wfm50 manual

X6-03
X6-03
X4-02
X4-02
X7-02
X9-04
X5-01
X5-02
X92
FUEL X54
AIR
1
X7-01
X53
BC
X56
X7-01
X3-0
X3-03
X3-04
1
X3-05
P
CO
X8-02
X8-02
L
X3-03
X7-02
1
L
X9-04
S
Geräte-Nr.: 0503020021
X8-0
1
X8-04
L
N
SV
X5-01
P
PE
Best.-Nr.: 600402
W-FM5
IGNITION
X5-02
SIEMENS
FM
VDE
X5-03
X5-03
N
X3-0
PE
FLANGE
L
FUSE 1
T6.3 IEC 60127-2/V
N LINE
L VOLTAGE
PE
PE
L
L
MOTOR
ALARM
MOTO
SAFETY
LOOP
L
PE
230 VAC
50 or 60 Hz
-20C to + 60C
1P - 4 F to +140 F
1
L
PE
CE-xxxxxxxxxxxxx
DIN
Rg.xxxxxxxxxxxxxx
Refer to data sheet 7543
X3-02
1
L
N
V3/PV
V1
•
N
PE
V2
PE
N
PE
P LT
L
LT
2
L
min
P min
ON/OFF
3
L
N
OPERATION
L
L
RESET
L
+
P air
L
X10-06 X3-02
1
X10-06
QRB/CL
X10-05
ION
QRB/
X10-05
QRA
P max/POC PE
LMV27.210A2WH
X75
1
QRA
L
max
FLAME
Siemens Building Technologies
HVAC Products GmbH
Made in Germany
X75
FUEL
P
1
PE
83250302 1/2018-08
Combustion Manager W-FM 50
COUNTER U
+
–
A
F
esc
VSD
info
h min s %
V
P
Installation and operating instruction
P
i
S
X64
VSD X74
Installation and operating instruction
Combustion Manager W-FM 50
1
User instructions .............................................................................................................. 5
1.1 Target group .................................................................................................................. 5
1.2 Symbols .......................................................................................................................... 5
1.3 Guarantee and Liability ............................................................................................... 6
2
Safety ..................................................................................................................................... 7
2.1 Designated application ...............................................................................................
2.2 When gas can be smelled .........................................................................................
2.3 Safety measures ...........................................................................................................
2.3.1 Normal operation ...................................................................................................
2.3.2 Electrical connection ............................................................................................
2.3.3 Gas supply ..............................................................................................................
2.4 Alterations to the construction of the equipment .................................................
2.5 Noise emission .............................................................................................................
2.6 Disposal .........................................................................................................................
3
7
7
7
7
7
8
8
8
8
Product description ........................................................................................................ 9
3.1 Function .......................................................................................................................... 9
3.1.1 Burner Control ....................................................................................................... 9
3.1.2 Low gas programme ............................................................................................. 9
3.1.3 Valve proving ....................................................................................................... 10
3.1.4 Variable speed drive .......................................................................................... 10
3.1.5 Calculation ........................................................................................................... 11
3.1.6 Data backup ........................................................................................................ 11
3.1.7 Referencing the actuator .................................................................................. 12
3.1.8 Program sequence ............................................................................................. 13
3.1.8.1 Operating phase .......................................................................................... 13
3.1.8.2 Gas direct ignition ....................................................................................... 14
3.1.8.3 Gas with ignition pilot valve ...................................................................... 15
3.1.8.4 Fuel oil EL modulating and multi-stage, heavy oil multi-stage .......... 16
3.1.8.5 Medium and heavy oil modulating ........................................................... 17
3.2 Inputs ............................................................................................................................ 18
3.2.1 Voltage supply .................................................................................................... 18
3.2.2 Safety circuit ........................................................................................................ 18
3.2.3 Reset ..................................................................................................................... 18
3.2.4 Air pressure switch ............................................................................................ 18
3.2.5 Minimum pressure switch ................................................................................. 19
3.2.6 Max. pressure switch ......................................................................................... 19
3.2.7 Valve proving gas pressure switch ................................................................ 20
3.2.8 Heavy oil immediate start ................................................................................. 20
3.2.9 Flame sensor ....................................................................................................... 21
3.2.10 Load controller analogue input ..................................................................... 22
3.2.11 Load controller building management ........................................................ 22
3.2.12 Load controller via contacts .......................................................................... 23
3.2.13 Fuel Meter ......................................................................................................... 23
3.3 Outputs ........................................................................................................................ 24
3.3.1 Alarm ..................................................................................................................... 24
3.3.2 Motor ..................................................................................................................... 24
3.3.3 Ignition .................................................................................................................. 24
3.3.4 Frequency converter .......................................................................................... 24
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Installation and operating instruction
Combustion Manager W-FM 50
3.3.5 Analogue output .................................................................................................
3.4 Technical data .............................................................................................................
3.4.1 Electrical data .....................................................................................................
3.4.2 Ambient conditions ............................................................................................
3.4.3 Dimensions ..........................................................................................................
4
25
26
26
26
27
Installation ........................................................................................................................ 28
4.1 Electrical connection ................................................................................................. 28
5
Operation .......................................................................................................................... 30
5.1 Operating interface ....................................................................................................
5.1.1 Operating panel ..................................................................................................
5.1.2 Display ..................................................................................................................
5.2 Displaying and adjusting parameters ....................................................................
5.2.1 Password .............................................................................................................
5.2.2 Manual load .........................................................................................................
5.3 Parameters ..................................................................................................................
5.3.1 Password level ....................................................................................................
5.3.2 Info level ...............................................................................................................
5.3.3 Service level ........................................................................................................
6
Commissioning .............................................................................................................. 46
6.1 Prerequisite .................................................................................................................
6.2 Adjusting the burner ..................................................................................................
6.2.1 Adjusting gas side .............................................................................................
6.2.2 Adjust modulation oil side ................................................................................
6.2.3 Adjust multi-stage oil side ................................................................................
6.3 Check combustion .....................................................................................................
6.4 Calculate gas throughput .........................................................................................
7
30
30
31
33
34
35
36
36
44
45
46
46
47
61
75
86
87
Servicing ............................................................................................................................ 88
7.1 Notes on servicing ..................................................................................................... 88
7.2 Service plan ................................................................................................................. 89
8
Troubleshooting ............................................................................................................ 90
8.1 Procedures for fault conditions ...............................................................................
8.1.1 Display OFF .........................................................................................................
8.1.2 Display OFF S .....................................................................................................
8.1.3 Fault .......................................................................................................................
8.1.4 Lockout .................................................................................................................
8.2 Fault history .................................................................................................................
8.3 Rectifying faults ..........................................................................................................
9
90
90
90
91
91
92
94
Technical documentation ....................................................................................... 102
9.1 Frequency converter ............................................................................................... 102
9.1.1 Frequency converter Nord size I … III ......................................................... 102
9.1.2 Frequency converter Nord size IV ................................................................ 104
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Installation and operating instruction
Combustion Manager W-FM 50
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10
Spares ............................................................................................................................... 106
11
Notes ................................................................................................................................. 108
12
Key word index ............................................................................................................ 109
4-112
Installation and operating instruction
Combustion Manager W-FM 50
1 User instructions
1 User instructions
Translation of original
operating instructions
This manual forms part of the equipment and must be kept on site.
Carefully read the manual prior to working on the unit.
1.1 Target group
The manual is intended for the operator and qualified personnel. 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,
serious injury or death.
WARNING
Danger with low risk.
Non observance can cause damage to the equipment and injury to personnel.
CAUTION
Important information
Requires direct action
Result after an action
Itemisation
Range of values
…
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Installation and operating instruction
Combustion Manager W-FM 50
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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Installation and operating instruction
Combustion Manager W-FM 50
2 Safety
2 Safety
2.1 Designated application
The combustion manager W-FM 50 is suitable for use with single fuel burners.
Improper use could:
endanger the health and safety of the user or third parties,
cause damage to the unit or other material assets.
2.2 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 contractor or gas supplier from outside of the building.
2.3 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. 7.2].
2.3.1 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.
2.3.2 Electrical connection
For work carried out on live components:
Observe the accident prevention instructions DGUV Regulation 3 and adhere to
local directives,
tools in accordance with EN 60900 should be used.
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Installation and operating instruction
Combustion Manager W-FM 50
2 Safety
2.3.3 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.
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.
Do not use combustion chamber inserts, which hinder flame burnout.
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 and components in a safe and environmentally friendly way
at an authorised location. Observe local regulations.
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Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3 Product description
3.1 Function
3.1.1 Burner Control
A burner control for oil and gas burners is integrated in the combustion manager.
It controls the sequence of operation, monitors the flame and communicates with all
components.
3.1.2 Low gas programme
The low gas pressure switch monitors the gas connection pressure from operating
phase Ph22. 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 carries out a safety shutdown
and initiates a restart after the low gas waiting time (10 seconds). This low gas
waiting time doubles after every unsuccessful start attempt. If the start attempts exceed the repetition limit value (parameter 223) 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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Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.1.3 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 valve 1):
Valve 1 remains closed, valve 2 opens,
the gas escapes and the pressure between valve 1 and valve 2 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, valve 1 is
leaking. The combustion manager initiates a controlled shutdown.
2. Test phase (function sequence for valve proving valve 2):
Valve 1 opens, valve 2 remains closed,
pressure between valve 1 and valve 2 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, valve 2
is leaking. The combustion manager initiates a controlled shutdown.
3s
1
2
3
4
5 80
10 s
3s
10 s
1
2
V1
81
82
1
2
3
4
5
P
83
V2
P
4
Valve 1
Valve 2
Pressure between valve 1 and valve 2
Valve proving gas pressure switch
Operating phases
3.1.4 Variable speed drive
Via an analogue output, the W-FM controls 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.
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Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.1.5 Calculation
A calculation can be triggered in modulating commissioning, if P1 and P9 are programmed. During a calculation, a straight line is generated from the operating point
displayed to P1 or P9. The values on the straight are adopted as the new operating
points.
Initiate a calculation after P9: Press and hold [+] key for 3 … 5 seconds.
Initiate a calculation after P1: Press and hold [–] key for 3 … 5 seconds.
If during commissioning only P1 and P9 are programmed, the combustion manager
initiates an automatic calculation when exiting P1 and calculates P2 to P8.
1
2
P1
P2
P3
P4
P5
P6
P7
P8
P9
P1
P2
P3
P4
P5
P6
P7
P8
P9
1 Automatic calculation
2 Calculation from P5 to P9
3.1.6 Data backup
In the ABE, the settings of the combustion manager can be saved via parameter 050 (Backup). If the unit needs to be replaced, or if the parameters have
unintentionally been altered, the data can be transferred back to the combustion
manager.
Data transfer (Restore) from ABE to the combustion manager is only possible if the
burner data is identical [ch. 5.3].
WARNING
Soot and CO formation because no combustion analysis has been carried
out.
At heat demand, the burner starts automatically approx. 30 seconds after the data
transfer (Restore).
Directly following the data transfer (Restore):
Check sequence of operation.
Carry out a combustion analysis at all load point.
Only in conjunction with frequency converter
Following data transfer (Restore) a speed standardisation with subsequent adjustment must be carried out.
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Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.1.7 Referencing the actuator
In operating phase Ph10 (Home Run) the combustion manager references the
actuators, whereby the actuator drives over a reference marker. The actuator then
drives back and determines the inner edge of the reference marker. All settings are
referenced to this position.
The combustion manager references the fuel actuators to the reference
marker OPEN and the air actuator to the reference marker CLOSED. The setting
range of the air damper shaft is limited mechanically, therefore the air actuator cannot drive to reference marker OPEN.
If the actuators have been mixed up, a reference fault is identified (fault code 85).
