6.1 Operating interface....................................................................................................53
6.1.1 Operating panel.................................................................................................. 53
6.1.2 Display .................................................................................................................. 54
6.2 Displaying and adjusting parameters ....................................................................55
6.2.1 Password ............................................................................................................. 56
6.3 Menu structure............................................................................................................57
6.4 Operation and system information.........................................................................66
6.4.1 Normal operation................................................................................................ 66
6.4.2 Fuel selection...................................................................................................... 66
6.4.3 Operating hours ................................................................................................. 67
6.4.4 Start-up counter................................................................................................. 67
6.4.5 Fuel Meter............................................................................................................ 68
6.4.6 Number of lockouts ........................................................................................... 69
6.4.7 Flame Signal........................................................................................................ 69
6.4.8 Product identification ........................................................................................ 69
6.4.9 Software version................................................................................................. 69
6.4.10 Burner identification........................................................................................ 70
6.5 Setting the display.....................................................................................................71
6.5.1 Setting the language ......................................................................................... 71
6.5.2 Set contrast......................................................................................................... 71
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6.5.3 Date/Time............................................................................................................. 72
6.5.4 Units ...................................................................................................................... 72
6.6 Interfaces .....................................................................................................................73
6.6.1 Select interfaces................................................................................................. 73
6.6.2 eBus...................................................................................................................... 74
6.6.3 Modbus................................................................................................................. 74
6.6.4 Trending data...................................................................................................... 75
6.7 Manual / Automatic / Off..........................................................................................76
6.8 Burner Control............................................................................................................77
6.8.1 Times..................................................................................................................... 77
6.8.2 Signalling start prevention................................................................................ 79
6.8.3 Normal or direct start ........................................................................................ 79
6.8.4 Oil pump............................................................................................................... 80
6.8.5 Forced intermittent............................................................................................. 80
6.8.6 Pre-purge Gas.................................................................................................... 80
6.8.7 Continuous running fan .................................................................................... 81
6.8.8 Additional air pressure switch......................................................................... 81
6.8.9 Configuring input X5-03 ..................................................................................82
6.8.10 Configuring output X4-03 ............................................................................. 83
6.8.11 Extraneous light................................................................................................ 83
6.8.12 Repetition counter........................................................................................... 83
6.9 Electronic compound................................................................................................84
6.9.1 Actuator ramps ................................................................................................... 84
6.9.2 Shutdown behaviour.......................................................................................... 84
6.9.3 Operating behaviour of frequency converter............................................... 85
6.9.4 SpecialPositions................................................................................................. 86
6.9.5 Creating load points, modulating operation................................................. 88
6.9.6 Operating and switch points, multi-stage operation.................................. 92
6.9.7 Load range........................................................................................................... 94
6.9.8 Load limit.............................................................................................................. 96
6.9.9 Start point ............................................................................................................ 96
6.10 O2 controller ............................................................................................................97
6.10.1 O2 controller operating mode ...................................................................... 98
6.10.2 O2 monitor......................................................................................................100
6.10.3 O2 trim.............................................................................................................102
6.10.4 O2 control parameters.................................................................................104
6.10.5 O2 start mode................................................................................................108
6.10.6 Type of Fuel ....................................................................................................109
6.10.7 O2 sensor .......................................................................................................110
6.10.8 Service interval for O2 sensor....................................................................110
6.10.9 Define temperature sensor..........................................................................111
6.10.10 Flue gas temperature warning threshold...............................................111
6.10.11 Combustion efficiency ...............................................................................112
6.10.12 O2 controller control variable...................................................................112
6.10.13 Status O2 controller................................................................................... 112
6.10.14 Air rating........................................................................................................112
6.10.15 Diagnostic code ..........................................................................................113
6.10.16 O2 content ...................................................................................................113
6.10.17 O2 setpoint ..................................................................................................114
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6.10.18 Combustion air temperature / CO switching threshold.....................114
6.10.19 Flue gas temperature .................................................................................114
6.10.20 O2 sensor temperature .............................................................................114
6.10.21 O2 sensor heating capacity .....................................................................115
6.10.22 O2 sensor wear and tear ..........................................................................115
6.10.23 Activate / deactivate O2 controller.........................................................115
6.11 CO monitor and CO controller ......................................................................... 116
6.11.1 Operating mode CO function.....................................................................118
6.11.2 Time delay limit value exceeded.................................................................118
6.12 Load controller ...................................................................................................... 119
6.12.1 Setpoint ...........................................................................................................119
6.12.2 Load controller operating mode.................................................................120
6.12.3 Sensor selection (actual value) ..................................................................122
6.12.4 Analogue inputs ............................................................................................. 123
6.12.5 Measuring range............................................................................................124
6.12.6 External setpoint ............................................................................................125
6.12.7 Analogue output.............................................................................................126
6.12.8 Control parameters of internal load controller ........................................128
6.12.9 Control variable calming ..............................................................................129
6.12.10 Fault signal suppression............................................................................129
6.12.11 Modulating switch differentials ................................................................130
6.12.12 Multi-stage switch differentials and switch thresholds ......................131
6.12.12.1 Multi-stage switch differentials ........................................................ 131
6.12.12.2 Multi-stage switch threshold ............................................................ 132
6.12.12.3 Low impact start.................................................................................. 132
6.12.13 Temperature sensor....................................................................................133
6.12.14 Boiler cold start function ...........................................................................134
6.12.15 Adaption........................................................................................................137
6.13 Actuators................................................................................................................ 138
6.13.1 Addressing......................................................................................................138
6.13.2 Delete curves..................................................................................................139
6.13.3 Position control ..............................................................................................139
6.14 VSD / Frequency converter................................................................................ 140
6.14.1 Frequency converter release contact .......................................................140
6.14.2 Speed measurement.....................................................................................140
6.14.3 Speed standardisation .................................................................................140
6.14.4 Actual speed...................................................................................................141
6.14.5 Setpoint output ..............................................................................................141
6.14.6 Speed deviation.............................................................................................141
6.15 Flue Gas Recirculation........................................................................................ 142
6.15.1 FGR function ..................................................................................................142
6.15.1.1 Fan on burner.......................................................................................... 142
6.15.1.2 Separate fan............................................................................................ 144
6.15.2 FGR Mode.......................................................................................................146
6.15.3 Define temperature sensor..........................................................................147
6.15.4 FGR sensor temperature .............................................................................147
6.15.5 FGR release....................................................................................................147
6.15.6 Temperature compensation ........................................................................148
6.15.7 Operating temperature.................................................................................150
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6.15.8 Position limit FGR damper ..........................................................................150
6.16 Data backup ..........................................................................................................151
6.16.1 Backup copy...................................................................................................151
6.16.2 Updating software.........................................................................................152
6.17 TÜV Test................................................................................................................. 153
6.17.1 Loss of flame...................................................................................................153
6.17.2 Safety temperature limiter............................................................................153
7 Commissioning............................................................................................................154
7.1 Prerequisite .............................................................................................................. 154
7.1.1 Adapting the motor to the frequency converter........................................154
7.2 Adjusting the burner............................................................................................... 155
7.2.1 Preparatory measures .....................................................................................155
7.2.1.1 Carry out speed standardisation .......................................................... 157
7.2.1.2 O2 module presetting ............................................................................. 158
7.2.1.3 Deactivate flue gas recirculation........................................................... 159
7.2.2 Adjusting gas side ...........................................................................................160
7.2.3 Adjust modulation oil side..............................................................................166
7.2.4 Adjust multi-stage oil side..............................................................................172
7.3 Load controller......................................................................................................... 176
7.3.1 Configure load controller................................................................................176
7.3.2 Adjust load controller ......................................................................................178
7.3.2.1 Modulating load control .......................................................................... 178
7.3.2.2 Modulating load control .......................................................................... 179
7.3.2.3 Boiler cold start function ........................................................................ 180
7.4 O2 controller............................................................................................................ 182
7.4.1 Set O2 monitor.................................................................................................182
7.4.2 Set O2 trim........................................................................................................183
7.4.3 Check and optimise O2 trim .........................................................................184
7.5 CO controller ........................................................................................................... 186
7.5.1 Set measurement amplifierLT3....................................................................186
7.5.2 Set CO control ................................................................................................. 187
7.6 Flue gas recirculation (temperature compensated) ........................................ 188
7.7 Set pressure switches ........................................................................................... 190
7.8 Concluding work..................................................................................................... 190
7.9 Check combustion.................................................................................................. 191
7.10 Calculate gas throughput................................................................................... 192
7.11 Ratings apportionment........................................................................................ 193
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8 Servicing..........................................................................................................................194
8.1 Notes on servicing.................................................................................................. 194
8.2 Service plan.............................................................................................................. 195
9 Troubleshooting ..........................................................................................................196
9.1 Procedures for fault conditions............................................................................ 196
9.1.1 Deactivating an alarm......................................................................................197
9.2 Fault............................................................................................................................ 198
9.3 Lockout...................................................................................................................... 199
9.4 Rectifying faults....................................................................................................... 200
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
10 Technical documentation.......................................................................................218
10.1 Frequency converter............................................................................................ 218
10.1.1 Frequency converter Nord size I … III ......................................................219
10.1.2 Frequency converter Nord size IV..............................................................220
11 Key word index ............................................................................................................222
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Page 8
1 User instructions
Translation of original
operating instructions
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
1 User instructions
This manual forms part of the equipment and must be kept on site.
Carefully read the manual prior to working on the unit.
1.1 Target group
The manual is intended for the operator and qualified personnel. They should be
observed by all personnel working with the unit.
Work on the unit must only be carried out by personnel who have the relevant training and instruction.
Persons with limited physical, sensory or mental capabilities may only work on the
unit if they are supervised or have been trained by an authorised person.
Children must not play with the unit.
1.2 Symbols
Immediate danger with high risk.
Non observance can lead to serious injury or death.
DANGER
Danger with medium risk.
Non observance can lead to environmental damage,
WARNING
CAUTION
… Range of values
serious injury or death.
Danger with low risk.
Non observance can cause damage to the equipment and injury to personnel.
Important information
Requires direct action
Result after an action
Itemisation
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
1 User instructions
1.3 Guarantee and Liability
Guarantee and liability claims for personal and equipment damage are excluded, if
they can be attributed to one or more of the following causes:
non approved application,
non-observance of the manual,
operation with faulty safety equipment,
continual operation despite a fault,
improper installation, commissioning, operation and service,
repairs, which have been carried out incorrectly,
the use of non original Weishaupt parts,
force majeure,
unauthorised modifications made to the unit,
the installation of additional components, which have not been tested with the
unit,
the installation of combustion chamber inserts, which impede full flame formation,
unsuitable fuels,
defects in the inlet lines.
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Page 10
2 Safety
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
2 Safety
The combustion manager W-FM 100/200 is suitable for use with:
oil burners
gas burner
dual fuel and triple fuel burners,
dual gas burners.
Improper use could:
endanger the health and safety of the user or third parties,
cause damage to the unit or other material assets.
2.1 When gas can be smelled
Avoid open flames and spark generation, for example:
do not operate light switches,
do not operate electronic equipment,
do not use mobile telephones.
Open doors and windows.
Close gas isolating valve.
Warn the inhabitants, do not ring door bells.
Leave the building.
Inform the heating contractor or gas supplier from outside of the building.
2.2 Safety measures
Safety relevant fault conditions must be eliminated immediately.
Components, which show increased wear and tear or whose design lifespan is or
will be exceeded prior to the next service should be replaced as a precaution.
The design lifespan of the components is listed in the service plan [ch.8.2].
2.2.1 Normal operation
All labels on the unit must be kept in a legible condition.
Stipulated settings, service and inspection work should be carried out at regular
intervals.
Only operate the unit with its cover closed.
Do not touch moving parts during operation.
Do not touch the oil carrying parts of medium and heavy oil burners during operation.
2.2.2 Electrical connection
For work carried out on live components:
Observe the accident prevention instructions DGUVRegulation3 and adhere to
local directives,
tools in accordance with EN 60900 should be used.
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
2 Safety
2.2.3 Gas supply
Only the gas supply company or an approved agent may carry out installation, alteration and maintenance work on gas appliances in buildings and properties.
Pipework must be subject to a combined load and valve proving test and/or usability testing relative to the pressure range intended, e. g. DVGW-TRGI, worksheet G 600.
Inform the gas supply company about the type and size of plant prior to installation.
Local regulations and guidelines must be observed during installation, e. g.
DVGW-TRGI, worksheet G 600; TRF Band 1 and Band 2.
The gas supply pipework should be suitable for the type and quality of gas and
should be designed in such a way that it is not possible for liquids to form, e. g.
condensate. Observe vaporisation pressure and vaporisation temperature of liquid petroleum gas.
Use only tested and approved sealing materials, whilst observing all process information.
Re-commission the appliance when changing to a different type of gas. Changing from LPG to Natural Gas and visa versa requires a conversion.
Carry out soundness test after each service and fault rectification.
2.3 Alterations to the construction of the equipment
All conversions require written approval from Max Weishaupt GmbH.
No additional components may be fitted, which have not been tested for use
with the equipment.
Do not use combustion chamber inserts, which hinder flame burnout.
Use only original Weishaupt replacement parts.
2.4 Noise emission
The noise emissions are determined by the acoustic behaviour of all components
fitted to the combustion system.
Prolonged exposure to high noise levels can lead to loss of hearing. Provide operating personnel with protective equipment.
Noise emissions can further be reduced with a sound attenuator.
2.5 Disposal
Dispose of all materials and components in a safe and environmentally friendly way
at an authorised location. Observe local regulations.
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Page 12
3 Product description
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.1 Variations
Type Version Functions
W-FM 100 LMV51.0… Burner Control
Low gas programme
Valve proving
LMV51.1… as type LMV51.0…
Load controller
W-FM 200 LMV52.2… as type LMV51.1…
Variable speed drive
O2 trim
LMV52.4… as type LMV52.2…
FGR with temperature compensation
CO monitor and CO controller function
3.2 Function
3.2.1 Burner Control
A burner control for oil, gas and dual fuel burners is integrated in the combustion
manager.
It controls the sequence of operation, monitors the flame and communicates with all
components.
3.2.2 Low gas programme
The low gas pressure switch monitors the gas connection pressure from phase21.
If the gas pressure set at the low gas pressure switch is not achieved, the combustion manager initiates a safety shutdown and starts the low gas programme.
In the low gas programme, the combustion manager initiates a restart after the low
gas waiting time (Parameter: DelayLackGas). This low gas waiting time doubles
after every unsuccessful start attempt. If the start attempts exceed the repetition
limit value (Parameter: StartRelease) the combustion manager goes to lockout.
The repetition counter and the low gas waiting time are automatically reset when
the burner starts.
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Page 13
Installation and operating instruction
V1
V2PP
3 s 10 s 10 s3 s
80 81 82 83
A
V1
V2
P
P
V1
V2
P
P
B
C
1
2
4
1
2
4
1
2
4
1
2
3
4
5
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.2.3 Valve proving
The valve proving gas pressure switch checks if the valves are tight. It signals the
combustion manager if the pressure increases or decreases to an impermissible
level during valve proving.
Valve proving is carried out automatically by the combustion manager:
after every controlled shutdown,
prior to burner start following lockout or power outage.
1. Test phase (function sequence for valve proving valve1):
Valve1 remains closed, valve2 opens,
the gas escapes and the pressure between valve1 and valve2 reduces,
valve 2 closes again,
both valves remain closed for 10 seconds.
If the pressure increases to above the value set during these 10 seconds, valve1 is
leaking. The combustion manager initiates a controlled shutdown.
2. Test phase (function sequence for valve proving valve2):
Valve 1 opens, valve 2 remains closed,
pressure between valve1 and valve2 increases,
valve 1 closes again,
both valves remain closed for 10 seconds.
If the pressure decreases to below the value set during these 10 seconds, valve2
is leaking. The combustion manager initiates a controlled shutdown.
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1 Valve 1
2 Valve 2
3 Pressure between valve 1 and valve 2
4 Valve proving gas pressure switch
5 Operating phases
A Direct ignition
B Ignition gas tube
C Gas ignition device
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3 Product description
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.2.4 Load controller
The W-FM 200 is equipped with an internal PID load controller as standard, with
the W-FM 100 the internal load controller is optional.
The load controller is suitable for multi-stage and modulating burners. In modulating
operation, control variables calming reduces the drive impulses and protects the
actuators.
It is possible to choose between two setpoints using an external contact.
