Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
83294002 • 2/2014-11
60040000
Conformity certification
Manufacturer:
Address:
Product: Combustion Manager
The product described above conforms with
the regulations of directives:
This product is labelled as follows:
Schwendi, 02.09.2014
ppa. ppa.
Dr. Schloen Denkinger
Manager Research Manager Production and
and Development Quality Management
Max Weishaupt GmbH
Max-Weishaupt-Straße
D-88475 Schwendi
W-FM 25
GAD 2009 / 142 / EC
PED
97 / 23 / EC
LVD 2006 / 95 / EC
EMC 2004 / 108 / EC
Sprachschlüssel
02
CE-0085
Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
1 User instructions ..................................................................................................................... 5
1.1 User guide ............................................................................................................. 5
1.1.1 Symbols ................................................................................................................. 5
1.1.2 Target group ......................................................................................................... 5
1.2 Guarantee and Liability ....................................................................................... 6
2 Safety ............................................................................................................................................ 7
2.1 Designated application ....................................................................................... 7
2.2 When gas can be smelled ................................................................................. 7
2.3 Safety measures .................................................................................................. 7
2.3.1 Normal operation ................................................................................................. 7
2.3.2 Electrical connection ........................................................................................... 7
2.3.3 Gas supply ............................................................................................................ 8
2.4 Alterations to the construction of the equipment ......................................... 8
2.5 Noise emission ..................................................................................................... 8
2.6 Disposal ................................................................................................................. 8
3 Product description ............................................................................................................... 9
3.1 Inputs and outputs ............................................................................................... 9
3.1.1 Gas burner ............................................................................................................ 9
3.1.2 Gas burner with speed control ...................................................................... 10
3.1.3 Oil burner ............................................................................................................ 11
3.1.4 Dual fuel burner ................................................................................................. 12
3.2 Technical data ................................................................................................... 13
3.2.1 Electrical data ................................................................................................... 13
3.2.2 Ambient conditions ........................................................................................... 13
3.2.3 Dimensions ......................................................................................................... 13
4 Operation .................................................................................................................................. 14
4.1 Operating panel ................................................................................................ 14
4.2 Display ................................................................................................................. 16
4.2.1 Info level .............................................................................................................. 17
4.2.2 Service level ....................................................................................................... 20
4.2.3 Parameter level .................................................................................................. 23
4.2.4 Access level ....................................................................................................... 28
4.3 Linearisation ....................................................................................................... 29
5 Installation ................................................................................................................................ 30
5.1 Replacing the combustion manager ............................................................. 30
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6 Commissioning ...................................................................................................................... 32
6.1 Gas burner ......................................................................................................... 32
6.2 Gas burner with speed control ...................................................................... 37
6.3 Oil burner ............................................................................................................ 42
6.4 Dual fuel burner ................................................................................................. 47
6.4.1 Adjusting gas side ............................................................................................ 47
6.4.2 Adjusting oil side ............................................................................................... 52
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
7 Troubleshooting .................................................................................................................... 57
7.1 Procedures for fault conditions ..................................................................... 57
7.1.1 Display off ........................................................................................................... 57
7.1.2 Display flashes ................................................................................................... 57
7.1.3 Detailed fault code ........................................................................................... 58
7.2 Rectifying faults ................................................................................................. 59
8 Spares ......................................................................................................................................... 64
9 Technical documentation ................................................................................................. 66
9.1 Program sequence ........................................................................................... 66
10 Notes ........................................................................................................................................... 68
11 Key word index ...................................................................................................................... 70
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
1 User instructions
1 User instructions
This installation and operating manual forms part of the appliance and must be kept
on site.
Observe installation and operating manual of the burner.
This installation and operating manual supplements the following chapters in the in-
stallation and operating manual of the burner:
Technical description and/or Product description
▪
Commissioning and operation and/or Commissioning
▪
Cause and rectification of faults and/or Troubleshooting
▪
Technical data.
▪
The chapter Display and operating modes and operation is replaced completely.