0° 1
2
90°
112°
108°
4
3
1
2
3
4
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Reference range CLOSED
Reference marker CLOSED (air actuator)
Reference range OPEN
Reference marker OPEN (fuel actuator)
12-112
-8°
-6°
Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.1.8 Program sequence
3.1.8.1 Operating phase
Ph00
Ph02
Ph10
Ph12
Ph22
Ph24
Ph30
Ph36
Ph38
Ph39
Ph40
Ph42
Ph44
Ph50
Ph52
Ph60
Ph62
Ph70
Ph72
Ph74
Ph78
Ph80
Ph81
Ph82
Ph83
Ph90
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Lockout phase
Safety phase
Home run
Standby
Fan / safety valve ON
Pre-purge position
Pre-purge
Ignition position
Pre-ignition
Test low gas pressure switch (fuel valve 1 opens, only with Gas)
Fuel release
Ignition OFF
Flame Signal
Flame stabilisation (only with Gas with pilot ignition)
Ignition pilot valve OFF (only with Gas with pilot ignition)
Operating setting 1
Operating setting 2
Post burn time
Post-purge position
Post-purge
Post-purge
Venting valve train (only during valve proving)
Test without pressure (only during valve proving)
Fill valve train (only during valve proving)
Test with operating pressure (only during valve proving)
Low gas waiting time
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Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.1.8.2 Gas direct ignition
1
00 02 10 12 22 24 30 36 38 39 40 42 44 60 62 70 72 74 78
2 X3-03:1, X3-04:1
3
X5-03:1
4
X10-05:2
5
X3-02:1
6
X5-01:2
7
X5-02:2
8
X9-04:2
9
0
q
w
e
X3-05:1
X4-02:3
X6-03:3
X8-02:1
X7-01:3
1
2
3
4
5
6
7
8
9
0
q
w
e
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Signal at input / output actuated
No signal on input
Input without influence
Operating phases
Safety circuit
Heat demand controller
Flame Signal
Air pressure switch
Minimum pressure switch
Max. pressure switch
Valve proving pressure switch
Fan motor
Ignition unit
Safety valve
Fuel valve 1
Fuel valve 2
14-112
80 81 82 83
90
Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.1.8.3 Gas with ignition pilot valve
1
00 02 10 12 22 24 30 36 38 40 42 44 50 52 60 62 70 72 74 78
2 X3-03:1, X3-04:1
3
X5-03:1
4
X10-05:2
5
X3-02:1
6
X5-01:2
7
X5-02:2
8
X9-04:2
9
0
q
w
e
r
X3-05:1
X4-02:3
X6-03:3
X8-02:1
X7-01:3
X7-02:3
1
2
3
4
5
6
7
8
9
0
q
w
e
r
83250302 1/2018-08 La
Signal at input / output actuated
No signal on input
Input without influence
Operating phases
Safety circuit
Heat demand controller
Flame Signal
Air pressure switch
Minimum pressure switch
Max. pressure switch
Valve proving pressure switch
Fan motor
Ignition unit
Safety valve
Fuel valve 1
Fuel valve 2
Ignition pilot valve
15-112
80 81 82 83
90
Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.1.8.4 Fuel oil EL modulating and multi-stage, heavy oil multistage
1
00 02 10 12 22 24 30 36 38 40 42 44 60 62 70 72 74 78
2 X3-03:1, X3-04:1
3
X5-03:1
4
X10-05
5
X3-02:1
6
X5-01:2
7
X5-02:2
8
9
0
q
w
e
X3-05:1
X4-02:3
X8-02:1
X7-01:3
(2
X7-02:3
(1
(2
1
2
3
4
5
6
7
8
9
0
q
w
e
83250302 1/2018-08 La
(1
X6-03:3
Only with heavy oil and long pre-ignition phase (parameter 281).
Only with operating mode 12 (oil modulating).
Signal on input / output activated
No signal on input
Input without influence
Operating phases
Safety circuit
Heat demand controller
Flame Signal
Air pressure switch
Minimum pressure switch
Max. pressure switch
Fan motor
Ignition unit
Safety valve
Fuel valve 1
Fuel valve 2
Fuel valve 3
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Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.1.8.5 Medium and heavy oil modulating
1
00 02 10 12 22 24 30 36 38 40 42 44 60 62 70 72 74 78
2
3
4
5
6
7
8
X3-04:1
9
0
q
w
e
r
X3-05:1
X5-03:1
X10-05
X3-02:1
X5-01:2
X5-02:2
X9-04:2
X4-02:2
X6-03:2
X8-02:1
X7-01:2
X7-02:2
(1
1
2
3
4
5
6
7
8
9
0
q
w
e
r
83250302 1/2018-08 La
(1
Only for evaluation in operating phase PH38 … PH62 (parameter 286).
Signal on input / output activated
No signal on input
Input without influence
Operating phases
Safety circuit
Heat demand controller
Flame Signal
Air pressure switch
Minimum pressure switch
Max. pressure switch
Heavy oil immediate start
Fan motor
Ignition unit
Safety valve
Fuel valve 1
Fuel valve 2
Fuel valve 3
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Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.2 Inputs
L
PE
N
X3-04
3.2.1 Voltage supply
L
The voltage supply is connected to inputs X3-04:3-5.
1
2
3
4
5
PE
N
L
The mains frequency is set in parameter 125.
L
PE
N
X3-04
3.2.2 Safety circuit
L
X3-03
L
In the diagnostic code, the inputs X3-03:1/2 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.
1
2
3
4
5
The repetition value can be set in parameter 215.
At input X3-04:1/2 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.
1
2
The burner flange limit switch is connected to input X3-03:1/2.
PE
N
X8-04
L
1
2
X3-04
RESET
OPERATION
1
2
3
4
5
X3-05
3.2.3 Reset
1
2
3
L
MOTOR
ALARM
MOTOR CONT
(1
(2
A reset button can be connected to input X8-04:1. Pressing this button in lockout
for 1 … 6 seconds will reset the combustion manager. Pressing the button for a
longer or shorter period will be ignored by the combustion manager and therefore
has no effect.
PE
N
L
With lockout function(1
If the push button is also required for manual lockout, it must be connected to
mains input X3-04:5 (L). If the combustion manager is in an operating phase,
pressing the push button for 1 to 6 seconds 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 output X3-05:2.
L
X3-02
3.2.4 Air pressure switch
1
2
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P
The closing contact of the air pressure switch is connected input X3-02. If the signal is missing once the fan has started, the combustion manager initiates a lockout.
The air pressure switch must have been deactivated, contact open, prior to the fan
starting.
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Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
PE
min
L
X5-01
3.2.5 Minimum pressure switch
1
2
3
P
The closing contact of the min. pressure switch is connected to input X5-01.
For burners without min. oil pressure switch, a bridge has to be connected to terminal 2 and terminal 3.
Low gas pressure switch
In gas operation, the combustion manager expects a signal at input X5-01:2 from
operating phase Ph22 . If the pressure drops below the value set, the pressure
switch contact opens and the combustion manager starts the low gas programme
[ch. 3.1.2].
Minimum oil pressure switch
In oil operation, the combustion manager expects a signal at input X5-01:2 from
operating phase Ph38 or operating phase Ph40 (depending on parameter 276). If the pressure drops below the value set, the pressure switch contact
opens and the combustion manager initiates a lockout. Lockout occurs in operating
phase Ph38 (pre-ignition) after a delay of 30 seconds. In all subsequent phases,
lockout occurs immediately.
PE
min
L
X5-02
3.2.6 Max. pressure switch
1
2
3
P
The opening contact of the max. pressure switch is connected to input X5-02.
For burners without max. oil pressure switch, a bridge has to be connected to terminal 2 and terminal 3.
High gas pressure switch
The combustion manager expects a signal at input X5-02:2 from operating
phase Ph40. If the value set at the pressure switch is exceeded, the pressure
switch contact opens and the combustion manager initiates a lockout.
Maximum oil pressure switch
The combustion manager expects a signal at input X5-02:2 from operating
phase Ph22 . If the value set at the pressure switch is exceeded, the pressure
switch contact opens and the combustion manager initiates a lockout. Lockout occurs in operating phase Ph22 (fan ON) after a delay of 30 seconds. In all subsequent phases, lockout occurs immediately.
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Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
PE
min
L
X9-04
3.2.7 Valve proving gas pressure switch
1
2
3
P
The opening contact of the valve proving gas pressure switch is connected to input X9-04. Input X9-04 is only activated during valve proving [ch. 3.1.3]. The time
of valve proving can be set in parameter 241 .
If the pressure set is not achieved in operating phase Ph81 (test without pressure), the contact closes.
If the pressure set is exceeded in operating phase Ph83 (test with operating
pressure), the contact opens.
PE
min
L
X9-04
3.2.8 Heavy oil immediate start
1
2
3
The input is only activates for the return flow temperature sensor on heavy oil burners. The release contact of the return flow temperature sensor is connected to input X9-04.
In modulating heavy oil operation, the combustion manager carries out a nozzle circulation for maximum 45 seconds. If the signal is present at X9-04 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.
During operation, the signal is monitored according to the setting of parameter 286.
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3 Product description
3.2.9 Flame sensor
If the flame signal in operating phase Ph44 does not correspond to the value required, the combustion manager initiates safety shutdown with restart.
If the flame signal during operation does not maintain the required value, the combustion manager initiates a controlled shutdown with restart. Two controlled shutdowns in sequence lead to lockout.
A flame signal at heat demand (operating phase Ph12) leads to start prevention.
A flame signal during pre-purge (operating phase Ph30 … Ph36) or post-purge
(operating phase Ph78) leads to lockout after one repetition and repeated occurrence.
Parameter 954 shows the current flame signal as a percentage value.
QRA
QRA
X10-06
QRA…
BR
1
2
+
The flame sensor QRA… (UV cell) is connected to input X10-06.
BU
Response limit extraneous light
Operation
Flame signal
Parameter 954
greater than 18 %
min 24 %
Ionisation electrode
QRB/C
QRB/C-N
X10-05
PE
ION
L
1
2
3
4
5
The ionisation electrode is connected to input X10-05:2.
Sensor current min.: 4 μA
Sensor current max.: 16 … 40 μA
Flame signal
Parameter 954
approx. 30 %
100 %
QRB…
QRB/C
QRB/C-N
L
X10-05
PE
ION
1
2
3
4
5
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The flame sensor QRB… (photo resistor) is connected to input X10-05:3/4.
Flame signal
Parameter 954
Response limit extraneous light (resistance less than approx. 10 %
400 kΩ)
Operation (resistance less than 230 kΩ)
approx. 16 %
Short circuit identification (resistance less than
–
0.5 kΩ)
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3 Product description
X5-03
L
4...20
GND
The contact for heat demand is connected to input X5-03:1 (burner ON/OFF).
°C
-
1
2
3
4
5
ON/OFF
+
1
2
3
4
X64
3.2.10 Load controller analogue input
The analogue load signal is connected to terminals X64:1 (4 … 20 mA) and
X64:2 (GND). A signal of less than 3 mA deactivates the analogue input and the
load pre-setting at input X5-03:2/3 has priority (parameter 942). If no load controller is connected to input X5-03:2/3, the combustion manager remains at the
current rating until heat demand is interrupted.
Modulating operation with load controller
In modulating operation, parameter 123 determines the minimum correcting element step.
Signal on X64:1/2
3 … 4 mA
20 mA
Load W-FM
20 %
100 %
Multi-stage operation (fuel oil only)
In multi-stage operation a hysteresis of 1 mA exists between the operating points,
which eliminates unnecessary load changes.
Two stage:
Signal on X64:1/2
3 … 5 … 12 mA
13 … 15 … 20 mA
Load W-FM
Stage 1
Stage 2
Three stage:
Signal on X64:1/2
3 … 5 … 7 mA
8 … 10 … 12 mA
13 … 15 … 20 mA
Load W-FM
Stage 1
Stage 2
Stage 3
3.2.11 Load controller building management
X5-03
ON/OFF
COM
X92
L
A BUS interface for building management can be connected to input COM X92:
Modbus: Bus-Interface Modbus OCI412.10 (Order No.: 660 285),
eBUS: Adapter MPA eBUS (Order No.: 743 090).
1
2
3
4
Interface
To ensure that load pre-setting is carried out by the building management system,
input X5-03:1 (burner ON/OFF) must be connected to voltage output X5-03:4 for
burner start.
The settings required for Bus communication are set in parameters 141 to 148.
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3 Product description
3.2.12 Load controller via contacts
The contact for heat demand is connected to input X5-03:1 (burner ON/OFF).
The load control distinguishes between multi-stage and modulating operation. The
operating mode is set in parameter 201 .
Modulating operation with load controller
X5-03
ON/OFF
L
1
2
3
4
°C
If input X5-03:2 (CLOSED) is activated, the burner capacity reduces.
If input X5-03:3 (OPEN) is activated, the burner capacity increases.
If none of the two inputs is activated, the burner capacity remains unchanged.
X5-03
1
2
3
4
X5-03
Operating mode sliding two stage with thermostat
1
2
3
4
ON/OFF
L
ON/OFF
L
If thermostats or pressure regulators are connected to inputs X5-03, the modulating fuel can only be operated in sliding two stage operation.