The boiler cold start function reduces the thermal load of the heat exchanger during
burner start.
3.2.5 Variable speed drive
Only the W-FM 200 is equipped with a frequency converter module for variable
speed control.
Via an analogue output (0/4-20 mA), the W-FM 200 control the frequency converter of the fan motor and matches the speed to the burner capacity. This reduces
electrical consumption.
The speed and the rotation direction are monitored by an inductive proximity switch
and an asymmetrical transmitter disc.
3.2.6 O2 trim / monitoring
Only the W-FM 200 is equipped with an O2 trim function. An additional O2 module
(PLL52…) is required for O2 trim.
A sensor measures the O2 content in the flue gas. During operation, the W-FM 200
compares the O2 content with the setpoints determined during commissioning. If
deviations occur, the W-FM 200 activates the air regulating devices and corrects
the O2 content. This increases the boiler efficiency.
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Installation and operating instruction
79 8382818070 72 74 76 786260544438363432302422212012100100 4240
X4-01:1
X3-04:1
X10-...
(2
X3-02:1
X4-01:3
X7-03:2
X9-03:4
X9-03:3
X9-03:2
X3-01:1
X4-02:3
79 8382818070 72 74 76 786260544438363432302422212012100100 4240
79 8382818070 72 74 76 786260544438363432302422212012100100 4240
X4-03:3
(4
X9-01:1
X9-01:4
X9-01:3
(1
(1
(3
(3
(3
1
3
2
Lockout phase
Safety phase
Home run
Standby
Start-up
Start release
Fan ON
Pre-purge position
Pre-purge
Ignition position
Pre-ignition
Fuel release
Ignition OFF
Flame Signal
Partial load position
Operating setting 1
Operating setting 2
Post burn time
Post-purge position
Post-purge
Direct start
Drain valve train
Test without pressure
Fill valve train
System pressure test
Valve
proving
Inputs
Fuel selection
Safety circuit
Heat demand
Flame Signal
Air pressure switch
Fan contactor contact
Start release Gas
Low gas pressure switch
High gas pressure switch
VP gas pressure switch
Outputs
Burner motor / Fan
Ignition
Pressure switch release
Start signal
Safety valve
Fuel valve 1
Fuel valve 2
Actuators
Full load
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Combustion manager W-FM 100 und W-FM 200
3.2.7 Program sequence
3.2.7.1 Gas direct ignition
3 Product description
(1
Signal only required to jump to Phase 79 (direct start)
(2
with QRI / QRA7x: Input X10-02:6
with ionisation electrode: Input X10-03:1
(3
Only with continuous running fan
(4
Signal is dependent on parameter: Start/PS valve (start signal or pressure switch release)
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Signal on input / output activated
No signal on input
Input without influence
Signal optional or depending on parameter settings
1 Fuel actuator
2 Actuators air, Aux1, Aux2 / frequency converter
3 Actuator flue gas recirculation
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3 Product description
79 8382818070 72 74 76 786260544438363432302422212012100100 4240 50 52
X4-01:1
X3-04:1
X10-...
(2
X3-02:1
X4-01:3
X7-03:2
X9-03:4
X9-03:3
X9-03:2
X3-01:1
X4-02:3
79 8382818070 72 74 76 786260544438363432302422212012100100 4240 50 52
79 8382818070 72 74 76 786260544438363432302422212012100100 4240 50 52
X4-03:3
(4
X9-01:1
X9-01:2
X9-01:4
X9-01:3
(1
(1
(3
(3
(3
(5
1
3
2
Lockout phase
Safety phase
Home run
Standby
Start-up
Start release
Fan ON
Pre-purge position
Pre-purge
Ignition position
Pre-ignition
Fuel release
Ignition OFF
Flame Signal
Partial load position
Operating setting 1
Operating setting 2
Post burn time
Post-purge position
Post-purge
Direct start
Drain valve train
Test without pressure
Fill valve train
System pressure test
Valve
proving
Inputs
Fuel selection
Safety circuit
Heat demand
Flame Signal
Air pressure switch
Fan contactor contact
Start release Gas
Low gas pressure switch
High gas pressure switch
VP gas pressure switch
Outputs
Burner motor / Fan
Ignition
Pressure switch release
Start signal
Safety valve
Ignition pilot valve
Fuel valve 1
Actuators
Full load
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Flame stabilisation
Ignition pilot valve OFF
Fuel valve 2
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.2.7.2 Gas with ignition pilot valve
(1
Signal only required to jump to Phase 79 (direct start)
(2
with QRI / QRA7x: Input X10-02:6
with ionisation electrode: Input X10-03:1
(3
Only with continuous running fan
(4
Signal is dependent on parameter: Start/PS valve (start signal or pressure switch release)
(5
If a pilot valve is fitted between fuel valve 1 and 2: Signal from Phase 40
If a gas ignition device is fitted in front of fuel valve 1: Signal from Phase 50
83054802 1/2018-07 La
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Page 17
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Signal on input / output activated
No signal on input
Input without influence
Signal optional or depending on parameter settings
1 Fuel actuator
2 Actuators air, Aux1, Aux2 / frequency converter
3 Actuator flue gas recirculation
3 Product description
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Page 18
3 Product description
7970 72 74 76 786260544438363432302422212012100100 4240
X4-01:2
X3-04:1
X10-...
(2
X3-02:1
X4-01:3
X5-01:2
X5-02:2
X6-01:1
X3-01:1
X6-02:3
X4-02:3
7970 72 74 76 786260544438363432302422212012100100 4240
7970 72 74 76 786260544438363432302422212012100100 4240
X4-03:3
(6
X6-03:3
X8-02/03
X7-02:3
X7-01:3
(1
(1
(3
(3
(3
(4
(5
(5
(4
(5
(5
1
3
2
Lockout phase
Safety phase
Home run
Standby
Start-up
Start release
Fan ON
Pre-purge position
Pre-purge
Ignition position
Pre-ignition
Fuel release
Ignition OFF
Flame Signal
Partial load position
Operating setting 1
Operating setting 2
Post burn time
Post-purge position
Post-purge
Direct start
Inputs
Fuel selection
Safety circuit
Heat demand
Flame Signal
Air pressure switch
Fan contactor contact
Minimum oil pressure switch
Max. oil pressure switch
Start release Oil
Outputs
Burner motor / Fan
Ignition
Pressure switch release
Start signal
Anti syphon valve
Fuel valve 1
Fuel valve 2
Actuators
Full load
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Fuel valve 3
Magnetic coupling / Oil pump
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.2.7.3 Light oil direct ignition
(1
Signal only required to jump to Phase 79 (direct start)
(2
with QRI / QRA7x: Input X10-02:6
with QRA2: Input X10-03:1
with QRB: Input X10-02:1
(3
Only with continuous running fan
(4
Signal depends on parameter: OnIgnPointOilIgnition (long or short pre-ignition)
(5
Signal depends on parameter: OilPumpCoupling (direct coupling)
(6
Signal depends on parameter: Start/PS valve
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Page 19
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Signal on input / output activated
No signal on input
Input without influence
Signal optional or depending on parameter settings
1 Fuel actuator
2 Actuators air, Aux1, Aux2 / frequency converter
3 Actuator flue gas recirculation
3 Product description
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Page 20
3 Product description
(5
(5
7970 72 74 76 786260544438363432302422212012100100 4240
X4-01:2
X3-04:1
X10-...
(2
X3-02:1
X4-01:3
X5-01:2
X5-02:2
X3-01:1
X6-02:3
X4-02:3
7970 72 74 76 786260544438363432302422212012100100 4240
7970 72 74 76 786260544438363432302422212012100100 4240
X4-03:3
(6
X6-03:3
X8-02/03
X7-02:3
X7-01:3
(1
(1
(3
(3
(3
(4
(4
X6-01:1
X6-01:3
(5
(5
1
3
2
Lockout phase
Safety phase
Home run
Standby
Start-up
Start release
Fan ON
Pre-purge position
Pre-purge
Ignition position
Pre-ignition
Fuel release
Ignition OFF
Flame Signal
Partial load position
Operating setting 1
Operating setting 2
Post burn time
Post-purge position
Post-purge
Direct start
Inputs
Fuel selection
Safety circuit
Heat demand
Flame Signal
Air pressure switch
Fan contactor contact
Minimum oil pressure switch
Max. oil pressure switch
Start release Oil
Outputs
Burner motor / Fan
Ignition
Pressure switch release
Start signal
Anti syphon valve
Fuel valve 1
Fuel valve 2
Actuators
Full load
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Fuel valve 3
Magnetic coupling / Oil pump
Heavy oil immediate start
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.2.7.4 Heavy oil direct ignition
(1
Signal only required to jump to Phase 79 (direct start)
(2
with QRI / QRA7x: Input X10-02:6
with QRA2: Input X10-03:1
with QRB: Input X10-02:1
(3
Only with continuous running fan
(4
Signal depends on parameter: OnIgnPointOilIgnition (long or short pre-ignition)
(5
Signal depends on parameter: OilPumpCoupling (direct coupling)
(6
Signal depends on parameter: Start/PS valve
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Page 21
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Signal on input / output activated
No signal on input
Input without influence
Signal optional or depending on parameter settings
1 Fuel actuator
2 Actuators air, Aux1, Aux2 / frequency converter
3 Actuator flue gas recirculation
3 Product description
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Page 22
3 Product description
(5
(5
7970 72 74 76 786260544438363432302422212012100100 4240
X4-01:2
X3-04:1
X10-...
(2
X3-02:1
X4-01:3
X5-01:2
X5-02:2
X3-01:1
X6-02:3
X4-02:3
7970 72 74 76 786260544438363432302422212012100100 4240
7970 72 74 76 78626054
52
52
52
50
50
504438363432302422212012100100 4240
X4-03:3
(6
X6-03:3
X8-02/03
X7-02:3
X7-01:3
(1
(1
(3
(3
(3
(4
(4
X6-01:1
X6-01:3
X9-03:4
X9-03:3
X7-03:2
(5
(5
X9-01:1
X9-01:2
1
3
2
Lockout phase
Safety phase
Home run
Standby
Start-up
Start release
Fan ON
Pre-purge position
Pre-purge
Ignition position
Pre-ignition
Fuel release
Ignition OFF
Flame Signal
Partial load position
Operating setting 1
Operating setting 2
Post burn time
Post-purge position
Post-purge
Direct start
Inputs
Fuel selection
Safety circuit
Heat demand
Flame Signal
Air pressure switch
Fan contactor contact
Minimum oil pressure switch
Max. oil pressure switch
Start release Oil
Outputs
Burner motor / Fan
Ignition
Pressure switch release
Start signal
Anti siphon valve Oil
Fuel valve 1 Oil
Fuel valve 2 Oil
Actuators
Full load
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Fuel valve 3 Oil
Magnetic coupling / Oil pump
Heavy oil immediate start
Flame stabilisation
Ignition pilot valve OFF
Low gas pressure switch
Start release Gas
High gas pressure switch
Safety valve Gas
Ignition pilot valve Gas
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.2.7.5 Heavy oil with gas pilot ignition
(1
Signal only required to jump to Phase 79 (direct start)
(2
(3
(4
(5
(6
with QRI / QRA7x: Input X10-02:6
with ionisation electrode on gas ignition device: Input X10-03:1
Only with continuous running fan
Signal depends on parameter: OnIgnPointOilIgnition (long or short pre-ignition)
Signal depends on parameter: OilPumpCoupling (direct coupling)
Signal depends on parameter: Start/PS valve
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Page 23
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Signal on input / output activated
No signal on input
Input without influence
Signal optional or depending on parameter settings
1 Fuel actuator
2 Actuators air, Aux1, Aux2 / frequency converter
3 Actuator flue gas recirculation
3 Product description
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Page 24
3 Product description
2
3
4
5
X3-04
PE
N
L
L
PE
N
L
SAFETY
LOOP
LINE
VOLTAGE
1
2
3
4
5
X3-04
PE
N
L
L
SAFETY
LOOP
LINE
VOLTAGE
1
1
2
X3-03
L
FLANGE
P
2
3
4
5
X3-04
PE
N
L
L
PE
N
L
SAFETY
LOOP
LINE
VOLTAGE
1
1
2
X3-01
L
L MOTOR
ALARM
2
3
4
X4-01
RESET
OIL
GAS
1
(2(1
1
2
X3-02
P
L
P
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.3 Inputs
3.3.1 Voltage supply
The voltage supply is connected to inputsX3-04:3-5.
3.3.2 Safety circuit
In the diagnostic code, the inputsX3-03:1/2 and X3-04:1/2 are combined as
safety circuit. If one of the inputs is open the W-FM carries out at least one safety
shutdown. If the repetition value is exceeded an open input leads to lockout.
The repetition value can be set in parameter RepetitCounter under
SafetyLoop, see [ch.6.8.12].
At inputX3-04:1/2 all external components of the safety circuit are switched in sequence, these include:
Emergency-Off switch
Safety time limiter (STL)
Low water safety interlock, etc.
The burner flange limit switch is connected to inputX3-03:1/2.
3.3.3 Reset
A reset button can be connected to inputX4-01:4. Pressing this button in lockout
will reset the combustion manager.
With lockout function
(1
If the push button is also required for manual lockout, it must be connected to
mains inputX3-04:5(L). If the combustion manager is in an operating phase pressing the button will initiate a manual lockout.
Without lockout function
(2
If the push button is not required to carry out manual lockout it must be connected
to alarm outputX3-01:2.
3.3.4 Air pressure switch
Depending on the burner configuration, the input is activated at the factory in the
OEM level.
The input is activated for:
gas burner
dual fuel burners,
oil burners with separately driven pump.
In these cases, the closing contact of the air pressure switch is connected to inputX3-02:1. The fan will only start, if no signal is present at the input during start
release. If the signal is missing once the fan has started, the combustion manager
83054802 1/2018-07 La
initiates a lockout.
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Page 25
Installation and operating instruction
2
3
4
X4-01
RESET
OIL
GAS
1
1
2
X3-02
P
L
P
1
2
X3-01
L
L MOTOR
ALARM
(1
2
3
4
X4-01
RESET
OIL
GAS
1
2
3
4
X5-03
ON/OFF
1
3
2
L
0 1 2
2
3
X5-01
PE
min
1
P
L
P
2
3
X5-02
PE
max
1
P
L
P
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.3.5 Fan contactor contact
The auxiliary contact (closer) of the fan contactor is connected to inputX4-01:3.
The fan will only start, if no signal is present at the input during start release. If the
signal is missing once the fan has started, the combustion manager initiates a lockout.
(1
Only with frequency converter:
For fans with frequency converter, the signal is generated via a bridge from outputX3-01:1 (burner motor / fan).
3.3.6 Fuel selection
The fuel selection switch is connected to inputX4-01:1/2. The fuel selection
switch has priority over fuel selection via display and operating unit(ABE) or building management system (BMS). Fuel selection via ABE or BMS is only possible if
no signal is present at input X4-01:1/2. There is no priority between ABE and
BMS, the last fuel selection is valid and is retained after power failure.
3.3.7 Minimum oil pressure switch
The closing contact of the minimum oil pressure switch is connected to inputX5-01. On burners without minimum oil pressure switch the input is deactivated.
In oil operation the combustion manager expects a signal at inputX5-01:2 from
Phase 38, in Phase44 with heavy oil with gas ignition device. If the pressure falls
below the value set, the pressure switch contact opens and the combustion manager initiates a lockout. In Phase38 (in Phase44 with heavy oil with gas ignition
device ) lockout occurs after a waiting time of 3seconds, in the following phases
lockout is immediate.
To avoid a lockout caused by pressure fluctuations during fuel release, the input reacts time delayed in Phase40 and42. The time delay can be adjusted in parameter
PressReacTime, see [ch.6.8.1].
3.3.8 Max. oil pressure switch
The opening contact of the max. oil pressure switch is connected to inputX5-02.
On burners without maximum oil pressure switch the input is deactivated.
In oil operation the combustion manager expects a signal at inputX5-02:2 from
Phase 22. If the value set at the pressure switch is exceeded, the pressure switch
contact opens and the combustion manager initiates a lockout. In Phase21 (start
release) lockout occurs after a waiting time of 120seconds, in the following phases
lockout is immediate.
To avoid a lockout caused by pressure fluctuations during fuel release, the input reacts time delayed in Phase40 and42. The time delay can be adjusted in parameter
PressReacTime, see [ch.6.8.1].