1.1 User guide
1.1.1 Symbols
DANGER
WARNING
CAUTION
Immediate danger with high risk.
Non observance can lead to serious injury or death.
Danger with medium risk.
Non observance can lead to environmental damage,
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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Range of values
1.1.2 Target group
These installation and operating instructions are intended for the operator and qualified personnel. They should be observed by all personnel working on 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 near or on the unit.
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
1 User instructions
1.2 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 installation and operating instruction,
▪
operation with faulty safety equipment,
▪
continual operation despite a fault,
▪
improper installation, commissioning, operation and service,
▪
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,
▪
repairs, which have been carried out incorrectly,
▪
the use of non original Weishaupt parts,
▪
unsuitable fuels,
▪
defects in the inlet lines,
▪
acts of God.
▪
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
2 Safety
2 Safety
2.1 Designated application
The combustion manager W-FM 25 is suitable for use with:
oil burners
▪
gas burners
▪
dual fuel burners.
▪
Improper use could:
endanger the health and safety of the user or third parties,
▪
cause damage to the appliance or other material assets.
▪
2.2 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 company or gas supplier from outside of the building.
▶
2.3 Safety measures
Safety relevant fault conditions must be eliminated immediately.
2.3.1 Normal operation
All labels on the unit must be kept in a legible condition,
▪
the unit should only be operated with its cover in the closed position,
▪
do not touch moving parts during operation,
▪
stipulated settings, service and inspection work should be carried out at regular
▪
intervals.
2.3.2 Electrical connection
For work carried out on live parts:
Observe the accident prevention instructions BGV A3 and adhere to local direc-
▪
tives,
tools in accordance with EN 60900 should be used.
▪
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Installation and operating instruction
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2 Safety
2.3.3 Gas supply
Only the gas supplier or an approved agent may carry out installation, alteration
▪
and maintenance work on gas appliances in buildings and properties.
Pipe work must be subject to a combined load and valve proving test and usability
▪
testing relative to the pressure range intended (e.g.
DVGW-TRGI, work sheet G 600).
Inform the gas supplier about the type and size of plant prior to installation.
▪
Local regulations and guidelines must be observed during installation (e. g.
▪
DVGW-TRGI, work sheet G 600; TRF Band 1 and Band 2).
The gas supply pipe work 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 in-
▪
formation.
Re-commission the appliance when changing to a different type of gas.
▪
Carry out soundness test after each service and fault rectification.
▪
2.4 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,
use only original Weishaupt replacement parts.
▪
2.5 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.
2.6 Disposal
Dispose of all materials used in a safe and environmentally friendly way. Observe local
regulations.
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Installation and operating instruction
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3 Product description
3 Product description
3.1 Inputs and outputs
3.1.1 Gas burner
8
11
-weishaupt-
L
N
X6
F7
X7
T1
T2
S3
B4
B5
T6
T7
T8
15
12
TWI TWI interface (Vision Box)
P free
TWI
NA free
FC free
AM Operating panel of remote reset
L/A Air damper actuator
G Gas butterfly valve actuator
1
Slot analogue module EM3/3 or Fieldbus module EM3/2
1 External liquid petroleum gas valve
G L/A AM FU NA P
3C Burner motor for continuous running fan
3N Burner motor or valve continuous running fan
4 Ignition unit
13
3
N
7
3
C
4
1
5 Multifunction assembly or double gas valve
6 free
7 Bridging plug No. 7
8 Gas meter (impulse generator)
11 Air pressure switch
12 Low / valve proving gas pressure switch
13 Ionisation
14 Remote reset (plug cable No. 14 required)
15 Bridging plug No. 15 or high gas pressure switch
6
5
X6 7 pole connection plug
X7 4 pole connection plug
F7 Internal unit fuse (6.3 AT)
14
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If a digital load converter (DLU) is used, this has to be replaced with the
analogue module EM3/3.