At heat demand input X5-03:2 (CLOSED) is activated and the burner drives to partial load. If the temperature drops below the value set, input X5-03:3 (OPEN) is activated and the burner drives to full load. If a signal is applied to input X5-03:3, input X5-03:2 is ignored.
P
P
P
P
P
P
P
Multi-stage operation (fuel oil only)
X5-03
ON/OFF
L
Two and three stage:
1
2
3
4
°C
Input
two stage
Stage 1
Stage 1
Stage 2
X5-03:1
X5-03:2
X5-03:3
Operating mode
three stage
Stage 1
Stage 2
Stage 3
X5-03
1
2
3
4
X5-03
If input X5-03:3 is activated during three stage operation, the burner drives to
stage 3, the signal from stage 2 is no longer relevant.
1
2
3
4
ON/OFF
L
ON/OFF
L
P
P
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 stage 3.
Change-over release:
P
P
A bridge connects terminals 2 and 3. At heat demand the burner drives to stage 1.
If inputs X5-03:2/3 are then activated simultaneously the burner drives via stage 2
to stage 3.
X75
3.2.13 Fuel Meter
1
2
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It is possible to connect a fuel meter with Reed contact to input X75. A prerequisite
for this is that no frequency inverter is connected and activated. The meter pulses
per unit volume must be set in parameter 128 . The impulse frequency must not
exceed 300 Hz.
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3 Product description
3.3 Outputs
MOTOR
ALARM
MOTOR CONT
X3-05
3.3.1 Alarm
A mains voltage signal is given at alarm output X3-05:2 in lockout (operating phase
Ph00).
1
2
3
In addition, start prevention can also be signaled. To do this, parameter 210
should be set to 1.
ALARM
MOTOR CONT
MOTOR
ALARM
MOTOR CONT
X3-05
MOTOR
X3-05
3.3.2 Motor
1
2
3
Normal operation
M
L
The fan motor is connected to output X3-05:1 via contactor or star delta switching.
N
The fan motor is connected to output X3-05:3 via contactor or star delta switching.
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 to the air pressure switch
and connected to output X3-05:1.
1
2
3
M
L
Continuous operation
N
PE
N
L
X4-02
3.3.3 Ignition
The ignition unit is connected to output X4-02.
1
2
3
Ignition behaviour Gas
Pre-ignition in operating phase Ph38 can be adjusted in parameter 226 .
Ignition behaviour Oil
In parameter 281 ,the switch-on point of ignition (operating phase Ph22 or
Ph38) is determined.
Pre-ignition in operating phase Ph38 can be adjusted in parameter 266 .
3.3.4 Frequency converter
0...10 V
10 V
X74
24 V
1
2
3
4
5
The frequency converter and the speed sensor are connected at output X74.
Frequency converter
Terminal
X74:1
X74:2
X74:3
Function
24 V input; supply from frequency converter
Signal acquisition
Speed setpoint signal (parameter 645)
Speed measurement
Terminal
X74:4
X74:5
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Function
Speed return signal (input actual speed)
10 V; supplied by combustion manager
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3 Product description
3.3.5 Analogue output
0...10 V
10 V
X74
24 V
1
2
3
4
5
Instead of the frequency converter, a load dependent analogue signal can be emitted at output X74:3. Prerequisite is an external 24 V DC voltage source at input X74:1/2.
The values given relate to an analogue signal of 0 … 10 V, if a signal of 2 … 10 V
or 0/2 … 10 V is set in parameter 645 the voltages listed will change.
Conversion: (original value x 0.8) + 2 =new value
Modulating operation
Rating
Off
Ignition load
Partial load (20 %)
Full load (100 %)
Curve point
–
P0
P1
P9
Analogue signal
0V
1V
2V
10 V
Curve point
–
P1
P2
Analogue signal
0V
5V
10 V
Curve point
–
P1
P2
P3
Analogue signal
0V
3V
5V
10 V
Two stage operation
Rating
Off
Stage 1
Stage 2
Three stage operation
Rating
Off
Stage 1
Stage 2
Stage 3
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3 Product description
3.4 Technical data
3.4.1 Electrical data
Combustion Manager
Mains voltage / Mains frequency
Consumption
Internal unit fuse
External fuse
Type of protection
230 V / 50 … 60 Hz
max 30 W
T6.3H, IEC 127-2/5
max 16 AB
IP 00
Display and operating unit (ABE)
Mains voltage
Consumption
Type of protection (front)
DC 5 V
max 50 mW
IP54 to IEC 529
Type of protection (rear)
Protection class
IP00 to IEC 529
II to DIN EN 60 730-1
Actuator
STE 50 1.2 Nm
DC/AC 24 V /
50 … 60 HZ
max 7.5 W
1.2 Nm
5 s / 90°
IP 54
II
Mains voltage
Consumption
Torque
Setting time
Type of protection
Protection class
STE 50 3 Nm
DC/AC 24 V /
50 … 60 HZ
max 10 W
3 Nm
4 s / 90°
IP 54
II
3.4.2 Ambient conditions
Temperature in operation
Temperature during transport / storage
relative humidity
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–20 … +60 °C
–20 … +60 °C
max 95 %, no dew point
Installation and operating instruction
Combustion Manager W-FM 50
3 Product description
3.4.3 Dimensions
Combustion manager
230 mm
217 mm
122 mm
135 mm
60 mm
Display and operating unit (ABE)
Recess dimension: 127 x 91 mm ± 0.5 mm
17 mm
96 mm
18 mm
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126,4 mm
132 mm
90,6 mm
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Installation and operating instruction
Combustion Manager W-FM 50
4 Installation
4 Installation
4.1 Electrical connection
DANGER
WARNING
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 16 AB 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 16 AB). 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:
Display and operating unit, load controller, safety interlock circuit, burner flange,
reset key - maximum 20 m (100 pF/m).
BCI interface maximum 20 m (100 pF/m).
Connecting the burner motor
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.
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4 Installation
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).
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5 Operation
5 Operation
5.1 Operating interface
5.1.1 Operating panel
Display and operating unit (ABE)
1
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F
1
A
-
+
5
2
4
3
[Enter]
[info]
2
3
2 and 3
4
5
4 and 5
info
s %
[+]
[–]
[+] and [–]
[A] Air
[F] Fuel
[F] and [A]
back-up of value changes;
entry to parameter and values
call up information
press for approx. 3 seconds: Info level
press for approx. 5 seconds: Service level
navigation through parameter structure;
changing values
press simultaneously: return/cancel
selects the damper position
selects the fuel supply
press simultaneously: selects the frequency
converter (optional)
OFF function
Press [ENTER] and any other key simultaneously.
Immediate lockout.
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Installation and operating instruction
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5 Operation
5.1.2 Display
The black cursor in the display shows the status of the inputs and outputs, the unit
of values and the active level.
1
2 3 4 5
6
S
u
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t
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r e w q 0 9 8 7
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
z
u
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Heat demand by the boiler control (start)
Burner motor
Ignition
Fuel valves
Flame signal on
Flame failure or lockout
Degree of angle setting
Percentage value
Second
Minute
Hour (together with volume = V/h)
Volume (m3, l, ft3, gal)
Actuator OPEN
Actuator CLOSED
Service level
Info level
Parameter level (engineer level)
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Installation and operating instruction
Combustion Manager W-FM 50
5 Operation
Display OFF
The parameter setting is missing, incomplete or has been deleted.
No heat demand from controller (input X5-03:1).
Safety circuit not closed at heat demand (input X3-03:1/2 and
X3-04:1/2).
Display Ph
The combustion manager is in an operating phase and waits for
signals or activates outputs depending on the program sequence.
The combustion manager is in an operating phase and shows
the remaining run time programmed (example: pre-purge).
Display Op
The combustion manager is in modulating operation and shows
the current load in percent.
The combustion manager is in multi-stage operation and shows
the current fuel stage.
When the fuel stage is changed, the additional display on or
of indicates the switching of the relevant fuel valve.
Display flashes
Manual load is activated. The combustion manager is in manual
load default.
Deactivate manual load:
Press and hold [esc] key for 5 seconds.
Fault display
During a fault condition, the display alternately shows the error code C and diagnostic code D [ch. 8.3].
The combustion manager is in lockout.
Once the fault has been rectified, the combustion manager has
to be reset [ch. 8.1.4].
The combustion manager initiates a safety shutdown.
The burner restarts automatically once the fault condition has
been rectified.
The combustion manager shows an occurrence, which does not
lead to a shutdown.
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Installation and operating instruction
Combustion Manager W-FM 50
5 Operation
5.2 Displaying and adjusting parameters
Password level (engineer level)
call up level
Press [F] and [A] keys simultaneously and then enter the
password [ch. 5.2.1].
Info-/Service level
The Info or Service level can only
be called up from the standard
display.
Press [Enter].
For Info level 1 … 3 s
For Service level 3 … 5 s
Next parameter
Press [+] key.
Press [+] key.
– or –
Briefly press [Enter].
Previous parameter
Press [–] key.
Press [–] key.
Press [Enter].
Press [Enter] 1 … 3 s.
Press [esc].
Press [Enter] 3 … 5 s.
One level lower
One level higher
– or –
Briefly press [esc] key.
Change value
Press [+] or [–] key.
not possible
Press [Enter].
not possible
Save value
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Installation and operating instruction
Combustion Manager W-FM 50
5 Operation
5.2.1 Password
Enter password
Press [F] and [A] simultaneously for approx. 2 seconds.
The display shows CodE.
Enter the first digit using [+] or [–] and confirm with [ENTER].
Repeat procedure until the password has been entered.
Exit password entry using [ENTER].
The display shows PArA (parameter level) for a short time and then changes
over to 400: SEt (setup).
S
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%
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%
Deactivating password
If no key is activated for 30 minutes, the combustion manager automatically deactivates the password and blocks the level.
In the password level, the password can be aborted early:
Press [esc] key until the display shows CLr CodE.
Let go of the [esc] key.
The combustion manager blocks the password level and changes to the operating display.
S
P
i
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S
S
P
i
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Installation and operating instruction
Combustion Manager W-FM 50
5 Operation
5.2.2 Manual load
If a signal is applied to input X5-03:1 (burner ON), each load setting within the load
limit can be selected manually. If manual load is activated, the current load flashing
in the operating display. Manual load can be activated using a key combination or
parameter 121 . If manual load is set via parameter 121 additional functions are
available.
Load default
---0.0 … 19.9
P0
20.0 … 100.0
P1 … P3
Function
Parameter 121
Manual load deactivated
Manual OFF, remains active even after
fuel changeover.
Initiate ignition position (multi stage operation only)
Initiate load setting within the load limits.
Key combination
not possible
not possible
not possible
Initiate load setting within the load limits.
Values outside of the load limits can be Only values within the load limits can be
adjusted, but not initiated. If the load lim- adjusted.
its are extended during active manual
load, the burner reacts accordingly.
For the duration of commissioning (400 Set), manual load is ignored.
With the exception of Manual OFF, manual load is deactivated during fuel changeover.
Manual load via key combination
Activate manual load:
Press and hold [F] key.
The display shows LoAd.
Set manual load using [+] or [-] key.
The manual load set flashes.
Manual load burner OFF:
Drive to minimum load position and release [F] and [-] keys.
Press [F] and [-] keys again.
Deactivate manual load:
Press and hold [esc] key for approx. 5 seconds.
S
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%
V
S
S
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s
%
5s
Manual load via parameter 121
Enter password [ch. 5.2.1].
Select parameter 121 .
Press [Enter].
Set manual load using [+] or [-] key.
Press [Enter].
Manual load is initiated.
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Installation and operating instruction
Combustion Manager W-FM 50
5 Operation
5.3 Parameters
5.3.1 Password level
Internal parameter (000: Int)
Parameter Function
050
Data backup [ch. 3.1.6]
Transfer of data sets between W-FM and ABE with identical burner identification (parameter 113). If
the backup or restore is incorrect, a negative value is displayed. The cause of the error is described in
error code 137 see.
Save from W-FM to ABE (Backup):
Press [Enter].
The display shows bAC_up.
Press [Enter].
Set 1 using [+] key and confirm with [Enter].
Following successful execution the display is reset to 0.
055
056
057
Save from ABE to W-FM (Restore):
Press [Enter].
The display shows bAC_up.
Press [+] key.
The display shows rEStorE.
Set 1 using [+] key and confirm with [Enter].
Following successful execution the display is reset to 0.
Burner identification of data backup (read only).
ASN excerpts of data backup (read only).
Software version when creating backup (read only).