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Page 26
3 Product description
2
3
X6-01
4
1
L
START
L
2
3
X6-01
4
1
L
START
L
2
3
X7-03
1
PE
L
START
CPI
L
2
3
X9-03
max
min
4
1
P
P
P
P
LT
(CPI)
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.3.9 Start release Oil
The start conditions for the oil operation are interrogated via inputX6-01:1, e.g.:
oil shut off combination limit switch,
oil temperature release contact (for heavy oil),
cooling air fan contact (WK burners with hot air, version ZMH).
For burners without start conditions, a bridge is connected between terminals1
and2.
In oil operation the combustion manager expects a signal at inputX6-01:1from
Phase 21. If the signal is missing after Phase21, the combustion manager initiates
a shutdown.
3.3.10 Heavy oil immediate start
The input is only activates on heavy oil burners with return flow temperature sensor.
The release contact of the return flow temperature sensor is connected to inputX6-01:3.
In heavy oil operation, the combustion manager carries out a nozzle circulation for
maximum 45seconds. If the signal is present at inputX6-01:3 before this time has
elapsed, the nozzle circulation is shortened accordingly. If the signal is missing after
this time has elapsed, the combustion manager initiates a home run with subsequent repetition.
Depending on the burner nozzle circulation is carried out in phase:
38 (with direct ignition),
44 (with gas ignition device).
If the signal fails after Phase44, the combustion manager initiates a safety shutdown.
3.3.11 Start release Gas
The input is activated in gas operation and in heavy oil operation with gas ignition
device.
The combustion manager expects a signal at inputX7-03:2 from Phase21. If the
signal is missing after Phase21, the combustion manager initiates a shutdown.
3.3.12 Valve proving gas pressure switch
The opening contact of the valve proving gas pressure switch is connected to inputX9-04:2. InputX9-04:2 is only activated during valve proving [ch.3.2.3].
If the pressure set is not achieved in Phase81 (test without pressure), the contact
closes.
If the pressure set is exceeded in Phase83 (test with system pressure), the contact
opens.
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Installation and operating instruction
L
2
3
X9-03
max
min
4
1
P
P
P
P
LT
(CPI)
L
2
3
X9-03
max
min
4
1
P
P
P
LT
(CPI)
P
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.3.13 High gas pressure switch
The input is activated in gas operation and in heavy oil operation with gas ignition
device. The opening contact of the high gas pressure switch is connected to inputX9-03:3.
On burners without high gas pressure switch the input is deactivated.
The combustion manager expects a signal at inputX9-03:3 from Phase40. If the
value set at the pressure switch is exceeded, the pressure switch contact opens
and the combustion manager initiates a lockout.
To avoid lockouts caused by pressure fluctuations when the valves open, the input
reacts time delayed in Phase40, 42 and50. The time delay can be adjusted in
parameter PressSigReactTime ,see [ch.6.8.1].
3.3.14 Low gas pressure switch
The input is activated in gas operation and in heavy oil operation with gas ignition
device. The closing contact of the low gas pressure switch is connected inputX9-03:4.
In gas operation, the combustion manager expects a signal at inputX9-03:4 from
Phase21. If the pressure drops below the value set, the pressure switch contact
opens and the combustion manager starts the low gas programme [ch.3.2.2].
To avoid lockouts caused by pressure fluctuations when the valves open, the input
reacts time delayed in Phase40, 42 and50. The time delay can be adjusted in
parameter PressSigReactTime ,see [ch.6.8.1].
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3 Product description
QRB
POWER QRI
L
N
PE
QRI / FSV
2
3
X10-02
4
5
6
1
BN
BK
QRB
POWER QRI
L
N
PE
QRI / FSV
2
3
X10-02
4
5
6
1
QRI
+
BN
BU
BK
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.3.15 Flame sensor
If the flame signal from Phase 44 does not correspond to the value required, the
combustion manager initiates safety shutdown with restart. The number of safety
shutdowns set in parameter LossOfFlame in sequence lead to lockout
[ch.6.8.12].
Depending on parameter ReactionExtranL , a flame signal in Standby
(Phase12) will lead to start prevention or lockout.
A flame signal during pre-purge (Phases30 to36) or post-purge (Phase76
and78) leads to lockout after one repetition and repeated occurrence.
The OperationalStat shows the current flame signal as a percentage value.
QRB…
The flame sensorQRB… (photo resistor) is connected to inputX10-02:1/4.
The flame sensor QRB is not suitable for continuous operation.
If the combustion manager is installed in a control panel, the sensor cable must be
routed separately (max100m).
Flame signal Sensor current Display
Minimum flame signal DC30μA approx. 35 %
Maximum flame signal DC70μA approx. 100 %
Extraneous light detection
from
DC5μA -
QRI
The flame sensor QRI (infrared) is connected to inputX10-02:2/4/6.
The flame sensor QRI is suitable for continuous operation. The combustion manager tests the flame sensor in cycles in operating position (Phase60) by simulating
a flame failure. The voltage at outputX10-02:2 is increased from14V to 21V for
0.5seconds. The signal voltage at the flame sensor therefore drops to 0V and the
combustion manager receives the expected Off signal at inputX10-02:6.
If the combustion manager is installed in a control panel, the sensor cable must be
routed separately (max100m).
Flame Signal Display
Min. signal voltage: DC 3.5 V (X10-02:6) approx. 50 %
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Installation and operating instruction
QRB
POWER QRI
L
N
PE
QRI / FSV
2
3
X10-02
4
5
6
1
45213
PE
45613
PE
+
UV
M
QRA73
AGM23
X10-03
ION
1
Combustion manager W-FM 100 und W-FM 200
3 Product description
QRA73
The flame sensorQRA73 (UV cell) is connected to inputX10-02:2-6 using
plugAGM23.
The flame sensorQRA73 is suitable for continuous operation. The combustion
manager tests the flame sensor in cycles in operating position (Phase60) by simulating a flame failure. The voltage at output X10-02:2 is increased 14 V to 21 V for
0.5 seconds. The signal voltage at the flame sensor therefore drops to 0 V
and the combustion manager receives the expected Off signal at input X10-02:6.
If the combustion manager is installed in a control panel, the connection must be
divided into 2 lines after theAGM23 plug and routed separately (max100m):
Supply line: Core 1, 2 and PE (L / N / PE),
Signal line (screened): Core 3, 4 and 5 (POWER QRI / N / QRI).
Flame Signal Display
Min. signal voltage: DC 3.5 V (X10-02:6) approx. 50 %
Ionisation electrode
The ionisation electrode is connected to inputX10-03:1.
If the combustion manager is installed in a control panel, the sensor cable must be
routed separately:
Max. length: 100 m,
Line capacity: 100 pF/m.
Flame signal Sensor current Display
Minimum flame signal DC6μA approx. 50 %
Maximum flame signal DC85μA approx. 100 %
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Page 30
3 Product description
2
3
4
X5-03
ON/OFF
1
3
2
L
P
P
2
3
4
X5-03
ON/OFF
1
3
2
L
2
3
4
X5-03
ON/OFF
1
3
2
L
P
P
P
P
P
2
3
4
X5-03
ON/OFF
1
3
2
L
P
P
2
3
4
X5-03
ON/OFF
1
3
2
L
P
P
2
3
4
X5-03
ON/OFF
1
3
2
L
P
P
2
3
4
X5-03
ON/OFF
1
3
2
L
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.3.16 External load controller (X5-03)
For operation with load controller via contacts, parameter LC_OptgMode must be
set to ExtLC X5-03 see [ch.6.12.2]. The contact for heat demand is connected
to inputX5-03:1 (burner ON/OFF).
Modulating operation with load controller
If inputX5-03:2 (CLOSED) is activated, the burner capacity reduces.
If inputX5-03:3 (OPEN) is activated, the burner capacity increases.
If none of the two inputs is activated, the burner capacity remains unchanged.
Modulating operation with thermostat
If thermostats or pressure regulators are connected to inputsX5-03, the modulating fuel can only be operated in sliding two stage operation.
At heat demand inputX5-03:2 (CLOSED) is activated and the burner drives to partial load. If the temperature drops below the value set, inputX5-03:3 (OPEN) is activated and the burner drives to full load.
Multi-stage operation (fuel oil only)
Two and three stage:
Input Operating mode
two stage three stage
X5-03:1 Stage 1 Stage 1
X5-03:2 Stage 1 Stage 2
X5-03:3 Stage 2 Stage 3
Low impact start:
At heat demand and with the bridge between terminal 1 and 2 the burner ignites in
stage 1 and then automatically drives to stage 2. If input X5-03:3 is also activated
the burner drives to stage3.
Alternatively, low impact start can be carried using a change-over contact.
Change-over release:
A bridge connects terminals2 and3. At heat demand the burner drives to stage1.
If inputsX5-03:2/3 are then activated simultaneously the burner drives via stage2
to stage3.
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Page 31
Installation and operating instruction
2
3
4
X5-03
ON/OFF
1
3
2
L
2
3
4
5
X62
0-10V
4-20mA
0
FE
1
+-
0/2 ... 10 V
0/4 ... 20 mA
X50
interface
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.3.17 External load controller (X62)
For operation with external load controller on the analogue input, parameter
LC_OptgMode must be set to Ext LC X62 see [ch.6.12.2].
The contact for heat demand is connected to inputX5-03:1 (burner ON/OFF).
The analogue load signal is connected to terminalsX62:2/4(0/2-10V) or
X62:3/4(0/4-20mA). In parameter Ext Inp X62 U/I the input must be
matched to the analogue signal [ch.6.12.4].
Modulating operation
In modulating operation, parameter MinActuatorStep determines the minimum
correcting element step [ch.6.12.9].
Signal on X62 Load W-FM
3 … 4 mA 20 %
20 mA 100 %
Multi-stage operation (fuel oil only)
In multi-stage operation a hysteresis of 1mA exists between the operating points,
which eliminates unnecessary load changes.
Two stage:
Signal on X62 Load W-FM
3 … 5 … 12 mA Stage 1
13 … 15 … 20 mA Stage 2
Three stage:
Signal on X62 Load W-FM
3 … 5 … 7 mA Stage 1
8 … 10 … 12 mA Stage 2
13 … 15 … 20 mA Stage 3
3.3.18 External load controller (Bus)
For the operation with external load controller via Bus connection, parameter
LC_OptgMode must be set to ExtLCBus ,see [ch.6.12.2]. The building
management system specifies the load signal via the bus connection.
In modulating operation, parameter MinActuatorStep determines the minimum
correcting element step [ch.6.12.9].
83054802 1/2018-07 La
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Page 32
3 Product description
W1
2
3
4
5
X62
0-10V
4-20mA
0
FE
1
W2
2
3
4
5
X62
0-10V
4-20mA
0
FE
1
W1
0-10V
4-20mA
2
3
4
5
X62
0-10V
4-20mA
0
FE
1
X50
W1
interface
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.3.19 Setpoint switch-over
When operating with internal load controller it is possible to switch between 2 setpoints. To do this, a potential free contact is connected to terminalX62:1/2.
Operating mode IntLC
Two internal setpoints(W1/W2) are available in operating mode IntLC . The
contact is used to switch between the setpoints.
Open: Setpoint W1 activated
Closed: Setpoint W2 activated
Operating mode IntLC X62
In operating mode IntLC X62 the building management system provides the
setpoint for the internal load controller via the analogue input.
In parameter Ext Inp X62 U/I , the input has to be matched to the analogue
signal [ch.6.12.4]. Parameters Ext Setpoint min/-max can be used to limit
the external setpoint [ch.6.12.6].
The contact is used to switch from the external setpoint to the internal setpoint W1.
If a voltage signal is present at inputX62:2, the voltage signal has to be separated
from inputX62:2 when switching over to the internal setpoint W1.
Open: External setpoint activated
Closed: Internal setpoint W1 activated
Operating mode IntLC Bus
In operating mode Int LC Bus the building management system provides the
setpoint for the internal load controller via the Bus connection. The contact is used
to switch from the external setpoint to the internal setpoint W1.
Open: External setpoint activated
Closed: Internal setpoint W1 activated
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Page 33
Installation and operating instruction
FE
2
3
X60
4
5
1
Pt100
Pt/Ni 1000
Pt100Pt/Ni 1000
P /
FE
0
4-20 mA
0-10 V2
3
X61
4
5
1
Power Supply
Sensor
TEMP.TEMP./PRES. INPUT
4...20 mA
GND
IN
0....10 V
FE
0
RESERVE
Pulse-In
Usensor
2
3
X70
5
4
1
2 wire
3 wire
BN
BU
BN
BK
BU
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.3.20 Temperature sensor
If the internal load controller is activated in parameter LC_OptgMode , a temperature sensor has to be connected to input X60 or a temperature or pressure sensor
has to be connected to input X61.
On W-FM 200 with flue gas recirculation(FGR), the FGR temperature sensor is
connected to inputX60:3/4 as standard and is not available for the load controller.
As an alternative, the flue gas temperature sensor on the O2 module (accessory)
can be used as FGR temperature sensor [ch.3.3.23]. The sensor used must be
defined in parameter FGR-sensor, see [ch.6.15.3].
On W-FM 200 with CO control the combustion air sensor is fitted to inputX60:3/4
and is not available for the load controller. Parameter AirTempX60PT1000
(OEM level) must be set to activated .
The internal temperature monitor function is only possible with temperature sensor
on input X60. If there is no external safety temperature limiter available in the safety
circuit, two temperature sensors (Pt100/Pt1000 or Pt100/Ni1000) must be connected for the internal temperature monitor function.
With different cable resistances in the three-wire circuit (Pt100) line compensation
is required.
Depending on the circuitry, the inputs must be configured via the following parameters:
Sensor selection [ch.6.12.3]
Ext Inp X61 U/I [ch.6.12.4]
Measuring range [ch.6.12.5]
Additional sensor for boiler start function [ch.6.12.14].
The voltage supply (20VDC) on terminalX61:1 can not be changed.
83054802 1/2018-07 La
3.3.21 Speed measurement
For operation with frequency converter (W-FM 200 only) the proximity switch for
speed measurement is connected to input X70.
Via the transmitter disc, the proximity switch detects 3 impulses per rotation. The
number of impulses must be defined in parameter Num Puls per R, see
[ch.6.14.2]. The direction of rotation is detected by the asymmetrical transmitter
disc (60°, 120°, 180°).
33-228
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3 Product description
FE
0
Pulse-In
Usensor
2
3
X71
4
1
GAS
2 wire
3 wire
FE
0
Pulse-In
Usensor
2
3
X72
4
1
OIL
2 wire
3 wire
2
3
X86
1
Pt/Ni 1000
FUEL GAS
Pt/Ni 1000
2
3
X87
1
Pt/Ni 1000
COMBUS-
TION. AIR
Pt/Ni 1000
2
3
X87
1
Pt/Ni 1000
COMBUS-
TION. AIR
Pt/Ni 1000
COx >max
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.3.22 Fuel Meter
It is possible to connect 2 fuel meters to the W-FM 200:
Gas meter: X71
Oil meter: X72
Supply (PIN 1) approx. 10 V DC / max 45 mA
Input (PIN 2) max 10 V DC
High level: min 3 V DC
Low level: max 1.5 V DC
Sensor Inductive sensor to DIN 19234 (Namur)
Open Collector (pnp)
Reed contact
Frequency max 300 Hz
The number of impulses per unit of volume must be set in parameter Pulse-
Value… .
3.3.23 Flue gas temperature sensor
The flue gas temperature sensor is connected to the O2 module input X86 (accessory).
The sensor has to be configured in parameter FlueGasTempSens, see
[ch.6.10.9].
Alternatively, the flue gas temperature sensor can be used as FGR temperature
sensor (flue gas recirculation). In parameter FGR sensor X86PtNi1000
must then be defined as FGR temperature sensor [ch.6.15.3].
3.3.24 Combustion air sensor / CO resistance circuit board
The combustion air temperature sensor is connected to the O2 module inputX87
(accessory).
The sensor has to be configured in parameter SupAirTempSens, see
[ch.6.10.9].
In conjunction with CO control, a resistance circuit board is connected to input
X87. The digital output3 of the CO measurement amplifier is connected to the O2
module via the resistance circuit board. The combustion air sensor then has to be
connected to input X60:3/4 [ch.3.3.20].
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Installation and operating instruction
2
3
X81
4
5
6
1
QGO...
B1
M
B2
M
G2
U3
B1
M
B2
M
G2
U3
Q4
Q5
QGO...