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8
11
-weishaupt-
L
N
X6
F7
X7
T1
T2
S3
B4
B5
T6
T7
T8
15
12
Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
3 Product description
3.1.2 Gas burner with speed control
TWI TWI interface (Vision Box)
P free
TWI
G L/A AM FU NA P
13
3
N
7
3
C
4
1
6
5
14
NA free
FC free
AM Digital/analogue converter (DAU01)
L/A Air damper actuator
G Coded plug (yellow)
1
Slot analogue module EM3/3 or Fieldbus module EM3/2
1 External liquid petroleum gas valve
3C Digital/analogue converter (DAU01)
3N Frequency converter
4 Ignition unit
5 Double gas valve and air pressure switch burner operation
6 free
7 Low gas pressure switch
8 Gas meter (impulse generator)
11 Air pressure switch pre-purge
12 Valve proving gas pressure switch
13 Ionisation
14 Remote reset (plug cable No. 14 required)
15 Bridging plug No. 15 or high gas pressure switch
X6 7 pole connection plug
X7 4 pole connection plug
F7 Internal unit fuse (6.3 AT)
If a digital load converter (DLU) is used, this has to be replaced with the
analogue module EM3/3.
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
3 Product description
3.1.3 Oil burner
8
11
-weishaupt-
L
N
X6
F7
X7
T1
T2
S3
B4
B5
T6
T7
T8
15
12
TWI TWI interface (Vision Box)
P free
TWI
NA free
FC free
AM Operating panel of remote reset
L/A Air damper actuator
G Coded plug (black)
1
Slot analogue module EM3/3 or Fieldbus module EM3/2
1 Safety solenoid valve (Y14)(1 or stage 1 solenoid valve (Y11)
G L/A AM FU NA P
3C Burner motor for continuous running fan
(2
3N Burner motor
4 Ignition unit
13
5 Stage 1 solenoid valve (Y11)
3
N
7
3
C
4
1
6 Stage 2 solenoid valve (Y12)
7 Bridging plug No. 7
8 Oil meter (impulse generator)
11 free
12 Bridging plug No. 12 or oil pressure switch
13 Flame sensor
14 Remote reset (plug cable No. 14 required)
(1
15 free
6
5
X6 7 pole connection plug
X7 4 pole connection plug
F7 Internal unit fuse (6.3 AT)
14
(1
Burner with safety solenoid valve
(2
Burner without safety solenoid valve
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If a digital load converter (DLU) is used, this has to be replaced with the
analogue module EM3/3.
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
3 Product description
3.1.4 Dual fuel burner
8
11
-weishaupt-
L
N
X6
F7
X7
T1
T2
S3
B4
B5
T6
T7
T8
15
12
TWI TWI interface (Vision Box)
P free
TWI
NA free
FC free
AM Operating panel of remote reset
L/A Air damper actuator
G Gas butterfly valve actuator
1
Slot analogue module EM3/3 or Fieldbus module EM3/2
1 Stage 1 solenoid valve (Y11)
G L/A AM FU NA P
3C Pump motor and safety solenoid valve Oil (Y14)
3N Burner motor and external LPG valve
4 Ignition unit
13
3
N
7
3
C
4
1
5 Multifunction assembly or double gas valve
6 Stage 2 solenoid valve (Y12)
7 Bridging plug No. 7
8 Fuel change-over
11 Air pressure switch
12 Low / valve proving gas pressure switch and oil pressure switch
13 Flame sensor
14 Remote reset (plug cable No. 14 required)
15 Bridging plug No. 15 or high gas pressure switch
6
5
X6 7 pole connection plug
X7 4 pole connection plug
F7 Internal unit fuse (6.3 AT)
14
If a digital load converter (DLU) is used, this has to be replaced with the
analogue module EM3/3.