General parameters (100: PArA)
Parameter
102
103
104
105
107
108
111
113
121
123
Function
Date of manufacture DD.MM.YY
Production number
Parameter default setting: Customer code
Parameter default setting: Version
Software version
Software variation
ASN excerpt for comparison with data backup (parameter 056)
Burner identification: Identical to the burner serial number (name plate). The burner identification has to
be reset if the combustion manager has been replaced.
Manual load
Minimum setting step in percent
Only load changes, which exceed the value set are initiated, this avoids unnecessary setting movements in modulating operation.
123.00: Load default from building management
123.01: Analogue load controller on X64
123.02: Load controller contact on X5-03
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Installation and operating instruction
Combustion Manager W-FM 50
5 Operation
Parameter Function
124
Flame failure test (TÜV test)
The flame failure test can only be carried out in operating setting 1 (operating phase Ph60). The flame
failure test closes the fuel valves and calculates the time up to flame failure. The calculated time is displayed in the diagnostic code in multiples of 0.2 seconds (example Loc.D: 8 = 1.6 seconds).
For the flame failure test the burner drives to the load defined under parameter 133 . If no load is
defined in parameter 133 , the flame failure test is carried out at the current load.
125
126
128
130
133
141
142
Press [Enter].
Set value 1 using [+] key and confirm with [Enter].
Following successful execution, the display alternately shows the error code Loc.c: 7 and diagnostic code Loc.d: x.
Mains frequency
0: 50 Hz
1: 60 Hz
Display illumination
Fuel meter
The value must correspond to the number of impulses per unit of volume (l, m³) of the fuel meter. If the
value is set to 0 , the fuel meter stops.
Delete error history [ch. 8.1]
Load for flame failure test
Operating mode building management
0: OFF
1: Modbus, the combustion manager operates as Slave, the RTU transfer mode is used (Remote Terminal Unit)
2: eBUS
Recurrence time if communication is interrupted (setting range: 0 … 7200 s)
If communication to the building management system fails, the next load controller according to priority
will be activated once this time has elapsed. If no other load controller is connected, the burner remains at the current load or it drives to the load defined in parameter 148.
143
Priority 1: Load controller building management
Priority 2: Load controller on analogue input X64
Priority 3: Load controller on input X5-03
Unit address of combustion manager as eBUS participant
144
145
146
1: Address 03
2: Address 13
3: Address 33
4: Address 73
5: Address F3
6: Address 1F
7: Address 3F
8: Address 7F
Send cycle in seconds for the eBUS 05 and 09
Unit address of combustion manager as Modbus participant
Baud rate Modbus
The Baud rate of the combustion manager and the building management system must be identical.
147
0: 9600
1: 19200
Parity Modbus
The parity of the combustion manager and the building management system must be identical.
0: no Parity bit
1: odd Parity bit
2: even Parity bit
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Installation and operating instruction
Combustion Manager W-FM 50
5 Operation
Parameter Function
148
Replacement load (setting range: 0 … 100 %)
Load default for communication failure with building management system.
161
162
–––: no replacement load
0 … 19.9: burner OFF
Number of lockouts
Operating hours since last reset
163
164
Reset:
Press [Enter].
Press [–] key.
The display shows 0, operating hours have been reset.
Total operating hours (voltage applied to combustion manager)
Start-ups since last reset
166
167
Reset:
Press [Enter].
Press [–] key.
The display shows 0, start-ups have been reset.
Total start-ups
Fuel volume since last reset
190
Reset:
Press [Enter].
Press [–] key.
The display shows 0, the fuel volume has been reset.
Position of actuators at lockout
0: Standby position
1: Post-purge position
191 … 193 not used
195
Repetition counter for heavy oil immediate start
Number of heavy oil start attempts with missing signal at input X9-04 until lockout.
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Installation and operating instruction
Combustion Manager W-FM 50
5 Operation
Burner control (200: PAr0)
Parameter Function
201
Operating mode
––: not defined (delete curves)
1: Gas direct ignition
2: Gas pilot ignition
5: fuel oil EL, MS and S two stage Z
6: fuel oil EL, MS and S three stage T
12: fuel oil EL modulating
23: fuel oil MS and S modulating
204
208
Other settings without function (3, 4, 7 … 11, 13 … 22 und 24 … 27).
not used
Program stop
210
0: deactivated
1: Pre-purge position (operating phase Ph24)
2: ignition position (operating phase Ph36)
3: interval time 1 (operating phase Ph44)
4: interval time 2 (operating phase Ph52)
Alarm at start prevention
Determines whether a signal is given at output X3-05:2 during start prevention.
211
0: no alarm (no signal at output X3-05:2)
1: Alarm (signal at output X3-05:2)
Fan run-up time (setting range: 2.0 … 60 s)
212
Time from fan start to start of actuators.
Switch off behaviour / max. time to partial load (setting range: 0.2 … 45 s.)
If heat demand is no longer present, the burner drives as far as possible to partial load in a predetermined time and then switches off.
215
The burner takes approx. 32 seconds to drive from 100% load to 20% (partial load).
Repetition counter safety circuit (setting range: 1 … 16)
221
Number of safety shutdowns by the safety circuit before lockout occurs [ch. 3.2.2].
Flame sensor Gas
222
0: QRC
1: ionisation electrode/QRA
Pre-purge Gas
When using a valve proving system and two Class A fuel valves pre-purge following a controlled shutdown can be omitted (to EN 676).
223
0: OFF
1: ON (pre-purge phase parameter 225)
Repetition counter low gas pressure switch (setting range: 1 … 16)
225
Number of safety shutdowns by the low gas pressure switch before lockout occurs [ch. 3.1.2].
Pre-purge time Gas in operating phase Ph30 (setting range: 20 … 3600 s)
226
Once the pre-purge positions have been reached, the combustion manager remains in Ph30 for the
duration of the time set.
Pre-ignition Gas (setting range: 0.2 … 3600 s)
230
Duration of pre-ignition time in operating phase Ph38.
Interval time 1 Gas
232
The interval time 1 in operating phase Ph44 acts as stabilisation time following flame formation.
Interval time 2 Gas
The interval time 2 in operating phase Ph52 acts as stabilisation time following flame formation.
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Installation and operating instruction
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5 Operation
Parameter Function
233
Post burn time Gas (setting range: 0.2 … 60 s)
236
The combustion manager remains in operating phase Ph70 for the duration of the time set, the flame
sensor is ignored during this time.
Post-purge time Gas (setting range: 0.2 … 6480 s)
Once the post-purge position has been reached, the combustion manager remains in operating
phase Ph74 for the duration of the time set, the flame sensor is ignored during this time.
Low gas pressure switch input / installation position
237
0: OFF
1: Low gas pressure switch fitted upstream of valve 1 (factory setting)
2: Low gas pressure switch fitted between valve 1 and valve 2, valve proving via low gas pressure
switch
High gas pressure switch
234
If a high gas pressure switch is fitted, set parameter to 1.
239
241
0: OFF
1: high gas pressure switch
2: valve closing contact
With forced intermittent activated, a controlled shutdown with subsequent restart is initiated after 23
hours and 45 minutes uninterrupted burner operation.
0: OFF
1: forced intermittent activated
Valve proving
In accordance with DIN EN 676 valve proving is not necessary if pre-purge is activated and the burner
rating is less than 1200 kW.
248
0: valve proving OFF (only with capacity < 1200 kW, parameter 222 must be set to 1: ON)
1: valve proving at stat-up
2: valve proving at shutdown (factory setting)
3: valve proving at stat-up and shutdown
Post-purge time 3 Gas (setting range: 0.2 … 6480 s)
261
The combustion manager remains in operating phase Ph78 for the duration of the time set except if a
new heat demand interrupts the post-purge time 3 in operating phase Ph78.
Flame sensor Oil
265
0: QRB
1: QRA
Pre-purge time Oil in operating phase Ph30 (setting range: 15 … 3600 s)
266
Once the pre-purge positions have been reached, the combustion manager remains in operating
phase Ph30 for the duration of the time set.
Pre-ignition time Oil (setting range: 0.6 … 3600 s)
270
Once the ignition positions have been reached, the combustion manager remains in operating phase
Ph38 for the duration of the time set.
Interval time 1 Oil
272
273
The interval time 1 in operating phase Ph44 acts as stabilisation time following flame formation.
not used
Post-burn time Oil (setting range: 0.2 … 60 s)
274
The combustion manager remains in operating phase Ph70 for the duration of the time set, the flame
sensor is ignored during this time.
Post-purge time Oil (setting range: 0.2 … 6480 s)
Once the post-purge position has been reached, the combustion manager remains in operating
phasePh74 for the duration of the time set, the flame sensor is ignored during this time.
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5 Operation
Parameter Function
276
Minimum oil pressure switch
277
0: OFF
1: active from operating phase Ph38
2: active from operating phase Ph40 with solenoid valve upstream of pressure switch (e.g. pump
with valve)
Max. oil pressure switch
If a max. oil pressure switch is fitted set parameter to 1.
279
0: OFF
1: oil pressure switch
2: valve closing contact
With forced intermittent activated, a controlled shutdown with subsequent restart is initiated after 23
hours and 45 minutes uninterrupted burner operation.
281
0: OFF
1: forced intermittent activated
Point of ignition Oil
284
0: ignition on in operating phase Ph38 (short pre-ignition)
1: ignition on in operating phase Ph22 (long pre-ignition at fan start)
Post-purge time 3 Oil (setting range: 0.2 … 6480 s)
286
The combustion manager remains in operating phase Ph78 for the duration of the time set except if a
new heat demand interrupts the post-purge time 3 in operating phase Ph78.
Evaluation of heavy oil immediate start
If the signal is missing during the operating phase set, the W-FM initiates a shutdown with a subsequent restart (repetition). The number of repetitions can be set in parameter 195 .
287
0: signal only required in operating phase Ph38
1: signal required in operating phases PH38 … PH62
Maximum waiting time for signal for heavy oil immediate start in operating phase PH38 (setting
range: 1 … 45 s)
Commissioning parameter (400: SEt)
Parameter set 400 is used to adjust the fuel air compound regulation (see Ch. 6).
Compound (500: PArA)
Parameter Function
501
Special positions fuel actuator
502
501.00: standby position (is activated in operating phases Ph10, Ph12 and Ph00 )
501.01: Pre-purge position (is only activated in operating phase Ph24 )
501.02: Post-purge position (is activated in operating phase Ph72 )
Special position air actuator
503
502.00: standby position (is activated in operating phases Ph10, Ph12 and Ph00 )
502.01: Pre-purge position (is activated in operating phase Ph24 )
502.02: Post-purge position (is activated in operating phase Ph72 )
Special positions frequency converter
522
503.00: standby position (is activated in operating phases Ph10, Ph12 and Ph00 )
503.01: pre-purge position (is activated in operating phase Ph24 )
503.02: Post-purge position (is activated in operating phase Ph72 )
Drive up ramp (setting range: 5 … 20 s)
523
The ramp should be at least 20% slower than that of the frequency converter.
Drive up ramp (setting range: 5 … 20 s)
The ramp should be at least 20% slower than that of the frequency converter.
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Installation and operating instruction
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5 Operation
Parameter Function
542
Activation of frequency converter
544
0: not activated
1: activated
Operating ramp modulating
Time for the actuators to drive from low load to high load.
545
Recommended factory setting: 32 s
Lower load limit (setting range: 20 … 100 %)
Defines the lower modulating limit (partial load). If no limit has been defined, the lower load limit in operation is automatically set to 20 %.
546
– – – –: no load limit defined (20 %)
Upper load limit (setting limit: 20 … 100 %)
Defines the upper modulating limit (full load). If no limit has been defined, the upper load limit in operation is automatically set to 100 %.
– – – –: no load limit defined (100 %)
Actuators (600: ACtr)
Parameter Function
601 … 613 Configuration of actuators
641
606.00: fuel actuator
606.01: air actuator
Speed standardisation
During speed standardisation, a setpoint signal of 95 % (9.5 V) is sent to the frequency converter. The
speed achieved is saved as 100% value, which means that a reserve of 5% is available during operation. The maximum frequency at the frequency converter must therefore be 52.6 Hz. If the frequency
converter is fitted to the burner, the maximum frequency has been factory preset. If the frequency converter is external, the maximum frequency has to be set to this value.
Starting standardisation:
Press [Enter].
Set value 1 using [+] key and confirm with [Enter].
The fan motor starts with the air damper open.
Following successful execution the display is reset to 0.
If a negative value appears (-X), the normalisation has failed.