GND
2
3
X89-2
1
QGO...
PE
NLQ5
Q4
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.3.25 O2 sensor
The O2 sensor is connected to the O2 module (accessory).
Connect the signal cable (3x2x0.25 mm2), twisted in pairs, to X81. Connect the
screen to one side of the creen clamp of the O2 module, cable length maximum
10m.
Connect separate cable (3x0.75 mm2) for the sensor heating to
outputX89-2:Q4/Q5.
The O2 sensor has to be configured in parameter O2 Sensor, see [ch.6.10.7].
Terminal Function
B1 / M Nernst voltage depending on the current O2 content
[ch.6.10.16].
B2 / M Thermo element of the O2 sensor (0…33mV), 700°C equal to
approx. 29.1mV.
Current operating temperature [ch.6.10.20].
G2 Voltage supply for temperature compensation
U3 Signal of temperature compensation
L (Q4)
N (Q5)
Pulsed voltage supply for sensor heating230V,N(Q5) is
switched. Parameter QGO HeatingLoad shows the current
heating capacity [ch.6.10.21].
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3 Product description
1
2
X3-01
L
L
MOTOR
ALARM
1
2
X3-01
L
L
MOTOR
ALARM
M
N
L
1
2
X6-02
3
PE
N
L
M
~
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.4 Outputs
3.4.1 Alarm
In lockout position (Phase00) a mains voltage signal is emitted at alarm outputX3-01:2.
Additionally, it is also possible to signal prevention. To do this parameter Alarm-
StartPrev is set to activated [ch.6.8.2]. The time, before a start prevention triggers an alarm is set in parameter AlarmDelay, see [ch.6.8.1].
Parameter Alarm act/deact is used to deactivate the alarm signal [ch.9.1.1].
The deactivation only affects the alarm output, lockout or start prevention are not
reset. Reset or burner start are reset automatically by the deactivation and the
alarm output is ready of use again.
3.4.2 Motor
The fan motor is connected to outputX3-01:1 via contactor or star delta switching.
Depending on parameter ContinuousPurge the output is controlled from
Phase22 or continuously [ch.6.8.7].
If an air pressure switch is fitted, continuous running fan is only possible via pressure switch relief. To do this, a vent valve has to be fitted and connected to outputX4-03.
3.4.3 Oil pump / magnetic coupling
Either the magnetic coupling, a separate oil pump or the anti syphon valve are connected to outputX6-02.
The type of oil pump coupling is set in parameter OilPumpCoupling, see
[ch.6.8.4].
Magnetic coupling / separate oil pump
On dual fuel burners with magnetic coupling or on burners with separate oil pump,
parameter OilPumpCoupling is set to Magnetcoupl . The switch-on point
of the ignition should be set to short pre-ignition (on in Ph38). In light oil operation, the output is controlled from the start of pre-ignition (phase38) to operating
setting2 (phase62). In heavy oil operation, the output is controlled in phase36, to
ensure oil pressure is available for the subsequent nozzle circulation.
Direct coupling
On oil burners with the oil pump directly coupled to the burner motor, the anti syphon valve is connected to outputX6-02. Parameter OilPumpCoupling must
be set to Directcoupl, this means that long ignition is activated automatically.
The output is controlled together with the fan from phase22 and remains activated
for a further 15seconds after the fan has switched off.
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Page 37
Installation and operating instruction
1
2
X4-03
3
PE
N
L
M
P
P
+
-
1
2
X4-03
3
PE
N
L
M
P
P
+
(START)
(START)
1
2
X4-02
3
PE
N
L
IGNITION
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.4.4 Start signal, pressure switch relief
OutputX4-03 is controlled depending on parameter Start/PS valve, see
[ch.6.8.10].
Start signal
If parameter Start/PS valve is set to Start signal , the output is controlled in phase21 to phase79.
Pressure switch relief
If an air pressure switch is fitted, continuous venting or direct start is only possible
via pressure switch relief. To do this, a normally open vent valve has to be fitted to
the air pressure switch and parameter Start/PS valve must be set to PS
Reli_Inv The output is controlled together with the fan motor, except at start
release (phase21) and direct start (phase79). The output is not controlled in
phase21 and79, the air pressure switch de-energises via the open vent valve and
the signal at inputX3-02:1 corresponds to the program sequence.
3.4.5 Ignition
The ignition unit is connected to outputX4-02.
Ignition behaviour Gas
In gas operation, the output is controlled in phase38 and40.
The pre-ignition time in phase 38 can be adjusted in parameter PreignitionT-
Gas, see [ch.6.8.1].
Ignition behaviour Oil
The switch-on point of the ignition is determined in parameter IgnOilPumpStart, see [ch.6.8.4].
The pre-ignition time in phase38 can be adjusted in parameter PreignitionTOil, see [ch.6.8.1].
ParameterIgnOilPumpStart Application
on in Ph38
Output is controlled in phase38 and40
(short pre-ignition).
on in Ph22
Output is controlled in phases22 to40
(long pre-ignition).
Dual fuel burners with magnetic coupling
between burner motor and oil pump.
Burners with separate pump or pump
station.
Burners with oil pump coupled directly
to the burner motor.
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3 Product description
1
2
X6-03
3
PE
N
L
SV
1
2
X6-02
3
PE
N
L
M
1
2
X3-01
L
L
MOTOR
ALARM
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.4.6 Anti syphon valve
If an anti syphon valve is fitted in the oil supply, the valve can be connected to outputX6-03, X6-02 or X3-01.
Output X6-03:
Dual fuel burners with magnetic coupling between burner motor and oil pump
Oil and dual fuel burners with separately driven oil pump
Output X6-02:
Oil burners with oil pump coupled directly to the burner motor (without continuous running fan)
Output X3-01:
Dual fuel burners with oil pump coupled directly to the burner motor (without
continuous running fan)
Oil burners with oil pump coupled directly to the burner motor (with continuous
running fan)
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Page 39
Installation and operating instruction
L
1
2
X7-01
3
PE
N
L
V2
1
2
X7-02
3
PE
N
L
V3
1
2
X8-02
3
4
N
PE
V1
L
1
2
X8-03
3
4
N
PE
V1
2
1
3
2
1
MSEL
1
2
X7-01
3
PE
N
L
V2
L
1
2
X8-02
3
4
N
PE
V1
MS
EL
L
1
2
X8-02
3
4
N
PE
V1
L
1
2
X8-03
3
4
N
PE
V1
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.4.7 Oil fuel valves
The oil solenoid valves are connected to the outputsX7-01, X7-02, X8-02 and
X8-03. The outputs are controlled according to the program sequence [ch.3.2.7].
Multi-stage operation
Output Light oil (EL)
Heavy oil (MS) three stage
X7-01 Stage 2 Stage 1
X7-02 Stage 3 Stage 2
X8-02 Stage 1 X8-03 Additional solenoid valve Additional solenoid valve
Nozzle circulation via outputX8-03 is not possible on three stage heavy oil burners,
as the combustion manager controls outputsX8-02 andX8-03 simultaneously. The
solenoid valve for nozzle circulation is connected to outputX4-02 (ignition) and
parameter IgnOilPumpStart must be set to on in Ph22 (long preignition) [ch.6.8.4].
Heavy oil (MS) two stage
Modulating operation
Output Light oil (EL) Heavy oil (MS)
X7-01 - Nozzle solenoid (nozzle head)
X8-02 Nozzle solenoid (nozzle head)
-or-
Solenoid valves
X8-03 Additional solenoid valves
(1
The solenoid valve in the supply is always switched electrically in series with the
(1
(1
Additional solenoid valves
Bypass valve (only with separate
pump station)
-
(1
solenoid valve in the return.
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3 Product description
N PE
2
1
1
2
X9-02
N
PE
L
1
2
X9-01
3
4
SV
L
PV
L V2
L
V1
SV
PV
L
1
2
X9-01
SV
L
PV
L
1
2
X9-01
SV
L
PV
(1
(2
V2 / V1
2
1
N PE
L
1
2
X9-01
3
4
SV
L PV
L
V2
L V1
P
1
2
X9-02
N
PE
L
1
2
X9-01
3
4
SV
L PV
L V2
L
V1
M1
M
2
1
2
X8-01
GAS
N
OIL
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.4.8 Fuel valves Gas
The fuel valves are connected to outputX9-01. The contacts are controlled in accordance with the program sequence [ch.3.2.7].
Output Fuel valve
X9-01:1 (SV) External gas solenoid valve (optional)
X9-01:2 (PV) Ignition gas valve(1
- or -
Gas ignition device
Main gas
X9-01:3 (V2)
X9-01:4 (V1)
(1
Only for burners with ignition gas tube.
(2
Only for heavy oil burners with gas ignition
Double gas valve
Valve 2
Valve 1
(2
83054802 1/2018-07 La
Valve lift monitoring
The two actuators (SKP15) of double gas valves type VGD (from DN125) are
equipped with limit switches. The limit switches monitor the valve lift and are
switched in sequence with the voltage supply of actuatorV2.
At burner start, the limit switches are bridged via a timer relay for approx.25
seconds. If both limit switches are closed once this time has elapsed, valveV2 remains open.
If a valve does not maintain the minimum lift, the relevant limit switch opens and interrupts the voltage from actuatorV2. ValveV2 closes and the combustion manager initiates a safety shutdown with restart. The number of safety shutdowns in sequence set in parameter LossOfFlame result in a lockout [ch.6.8.12].
Alternatively with pressure regulator on double gas valve:
If a pressure regulator (SKP25) is mounted on the gas double valve, a low gas
pressure switch monitors the valve lift. In this case, the contact of the gas pressure
switch is connected in series with the power supply of actuator V2. When starting
the burner, the gas pressure switch is bridged by a time relay for approx. 5
seconds.
3.4.9 Operational display
OutputX8-01 is controlled together with valve1 of the current fuel. The output may
only be used as the operating display.
40-228
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Installation and operating instruction
FE
1
2
X63
3
0
4-20 mA
FE
1
2
X73
3
4
6
5
Start OUT
0
U1
WH
BN
GN
YE
GY
Combustion manager W-FM 100 und W-FM 200
3 Product description
3.4.10 Analogue output
If the combustion manager is equipped with an internal load controller, a system
value can be issued at output X63 via an analogue signal(0/4 … 20mA). The output can be configured in parameter Analog Output, see [ch.6.12.7].
Load signal
If the parameter Selection analog output is set to Load the analogue
signal corresponds to defined values. For different scaling, the parameter has to be
set to Load 0 .
Modulating operation:
Burner capacity OFF 0 % 100 %
Analogue signal 4 mA 4 mA 20 mA
Multi-stage operation:
Burner capacity OFF Stage 1 Stage 2 Stage 3
Analogue signal 4 mA 5 mA 10 mA 15 mA
3.4.11 Frequency converter
The frequency converter is connected to output X73 using a screened cable
(W-FM 200 only). The screen must be connected to ground on both sides.
Terminal
(W-FM 200)
X73:1/2 Enable contact:
X73:3 Alarm input:
X73:4/5 Setpoint output (0/4…20mA):
Function
The enable contact for the frequency converter closes from a de-
sired speed greater than 0%.
The switch status in phase10 (home run) for the standby position
(0%) can be specified via parameter ReleasecontctVSD, see
[ch.6.14.1].
A signal from the frequency converter(DC12…24V) results in
a safety shutdown.
The output and input (W-FM 200 / frequency converter) must be
matched. The output signal can be set in parameter Setpoint
Output, see [ch.6.14.5].
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3 Product description
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.5 Technical data
3.5.1 Electrical data
Combustion Manager
Mains voltage / Mains frequency (120) 230 V / 50 … 60 Hz
Consumption max 30 W
Internal unit fuse T6.3H, IEC 127-2/5
External fuse max 16 AB
Type of protection IP 00
Total contact load outputs max 5A
Fan motor (output X3-01:1) 1A
Alarm (output X3-01:2) 1A
Ignition (output X4-02) (1.6) 2A
Pressure switch relief (output X4-03) 0.5A
Magnetic coupling (output X6-02) (1.6) 2A
Oil fuel valves (1.6) 1A
Fuel valves Gas (1.6) 2A
Display and operating unit (ABE)
Mains voltage AC 24 V
Consumption max 50 mW
Type of protection (front)
Type of protection (rear)
Transformer
Mains voltage / Mains frequency (120) 230 V / 50 … 60 Hz
Secondary 1 AC 12 V
Secondary 2 2 x AC 12 V
Actuator
SQM45… SQM48.497A SQM48.697A SQM91.391A9
Mains voltage AC 2 x 12 V AC 2 x 12 V AC 2 x 12 V AC 2 x 12 V
Consumption 9 … 15 VA 26 … 34 VA 26 … 34 VA approx. 40 VA
Torque 3 Nm 20 Nm 35 Nm 60 Nm
Setting time 10 s / 90° 30 s / 90° 60 s / 90° 30 s / 90°
Type of protection IP 54 IP 54 IP 54 IP 66
IP54 to ICE 529
IP00 to ICE 529
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3 Product description
O2 module
Mains voltage / Mains frequency (120) 230 V / 50 … 60 Hz
Consumption O2 module
Consumption O2 sensor
Internal unit fuse 2.5 T, IEC 127-2/1
External fuse max 16 AB
Type of protection IP 44
O2 sensor
Mains voltage / Mains frequency (120) 230 V / 50 … 60 Hz
Consumption max 90 W
Type of protection IP 44
Permissible flue gas velocity 1 … 10 m/s
Flue gas temperature max 300 °C
Permissible fuels QGO 20:
max 4 W
max 90 W
Natural and Liquid Petroleum Gas
Fuel oil EL
QGO 21:
Natural and Liquid Petroleum Gas
Fuel oil EL
Heavy oil to DIN 51603-3
and DIN 51603-5
3.5.2 Ambient conditions
Temperature in operation –20 … +60 °C
Temperature during transport / storage –20 … +60 °C
relative humidity max 95 %, no dew point
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3 Product description
82 mm
260 mm
232 mm
250 mm
19
24
49 mm
96 mm
90,2 mm
135,8 mm
126 mm
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
3.5.3 Dimensions
Combustion Manager
Display and operating unit (ABE)
Recess dimension: 127 x 91 mm ± 0.5 mm
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Installation and operating instruction
79,5 mm
102,5 mm
120 mm
10,5 mm
40,5 mm
55,5 mm
9 mm
87 mm
66,5 mm
Combustion manager W-FM 100 und W-FM 200
Transformer
3 Product description
83054802 1/2018-07 La
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Page 46
4 Installation
90 mm
51 mm
180 / 260 mm
53,5 mm
48 mm
QGO 21
QGO 20
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
4 Installation
4.1 Installing O2 sensor
O2 trim is only possible with W-FM 200 with O2 module.
For O2 measurement, an O2 sensor must be fitted in the flue gas pipe and connected to the O2 module. The distance between O2 sensor and O2 module must be no
more than 10m.
Flange dimensions
CAUTION
Prerequisite
Damage to the O2 sensor caused by overheating
Flue gas temperature above 300°C can damage the O2 sensor.
Avoid flue gas temperatures above 300°C at the O2 sensor.
Install O2 sensor only with the corresponding flange.
It must not be possible for extraneous air to enter in front of the sensor and at a
distance of 2xØ of the flue gas pipe behind the sensor.
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Installation and operating instruction
45°
45°
5°
QGO 21
QGO 20
min 1 x Ø
Ø
1
≥ 10 mm
2
3
2
31
QGO 20
QGO 21
4
Combustion manager W-FM 100 und W-FM 200
4 Installation
Installation position
Install the sensor as close as possible to the flue gas outlet of the boiler, but at
least at a distance of 1xØ of the flue gas pipe.
Sensor in the horizontal part of the flue gas pipe:
QGO 20: vertically from above or at an angle of 45°.
QGO 21: horizontal
Sensor in the vertical part of the flue gas pipe:
With a downward inclination of approx. 5°.
Installation
Weld flange gastight to flue gas pipe1, with QGO20 observe the position of
the flue gas outlet openings4.
Install O2 sensor2, ensuring correct alignment of the seal3.
Cable entry must be made on the opposite side to the flue gas flow.
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Page 48
5 Installation
DANGER
WARNING
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
5 Installation
5.1 Electrical connection
Risk of electric shock
Working on the device when voltage is applied can lead to electric shock.
Isolate the device from the power supply prior to starting any work.
Safeguard against accidental restart.