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
3 Product description
3.2 Technical data
3.2.1 Electrical data
Mains voltage/frequency 230 V / 50 … 60 Hz
Consumption max 12 W
Internal unit fuse 6.3 A slow
Type of protection IP 40
3.2.2 Ambient conditions
Temperature in operation -20 … +60 °C
Temperature during transport / storage -20 … +70 °C
Relative humidity DIN 60730-1,
no dew point
3.2.3 Dimensions
275 mm
92 mm 60 mm
-weishaupt-
80 mm 46 mm
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Installation and operating instruction
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4 Operation
4 Operation
4.1 Operating panel
No. Key Function
1 [G] Gas Select gas butterfly valve actuator or speed
control
2
3
4
5
3 and 5 [+] and [ENTER] press approx. 2 seconds = Parameter level
[–]
[+]
[L/A] Air Select air damper actuator
[ENTER] Reset burner; call up information
Change values
press approx. 0.5 seconds = Info level
press approx. 2 seconds = Service level
(only possible with display
OFF
)
Various actions (e. g. changing the display, reset) are only triggered when the key is
released.
Operating level
The current actuator position or the fan speed can be displayed by pressing keys in
operating level (10).
Displaying air damper setting:
Press key [L/A].
▶
Displaying gas butterfly valve setting or fan speed:
Press key [G].
▶
Off function
Press keys [ENTER], [L/A] and [G] simultaneously.
▶
Immediate lockout with error
✓
18h
.
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
4 Operation
Operating phase
The exact operating phase of the combustion manager can also be displayed. This
simplifies determining the cause of the fault during troubleshooting (see Ch. 9.1).
The display can be called up in Standby (
Press and hold keys [+] and [–] simultaneously for approx. 3 seconds.
▶
The combustion manager changes to operating display. In the display, the current
✓
operating phase is shown with a number.
Switching back to standard display:
Press and hold keys [+] and [–] simultaneously for approx. 3 seconds.
▶
OFF
).
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
4 Operation
4.2 Display
Operating panel
The display shows the current operating status and operating data.
1
Setting level activated
2
Start phase activated
3
Info level activated
4
Actuator runs CLOSED
5
Actuator runs OPEN
6
Burner in operation
7
Lockout
8
Service level activated
No heat demand
No heat demand
(fuel selected: Gas)
No heat demand
(fuel selected: Oil)
Shutdown via contact X3:7 (plug No. 7)
Programming not completed
Programming of gas part not completed
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Programming of oil part not completed
Switch off via Fieldbus
Insufficient gas low gas pressure switch
Low voltage (display flashes)
Connection to Fieldbus faulty (display flashes)
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
4 Operation
4.2.1 Info level
Gas burner / gas burner with speed control
Burner data can be interrogated in the Info level.
Press [Enter] key approx. 0.5 seconds.
▶
The Info level is activated.
✓
Press [Enter] to reach the next information.
▶
l,m³
No. Information
0
1
2
3
4
5
6
7
8
9
11
12
13
Total gas consumption in m³ (via X3:8)
Reset value:
Press [L/A] and [+] keys simultaneously for ca. 2 secs.
▶
Operating hours
- no function Burner starts
Device item number
Index of device item number
Unit number
Production date (DDMMYY)
Fieldbus address
Valve proving behaviour
- no function Current gas consumption (0.1 m³/h)
Analogue module EM3/3 or Fieldbus module EM3/2 available
0
= No
1
= Yes
After information 13 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
4 Operation
Oil burner
Burner data can be interrogated in the Info level.
Press [Enter] key approx. 0.5 seconds.
▶
The Info level is activated.
✓
Press [Enter] to reach the next information.
▶
l,m³
No. Information
0
1
2
3
4
5
6
7
8
10
11
12
13
Total oil consumption in litres (via X3:8)
Reset value:
Press [L/A] and [+] keys simultaneously for ca. 2 secs.
▶
Operating hours stage 1
Operating hours stage 2
Burner starts
Device item number
Index of device item number
Unit number
Production date (DDMMYY)
Fieldbus address
Oil pressure switch function
- no function Current oil consumption (0.1 l/h)
Analogue module EM3/3 or Fieldbus module EM3/2 available
0
= No
1
= Yes
After information 13 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
4 Operation
Dual fuel burner
Burner data can be interrogated in the Info level.