642
The combustion values must be checked after every speed standardisation.
Standardised speed
During speed standardisation a 95% signal is signalled to the frequency converter and the speed
achieved is saved as the standard speed.
642.00: Standard speed saved from micro controller 1.
642.01: Standard speed saved from micro controller 2.
645
The speeds of the two micro controllers may vary by up to 1.5 %.
Analogue output X74
This output can be used to signal a load dependent analogue signal [ch. 3.3.5] or to activate a frequency converter [ch. 3.3.4]. In conjunction with a frequency converter the voltage at output X74 and
and at setpoint input of the frequency converter must be set identically.
0: DC 0 … 10 V
1: DC 2 … 10 V
2: DC 0/2 … 10 V
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5 Operation
Parameter Function
652
Activation of the frequency converter with safety circuit open
653
0: no activation
1: frequency converter is activated with 0
Speed monitoring in standby, standby speed 0 %
0: no speed monitoring
1: speed monitoring activated
Fault history (700: HISt)
Parameter set 700 is used to localise and correct faults [ch. 8.2].
Process data (900: dAtA)
Parameter Function
903
Current capacity
922
903.00: Fuel
903.01: Air
Actuator step position
935
922.00: fuel actuator
922.01: air actuator
Absolute speed
936
Current actual speed (recorded by transmitter disc on motor)
Standardised speed
942
Current speed signal in percent.
Active load source (load controller)
The parameter shows the load source currently active. If more than one load source is available, the
combustion manager prioritises to the sequence listed below. The priority cannot be altered.
947
1: load by curve setting
2: manual load
3: load controller via building management
4: external load controller via analogue input X64 terminal 1 / terminal 2
5: external load controller via contacts X5-03 terminal 2 / terminal 3
Contact interrogation W-FM (bit coded output)
947.00: inputs
1: min. pressure switch
2: max. pressure switch
4: internal fuel selection
8: air pressure switch
16: load controller OPEN
32: load controller ON
64: load controller CLOSED
128: safety circuit
947.01: outputs
948
1: safety valve
2: ignition
4: fuel valve 1
8: fuel valve 2
16: fuel valve 3 / pilot valve
32: internal fuel selection 1
Contact return signal network meter
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Installation and operating instruction
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5 Operation
Parameter Function
950
Relay nominal condition (Bit coded output)
951
1: alarm
2: safety valve
4: ignition
8: fuel valve 1
16: fuel valve 2
32: fuel valve 3 / pilot valve
Mains voltage (standardised)
Value displayed x factor = current voltage
954
960
961
981
982
992
Factor 230 V: 1.683
Factor 120 V: 0.843
Current flame signal in percent [ch. 3.2.9]
Current fuel throughput
Current operating phase [ch. 3.1.8]
Fault history: fault codes
Fault history: diagnostic codes
Fault flags
5.3.2 Info level
In the Info level, parameter values can be displayed but not altered.
Select parameter using [+] or [-] key.
Press [Enter] 1 … 3 s.
Parameter value appears.
Parameters
167
162
164
163
166
113
107
108
102
103
104
105
143
Function
Fuel volume since last reset
Operating hours since last reset
Start-ups since last reset
Total operating hours (voltage applied to combustion manager)
Total start-ups
Burner identification: identical to the burner serial number (name plate)
Software version
Software variation
Date of manufacture DD.MM.YY
Production number
Parameter default setting: Customer code
Parameter default setting: Version
Unit address of combustion manager as eBUS participant
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Installation and operating instruction
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5 Operation
5.3.3 Service level
In the service level, parameter values can be displayed but not altered.
Select parameter using [+] or [-] key.
Press [Enter] 1 … 3 s.
Parameter value appears.
Parameters
954
960
121
922
Function
Current flame signal in percent [ch. 3.2.9]
Current fuel throughput
Manual load
Actuator step position
936
922.00: fuel actuator
922.01: air actuator
Standardised speed
161
701
…
725
Current speed signal in percent
Number of lockouts
FaultHistory [ch. 8.1.3]
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
6 Commissioning
6.1 Prerequisite
Commissioning must only be carried out by qualified personnel.
Only correctly carried out commissioning ensures the operational safety.
Observe the prerequisites for commissioning in the installation and operating
manual of the burner. This manual contains detailed information about:
general installation regulations,
nozzle selection,
connecting measuring devices,
replacing filter inserts,
checking the gas connection pressure,
carrying out soundness test,
venting the gas valve train,
setting the gas pressure regulator,
pre-setting the pressure switch.
6.2 Adjusting the burner
In addition to this chapter, the information about adjustment in installation and operating manual of the burner should be observed. This manual contains detailed information about:
speeds (in in conjunction with frequency converter),
pump pressure,
flow and return pressure,
default settings,
mixing pressure.
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6 Commissioning
6.2.1 Adjusting gas side
Prerequisite
Open gas isolating valve.
Pressure in gas valve train increases.
Close isolating valve.
Switch on voltage supply.
The display shows either OFF UPr or OFF.
S
S
P
i
P
i
V
h min s %
V
h min s %
burner off and not programmed
burner off
OFF UPr
OFF
1. Enter password
Press [F] and [A] simultaneously for approx. 2 seconds.
The display shows CodE.
Enter the first digit using [+] or [–] and confirm with [ENTER].
Repeat procedure until the password has been entered.
Exit password entry using [ENTER].
The display shows PArA (parameter level) for a short time and then changes
over to 400: SEt (setup).
S
P
i
V
h min
s
%P
i
S
S
P
i
S
V
h min
s
%
V
h min
s
%P
i
V
h min
s
%
2. Switch on burner
Ensure there is a demand for heat.
A black dash appears below the S symbol (start).
A heat demand from the boiler controller is required for the duration of commissioning, that means signal on input X5-03:1.
S
P
i
V
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
3. Start setup
Press [ENTER].
If the combustion manager has been pre-programmed, the display shows run 1.
Select type of setting (from step 9).
If the combustion manager has not been programmed, the display shows parameter
201 2.
Define parameters 201, 542 and 641 and set P0 (from step 4).
201: Operating mode
542: Activation of frequency converter
641: Speed standardisation
S
P
i
1
S
V
h min
s
%
V
h min
s
%
P
i
V
h min
s
S
%
P
i
2
4. Set operating mode
The following steps must only be carried out if the combustion manager is not programmed. If the combustion manager has been pre-programmed, proceed with
step 9.
Press [ENTER].
The display shows only the parameter value.
Set operating mode using [+] or [–] keys and confirm with [Enter].
1: direct ignition
2: pilot ignition
Exit entry using [esc].
The display shows parameter 201 with the current operating mode.
S
S
P
i
P
i
V
h min
s
%
S
%
P
i
V
S
P
i
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6 Commissioning
5. Activate/deactivate frequency converter
Press [+] key.
The display shows parameter 542.
Press [Enter].
The display shows only the parameter value.
Activate or deactivate the frequency converter using [+] or [–] and confirm with
[ENTER].
0: without frequency converter
1: with frequency converter
Exit entry using [esc].
The display shows parameter 542 with the current setting.
S
S
P
i
P
i
V
h min
s
S
%
%
P
i
V
h min
s
%
S
P
i
V
h min
s
%
6. Carry out speed standardisation
Speed standardisation must only be carried out in conjunction with a frequency
converter.
If no frequency converter is fitted, skip speed standardisation 641 using the [+]
key.
Press [+] key.
The display shows parameter 641.
Press [ENTER].
Set value to 1 using the [+] and start speed standardisation by pressing
[ENTER].
Check rotation direction of burner motor
The fan motor starts with open air damper setting. Once standardisation is complete, the display changes form 1 to 0.
Exit speed standardisation using [esc].
The standardised speed can be read in parameter 642.
S
S
S
P
i
P
i
P
i
V
h min
s
S
%
V
S
P
i
V
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%
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i
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% m 3 m 3/h l
P
i
s
%
V
h min
s
%
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
7. Preset ignition load point
Press [+] key.
The display shows the ignition load point P0.
press and hold [A] and using [+]/[–] set air damper setting 4.0 … 9.0.
Press and hold [F] and set gas butterfly valve setting 8.0 … 13.0° using [+]/[–].
Only in conjunction with frequency converter
The ignition speed must not be less than 70 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed using [+]/[–].
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
h min
s
%
S
P
i
V
h min
s
%
8. Preset full load point
Press [+] key.
The display shows the full load point P9.
Press and hold [A] and using [+]/[–] set air damper setting from setting diagram.
Press and hold [F] and set gas butterfly valve setting 45.0 … 50.0° using [+]/[–].
Only in conjunction with frequency converter
Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % using
[+]/[–].
Press [+] key.
Exit pre-setting.
The display changes to run.
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
V
S
P
i
V
h min
s
%
V
h min
s
%
S
P
i
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Combustion Manager W-FM 50
6 Commissioning
9. Select type of setting
The following can be selected as type of setting:
Adjustment with flame
Pre-setting without flame
Pre-setting without flame is only used, if the operating points are known, for example if the combustion manager is exchanged.
Adjustment with flame 1
Press [Enter].
Check rotation direction of burner motor
The burner starts pre-purge Ph12 and stops in ignition position Ph36 without
flame formation.
The display shows the ignition load point P0.
Set mixing pressure in ignition position (from step 11).
Pre-setting without flame 2
Briefly press [esc] key.
The display shows the ignition load point P0.
The black dash below the S symbol disappears.
Pre-set operating points without flame (from step 10).
S
S
1
P
i
P
i
S
V
h min
s
%
P
i
V
h min
s
S
%
2
V
P
i
V
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i
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
10. Pre-set points without flame
This step must only be carried out, if the type of setting without flame has been selected previously. The adjustment with flame (from step 11) is not replaced by this
process.
Press [+] key.
The display shows the operating point P1.
Press and hold [A] and pre-set air damper setting using [+]/[–].
Press and hold [F] and pre-set gas butterfly valve setting using [+]/[–].
Only in conjunction with frequency converter
Press and hold [A] and [F] (VSD) simultaneously and pre-set speed using [+]/
[–].
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
P
i
%
S
V
h min
s
%
P
i
V
h min
s
%
S
P
i
V
h min
s
%
Press [+] key.
The display shows CALC. The combustion manager starts the calculation.
The display then shows the operating point P2.
Set position air damper setting [A] and gas butterfly valve [F], with optional frequency converter also set speed [A] and [F] (VSD).
Using the [+] key select and pre-set points P3 to P9 in sequence.
S
P
i
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
P
i
%
S
V
h min
s
%
P
i
V
S
P
i
V
h min
s
%
S
S
P
i
P
i
V
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
Exit pre-setting using [esc].
The display shows 400 SEt.
Press [ENTER].
The display shows run.
Press [ENTER].
Check rotation direction of burner motor
The burner starts pre-purge and stops in ignition position without flame formation.
The display shows the ignition load point P0.
S
P
i
V
h min
s
%
S
P
i
V
h min
s
%
S
P
i
V
h min
s
%
11. Check mixing pressure in ignition position
The mixing pressure in ignition position must be 0.5 … 2 mbar above the combustion chamber pressure.
If necessary, adjust mixing pressure via air damper setting:
Only in conjunction with frequency converter
The ignition speed must not be less than 70 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed using [+]/[–].
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
V
S
P
i
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Combustion Manager W-FM 50
6 Commissioning
12. Check gas valves
Press [+] key and ensure that the valves open and close correctly.
The burner attempts to ignite.
The low gas pressure switch reacts.
After the interruption, the display shows OFF UPr.
Open gas isolating valve.
Press [ENTER], until the burner starts again.
The display shows P0 again with the values set for mixing pressure in ignition
position.
13. Igniting the burner
Press [+] key.
The burner starts and stops in ignition position.
The display shows the following operating phases:
PH 38: Ignition ON
PH 40: Fuel valve
Ph 42: Ignition OFF
PH 44: Flame in ignition position
S
P
i
S
P
i
V
S
P
i
%
h
V
h
S
%
V
h
P
i
S
%
V
h min
P
i
l
%
V
h min
s
%
14. Adjust setting pressure on pressure regulator
Check the setting pressure at the pressure regulator and if necessary adjust.
15. Check combustion
Determine combustion values at ignition position.
Set O2 content approx. 4 … 5 % above gas butterfly valve setting.
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Combustion Manager W-FM 50
6 Commissioning
16. Pre-set operating point P1
Press [+] key.
The display shows the operating point P1.
Pre-set gas throughput [F] and air quantity [A] whilst observing combustion values.
Operating point P1 must lie below the partial load required and within the capacity graph.