Electric shock despite disconnection from the voltage supply
It is possible that electrical components on burners with frequency converters continue to carry voltage and cause electric shock even after the voltage supply has
been disconnected.
Wait approx. 5 minutes before commencing work.
Electric voltage has dissipated.
The electrical connection must only be carried out by qualified electricians. Observe local regulations.
Connect combustion manager
Use cable entry grommets on the housing.
Connect wiring to wiring diagram enclosed.
Control circuits, which are taken directly via a 16AB fuse from a 3 phase or
single phase alternating current supply, must only be connected between a phase
conductor and earth potential neutral conductor.
On mains supply, which does not have a neutral, the control voltage must be supplied via an isolating transformer. The pole of the transformer, which is to be used
as the neutral conductor, must be earthed.
Phase L must not be mixed up with the neutral conductor N. Contact protection will
otherwise no longer be given. Malfunctions, which endanger operational safety
could occur.
The cable cross section of the voltage supply must be suitable for the nominal current of the external fuse (maximum 16AB). All other cable connections must be
suitable for the relevant internal unit fuse (T6.3H).
Earthing and neutral conductor must conform to local regulations.
The following applies for cable length:
all cable lengths maximum 100 m,
use only original Weishaupt parts as Bus line,
install Bus line as line configuration.
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Installation and operating instruction
12V
12VUN12V
X10-01
G
G0LN
X52FEX51
X51
CANL
CANH
CANL
CANH
5
3
X3-04
NLPE
W-FM ...
5
12V
12VUN12V
SQM...
M
SQM...
M
SQM...
M
5
5
N
L
12V
12VUN12V
X10-01
GG0LNX52FEX51
X51
CANL
CANH
CANL
CANH
SQM...
M
SQM...
M
SQM...
M
5
5
5
5
5
O2
X3-04
NLPE
W-FM 200
4 AT
4 AT
4 AT
4 AT
6,3 AT
4 AT
4 AT
6,3 AT
6,3 AT
1
2
4
3
4
4
1
5
2
Combustion manager W-FM 100 und W-FM 200
5 Installation
Bus connection / supply voltage
The CAN Bus line must not exceed a total length of 100 m. A second source transformer is required from a line length of 20m between the combustion manager and
the last actuator, e.g. if the combustion manager is fitted to control panel. In this
case transformer1 feeds the combustion manager and ABE, transformer2 feeds
the actuators. In so doing, the power supply of the CAN bus line (AC1 and AC2)
between combustion manager and the first actuator must not be connected.
The ends of the bus line must be terminated with a bus termination resistor. The
bus termination is permanently installed in the ABE. On the last actuator or at the
O2 module, the bus termination must be set via a jumper. Bus termination must be
deactivated for all other participants.
The screen of the bus line must be terminated at both ends.
1 Burner
2 Bus termination
3 Control panel
4 Transformer
5 O2 module
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Page 50
5 Installation
1
2 3 4
5
6
7 8 9
18
CAN
X70
COM 2
X72
1
2 3 4
5
6
7 8 9
COM 1
X71
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Display and operating unit (ABE)
The ABE is equipped with 3 interfaces.
CAN (X70): CAN Bus connection to the combustion manager
COM 1 (X71): RS-232 for PC connection
COM 2 (X72): RJ45 connection building management system via Bus interface
The COM interfaces can not be used at the same time
PIN CAN (X70) COM 1 (X71) COM 2 (X72)
1 - - TXD
2 CAN L RXD 3 GND TXD RXD
4 VAC 2 - GND
5 - GND U 1
6 - - GND
7 CAN H - U 2
8 VAC 1 - -
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
5 Installation
Connect burner / fan motor, pump station
The motor must be protected against thermal overload and short circuit. Weishaupt
recommend the use of a motor protection switch.
Open terminal box on motor.
Connect voltage supply to wiring diagram enclosed, observe motor rotation.
Variable speed drive (optional)
If the frequency converter is located on the motor, the cable to the frequency converter is not screened.
If the frequency converter is separate the control line and the motor connection
must be screened.
Apply screen to the screen clamp on frequency converter.
Use screen cable glands (metal) on the burner.
Connect gas valve train
Observe wiring diagram supplied.
Connect double gas valve (plug K32).
Solenoid coil on W-MF or DMV
Actuator on VGD.
Connect limit switch for valve lift monitoring (plug S33 / S35), only with VGD.
Connect ignition gas valve (plug K31).
Connect low gas pressure switch (plug B31).
Connect valve proving gas pressure switch (plug B32).
If required, connect high gas pressure switch (plug B33).
Connect connection cable to burner using cable entry W-FM.
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5 Installation
2
3
X81
4
5
6
1
QGO...
B1
M
B2
M
G2
U3
GND
2
3
X89-2
1
QGO...
PE
NLQ5
Q4
Q5
Q4
G2
M
M
B1
U3
B2
PLL...QGO...
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Connect O2 sensor
The O2 sensor is connected to the O2 module (accessory).
Connect the signal cable (3x2x0.25 mm2), twisted in pairs, to X81. Connect the
screen to one side of the creen clamp of the O2 module, cable length maximum
10m.
Connect separate cable (3x0.75 mm2) for the sensor heating to
outputX89-2:Q4/Q5.
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Installation and operating instruction
4
3
2
1
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.1 Operating interface
6.1.1 Operating panel
Display and operating unit (ABE)
6 Operation
1 Dial knob navigation through parameter structure; chan-
ging values
2 [Enter] select
3 [esc] return/cancel
4 [info] return to operating display
OFF function
Press [ENTER] and [esc] simultaneously.
Immediate lockout.
The lockout is stored in the fault history.
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6 Operation
1
Normal operation
Status/Reset
Fault history
Lockout history
Normal operation
Status/Reset
Fault history
Lockout history
Operating display
Operation
Manual operation
Param & Display
Lockout
Air pressure is
off
Safety
shutdown
Safety loop
is open
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6.1.2 Display
The ABE is equipped with a 4 line display with 16 characters per line. The dial
knob is used to scroll through the display, the cursor1 indicates the position selected.
Operating display
The [info] key is used to jump from any menu level to the
operating display menu. The [esc] key is used to return the
display to the menu point previously used.
Menu level 1
The [esc] key is used to leave any position and to go back
all the way to menu level 1 [ch.6.3].
Fault display
During a fault condition, the display alternately shows the shutdown behaviour and
the fault diagnosed as a plain text display.
The combustion manager is in lockout. Once the fault has
been rectified, the combustion manager has to be reset for
restart [ch.9.1].
The combustion manager initiates a safety shutdown.
The burner restarts automatically once the fault condition
has been rectified.
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Call up menu level 1
Normal operation
Status/Reset
Fault history
Lockout history
Operating display
Operation
Manual operation
Param & Display
Updating
Enter PW
TÜV Test
Operating display
Operation
Manual operation
Param & Display
Operating display
Operation
Manual operation
Param & Display
Boiler setpoint
User Maxload
Fuel
Date/Time
Boiler setpoint
User Maxload
Fuel
Date/Time
Operating display
Operation
Manual operation
Param & Display
Auto/Manuel/Off
Time
SwitchOffBeh
ProgramStop
Program stop
Curr: deactivated
New: 36 Ignpos
Auto/Manuel/Off
Time
SwitchOffBeh
ProgramStop
Program stop
Curr: deactivated
New: 36 Ignpos
Navigating through the level
One level lower
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.2 Displaying and adjusting parameters
Press [esc] key until menu level 1 is displayed.
Turn dial knob.
Cursor switches to the next menu point.
If a level has more than 4 menu points, the display scrolls up and down.
Press [ENTER].
One level higher
Change value
Save value
Press [esc] key.
Press [ENTER].
Selected parameter is displayed.
Turn dial knob.
New value is displayed.
Press [ENTER].
The value changed is applied and saved.
Do not accept value:
Press [esc] without first confirming with [Enter] key.
Exit parameter without changing the value.
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6 Operation
Enter PW
TÜV Test
Manual operation
Param & Display
Updating
Enter PW
Access without PW
Access with HE
Access with OEM
Access with SBT
Enter
Password
:9876••••
Operating display
Operation
Manual operation
Param & Display
Param & Display
Updating
Enter PW
Deactivate PW
Password has
been deactivated
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6.2.1 Password
Enter password
HE password: 9876
Select Enter PW in menu level1 and press the [Enter].
Select Access with HE and press [Enter].
Set first character using the dial knob and confirm with [Enter].
A star appears and the cursor moves to the next position.
Repeat procedure until the password has been entered.
Confirm password with [Enter].
Display changes to menu level 1.
Deactivating password
If no key is activated for 120 minutes, the combustion manager automatically deactivates the password and blocks the password level.
Select Deactivate PW in menu level 1 and press [Enter].
The display shows Password has been deactivated.
Press [esc] key.
Display changes to menu level 1.
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6.3 Menu structure
Values in the square brackets show the factory setting.
Operating display
Normal operation
Status/Reset
Fault history
Lockout history
Alarm act/deact
Operation
Boiler setpoint
Setpoint W1
Setpoint W2
Load limitAB
UserMaxLoadMod [100 %]
UserMaxLoadStg [S3]
Fuel
CurrentFuel
FuelSelect
6 Operation
Date/Time
Display the clock
Date
Time
Weekday
Set the clock
Date
Time
Weekday
Hours run
Gas operation
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
TotalHours
SystemOnPower
StartCounter
GasStartCount
OilStartCount
TotalStartCountR
TotalStartCount
Fuel meter
(1
Curr Flow Rate
Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset DateGas
Reset DateOil
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Number of lockouts
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6 Operation
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Operation (continued)
O2 module
curr. O2 value
O2 setpoint(1
Inlet air temperature
Flue gas temperature(1
CombEfficiency
(1
(1
(1
Burner identification
Operating mode selection
Interface PC
GatewayBASon
GatewayBASoff
Type of Gateway [Modbus]
O2Ctrl activate
(1
Manual operation
SetLoad
Autom/Manual/Off [Automatic]
Param & Display
Burner Control
(2
Times
TimeStartup1
MinTimeStartRel [1 s]
FanRunUpTme [2 s]
PrepurgeTmeGas [20 s]
PrepurgeTmeOil [15 s]
PrepurgeSafeGas [20 s]
PrepurgeSafeOil [15 s]
PrepurgePtl1Gas [0.2 s]
PrpurgePt3Gas [0.2 s]
PrepurgePt1Oil [0.2 s]
PrepurgePt3Oil [0.2 s]
PreIgnTime_Gas [2 s]
PreIgnTime_Oil [2 s]
MinOnTime Oil pump [1 s]
TimeStartup2
Interval1Gas [2 s]
Interval1Oil [2 s]
Interval2Gas [2 s]
Interval2Oil [2 s]
PressReacTime [2 s]
TimeShutdown
MaxTmeLowFire [45 s]
AfterburnTme [8 s]
PostpurgeT1Gas [0.2 s]
PostpurgeT1Oil [0.2 s]
PostpurgeT3Gas [5 s]
PostpurgeT3Oil [5 s]
PostpurgeT3long [0 s](1
DelayLackGas [10 s]
(1
W-FM 200 only
(2
only with HE password
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Param & Display (continued)
Times in general
AlarmDelay [35 s]
DelayStartPrev [35 s]
PostpurgeLockout [0.2 s]
MaxTmeStartRel [120 s]
6 Operation
Configuration
ConfigGeneral
AlarmStartPrev [deactivated]
StandbyError [deactivated]
NormDirectStart[NormalStart]
OilPumpCoupling
IgnOilPumpStart
ForcedIntermit [activated]
Skip PrepurgeGas [deactivated]
ContinuousPurge [deactivated]
ConfigIn/output
RotSpeed PS on(1 [80]
RotSpeed PS off(1 [50]
Config X5-03 [LMV5x hrs]
Start/PS-Valve
ConfigFlamDet
ReacExtranLight [Startblock]
FlameSignal
RepetCounter
LossOfFlame [2]
HeavyOil [3]
StartRelease [10]
SafetyLoop [16]
(2
(2
(2
ProductID
ASN ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW Version
Ratio control
SettingGas / Oil
SpecialPositions
HomePos
PrepurgePos
IgnitionPos
PostpurgePos
ProgramStop [deactivated]
ResetIgnitPos
CurveParams
LoadLimits
MinLoad [0 %]
MaxLoad [100 %]
(1
W-FM 200 only
(2
only with HE password
(2
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6 Operation
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Param & Display (continued)
Load mask out
LoadMaskLowLimit [0 %]
LoadMaskHighLim [0 %]
FC(1 [activated]
StartPoint Op [1]
Autom/Manual/Off [Automatic]
(2
Times
OperRampMod
OperRampStage
TimeNoFlame
ShutdownBehav(2 [Rest pos]
ProgramStop(2 [deactivated]
O2Contr/Alarm
(1
Gas/Oil settings
Operating mode
O2 trim
(2
O2 monitor
(2
(2
O2 Alarm
O2 MaxValue [15]
NumMinUntilDeact [1]
Controller parameter
PI
LowFireAdaptPtNo(2 [2]
O2CtrlThreshold(2 [0 %]
LoadCtrlSuspend(2 [5 %]
O2ModOffset(2 [0 %]
Type Air Change(2 [like theory]
O2MaxManVariable(2 [35%]
O2MinManVariable(2 [-35%]
Startmode
O2InitOffset(2 [0 %]
NoTauSuspend(2 [10]
Adjust. Temp O2 [20 °C]
Type of Fuel
Fuel user-def
V_LNmin
V_afNmin
V_atrNmin
A2
B/1000
(2
COx
OptgMode COx Gas [deactivated]
OptgMode COx Oil [deactivated]
Time COx alarm [20 s]
(1
W-FM 200 only
(2
only with HE password
(2
(2
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Param & Display (continued)
Process data
CombEfficiency
Man Var O2Ctrl
State O2Ctrl
Air-Related Load
Diag Reg State
Load controller
Controller parameters
ContrlParamList
StandardParam
P Part (Xp) [15 %]
I Part (Tn) [320 s]
D Part (Tv) [40 s]
MinActuatorStep [1 %]
SW_FilterTmeCon [3 s]
SetpointW1
SetpointW2
Sd_ModOn [1 %]
Sd_ModOff [10 %]
Sd_Stage1On [-2 %]
Sd_Stage1Off [10 %]
Sd_Stage2Off [8 %]
Sd_Stage3Off [6 %]
ThreshStage2On[300]
ThreshStage3On [600]
TempLimiter
(2
TL_ThreshOff [95 °C]
TL_SD_On [-5 %]
6 Operation
Cold start
ColdStartOn (2 [deactivated]
ThresholdOn(2 [20 %]
StageLoad(2 [15 %]
StageSetp_Mod(2 [5 %]
StageSetp_Stage(2 [5 %]
MaxTmeMod(2 [3 min]
MaxTmeStage(2 [3 min]
ThresholdOff(2 [80 %]
AdditionalSens(2 [deactivated]
Temp. ColdStart
SetpAddSensor
Release Stages(2 [Release]
Configuration
LC_OptgMode [Int LR]
Sensor Select(2 [Pt100]
MeasureRangePtNi(2 [150 °C / 302 °F]
var.RangePtNi(2 [850 °C]
Ext Inp X61 U/I(2 [0 … 10 V]
MRange TempSens(2 [90 °C]
MRange PressSens(2 [2 bar]
Ext Inp X62 U/I(2 [4 … 20 mA]
Ext MinSetpoint(2 [0 %]
Ext MaxSetpoint(2 [60 %]
(1
W-FM 200 only
(2
only with HE password
(2
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6 Operation
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Param & Display (continued)
Analogue output
(2
OutValuSelection [Load]
CurrMod 0/4mA [4 … 20 mA]
Scale20mA perc [100 %]
Scale20mA temp [850 °C]
Scale20mA press [2 bar]
Scale20mA angle [90°]
Scale 0/4mA [0 %]
Adaption
StartAdaption
AdaptionLoad [100 %]
SW Version
ABE
Times
Sum/WinterTime[Automatic]
Time EU/US
Language
DateFormat
PhysicalUnits
eBUS
Address [1]
SendCycleBU [30 s]
Modbus
Address [1]
Baud rate [19200 bit/s]
Parity [none]
Timeout [30 s]
Local / Remote
Remote Mode
W3
Display contrast
ProductID
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW Version
83054802 1/2018-07 La
Actuators
Addressing
1 AirActuator
2 GasActuator. (Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2(1
6 AuxActuator3
Rotation direction
DeleteCurves
(1
W-FM 200 only
(2
only with HE password
(2
(2
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Param & Display (continued)
ProductID
1 AirActuator
2 GasActuator. (Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2(1
6 AuxActuator3
SW Version
1 AirActuator
2 GasActuator. (Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2(1
6 AuxActuator3
VSD module
(1
Configuration
Releasecontct.VSD
(2
[closed]
6 Operation
Speed
Num Puls per R
Standardisation
StandardisedSp
Absolute Speed
Setpoint Output
Fuel meter
PulseValueGas [1]
PulseValueOil [1]
Process data
Max Stat Dev
Max Dyn Dev
NumDev >0.3%
NumDev >0.5%
Absolute Speed
Product identification
ASN Production date
SerialNumber
ParamSet Code
ParamSet Vers
SW Version
O2 module
(1
Configuration
O2 Sensor [no sensor]
O2SensServTim [0]
O2SensServTimRes
SupAirTempSens [no sensor]
FlueGasTempSens [no sensor]
MaxTempFlGasGas [300 °C]
MaxTempFlGasOil [300 °C]
(1
W-FM 200 only
(2
only with HE password
(2
[3]
(2
(2
(2
[4 … 20 mA]
(2
(2
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6 Operation
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Param & Display (continued)
Process Data
Current O2 value
O2 Setpoint
SupplyAirTemp
FlueGasTemp
CombEfficiency
QGO SensorTemp
QGOHeatingLoad
QGO Resistance
ProductID
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW Version
Flue gas recirculation
(1
FGR-Mode [Aux3 Curve]
FGR-sensor [X86PtNi1000]
actTmpFGR-sensor
ThresholdFGR Gas
ThresholdFGR Gas [300 s]
FGR Factor Gas [100]
Operating temp Gas
ThresholdFGR Oil
ThresholdFGR Oil [300 s]
Factor FGR Oil [100]
Operation TempOil
FGR MinPos [0]
FGR MaxPos Fact [10]
SystemConfig
LC_OptgMode [IntLC]
Ext Inp X62 U/I(2 [4 … 20 mA]
TempLimiter
TL_Thresh_Off [95 °C]
TL_SD_On [-5 %]
Sensor Select [Pt100]
MeasureRangePtNi [150 °C / 302 °F]
O2Ctrl/LimitrGas(2 [man deact]
O2Ctrl/LimitrOil(2 [man deact]
LC Analog output(2 [Load]
allowed Pot.diff(2 [15]
Hours run
GasFiring
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
TotalHours
SystemOnPower
(1
W-FM 200 only
(2
only with HE password
(2
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Param & Display (continued)
Reset
GasFiring
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
StartCounter
GasStartCount
OilStartCount
TotalStartCountR
TotalStartCount
Reset
GasStartCount
OilStartCount
TotalStartCountR
Fuel meter
Curr Flow Rate
Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset DateGas
Reset DateOil
6 Operation
Updating
ParamBackup
Backup info
Date
TimeOfDay
BU included?