Press [Enter] key approx. 0.5 seconds.
▶
The Info level is activated.
✓
Press [Enter] to reach the next information.
▶
l,m³
No. Information
0
1
2
3
4
5
6
7
8
9
10
11
12
13
- no function Operating hours in gas operation or oil operation stage 1
Operating hours in oil operation stage 2
Total burner starts
Device item number
Index of device item number
Unit number
Production date (DDMMYY)
Fieldbus address
Valve proving behaviour
Oil pressure switch function
- no function -
- no function Analogue module EM3/3 or Fieldbus module EM3/2 available
0
= No
1
= Yes
After information 13 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
4 Operation
4.2.2 Service level
Gas burner / dual fuel burner (Gas operation)
The service level gives information about:
Actuator position of individual operating points
▪
The most recent fault
▪
Flame signal during operation.
▪
Press [ENTER] key for approx. 2 seconds.
▶
The service level is activated.
✓
Press [Enter] to reach the next information.
▶
No. Information
0
1
2
3
4
5
6
7
8
9
10
…
Actuator position in operating point P
Actuator position in operating point P
Actuator position in operating point P
Actuator position in operating point P
Actuator position in operating point P
Actuator position in operating point P
Actuator position in operating point P
Actuator position in operating point P
Actuator position in operating point P
Actuator position in operating point P
18
most recent fault … ninth last occurred fault
Display additional information:
0
1
2
3
4
5
6
7
8
9
1. Detailed fault code / operating phase
Press [+] key.
▶
2. Detailed fault code
Press keys [+] and [-] simultaneously.
▶
3. Detailed fault code
Press key [L/A].
▶
Repetition counter
Press key [G].
▶
19
After information 19 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
Flame signal:
00
= no flame ... 58 = high intensity
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
4 Operation
Gas burner with speed control
The service level gives information about:
Actuator position of individual operating points
▪
The most recent fault
▪
Flame signal during operation.
▪
Press [ENTER] key for approx. 2 seconds.
▶
The service level is activated.
✓
Press [Enter] to reach the next information.
▶
No. Information
0
1
9
10
…
Fan speed and air damper setting in operating point P
Fan speed and air damper setting in operating point P
Fan speed and air damper setting in operating point P
18
most recent fault … ninth last occurred fault
Display additional information:
0
1
9
1. Detailed fault code / operating phase
Press [+] key.
▶
2. Detailed fault code
Press keys [+] and [-] simultaneously.
▶
3. Detailed fault code
Press key [L/A].
▶
Repetition counter
Press key [G].
▶
19
After information 19 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
Flame signal:
00
= no flame ... 58 = high intensity
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Installation and operating instruction
Replacing combustion manager W-FM 20 … 24 with W-FM 25
4 Operation
Oil burner / dual fuel burner (oil operation)
The service level gives information about:
Actuator position of individual operating points
▪
The most recent fault
▪
Flame signal during operation.
▪
Press [ENTER] key for approx. 2 seconds.
▶
The service level is activated.
✓
Press [Enter] to reach the next information.
▶
No. Information
0
1
2
3
9
10
…
Actuator position in operating point P
Actuator position in operating point P
Actuator position in operating point P2 (switch off point stage 2 when
running closed)
Actuator position in operating point P3 (switch on point stage 2 when
running open)
Actuator position in operating point P
18
most recent fault … ninth last occurred fault
Display additional information:
0
1
9
1. Detailed fault code / operating phase
Press [+] key.
▶
2. Detailed fault code
Press keys [+] and [-] simultaneously.
▶
3. Detailed fault code
Press key [L/A].
▶
Repetition counter
Press key [G].
▶
19
After information 19 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
Flame signal
Oil burner:
255
Dual fuel burner:
00
121
…
= no flame ... 58 = high intensity
= no flame ... 1 = high intensity
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