Only in conjunction with frequency converter
Select speed in operating point P1 as low as possible, but not less than 50 %.
Observe flame stability.
Slowly reduce speed using [F] and [A] (VSD), whilst opening air damper setting
alternately using the [A] key.
Press [+] key.
The display shows operating point P2.
If no other points have been defined, the combustion manager carries out a calculation and calculates all missing points up to P9, the display briefly shows
CALC.
S
P
i
S
V
h min
s
P
i
%
S
V
h min
s %
P
i
S
V
h min
s
%
P
i
V
S
m
P
i
V
h min
s
%
S
P
i
S
V
h min
s
%
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i
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
17. Drive to full load
Using the [+] key, drive to the points in sequence up to P9.
Check combustion values at each point and if necessary correct via the gas butterfly valve setting [F].
S
P
i
S
V
h min
s
P
i
%
V
h min
%
s
S
P
i
V
h min
s
%
S
S
P
i
P
i
V
h min
s
%
V
h min
s
%
18. Adjust full load
When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
Only in conjunction with frequency converter
Select speed at full load as low as possible, but not less than 80 %. Observe flame
stability.
Calculate gas throughput (operating volume VB) required [ch. 6.4].
Set gas butterfly setting [F] in full load point to approx. 60 … 70°.
Adjust setting pressure at the pressure regulator until gas throughput (VB) is
achieved.
Check combustion values
Determine combustion limit and set excess air [ch. 6.3].
Determine gas throughput again.
If necessary adjust setting pressure at pressure regulator and reset excess air.
The setting pressure must not be altered once this work has been completed.
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
V
S
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i
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
19. Re-define point 1 (only for ZMI)
This step should only be carried out on burners in version ZMI. On burners of different version, skip this step and proceed with step 20.
Drive to P1 using the [–] key.
Reduce gas butterfly valve setting [F] until minimum burner rating has been
achieved.
Check combustion values and if necessary adjust whilst observing the minimum
air damper setting [A].
Minimum air damper setting [A]
Combustion head
Combustion head
CLOSED
OPEN
Natural Gas
Without variable speed drive
with VSD
Liquid Petroleum Gas
Without variable speed drive
with VSD
0°
5°
3°
8°
0°
5°
8°
13°
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
P
i
%
V
h min
s
%
S
P
i
V
h min
s
%
To achieve a constant operating behaviour, it is necessary to initiate a calculation
from P9 to P1.
Drive to P9 using the [+] key.
Press [–] for approx. 4 seconds.
The display shows CALC.
Release [–] key.
The combustion manager starts the calculation.
The display then shows the operating point P8.
S
S
P
i
P
i
V
h min
s
%
V
h min
P
i
S
s
%
V
Continue with Adjusting operating points (step 21).
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
20. Initiate a calculation
To achieve a constant operating behaviour, it is necessary to initiate a calculation
from P9 to P1.
Press [–] for approx. 4 seconds.
The display shows CALC.
Release [–] key.
The combustion manager starts the calculation.
The display then shows the operating point P8.
S
S
P
i
P
i
V
h min
s
%
V
h min
P
i
S
s
%
V
h min
s
%
21. Adjusting the operating points
If the [–] key is pressed again for more than 4 seconds, a calculation is started from
the point shown to P1.
Briefly press [–] key, to ensure points calculated or set are not overwritten.
The operating points should only be adjusted via the fuel supply [F]. Changes to the
air quantity influence the linearity, which has a negative effect on the load control
and VSD.
Check combustion values
Press and hold [F] key and using [+]/[–] optimise combustion values.
Optimise combustion values at each operating point, until P1 has been
reached.
S
P
i
S
V
h min
s
%
P
i
V
h min
s
%
S
P
i
V
h min
s
%
S
S
P
i
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i
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h min
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
22. Define upper load limit (full load)
Full load can be limited via parameter 546 .
Exit setting mode using [esc].
The display shows 546 – – – –. Full load has not been defined, that means
full load ≙ P9 (100 % load assignment).
If full load is to be limited:
Press [Enter].
The display shows only the parameter value.
Set load limit using [+] or [–] and confirm with [ENTER].
Burner drives to value set.
Exit entry using [esc].
The display shows 546 with the current upper load limit.
S
S
P
i
P
i
S
V
h min
s
%
%
P
i
V
h min
s
%
S
P
i
V
h min
s
%
23. Define lower load limit (partial load)
Partial load can be limited via parameter 545.
When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
Press [+] key.
The display shows 545 – – – –.
Partial load has not been defined, that means partial load ≙ P1.
Press [Enter].
The display shows only the parameter value.
Set load limit using [+] or [–] and confirm with [ENTER].
Burner drives to value set.
Determine fuel throughput and if necessary adjust load limit.
Exit entry using [esc].
The display shows 545 with the current lower load limit.
S
S
P
i
P
i
S
V
h min
s
%
%
P
i
V
S
P
i
V
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%
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h min
s
%
Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
24. Save points
Exit level using [esc].
The display shows 400 SEt.
Exit entry using [esc].
The display shows oP (Operate) with the current rating.
S
S
P
i
S
P
i
V
h min
s
%
P
i
V
h min
s %
V
h min
s
%
25. Check start behaviour
Switch off and restart burner.
Check start behaviour and if necessary correct ignition position.
If the ignition position has been altered:
Re-check start behaviour.
26. Carry out data backup
Press keys [F] and [A] simultaneously.
Select 000: Int using [-] key and confirm with [ENTER].
The display shows parameter 050.00: 0
Press [Enter].
The display shows bAC_up.
Press [Enter].
Set 1 using [+] key and confirm with [ENTER].
Following successful data backup the display is reset to 0 .
The values have been backed up from the combustion manager to the ABE.
Exit levels using [esc].
27. Set pressure switch and carry out concluding work
For further details see burner installation and operating manual.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
6.2.2 Adjust modulation oil side
Prerequisite
Open oil shut off devices.
Switch on voltage supply.
The display shows either OFF UPr or OFF.
S
S
P
i
P
i
V
h min s %
V
h min s %
burner off and not programmed
burner off
OFF UPr
OFF
1. Enter password
Press [F] and [A] simultaneously for approx. 2 seconds.
The display shows CodE.
Enter the first digit using [+] or [–] and confirm with [ENTER].
Repeat procedure until the password has been entered.
Exit password entry using [ENTER].
The display shows PArA (parameter level) for a short time and then changes
over to 400: SEt (setup).
S
P
i
V
h min
s
%P
i
S
S
P
i
S
V
h min
s
%
V
h min
s
%P
i
V
h min
s
%
2. Switch on burner
Ensure there is a demand for heat.
A black dash appears below the S symbol (start).
A heat demand from the boiler controller is required for the duration of commissioning, that means signal on input X5-03:1.
S
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i
V
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
3. Start setup
Press [ENTER].
If the combustion manager has been pre-programmed, the display shows run 1.
Select type of setting (from step 9).
If the combustion manager has not been programmed, the display shows parameter
201 2.
Define parameters 201, 542 and 641 and set P0 (from step 4).
201: Operating mode
542: Activation of frequency converter
641: Speed standardisation
S
P
i
1
S
V
h min
s
%
V
h min
s
%
P
i
V
h min
s
S
%
P
i
2
4. Set operating mode
The following steps must only be carried out if the combustion manager is not programmed. If the combustion manager has been pre-programmed, proceed with
step 9.
Press [ENTER].
The display shows only the parameter value.
Set operating mode using [+] or [–] keys and confirm with [Enter].
12: fuel oil EL modulating
23: medium and heavy oil modulating
Exit entry using [esc].
The display shows parameter 201 with the current operating mode.
S
S
P
i
P
i
V
h min
s
%
S
%
P
i
V
S
P
i
V
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s
%
Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
5. Activate/deactivate frequency converter
Press [+] key.
The display shows parameter 542.
Press [Enter].
The display shows only the parameter value.
Activate or deactivate the frequency converter using [+] or [–] and confirm with
[ENTER].
0: without frequency converter
1: with frequency converter
Exit entry using [esc].
The display shows parameter 542 with the current setting.
S
S
P
i
P
i
V
h min
s
S
%
%
P
i
V
h min
s
%
S
P
i
V
h min
s
%
6. Carry out speed standardisation
Speed standardisation must only be carried out in conjunction with a frequency
converter.
If no frequency converter is fitted, skip speed standardisation 641 using the [+]
key.
Press [+] key.
The display shows parameter 641.
Press [ENTER].
Set value to 1 using the [+] and start speed standardisation by pressing
[ENTER].
Check rotation direction of burner motor
The fan motor starts with open air damper setting. Once standardisation is complete, the display changes form 1 to 0.
Exit speed standardisation using [esc].
The standardised speed can be read in parameter 642.
S
S
S
P
i
P
i
P
i
V
h min
s
S
%
V
S
P
i
V
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%
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S
%
P
i
h min
% m 3 m 3/h l
P
i
s
%
V
h min
s
%
l/h
Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
7. Preset ignition load point
Press [+] key.
The display shows the ignition load point P0.
The ignition load point P0 is factory preset, see burner data sheet. If values are
available proceed with step 8. If the combustion manager is not programmed (e. g..
if it has been replaced) the air damper position and the position of the oil quantity
regulator must be enter
Press and hold [A] and using [+]/[–] set air damper setting.
Press and hold [F] and using [+]/[–] set position of oil quantity regulator.
Only in conjunction with frequency converter
The ignition speed should be 100 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % using [+]/[–] key.
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
h min
S
P
i
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
8. Preset full load point
Press [+] key.
The display shows the full load point P9.
Press and hold [A] and using [+]/[–] set air damper setting from setting diagram,
see burner installation and operating manual.
Determine the position of the oil quantity regulator from the burner data sheet.
Press and hold [F] and set value using [+]/[–] key.
Only in conjunction with frequency converter
Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % using
[+]/[–].
Press [+] key.
Exit pre-setting.
The display changes to run.
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
V
S
P
i
V
h min
s
%
V
h min
s
%
S
P
i
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
9. Select type of setting
The following can be selected as type of setting:
Adjustment with flame
Pre-setting without flame
Pre-setting without flame is only used, if the operating points are known, for example if the combustion manager is exchanged.
Adjustment with flame 1
Press [Enter].
Check rotation direction of burner motor
The burner starts pre-purge Ph12 and stops in ignition position Ph36 without
flame formation.
The display shows the ignition load point P0.
Set mixing pressure in ignition position (from step 11).
Pre-setting without flame 2
Briefly press [esc] key.
The display shows the ignition load point P0.
The black dash below the S symbol disappears.
Pre-set operating points without flame (from step 10).
S
S
1
P
i
P
i
S
V
h min
s
%
P
i
V
h min
s
S
%
2
V
P
i
V
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%
P
i
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h min
s
%
h min
s
%
Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
10. Pre-set points without flame
This step must only be carried out, if the type of setting without flame has been selected previously. The adjustment with flame (from step 11) is not replaced by this
process.
Press [+] key.
The display shows the operating point P1.
Press and hold [A] and pre-set air damper setting using [+]/[–].
Press and hold [F] key and using [+]/[–] key preset position of oil quantity regulator.
Only in conjunction with frequency converter
Press and hold [A] and [F] (VSD) simultaneously and pre-set speed using [+]/
[–].
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
P
i
%
S
V
h min
s
%
P
i
V
h min
s
%
S
P
i
V
h min
s
%
Press [+] key.
The display shows CALC. The combustion manager starts the calculation.
The display then shows the operating point P2.
Set position air damper setting [A] and oil quantity regulator [F], with optional frequency converter also set speed [A] and [F] (VSD).
Using the [+] key select and pre-set points P3 to P9 in sequence.
S
P
i
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
P
i
%
S
V
h min
s
%
P
i
V
S
P
i
V
h min
s
%
S
S
P
i
P
i
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
Exit pre-setting using [esc].
The display shows 400 SEt.
Press [ENTER].
The display shows run.
Press [ENTER].
Check rotation direction of burner motor
The burner starts pre-purge and stops in ignition position without flame formation.
The display shows the ignition load point P0.
S
P
i
V
h min
s
%
S
P
i
V
h min
s
%
S
P
i
V
h min
s
%
11. Check mixing pressure in ignition position
The mixing pressure in ignition position must be 2 … 5 mbar above the combustion
chamber pressure.
If necessary, adjust mixing pressure via air damper setting:
Only in conjunction with frequency converter
The ignition speed should be 100 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % using [+]/[–] key.