AZL included?
LC included?
SA1 included?
SA2 included?
SA3 included?
SA4 included?
SA5 included?
SA6 included?
VSD included?
O2 included?
LMV5x -> AZL
AZL -> LMV5x
Load SW from PC
(2
(2
(2
Enter PW
Deactivate PW
(2
TÜV Test
LossFlameTest(2
SLT Test
SLT TestlloadMod [100 %]
SLT Testload Stg [S3]
(1
W-FM 200 only
(2
only with HE password
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.4 Operation and system information
6.4.1 Normal operation
Operating display Normal operation
In menu Normal operation you can switch between the standard display and
the position display.
Press [ENTER].
Display changes.
Depending on the current operating phase, the standard display shows the following information:
Setpoint and actual value
Fuel selected
Current operating phase (clear text and number)
Fuel and air actuator positions
Current burner capacity and flame signal
The position display shows the following information:
Actuator positions
Speed
O2 content
Burner capacity
6.4.2 Fuel selection
Operation Fuel Current fuel
Fuel selection
Current fuel
The fuel selected is shown in parameter CurrentFuel (read only).
Fuel selection
With dual-fuel burners you can switch between oil and gas operation. A fuel
change during operation will initiate a restart.
Fuel selection is possible via:
Fuel selection switch on input X4-01:1/2 [ch.3.3.6]
Parameter fuel selection (ABE)
Building management system (BMS) on Bus connection.
The fuel selection switch on inputX4-01:1/2 has priority. Fuel selection via ABE or
BMS is only possible if no signal is present at inputX4-01:1/2. There is not priority
between ABE and BMS, the last fuel selection is valid and is retained after power
failure.
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6.4.3 Operating hours
Operation HoursRun
or
Param & Display HoursRun
Access in menu Operation/HoursRun is read only.
The individual operating hours counters can be reset in Param & Display/
HoursRun/Reset/… .
Parameters Function
Gas operation Operating hours Gas (can be reset)
OilStage1/Mod Operating hours Oil stage1 / modulating operation (can
OilStage2 Operating hours Oil stage2 (can be reset)
OilStage3 Operating hours Oil stage3 (can be reset)
TotalHoursReset Total operating hours (can be reset)
TotalHours Total operating hours ( read only, can not be reset)
SystemOnPower Operating hours with voltage applied to device (read only,
Reset Reset only possible under Param & Display /
6 Operation
be reset)
can not be reset)
HoursRun
6.4.4 Start-up counter
Operation StartCounter
or
Param & Display StartCounter
Access in menu Operation/StartCounter is read only.
The individual start counters can be reset via Param & Display/Start-
Counter/Reset/… .
Parameters Function
GasStartCount Burner starts Gas (can be reset)
OilStartCount Burner starts Oil (can be reset)
TotalStartCountR Total burner starts Gas and Oil (can be reset)
TotalStartCount Total burner starts Gas and Oil (read only, can not be re-
Reset Reset only possible under Param & Display /
set)
StartCounter
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Installation and operating instruction
Example
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.4.5 Fuel Meter
Only possible with W-FM 200.
Configuring the inputs
Param & Display VSD module Configuration Fuel Meter
In menu Fuel Meter , the input for the relevant fuel meter is configured
[ch.3.3.22].
Parameters Function
PulseValueGas Number of impulses per volume unit of the gas meter at
input X71
PulseValueOil Number of impulses per volume unit of the oil meter at in-
put X72
The impulses per volume unit are entered in parameter Pulse value… with
4decimal places.
Using the number of impulses set in parameter Pulse value… the W-FM calculates the current fuel throughput.
In full load, the impulse frequency must not exceed 300Hz.
In partial load, the impulse frequency must be minimum 0.1Hz. If the fuel meter
does not supply a signal for 10seconds, no fuel throughput is detected.
Gas meter: 100 impulses/m
Full load throughput: 300 m3/h
Partial load throughput: 50 m3/h
Full load frequency: 100 Imp/m3 x 300 m3/h = 30000 Imp/h
Partial load frequency: 100 Imp/m3 x 50 m3/h = 5000 Imp/h
3
30000 Imp/h ÷ 3600 s = 8.333 Hz
5000 Imp/h ÷ 3600 s = 1.389 Hz
Fuel throughput
Operation Fuel Meter
or
Param & Display Fuel Meter
If a fuel meter is connected, the parameters show the fuel consumption.
Parameters Function
Curr Flow Rate Current fuel throughput (read only, can not be reset)
Volume Gas Total gas throughput (read only, can not be reset)
Volume Oil Total oil throughput (read only, can not be reset)
Volume Gas R Gas throughput (can be reset via Enter)
Volume Oil R Oil throughput (can be reset via Enter)
ResetDateGas Reset date fuel volume Gas
ResetDateOil Reset date fuel volume Oil
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.4.6 Number of lockouts
Operation LockoutCounter
The parameterLockoutCounter shows the number of faults with lockout since
commissioning (can not be reset).
6.4.7 Flame Signal
Param & Display Burner Control Configuration ConfigFlameDet Flame Signal
The parameter FlameSignal shows the current flame signal [ch.3.3.15].
6.4.8 Product identification
Param & Display Burner Control ProductID
or
Param & Display AZL ProductID
or
Param & Display Actuators ProductID
or
Param & Display VSD module ProductID
or
Param & Display O2 module ProductID
In menu ProductID the following information is displayed for all components
selected:
ASN (type description)
Production date
Identification number
Customer code parameters
Version parameters
6.4.9 Software version
Param & Display Burner Control SW Version
or
Param & Display LoadController SW Version
or
Param & Display AZL SW Version
or
Param & Display Actuators SW Version
or
Param & Display VSD module SW Version
or
Param & Display O2 module SW Version
In parameter SW Version the software version of the selected components is
shown.
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6 Operation
6.4.10 Burner identification
Operation BurnerID
The parameter BurnerID shows the burner specific serial number.
The burner identification serves as copy protection. Burner specific data in the
memory of the ABE can not be transferred to another W-FM.
If a W-FM is delivered without burner identification and the backup copy from the
ABE is installed, the W-FM adopts the burner identification of the backup copy
[ch.6.16.1].
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6.5 Setting the display
6.5.1 Setting the language
Param & Display AZL Language
The language for the display can be set in parameter Language .
If the language required is not available, the display and operating unit (ABE) with
the relevant group of languages should be used.
Group of languages (ABE) Languages
Western Europe 1 English, German, French, Italian, Spanish, Por-
tuguese
Western Europe 2 English, Dutch, Danish, Swedish, Norwegian,
Finnish
Eastern Europe 1 English, Polish, Hungarian, Czech, Croatian, Slove-
nian
Eastern Europe 2 English, German, Russian, Bulgarian, Turkish, Ru-
manian
6 Operation
6.5.2 Set contrast
Param & Display AZL Display Contrast
The contrast of the display can be changed and saved using parameter Display
Contrast .
If the operating display is in normal operation, the contrast can be changed using
the dial knob of the ABE.
Press and hold [Enter].
Set the contrast using the dial knob.
The setting will remain until the power supply is interrupted
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6 Operation
6.5.3 Date/Time
Display date and time
Operation Date/TimeOfDay DisplayClock
Set time
The date, time and weekday can be displayed in menu DisplayClock.
The date, time and weekday are set using SetClock.
Summer/Winter time
Param & Display AZL Times Sum/WinterTime
Parameter Sum/WinterTime is used to select manual or automatic changeover
from summertime to wintertime.
Parameter Time EU/US is used to select the European or American summertime or wintertime.
Date
TimeOfDay
Weekday
Time EU/US
Date format
Param & Display AZL DateFormat
Parameter DateFormat is used to select the date formatDD.MM.YY or
YY.MM.DD.
6.5.4 Units
Param & Display AZL PhysicalUnits
Parameter PhysicalUnits is used to select the formats °C/bar or °F/psi.
All relevant values will be displayed and adjusted in the unit selected.
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6.6 Interfaces
6.6.1 Select interfaces
Operation OptgModeSelect InterfacePC
Gateway BASon
Gateway BASoff
Type of Gateway
Menu OptgModeSelect is used to select the serial interface in the operating
and display unit (COM1 or COM2) [ch.5.1].
The COM interfaces can not be used at the same time.
Interface for PC (COM 1)
The combustion manager can be programmed and operated via PC-Tool (Software: ACS450). The display and operating unit serves as interface.
Select parameter InterfacePC and confirm with [Enter].
The interface is activated until the [esc] key is used to exit from parameter In-
terfacePC .
6 Operation
Interface for building management system (COM 2)
The building management system can be connected to the ABE using an external
Bus interface allowing it to access the W-FM.
Activating the interface:
Select parameter Gateway BMS on and confirm with [Enter].
The interface in the display and operating unit (ABE) has been activated and the
building management system can access the W-FM. The ABE remains functional.
Deactivating the interface:
Select parameter Gateway BMS off and confirm with [Enter].
The interface of the display and operating unit (ABE) for the building management system is deactivated. Only the ABE can access the W-FM.
Select Bus protocol:
Select Bus protocol in parameter Type of Gateway and confirm with
[Enter].
eBus [ch.6.6.2]
Modbus [ch.6.6.3]
Data output [ch.6.6.4]
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6 Operation
6.6.2 eBus
Param & Display AZL eBus Address
SendCycleBU
For Bus communication, the interface has to be activated and the bus protocol has
to be defined.
eBus address
Parameter Address defines the eBus address, which is used to communicates
with the W-FM.
Send cycle
Parameter SendCycleBU defines the time for the send cycle. The W-FM transmits its operating data to the eBus participants in the cycle set.
6.6.3 Modbus
Param & Display AZL Modbus
For Bus communication, the interface has to be activated and the bus protocol has
to be defined.
The display and operating unit (ABE) operates as Slave in the Modbus protocol.
The RTU-Modus is used for transfer.
Modbus address
Parameter Address determines the Modbus address of the display and operating unit (ABE).
Baud rate
Parameter Baudrate determines the transfer speed. The Baud rate of the display and operating unit (ABE) and the Modbus participant connected must be
identical.
Parity
Parameter Parity determines the type of parity protocols. The parity of the display and operating unit (ABE) and the Modbus participant connected must be
identical.
Time out
Parameter Timout determines how long after Modbus communication fails the
display and operating unit (ABE) switches from Remote to Local .
If building management is deactivated or the Modbus connection fails, the internal
load controller of the W-FM takes over the control and the internal setpoint (W1) is
activated. Prerequisite is that the W-FM is equipped with an internal load controller
and has been configured [ch.6.12].
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6 Operation
Local / Remote
Setting Function
local The operating modes for the load controller via Bus
ExtLC Bus or IntLC Bus have no influence
[ch.6.12.2].
The internal load controller takes over the control and the
internal setpoint W1 is activated.
remote Setting for load control via Bus [ch.6.12.2].
If the operating mode ExtLC Bus has been selected,
the building management system determines the load.
If operating mode IntLC Bus has been selected, the
building management system determines the setpoint.
If Modbus communication fails, the W-FM automatically
changes into local mode. When communication is
restored, the mode has to be set to remote either via
the ABE or via Modbus signal.
Remote mode
Parameter Remote mode is read only, the setting is made via Modbus (building
management system).
Setting Function
Auto Setpoint W3 is determined by the building management
system.
On Load is determined by the building management system.
Off The internal load controller takes over the control.
External setpoint W3
Parameter W3 is read only, the setting is made via Modbus (building management
system).
6.6.4 Trending data
Operation OptgModeSelect Type of Gateway Data output
In Bus protocol Data output the interface COM2 sends trending data for data
recording.
Interface configuration in menu Modbus is required for data output [ch.6.6.3].
Data recording is not possible for diagnostic purposes during servicing and without
peripherals and software.
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6 Operation
6.7 Manual / Automatic / Off
ManualOperation SetLoad
Autom/Manual/Off
or
Param & Display RatioControl Autom/Manual/Off
Operating mode
Parameter Autom/Manual/Off determines the operating mode. In Remote operation the parameter is read only and can not be altered [ch.6.6.3].
Setting Function
Automatic The burner starts if there is a heat demand at in-
putX5-03:1.
The load controller determines the burner capacity.
Manuel The burner starts if there is a heat demand at input
X5-03:1.
Parameter SetLoad determines the burner capacity.
Burner Off Burner drives to or remains in Standby (Phase12). A
message, that the W-FM is set to Burner Off in
manual operation does not appear.
Target load
Load, to which the burner drives in Manuel operating mode.
In modulating operation, the target load can be set within the load limits [ch.6.9.7].
In multi-stage operation, one of the stages can be selected as the target load.
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6 Operation
6.8 Burner Control
6.8.1 Times
Param & Display Burner Control Times TimesStartup1
TimesStartup2
TimesShutdown
TimesGeneral
TimeStartup1
Time Parameters Function
Start release MinTimeStartRel Minimum residence time in phase21.
The W-FM remains at least the time set in phase21, even
if the start criteria have already been met.
Fan run-up time FanRunupTime Residence time in phase22.
Once this time has elapsed the burner drives to prepurge position.
Pre-purge PrepurgeTmeGas
PrepurgeTmeOil
PrepurgeSafeGas
PrepurgeSafeOil
PrepurgePt1Gas
PrepurgePt1Oil
PrepurgePt3Gas
PrepurgePt3Oil
Pre-ignition
Nozzle circulation
Oil pump ON time MinONTmeOilPump Residence time in phase36 (heavy oil operation only).
PreIgnitionTGas
PreIgnitionTOil
Time from reaching the pre-purge position until driving to
ignition position. The time is divided into the phases 30 to
34. The W-FM remains in phase 30 for the time set under
PrepurgeTimeTl1… and then drives to phase 34 via
phase 32. The rest of the time, the W-FM remains in
phase34, or at least for the duration set under Pre-
purgeTimeTl3… .
Pre-purge time after the following occurrences:
Lockout or safety shutdown
Power failure
Standby longer than 24h
For the duration of this time, auxiliary actuator 3 (FGR) remains in phase30 and the fuel actuators remain in
standby position. The air determining actuators remain in
pre-purge position.
Minimum duration in phase34. The air determining actuators and auxiliary actuator 3 (FGR) remain in pre-purge
position. The fuel actuators remain in standby position.
Residence time in phase38.
Once this time has elapsed, fuel is released for ignition.
On heavy oil burners without return flow temperature
sensor, nozzle circulation can be extended via Pre-
IgnitionTOil .
In heavy oil operation, the time in phase36 can be extended to allow oil pressure to build-up for ignition.
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6 Operation
TimeStartup2
Time Parameters Function
Flame stabilisation Interval1Gas
Interval1Oil
Residence time in phase44.
Once this time has elapsed the burner drives to partial
load.
Interval2Gas
Interval2Oil
Residence time in phase52.
Once this time has elapsed the burner drives to partial
load.
Pressure switch
reaction time
PressReacTime Time delay in phase40, 42 and 52.
The pressure switches are interrogated in phase 40, 42
and 52 by the time delay set.
Prevents shutdown caused by pressure fluctuation when
opening the fuel valves.
TimeShutdown
Time Parameters Function
Load shutdown MaxTmeLowFire Residence time in phase62.
If there is no longer a demand for heat, the W-FM reduces the burner capacity and closes the fuel valves after
the time set has elapsed. If partial load is reached before
the time has elapsed, the fuel valves close immediately.
Anti siphon valve AfterburnTme Residence time in phase70.
Once the time has elapsed, the anti siphon valve at outputX6-03 closes and the actuators for air and fuel drive
to post-purge position.
Post-purge time PostpurgeT1Gas
PostpurgeT1Oil
Residence time in phase74.
Post-purge time1 in phase74 is always executed. Once
this time has elapsed, the auxiliary actuator 3 (FGR)
drives to post-purge position.
Post-purgeT3Gas
Post-purgeT3Oil
Residence time in phase78.
Post-purge time3 in phase78 is interrupted at heat demand. Once the time has elapsed without heat demand,
the W-FM goes to Standby.
PostpurgeT3long
(W-FM 200 only)
Additional residence time in phase78.
The PostpurgeT3long is added to both fuel dependent times PostpurgeT3Gas / Oil .
Times in general
Time Parameters Function
Alarm delay during start prevention
AlarmDelay Time delay until a start prevention at heat demand is is-
sued at outputX3-01:2. The function Alarm during start
prevention must be activated in parameter AlarmDelay.
Message start prevention DelayStartPrev Time delay until a start prevention at heat demand is
shown in the display of the ABE.
Post-purge time lockout PostpurgeLockout If lockout occurs, the fan motor at output X3-01:1 runs on
by the time specified.
Heavy oil immediate start MaxTmeStartRel Maximum waiting time for signal at inputX6-01:3.
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6.8.2 Signalling start prevention
Alarm at start prevention
Param & Display Burner Control Configuration ConfigGeneral AlarmStartPrev
If parameter AlarmStartPrev is activated, start prevention is also signalled at
outputX3-01:2 [ch.3.4.1].
Start prevention in Standby
Param & Display Burner Control Configuration ConfigGeneral Standby Error
If parameter Standby error is activated, faults are also recognised as start
prevention in Standby and are displayed in the ABE.
6.8.3 Normal or direct start
Param & Display Burner Control Configuration ConfigGeneral NormDirectStart
Start prevention at heat demand during shutdown in phase78.
Normal start
If NormalStart is activated, the fan switches off and the burner only starts after
a home run in phase10.
Direct start
If DirectStart is activated the fan continues to run and the W-FM jumps via
phase79 to phase24.
In conjunction with an air pressure switch direct start is only possible with a release
valve at outputX4-03 [ch.3.4.4]. In menu Config input /output the parameter Start/PS-valve must therefore be set to PS Reli_Inv .
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6 Operation
6.8.4 Oil pump
Param & Display Burner Control Configuration ConfigGeneral OilPumpCoupling
IgnOilPumpStart
Control of oil pump and switch on point of pre-ignition in oil operation [ch.3.4.3].
Magnetic coupling / separate oil pump
For burners with magnetic coupling or separate oil pump:
Set parameter OilPumpCoupling to Magnetcoupl.
Set parameter IgnOilPumpStart to On in Ph38 .
Direct coupling
For burners with oil pump coupled directly to the burner motor.
Set parameter OilPumpCoupling to Direct coupl .
The long pre-ignition (on in Ph22) is automatically activated in parameter
IgnOilPumpStart .
6.8.5 Forced intermittent
Param & Display Burner Control Configuration ConfigGeneral ForcedIntermit
With ForcedIntermit activated, the W-FM initiates a controlled shutdown with subsequent restart after 23h50min uninterrupted burner operation. If the burner is
not suitable for continuous operation, forced intermittent has to be activated.
6.8.6 Pre-purge Gas
Param & Display Burner Control Configuration ConfigGeneral Skip PrepurgeGas
If the parameter is activated, the W-FM skips pre-purge in gas operation (Phase24
to34). According to EN 676 only allowed with Class A valves in conjunction with
valve proving system.
Pre-purge is not skipped after:
Lockout
24 h Standby
Power failure
Safety shutdown due to low gas
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6 Operation
6.8.7 Continuous running fan
Param & Display Burner Control Configuration ConfigGeneral ContinuousPurge
If ContinuousPurge is activated, the fan runs in each operating phase.
If an air pressure switch is fitted, continuous purge is only possible with a relief
valve at outputX4-03 [ch.3.4.4]. For this, parameter Start/PS-valve must be
set to PS Reli_Inv in menu Config Input /Output.
Setting Function
deactivated In phases00 to21, outputX3-01:1 (fan) is not activated.
In Phase00 to21, the frequency converter is controlled
with the idle speed (HomePosVSD) set, even if the safety
circuit / burner flange is open.
activated OutputX3-01:1 (fan) and the frequency converter are al-
ways activated, even if the safety circuit / burner flange
are open.
off Sloop OutputX3-01:1 (fan) and the frequency converter are al-
ways activated, except if the safety circuit / burner flange
are open.
deact/VSD-SL In phases00 to21, outputX3-01:1 (fan) is not activated.
In Phase00 to21, the frequency converter is controlled
with the idle speed (HomePosVSD) set, except if the
safety circuit / burner flange is open.
6.8.8 Additional air pressure switch
Param & Display Burner Control Configuration Config input/
output
The speed range set is monitored by an additional air pressure switch.
In the OEM level, the additional air pressure switch is deactivated, the function is
not used in standard applications.
Parameters Function
RotSpeed PS on The additional air pressure switch must supply an ON sig-
nal above the speed set.
RotSpeed PS off The additional air pressure switch must supply an OFF
signal below the speed set.
RotSpeed PS on
RotSpeed PS off
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6 Operation
6.8.9 Configuring input X5-03
Param & Display Burner Control Configuration Config input/
output
Parameter Config X5-03 determines how the W-FM reacts to signals at inputX5-03.
Load controller multi-stage operating mode
If a load controller is connected to inputX5-03 [ch.3.3.16], the parameter determines the control of the operating stages.
Setting Input X5-03 Operating mode
Pin 2 Pin 3 two stage three stage
LMV2/3 inv
(Standard)
LMV5x std
(with KS40
load controller)
LMV2/3 std
(special application)
0 0 Stage 1 Stage 1
1 0 Stage 1 Stage 2
0 1 Stage 2 Stage 3
1 1 Stage 2 Stage 3
0 0 Stage 1 Stage 1
1 0 Stage 1 Stage 1
0 1 Stage 2 Stage 2
1 1 Stage 2 Stage 3
0 0 Stage 1 Stage 1
1 0 Stage 2 Stage 3
0 1 Stage 2 Stage 2
1 1 Stage 2 Stage 3
Config X5-03
Deactivate O2 trim / stop in phase 36
If function DeaO2/Stp36 is set in parameter Config X5-03 , inputX5-03
can be used to deactivate O2 trim or to trigger a stop function. For this setting,
parameter LC_OptgMode must not be set to ExtLC X5-03 .
Input Function
Pin 2 (X5-03) Mains voltage input atX5-03:2 deactivates O2 trim and the
W-FM 200 operates to the compound curves. The function O2
alarm remains activated.
Pin 3 (X5-03) If no mains voltage is applied to inputX5-03:3, the burner stops
at the start in phase36. If the stop function is not used in conjunction with the O2 deactivation, fit a bridge at inputX5-03
between terminals3 and4.
Deactivate O2 trim via operating mode
If the function AutoDeactO2is set in parameter Config X5-03 and if mains
voltage is applied to inputX5-03:2, the operating mode of the O2 controller
changes from conAutoDeac to auto deact. The O2 controller is deactivated
and the burner operates to the compound curves. The function O2 alarm remains
activated. No message will be shown on the display. If voltage is no longer applied
to inputX5-03:2, the operating mode changes back to conAutoDeac and O2
trim is reactivated [ch.6.10.1]. For this setting, parameter LC_OptgMode must
not be set to ExtLC X5-03 .
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6 Operation
6.8.10 Configuring output X4-03
Param & Display Burner Control Configuration Config input/
output
Parameter Start/PS valve determines if outputX4-03 is used for a start signal or for pressure switch relief [ch.3.4.4].
Setting Function
Start signal OutputX4-03:3 is activated in phase21 to79.
PS Relief OutputX4-03:3 is activated in phase79.
Function is not used.
PS Reli_Inv In phase21 and phase79 the relief valve at out-
putX4-03:3 is de-energised and the air pressure switch
is tested.
Start/PS valve
6.8.11 Extraneous light
Param & Display Burner Control Configuration ConfigFlameDet ReacExtranLight
Parameter ReacExtranLight determines the reaction if extraneous light is
present in Standby (Phase12).
Setting Function
Lockout Flame signal in phase12 triggers a lockout.
Startblock A flame signal in phase 12 leads to start prevention.
6.8.12 Repetition counter
Param & Display Burner Control Configuration RepetitCounter
The parameters in menu RepetitCounter determine the number of safety
shutdowns until shutdown with lockout is initiated. Changes in the repetition
counter are only adapted after a reset or if the voltage supply has been interrupted.
Parameters Function
LossOfFlame Number of safety shutdowns due to missing flame signal.
Range: (1 … 2)
HeavyOil Number of safety shutdowns caused by return temperat-
ure sensor for nozzle circulation not being released
[ch.3.3.10].
Range: (1 … 3 … 16(1)
StartRelease Number of start preventions with display messages nozzle
circulation [ch.3.3.10].
Range: (1 … 10 … 16(1)
SafetyLoop Number of safety shutdowns caused by the safety circuit
not being released [ch.3.3.2].
Range: (1 … 16(1)
(1
Repetition value 16 means not limited, no shutdown with lockout is initiated.
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6 Operation
6.9 Electronic compound
6.9.1 Actuator ramps
Param & Display RatioControl Times OperatRampMod
OperatRampStage
Ramp
The ramps determine the speed of the actuators for a distance of 90°. The ramp
times must not fall below the time of the slowest actuator, see actuator name plate.
Parameters Function
OperatRampMod Ramp time for modulating operation for phases60 and
62. In operating position, all actuators operate at this
speed.
OperatRampStage Ramp time for multi-stage operation for phases60 and
62. In operating position, all actuators operate at this
speed.
Ramp Ramp time outside the operating position for modulating
and multi-stage operation. All actuators operate at this
speed in pre-purge, ignition, post-purge and standby position.
Only in conjunction with frequency converter
The ramp time of the frequency converter must be less than the ramp time set in
the W-FM (recommendation: 30%).
6.9.2 Shutdown behaviour
Param & Display RatioControl ShutdownBehav
Parameter ShutdownBehav determines the behaviour during lockout.
Setting Function
Unchanged The actuators remain in the position they were in at the
time of the lockout.
PostpurgeP If lockout occurs, the W-FM initiates a post-purge.
HomePos If lockout occurs, the actuators drive to standby position.
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6.9.3 Operating behaviour of frequency converter
Only possible with W-FM 200.
Param & Display RatioControl GasSettings
OilSettings
Parameter VSD determines the operating behaviour of the frequency converter.
The operating behaviour can be set individually for each fuel.
Setting Function
deactivated No frequency converter available.
The inputs and outputs for variable speed drive are not
activated.
activated Only in conjunction with a frequency converter.
The inputs and outputs for variable speed drive are activated.
air influen Only in conjunction with a frequency converter.
The inputs and outputs for variable speed drive are activated and the frequency converter is included in O2 trim.
6 Operation
VSD
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6 Operation
6.9.4 SpecialPositions
Param & Display RatioControl GasSettings
OilSettings
If the burners is in operating position (phases60 and62), the actuators and the
speed are driven by the compound curves. Outside of the operating position, the
actuators and the speed are driven according to the SpecialPositions .
In the special positions, the actuators can be set independently.
Special positions are fuel specific and must be set separately for each fuel on dual
fuel burners.
Setting Actuator
…PosGas: Gas butterfly valve
…PosOil: Oil quantity regulator
…PosAir: Air dampers
…PosAux1: Adjustable mixing head
…PosAux2: Auxiliary actuator for special applications (W-FM 200
only)
…PosAux3: Auxiliary actuator for special applications,
damper for flue gas recirculation (W-FM 200 only)
…PosVSD: VSD (only in conjunction with frequency converter,
W-FM 200)
SpecialPositions
Home Pos
PrepurgePos
IgnitionPos
PostpurgePos
ProgramStop
ResetIgnitPos
Standby positions
Parameter StandbyPos determines the positions for phases00 to22.
Pre-purge position
Parameter PrepurgePos determines the positions of the air influencing actuators for pre-purge in phases30 to34. The exception is the auxiliary actuator3 (flue
gas recirculation), which only drives to pre-purge position from phase 32.
Ignition position
Parameter IgnitionPos determines the positions for the ignition process in
phases36 to54.
Individual ignition positions can be deleted in parameter ResetIgnitPos . If a
relevant ignition position is not defined, the W-FM initiates a start prevention at
heat demand. Se installation and operating manual of burner for the ignition position.
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6 Operation
Post-purge position
Parameter PostpurgePos defines the positions for post-purge in phases74
to78. The exception is auxiliary actuator3 (flue gas recirculation), which only drives
to the post-purge position after phase76.
The speed PostpurgePosVSD must not be set below 10%.
Program stop
Using parameter ProgramStop, the program sequence can be stopped in
defined phases. Parameter ProgramStop can also be called up in menu Param
& Display/RatioControl.
Setting Function
deactivated No program stop
24 PrePurgP Stop in phase 24, pre-purge position
32 PrePFGR Stop in phase 32, auxiliary actuator3 in pre-purge position
36 IgnitPos Stop in phase 36, ignition position
44 Interv 1 Stop in phase 44, flame signal
52 Interv 2 Stop in phase 52, ignition pilot valve OFF
72 PostPPos Stop in phase 72, post-purge position
76 PostPFGR Stop in phase 76, auxiliary actuator3 in post-purge posi-
tion
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Point|Load:15.0
|Fuel:10.0
Manual |Air :15.0
|Aux1: 0.0
2
1
0
10
20
30
40
50
60
70
80
90
0 10 20 30 40 50 60 70 80 90 100
0
10
20
30
40
50
60
70
80
90
100
P1 P2 P3 P4 P5 P6 P7 P8 P9
2
1
4
5
6
7
3
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.9.5 Creating load points, modulating operation
Param & Display RatioControl GasSettings
OilSettings
Depending on the load signal, the W-FM controls the actuators in compound in
modulating operation. Each actuator has its own compound curve. The compound
curves are formed from defined load points. 15load points can be defined for the
compound curves, a minimum of 5load points are required. On dual fuel burners,
the compound curves for each fuel can be set separately. In menu Point 1,
load points can be adjusted or deleted to optimise combustion. In menu Manual
2 new load points are set.
During initial commissioning, set load points up to full load. Once full load has been
regulated, optimise combustion in load point 1. Load point 1 must be within the capacity graph and below below partial load. Now delete all load points between
point 1 and full load. Starting at point 1, set new load points until full load is
achieved. Optimise combustion in the current point before setting a new load point.