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
%
P
i
V
S
P
i
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
12. Check pump pressure
The pump pressure in ignition position must be approx. 1 … 2 bar less than that of
the full load pressure, see burner data sheet.
Check pump pressure at pressure gauge.
Remove closing cap 1 (types T and TA only).
Undo locknut 2 (types T and TA only).
Set pump pressure using pressure regulating screw 3.
increase pressure: clockwise rotation,
decrease pressure: anticlockwise rotation.
3
3
1
+
1
3
2
2
3
13. Igniting the burner
Press [+] key.
The burner starts and stops in ignition position.
The display shows the following operating phases:
PH 38: Ignition ON
PH 40: Fuel valve
Ph 42: Ignition OFF
PH 44: Flame in ignition position
S
P
i
S
P
i
V
S
P
i
%
h
V
h
S
%
V
h
P
i
S
%
V
h min
P
i
l
%
V
h min
s
%
14. Check combustion
Determine combustion values at ignition position.
Set O2 content of approx. 4 … 5 % by positioning the oil quantity regulator [F]
whilst observing the return pressure.
Fuel oil EL: min 6 … 8 bar
Heavy oil: min 12 bar
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
15. Pre-set operating point P1
Only in conjunction with frequency converter
In oil operation, the speed should only be reduced so far, that the pump pressure
set at full load does not fall by more than 15 %.
Press [+] key.
The display shows the operating point P1.
Check combustion values and correct if necessary.
Press [+] key.
The display shows operating point P2.
If no other points have been defined, the combustion manager carries out a calculation and calculates all missing points up to P9, the display briefly shows
CALC.
S
P
i
S
V
h min
s
P
i
%
S
V
h min
P
i
s %
S
V
h min
s
P
i
%
V
S
h min
s
%
m
P
i
V
h min
s
%
S
P
i
S
V
h min
s
m
P
i
%
V
l
h min
l/h
s
%
16. Drive to full load
Using the [+] key, drive to the points in sequence up to P9.
Check combustion values at each point and correct via the position of the oil
quantity regulator [F].
S
P
i
S
V
h min
s
%
P
i
V
h min
s
%
S
P
i
V
h min
s
%
S
S
P
i
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i
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h min
s
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
17. Adjust full load
When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
Only in conjunction with frequency converter
Select speed at full load as low as possible, but not less than 80 %. Observe flame
stability.
The burner has been factory pre-sized for a specific oil throughput, see burner data
sheet.
Set pump pressure and oil quantity regulator position to the data given on the
burner data sheet.
Determine oil throughput, if necessary adjust position of oil quantity regulator [F]
until the oil throughput required is achieved.
Check combustion values
Determine combustion limit and set excess air [ch. 6.3].
S
P
i
S
V
h min
s
%
P
i
S
V
h min
s
P
i
%
V
S
h min
s
%
P
i
V
h min
s
%
The pump pressure must not be altered once this work has been completed.
18. Initiate a calculation
To achieve a constant operating behaviour, it is necessary to initiate a calculation
from P9 to P1.
Press [–] for approx. 4 seconds.
The display shows CALC.
Release [–] key.
The combustion manager starts the calculation.
The display then shows the operating point P8.
S
S
P
i
P
i
V
h min
s
%
V
h min
P
i
S
s
%
V
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
19. Adjusting the operating points
If the [–] key is pressed again for more than 4 seconds, a calculation is started from
the point shown to P1.
Briefly press [–] key, to ensure points calculated or set are not overwritten.
The operating points should only be adjusted via the fuel supply [F]. Changes to the
air quantity influence the linearity, which has a negative effect on the load control
and VSD.
Check combustion values
Press and hold [F] key and using [+]/[–] optimise combustion values.
Optimise combustion values at each operating point, until P1 has been
reached.
S
P
i
S
V
h min
s
P
i
%
V
h min
s
%
S
P
i
V
h min
%
s
S
S
P
i
P
i
V
h min
%
s
V
h min
s
%
20. Define upper load limit (full load)
Full load can be limited via parameter 546 .
Exit setting mode using [esc].
The display shows 546 – – – –. Full load has not been defined, that means
full load ≙ P9 (100 % load assignment).
If full load is to be limited:
Press [Enter].
The display shows only the parameter value.
Set load limit using [+] or [–] and confirm with [ENTER].
Burner drives to value set.
Exit entry using [esc].
The display shows 546 with the current upper load limit.
S
S
P
i
P
i
S
V
h min
s
%
%
P
i
V
S
P
i
V
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s
%
72-112
h min
s
%
Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
21. Define lower load limit (partial load)
Partial load can be limited via parameter 545.
When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
Press [+] key.
The display shows 545 – – – –.
Partial load has not been defined, that means partial load ≙ P1.
Press [Enter].
The display shows only the parameter value.
Set load limit using [+] or [–] and confirm with [ENTER].
Burner drives to value set.
Determine fuel throughput and if necessary adjust load limit.
Exit entry using [esc].
The display shows 545 with the current lower load limit.
S
S
P
i
P
i
S
V
h min
s
%
%
P
i
V
h min
s
%
S
P
i
V
h min
s
%
22. Save points
Exit level using [esc].
The display shows 400 SEt.
Exit entry using [esc].
The display shows oP (Operate) with the current rating.
S
S
P
i
S
P
i
V
h min
s
%
P
i
V
h min
s %
23. Check start behaviour
Switch off and restart burner.
Check start behaviour and if necessary:
correct ignition position,
increase oil temperature at oil preheater.
If the ignition position has been altered:
Re-check start behaviour.
If the oil temperature has been altered:
Re-check start behaviour.
Restart each point and check combustion values.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
24. Carry out data backup
Press keys [F] and [A] simultaneously.
Select 000: Int using [-] key and confirm with [ENTER].
The display shows parameter 050.00: 0
Press [Enter].
The display shows bAC_up.
Press [Enter].
Set 1 using [+] key and confirm with [ENTER].
Following successful data backup the display is reset to 0 .
The values have been backed up from the combustion manager to the ABE.
Exit levels using [esc].
25. Set pressure switch and carry out concluding work
For further details see burner installation and operating manual.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
6.2.3 Adjust multi-stage oil side
Only in conjunction with frequency converter
When using a frequency converter please note:
Ignition speed and speed in full load should be 100 %.
It is recommended that the speed at the on and off switch points is 100 %.
Speed at the operating points below full load must only be reduced so far as to
ensure safe operating behaviour whilst:
maintaining speed at 60 %,
maintaining minimum pump pressure, see installation and operating manual of
burner.
Prerequisite
Open oil shut off devices.
Switch on voltage supply.
The display shows either OFF UPr or OFF.
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burner off and not programmed
burner off
OFF UPr
OFF
1. Enter password
Press [F] and [A] simultaneously for approx. 2 seconds.
The display shows CodE.
Enter the first digit using [+] or [–] and confirm with [ENTER].
Repeat procedure until the password has been entered.
Exit password entry using [ENTER].
The display shows PArA (parameter level) for a short time and then changes
over to 400: SEt (setup).
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2. Switch on burner
Ensure there is a demand for heat.
A black dash appears below the S symbol (start).
A heat demand from the boiler controller is required for the duration of commissioning, that means signal on input X5-03:1.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
3. Start setup
Press [ENTER].
If the combustion manager has been pre-programmed, the display shows run 1.
Select type of setting (from step 9).
If the combustion manager has not been programmed, the display shows parameter
201 2.
Define parameters 201, 542 and 641 and set P0 (from step 4).
201: Operating mode
542: Activation of frequency converter
641: Speed standardisation
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4. Set operating mode
The following steps must only be carried out if the combustion manager is not programmed. If the combustion manager has been pre-programmed, proceed with
step 9.
Press [ENTER].
The display shows only the parameter value.
Set operating mode using [+] or [–] keys and confirm with [Enter].
5: two stage
6: three stage
Exit entry using [esc].
The display shows parameter 201 with the current operating mode.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
5. Activate/deactivate frequency converter
Press [+] key.
The display shows parameter 542.
Press [Enter].
The display shows only the parameter value.
Activate or deactivate the frequency converter using [+] or [–] and confirm with
[ENTER].
0: without frequency converter
1: with frequency converter
Exit entry using [esc].
The display shows parameter 542 with the current setting.
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6. Carry out speed standardisation
Speed standardisation must only be carried out in conjunction with a frequency
converter.
If no frequency converter is fitted, skip speed standardisation 641 using the [+]
key.
Press [+] key.
The display shows parameter 641.
Press [ENTER].
Set value to 1 using the [+] and start speed standardisation by pressing
[ENTER].
Check rotation direction of burner motor
The fan motor starts with open air damper setting. Once standardisation is complete, the display changes form 1 to 0.
Exit speed standardisation using [esc].
The standardised speed can be read in parameter 642.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
7. Preset ignition load point
Only in conjunction with frequency converter
The ignition speed should be 100 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % using [+]/[–] key.
Press [+] key.
The display shows the ignition load point P0.
Press and hold [A] and using [+]/[–] set air damper setting, see burner installation and operating manual.
Press [+] key.
Exit ignition load point pre-setting.
The display changes to run.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
8. Select type of setting
The following can be selected as type of setting:
Adjustment with flame
Pre-setting without flame
Pre-setting without flame is only used, if the operating points are known, for example if the combustion manager is exchanged.
Adjustment with flame 1
Press [Enter].
Check rotation direction of burner motor
The burner starts pre-purge Ph12 and stops in ignition position Ph36 without
flame formation.
The display shows the ignition load point P0.
Set mixing pressure in ignition position (from step 10).
Pre-setting without flame 2
Briefly press [esc] key.
The display shows the ignition load point P0.
The black dash below the S symbol disappears.
Pre-set operating points without flame (from step 9).
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
9. Pre-set points without flame
This step must only be carried out, if the type of setting without flame has been selected previously. The adjustment with flame (from step 10) is not replaced by this
process.
Using [+] key select and pre-set the following points in sequence:
Point 1 (ignition stage)
Switch point from P1 to P2
Operating point 2
Switch point from P2 to P3 (only with three stage operation)
Operating point 3 (only with three stage operation)
P1
P2on
P2
P3on
P3
Press and hold [A] and pre-set air damper setting using [+]/[–].
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Using [–] key select and pre-set the following points:
Switch point from P3 to P2
Switch point from P2 to P1
P3oF
P2oF
Press and hold [A] and pre-set air damper setting using [+]/[–].
Exit pre-setting using [esc].
The display shows 400 SEt.
Press [Enter].
The display shows run.
Press [Enter].
The burner starts pre-purge and stops in ignition position without flame formation.
The display shows the ignition load point P0.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
10. Check mixing pressure in ignition position
The mixing pressure in ignition position must be 2 … 5 mbar above the combustion
chamber pressure.
If necessary, adjust mixing pressure via air damper setting:
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11. Check pump pressure
The pump pressure must be set according to the nozzle selected.
Check pump pressure at pressure gauge.
Remove closing cap 1 (types T and TA only).
Undo locknut 2 (types T and TA only).
Set pump pressure using pressure regulating screw 3.
increase pressure: clockwise rotation,
decrease pressure: anticlockwise rotation.
3
3
1
+
1
3
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2
2
3
Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
12. Igniting the burner
Press [+] key.
The burner starts and stops in ignition position.
The display shows the following operating phases:
PH 38: Ignition ON
PH 40: Fuel valve
Ph 42: Ignition OFF
PH 44: Flame in ignition position
Check pump pressure.
Check combustion values
Standard: approx. 5 % O2 content
3LN (multiflam): approx. 4 … 4.5 % O2 content
If necessary adjust air damper setting whilst observing the mixing pressure.
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13. Adjusting operating point P1
Press [+] key.
The display shows point P1.
If P1 has not been pre-set, the values from P0 are adopted for P1 .
Pre-set air damper setting [A] whilst observing the combustion values.
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14. Determine switch point P2on
Press [+] key.
The display shows P2on.
Valve operating point 2 remains closed.
If P2on has not been pre-set, the values from P1 are adopted for P2on .
Set excess air (O2 content approx. 7 %) via air damper setting [A] whilst observing flame stability.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
15. Set pre-set point P2_d
Press [+] key.
The display shows the pre-set point P2_d.
Valve operating point 2 remains closed.
Pre-set air damper setting [A] expected for the operating point P2 .
The value is not activated yet.
The pre-set point reduces insufficient air during the activation of operating
point P2.
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16. Activate operating point P2
Press [+] key.
The display shows P2.
Valve operating point 2 opens.
The preset air damper setting from P2_d is activated.