To ensure an even speed characteristic curve, the speed of the new load points
should not be altered.
To ensure that control is possible across the entire load range in conjunction with
O2 trim point 1 must be approx. 50% below partial load (point 2).
CurveParams Point
Man
83054802 1/2018-07 La
1 Burner capacity in %
2 Actuator position in degree of angle
3 Speed in %
4 Fuel Fuel
5 Air damper Air
6 Mixing head Aux1
7 Frequency converter VSD
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Installation and operating instruction
Point|Load:10.0
|Fuel:10.0
Manual |Air :15.0
|Aux1: 0.0
O2
XXXX
|Load:10.0
|Fuel:10.0
|Air :20.0
|Aux1: 0.0
Manual
:10.0
O2
XXXX
|Load:15.0
|Fuel:14.4
|Air :23.8
|Aux1: 5.0
Manual
:15.0
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :23.8
|Aux1: 5.0
O2
XXXX
Point
|Load:15.0
|Fuel:14.4
|Air :23.8
|Aux1: 5.0
Manual
Point
:1
|Load:10.0
|Fuel:10.0
|Air :20.0
|Aux1: 0.0
O2
XXXX
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :23.8
|Aux1: 5.0
O2
XXXX
Point
: 2
|Change
|point?
|
|
Manual
Actuator
positions
With start
Without start
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :23.8
|Aux1: 5.0
O2
XXXX
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :28.5
|Aux1: 5.0
O2
XXXX
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :28.5
|Aux1: 5.0
O2
XXXX
Save
point->ENTER
cancel->ESC
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :28.5
|Aux1: 5.0
O2
XXXX
Combustion manager W-FM 100 und W-FM 200
6 Operation
Setting new load points
Select Manual and confirm with [ENTER].
Increase burner rating using dial knob whilst observing combustion values (excess air) and flame stability.
Set load point using [ENTER] key if either:
the O2 content in the flue gas increases to above 7%,
the soot limit is reached,
the CO content increases,
the flame reaches the limit of stability.
The new load point is displayed in menu Point and can be adjusted.
Editing load points
Select Point and confirm with [ENTER].
Select load point using dial knob and confirm with [ENTER] key.
Confirm query Change point? with [ENTER].
Confirm query With start with [ENTER].
The curve points can be changed and the actuators are synchronised.
Select actuator using the dial knob and press [Enter].
Change values using the dial knob and confirm with [ENTER].
Once combustion has been optimised, exit point using [esc] and save with
[Enter].
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6 Operation
Point
|Load: 0.0
|Fuel:0.0
|Air :23.8
|Aux1: 5.0
Manual
Point
: 1
|Load:10.0
|Fuel:10.0
|Air :20.0
|Aux1: 0.0
O2
XXXX
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :23.8
|Aux1: 5.0
O2
XXXX
Point
: 2
|Change
|point?
|delete?
|
Manual
Point
: 2
|Load:24.3
|Fuel:22.1
|Air :32.9
|Aux1:27.6
O2
XXXX
Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
Deleting load points
Select menu Point and confirm with [Enter].
Select load point using dial knob and confirm with [ENTER] key.
Select Delete point? and confirm with [Enter].
Load point is deleted.
Load points above this will be renumbered. The display shows the next higher
load point in the current numbering. If the last load point was deleted, the actuator positions show XXXX .
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Installation and operating instruction
Load [%] =
Throughput load point
Throughput full load
100
Point
|Load:15.0
|Fuel:14.4
|Air :23.8
|Aux1: 5.0
Manual
Point
:1
|Load:10.0
|Fuel:10.0
|Air :20.0
|Aux1: 0.0
O2
XXXX
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :23.8
|Aux1: 5.0
O2
XXXX
Point
: 2
|Change
|point?
|
|
Manual
Actuator
positions
With start
Without start
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :28.5
|Aux1: 5.0
O2
XXXX
Point
: 2
|Load:29.3
|Fuel:14.4
|Air :28.5
|Aux1: 5.0
O2
XXXX
Point
: 2
|Load:29.3
|Fuel:14.4
|Air :28.5
|Aux1: 5.0
O2
XXXX
Save
point->ENTER
cancel->ESC
Point
: 2
|Load:15.0
|Fuel:14.4
|Air :28.5
|Aux1: 5.0
O2
XXXX
Combustion manager W-FM 100 und W-FM 200
6 Operation
Ratings apportionment
The load points are automatically assigned relative to the capacity. Incorrect load
distribution can cause operating problems during the load control.
Assign capacity in % for load point using the following formula.
Enter the calculated capacity for load point in Load.
Select Point and confirm with [ENTER].
Select load point using dial knob and confirm with [ENTER] key.
Confirm query Change point? with [ENTER].
Confirm query With start with [ENTER].
Confirm line Load with [Enter].
Calculate actual load.
Set load using dial knob and confirm with [Enter].
Exit point using [esc] and save with [ENTER].
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Installation and operating instruction
2
1
5
3
4
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.9.6 Operating and switch points, multi-stage operation
Param & Display RatioControl OilSettings CurveParams CurveSet
Two or three stage operation is specified depending on the burner execution. A
three stage burner can also be operated two stage with low impact start or
change-over release. The change-over behaviour between the operating stages is
optimised via separate switch on and off points.
Operating stages
BS1, BS2, BS3
Switch-on points
ES2, ES3
Switch-off points
AS2, AS3
(1
BS3, ES3 and AS3 only with three stage operation
(1
(1
(1
Excess air for the relevant fuel quantity is set in the operating stages.
In the switch-on point, the air quantity for the change-over process into the next
higher stage is set.
If the switch-on point is exceeded, the solenoid valve of the next stage opens.
If the switch-on point is activated directly the solenoid valve remains closed, only
the air influencing actuators drive to the switch-on position and the flame stability
can be checked prior to the change-over.
In the switch-off point, the air quantity for the change-over process into the next
lower stage is set.
If the switch-on point is not maintained, the solenoid valve of the previous stage
closes. Switch-off points must not be activated directly, as the solenoid valve of
the previous stage remains open and only the air influencing actuators drive to the
switch off position. This leads to soot formation caused by insufficient air.
1 Air damper position
2 Operating stage 1 (BS1)
3 Switch-on point 2 (ES2), solenoid valve stage2 opens above
4 Operating stage 2 (BS2)
5 Switch-off point 2 (AS2), solenoid valve stage2 closes below
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Installation and operating instruction
CurveSet
Actuator
positions
With start
Without start
Point
:AS2
|Air :30.0
O2
XXXX
|VSD : 100
Point
:AS2
|Air :30.0
O2
XXXX
|VSD : 100
Point
:AS2
|Air :25.0
O2
XXXX
|VSD : 100
Point
:AS2
|Air :25.0
O2
XXXX
|VSD : 100
Save
point->ENTER
cancel->ESC
CurveSet
Point
:BS1
|VSD : 100
|Air :20.0
|
|
|
O2
XXXX
Point
:AS2
|VSD : 100
|Air :25.0
|
|
|
O2
XXXX
Combustion manager W-FM 100 und W-FM 200
6 Operation
Two options are available fort he setting of the operating and switch points.
With start:
The actuator and frequency converter follow the current adjustment via dial knob.
With this option, the operating stages and switch-on points are set during burner
operation.
In the operating stages, the combustion is optimised.
In the switch-on points, the excess air for the change-over process to the next operating stage is determined. Excess air for the switch-on point is approx.7% O2
residual content.
The switch-off points must not be activated during burner operation, as this leads
to soot formation caused by insufficient air.
Without start:
With this option, the operating stages and change-over points can be pre-set
without the actuator and frequency converter following. Pre-setting values see installation and operating manual of burner.
Setting operating and switch points
Select menu CurveSet and confirm with [Enter].
Choose appropriate option with the dial knob and confirm with [Enter].
With start: Optimise operating stages and switch-on points
Without start: Pre-set values and optimise switch-off points
Select operating stage or switch point using dial knob and confirm with [Enter].
Select Air actuator and confirm with [Enter].
The selection option VSD only appears in conjunction with a frequency converter.
Use dial knob to change the value and confirm with [Enter].
Pre-setting values see installation and operating manual of burner.
Exit entry using [esc] and save with [ENTER].
Exit level using the [esc] key.
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Installation and operating instruction
0 % 100 %
P1
1
3
2
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.9.7 Load range
LoadLimits
Param & Display RatioControl GasSettings
OilSettings
In modulating operation, the load limits restrict the load range within the compound
curves programmed. On dual fuel burners, the load limits for each fuel can be set
separately.
Minimum load:
Parameter MinLoad_… limits the load range downward (partial load). Minimum
load can not be set below load point1, in conjunction with O2 trim not below load
point2.
Maximum load:
Parameter MaxLoad_… limits the load range upwards (full load).
LoadLimits MinLoad_…
MaxLoad_…
1 Minimum load MinLoad_…
2 Maximum load MaxLoad_…
3 Load range
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Installation and operating instruction
0 % 100 %
P1
1
3
2
Combustion manager W-FM 100 und W-FM 200
Fade-out partial range
Param & Display RatioControl GasSettings
OilSettings
Parameter Load Mask out can be used to fade out part of the load range,
which could lead to operating problems due to site conditions. On dual fuel burners, the partial range for each fuel can be set separately. The faded-out partial
range can be driven through but not started directly. The burner drives from the
bottom to the lower limit and passes through the partial range only when the load
setpoint reached the upper limit. From the upper range, the burner remains at the
upper limit and drives through the partial range only when the load setpoint has
reached the lower limit.
Lower limit partial range:
Parameter LoadMaskLowLimit determines the lower limit. The lower limit can
not be set above the upper limit.
Upper limit partial range:
Parameter LoadMaskHighLim determines the upper limit. The upper limit can
not be set below the lower limit.
6 Operation
Load mask out LoadMaskLowLimit
LoadMaskHighLim
1 Lower limit partial range LoadMaskLowLimit
2 Upper limit partial range LoadMaskHighLim
3 Faded-out partial range
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.9.8 Load limit
Operation User Maxload User MaxLoadMod
User MaxLoad Stg
Parameters Function
User MaxLoadMod Load limit for modulating operation.
Further restricts full load within the load limits [ch.6.9.7].
User MaxLoadStg Load limit for multi-stage operation.
The burner drives only to the stage set.
6.9.9 Start point
Param & Display RatioControl GasSettings
OilSettings
Parameter StartPointOp determines the load point for partial load position in
phase54. In phase54, the burner drives to the load point set, when the load point
is reached, the W-FM changes over to phase60 and load control is released.
StartPointOp
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Installation and operating instruction
0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
5,5
6,0
6,5
0102030405060708090100
2
1
3
4
5
6
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.10 O2 controller
O2 trim is only possible in modulating operation with W-FM 200 with O2 module.
O2 trim is fuel specific and must be set separately for each fuel on dual fuel burners.
O2 trim and O2 monitor in conjunction with the O2 residual content are at the combustion limit and the resulting O2 compound curve.
An idealised minimum O2 value is advantages for the control behaviour. When optimising the minimum O2 value increase rather than decrease. In conjunction with
CO control (accessory) the minimum O2 value must be set to approx.0.25to0.5percentage points below the combustion limit.
1 Burner capacity [%]
2 O2 content in the flue gas [%]
3 O2 residual content at the combustion limit
4 Minimum O2 value for O2 monitor
5 O2 setpoint for O2 trim
6 O2 compound, excess air in the load points 20to 25%
With frequency converter
On burners with frequency converter, parameter VSD can be used to determine if
the frequency converter is to be included in O2 trim [ch.6.9.3].
Pre-control
The O2 controller is equipped with a pre-control function. The pre-control calculates the air ratings reduction for the entire load range relative to the fuel on the
basis of measured values during commissioning. If the load is changed, the air influencing actuators drive to the calculated position, whilst the fuel actuator drives to
its load position. O2 trim is only activated if temperature or air pressure deviations
occur and and then drives the air influencing actuators.
To ensure the pre-control operates correctly, the load apportionment must match
the fuel throughput in each load point [ch.6.9.5].
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.10.1 O2 controller operating mode
Param & Display O2Ctrl/Limit GasSettings
OilSettings
or
Param & Display SystemConfig O2Ctrl/LimitGas
O2Ctrl/LimitOil
Using operating mode:
the O2 controller and O2-monitor can be activated or deactivated,
the behaviour when a fault occurs can be defined.
The operating mode can be set separately for each fuel.
Deactivating manually (man deact)
Parameter man deact deactivates the O2 controller and O2 monitor and the
burner operates to the compound curves. This parameter is only used to create the
compound curve during commissioning, it is not suitable for normal operation.
O2 monitor only (O2 Alarm)
Parameter O2 Alarm only activates the O2 monitor.
If the O2 sensor has not reached the operating temperature at burner start, a start
prevention is initiated. If the O2 monitor is triggered or if an O2 fault occurs, the
W-FM initiates a controlled shutdown with single repetition, then lockout occurs.
Operating mode
O2 controller and O2 monitor (O2Control)
Parameter O2Control activates the O2 controller and O2 monitor.
If the O2 sensor has not reached the operating temperature at burner start, a start
prevention is initiated. If the O2 monitor is triggered or if an O2 fault occurs, the
W-FM initiates a controlled shutdown with single repetition, then lockout occurs.
Automatically deactivate control (conAutoDeac)
Parameter conAutoDeac activates the O2 controller and O2 monitor.
The burner starts before the O2 sensor has reached operating temperature. O2 trim
only starts once the operating temperature has been reached and the sensor test
has been successfully carried out.
If the maximum O2 monitor is triggered or if an O2 fault occurs, the W-FM changes
over to operating mode auto deact.
If the minimum O2 monitor is triggered the W-FM drives back to the compound
curves. After a time of 3 times Tau the O2 content is tested again. The time constant Tau is determined automatically during standardisation [ch.6.10.4].
When the O2 content exceeds the minimum limit the W-FM releases O2 trim.
If the O2 content drops below the minimum limit, the W-FM initiates a safety
shutdown with repetition. The number of repetitions can be set in parameter
NumMinUntilDeact , see [ch.6.10.2]. If the number of repetitions is exceeded, the W-FM changes over to operating mode auto deact.
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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
6 Operation
Automatic deactivation (auto deact)
Do not select this operating mode.
Parameter auto deact is automatically activated when a fault occurs in operating mode conAutoDeac . The O2 controller is deactivated and the burner operates to the compound curves. A fault message appears in the display. If the operating mode is changed over the fault message disappears [ch.6.10.23].
The O2 controller can also be deactivated via a signal at input X5-03:2 [ch.6.8.9].
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Installation and operating instruction
Operating mode
O2 trim
O2 monitor
Control parameters
O2 monitor
O2 MaxValue
NumMinUntilDeact
Point: 1 13.9%
O2 MinValue :XXXX
P-Air manual:
Point: 9 100%
O2 MinValue :XXXX
P-Air manual:
Point: 9 100%
O2 MinValue :XXXX
P-Air manual:
Point: 9 100%
O2 MinValue :XXXX
P-Air manual:
1
2
Combustion manager W-FM 100 und W-FM 200
6 Operation
6.10.2 O2 monitor
Param & Display O2Ctrl/Limit GasSettings
OilSettings
The W-FM monitors the O2 content in the flue gas using a sensor on the O2 module. The limit values for the O2 alarm are defined using parameters O2 MinValue
and O2 MaxValue .
O2 minimum monitor
In parameter O2 Alarm , the setting under O2 MinValue stipulates the lower
limit for the O2 monitor.
If the O2 content in the flue gas drops below this lower limit for more than
3seconds, the W-FM reacts in accordance with the operating mode set
[ch.6.10.1].
An O2 MinValue has to be defined as the lower limit in each load point. The
O2 MinValue results from the O2 content in the flue gas at the combustion limit.
The O2 MinValue can be entered direct at each load point or can be determined by reducing the air rating:
Select menu O2 Alarm and confirm with [Enter].
Select load point using dial knob and confirm with [ENTER] key.
Select entry type1 or 2.
O2 Alarm O2 Alarm
O2 MaxValue
NumMinUntilDeact
83054802 1/2018-07 La
1 Direct entry (O2 MinValue)
If the O2 min value for the load point is known, the value can be assigned directly.
2 Determine O2 min value (P-Air Manual)
The air rating is reduced manually in the load point, the O2 content is determined and saved as O2 MinValue.
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