Pre-set air damper setting [A] whilst observing the combustion values.
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17. Adjust full load
When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
Repeat procedure for three stage operation:
switch point P3on (step 14),
pre-set point P3_d (step 15),
operating point P3 (step 16).
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Determine fuel throughput and if necessary adjust pump pressure.
Check combustion values
Determine combustion limit and set excess air [ch. 6.3].
The pump pressure must not be altered once this work has been completed.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
18. Initiate partial load
Press [–] key.
The display shows switch point P3oF.
The switch point determines, at which air damper setting the valve of the stage
above closes. The point itself can not be activated.
Adapt air damper setting [A].
The switch point must lie minimum 5° above the switch point of the respective
stage.
Press [–] key and observe switch off behaviour.
Check combustion values in operating point P2 .
Set excess air via air damper setting [A], do not alter fuel pressure in the process.
Repeat procedure for operating point P1.
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19. Check operating behaviour
Activate operating points several times using the [+] and [–] keys and observe
the switch-over behaviour.
If the flame is unstable or a pressure surge occurs:
Decrease air damper setting [A] in the change-over point.
If soot or CO is formed:
Increase air damper setting [A] in the change-over point.
20. Save points
The operating point P1 must be activated once, otherwise the display shows
OFF UPr when exiting commissioning and the combustion manager remains unprogrammed.
Activate operating point P1 .
Press [esc] twice.
The display shows oP (Operate) and an operating point.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
21. Check start behaviour
Switch off and restart burner.
Check start behaviour and if necessary:
correct ignition position,
increase oil temperature at oil preheater.
If the ignition position has been altered:
Re-check start behaviour.
If the oil temperature has been altered:
Re-check start behaviour.
Restart each point and check combustion values.
22. Carry out data backup
Press keys [F] and [A] simultaneously.
Select 000: Int using [-] key and confirm with [ENTER].
The display shows parameter 050.00: 0
Press [Enter].
The display shows bAC_up.
Press [Enter].
Set 1 using [+] key and confirm with [ENTER].
Following successful data backup the display is reset to 0 .
The values have been backed up from the combustion manager to the ABE.
Exit levels using [esc].
23. Set pressure switch and carry out concluding work
For further details see burner installation and operating manual.
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Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
6.3 Check combustion
Determine excess air
Slowly close air damper(s) in the relevant operating point, until the combustion
limit is reached (CO content approx. 100 ppm or smoke number approx. 1).
Measure and document O2 content.
Read air number (λ).
Increase air number to ensure sufficient excess air:
by 0.15 … 0.2 (equates to 15 … 20 % excess air),
by more than 0.2 for more difficult conditions, such as:
dirty combustion air,
fluctuating intake temperature,
fluctuating chimney draught.
Example
λ + 0.15 = λ*
Set air number (λ*), do not exceed CO content of 50 ppm.
Measure and document O2 content.
Check flue gas temperature
Check flue gas temperature.
Ensure that the flue gas temperature complies with the data provided by the
boiler manufacturer.
If necessary adjust flue gas temperature, e g.:
Increase burner capacity in partial load to avoid condensation in the flue gas
ducts, except on condensing units.
Reduce burner capacity in full load to improve efficiency.
Adjust heat exchanger to the data provided by the manufacturer.
Determine flue gas losses
Drive to full load.
Measure combustion air temperature (tL) near the air damper(s).
Measure oxygen content (O2) and flue gas temperature (tA) at the same time at
one point.
Determine flue gas losses using the following formula:
qA =
qA
tA
tL
O2
83250302 1/2018-08 La
(tA - tL ) (
A2
)+B
21- O2
Flue gas losses [%]
Flue gas temperature [°C]
Combustion air temperature [°C]
Volumetric content of oxygen in dry flue gas [%]
Fuel factors
Natural Gas
A2
B
0.66
0.009
86-112
Liquid Petroleum Fuel oil
Gas
0.63
0.68
0.008
0.007
Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning
6.4 Calculate gas throughput
Formula symbol
VB
f
QN
η
Hi
Explanation
Operating volume [m3/h]
Volume measured at gas meter at current pressure and
temperature (gas throughput).
Standard volume [m3/h]
Volume gained by gas at 1013 mbar and 0 °C.
Conversion factor
Heat rating [kW]
Boiler efficiency (e. g. 92 % ≙ 0.92)
Calorific value [kWh/m3] at 0 °C and 1013 mbar
tGas
PGas
PBaro
VG
TM
Gas temperature at gas meter [°C]
Pressure at gas meter [mbar]
Barometric air pressure [mbar], see table
Gas throughput determined at gas meter
Measuring time [seconds]
VN
Example values
–
–
–
6000 kW
0.92
10.35 kW/m3 (Natural Gas
E)
10 °C
250 mbar
500 m ≙ 955 mbar
18.2 m³
120 seconds
Calculate normal volume
Calculate the normal volume (VN) using the following formula.
QN
VN =
η
VN =
Hi
6000 kW
= 630.1 m³/h
0.92 10.35 kW/m³
Calculate conversion factor
Determine gas temperature (tGas) and pressure (PGas) at gas meter.
Determine barometric air pressure (PBaro) from table.
Height
0
100 200
above
sea level [m]
PBaro
1013 1001 990
[mbar]
300
400
500
600
700
800
900
1000 1100 1200 1300
978
966
955
943
932
921
910
899
888
877
866
Calculate conversion factor (f) using the following formula.
f=
PBaro + PGas
1013
273
273 + tGas
f=
955 + 250
273
= 1.148
1013
273 + 10
Calculate operating volume (gas throughput) required
VB =
VN
f
VB =
630.1 m³/h
= 548.9 m³/h
1.148
Determine current operating volume (gas throughput)
Measure gas throughput (VG) at gas meter, measuring time (TM) should be a minimum of 60 seconds.
Calculate operating volume (VB) using the following formula.
VB =
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3600 VG
TM
87-112
VB =
3600 18.2 m³
= 546.0 m³/h
120 s
Installation and operating instruction
Combustion Manager W-FM 50
7 Servicing
7 Servicing
7.1 Notes on servicing
DANGER
DANGER
Risk of explosion due to leaking gas
Improper service work can lead to escaping gas and explosion.
Close fuel shut off devices prior to starting work.
Care should be taken when dismantling and assembling gas carrying components.
Close the screws on the test points ensuring the tests points are sealed.
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.
Danger of getting burned on hot components
Hot components can lead to burns.
Allow components to cool.
WARNING
Servicing must only be carried out by qualified personnel. The combustion plant
should be serviced annually. Depending on site conditions more frequent checks
may be required.
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. 7.2].
Weishaupt recommends a service contract is entered into to ensure regular inspections.
The following components must only be replaced and must not be repaired:
combustion manager
flame sensor
actuator
gas valve
oil solenoid valve
nozzle head (shut off needle),
pressure regulator
pressure switch
Prior to every servicing
Inform the operator about the extent of service work to be carried out.
Switch off mains switch of installation and safeguard against accidental reactivation.
Close fuel shut off devices.
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Combustion Manager W-FM 50
7 Servicing
Following servicing
Check tightness of oil and gas carrying components.
Check function of:
adjustable mixing head,
ignition,
flame monitoring,
gas carrying components (gas connection pressure and setting pressure),
oil pump (pump pressure and suction resistance),
pressure switch
Check control and safety devices.
Check combustion values, if necessary re-adjust the burner.
Enter combustion values and settings in the commissioning record and/or test
sheet.
7.2 Service plan
For detailed information see installation and operating manual of burner.
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Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
8 Troubleshooting
8.1 Procedures for fault conditions
Check prerequisites for operation:
Voltage supply available.
Heating switch is set to On.
The combustion manager recognises irregularities of the burner and displays these
on the display and operating unit (ABE).
The following conditions can occur:
Display OFF [ch. 8.1.1]
Display OFF S [ch. 8.1.2]
Fault [ch. 8.1.3]
Lockout [ch. 8.1.4]
8.1.1 Display OFF
The following faults may be corrected by the operator:
Fault
Cause
Rectification
Burner not operating
Temperature regulator or pressure reguAdjust temperature regulator or preslator on heat exchanger has been set insure regulator on heat exchanger.
correctly
Boiler or heating circuit control is not
Check function and setting of boiler
functioning or has not been set correctly
or heating circuit control.
8.1.2 Display OFF S
The following faults may be corrected by the operator:
Fault
Cause
Safety circuit open
Temperature limiter or pressure limiter
on heat exchanger has triggered(1
Low water safety interlock on heat exchanger has triggered(1
Rectification
Reset temperature limiter or pressure
limiter on heat exchanger.
Top up water.
Reset low water safety interlock on
heat exchanger.
(1
Notify your heating contractor or Weishaupt Customer Service if the problem occurs repeatedly.
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Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
8.1.3 Fault
If a fault occurs, the combustion manager initiates a controlled shutdown.
The display and operating unit alternates between Err.c: (error code) and
Err.d: (diagnostic code).
The burner restarts automatically as soon as the fault condition has been rectified.
Example
Faults must only be rectified by qualified personnel.
Read the fault code and proceed according to the fault message [ch. 8.3].
8.1.4 Lockout
If a lockout condition occurs, the combustion manager initiates a fault shutdown
and burner lockout.
The display and operating unit alternates between Loc.c: (error code) and
Loc.d: (diagnostic code).
Once the fault has been rectified, the combustion manager has to be reset for restart.
Example
Lockouts must only be rectified by qualified personnel.
Read the fault code and proceed according to the fault message [ch. 8.3].
Resetting
WARNING
Damage resulting from incorrect fault repair
Incorrect fault repair can cause damage to the equipment and injure personnel.
Do not carry out more than 2 lockout resets successively.
Faults must be rectified by qualified personnel.
If the ABE displays a fault:
Press [Enter] for approx. 2 seconds.
rESEt is displayed.
Release key.
The burner has been reset.
Exchanging the unit
If the combustion manager or the ABE are replaced:
Select and check fault history and lockout history and include a copy when returning the unit for exchange.
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Combustion Manager W-FM 50
8 Troubleshooting
8.2 Fault history
The combustion manager stores the last 25 faults and lockouts in the fault history
(parameter 700), 701 is the fault, which occurred last. The fault history can be
called up in the service level or password level.
Display faults
Select service level or password level [ch. 5.2]
Select parameter 700 using the [+] key and confirm with [Enter] (password level
only).
Select faults in sequence using [+] or [–] key.
press [Enter] (press service level 1 … 3 s).
Fault level flashes.
Select fault level in sequence using [+] or [–] key.
If fault levels 05 and 06 show ·-·- in the display:
press [Enter] (press service level 1 … 3 s).
Value is displayed.
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701
01
02
…
03
725
04
05
06
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Definition
Fault codes
Diagnostic code
Fault class (arranges faults by
priority)
Operating phase
Start-up counter
0: Lockout, highest priority
1: Safety shut down with software reset
2: Low voltage
3: Safety shut down in safety phase
4: Safety shutdown start prevention
5: Safety shutdown shutdown
6: Signal without switch off reaction
Operating phase at time of fault [ch. 3.1.8].
Number of start-ups at time of fault.
Rating
Press [Enter] to display.
Load at time of fault. Press [Enter] to display.
92-112
Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
Delete faults
Only the fault history in the service level can be deleted. The fault history in the
password level is not affected by the deleting process.
Enter password [ch. 5.2.1].
Select parameter 130.
Press [Enter].
The display shows value 0.
Set value to 1 within 3 seconds using [+] key, confirm with [Enter] key, then set
value to 2 and confirm again with [Enter] key.
When the display changes to 0 the delete process has been completed. If the
display shows -1 the duration of 3 seconds was exceeded and the delete process was aborted.
S
S
P
i
P
i
S
V
h min s
%
P
i
V
h min s
%
V
h min s
%
V
h min s
%
S
P
i
3s
S
P
i
V
83250302 1/2018-08 La
93-112
h min s
%
Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
8.3 Rectifying faults
Fault code
Diagnostic
codes
1
2
Cause
0
No air pressure switch signal from operating phase PH24
1
4
0
1
2
0
Air pressure switch signal prior to operating phase Ph22
Air pressure switch signal prior to start-up
Flame signal during pre-purge
Flame signal during shutdown
Flame signal during start-up
Loss of flame
3 … 255
Flame failure due to TÜV test
12
81
83
Valve proving V1 leaking
Valve proving V2 leaking
14
20
0
1
64
0
POC open
POC closed
POC open prior to start-up
Low pressure switch has reacted
21
1
0
Low gas programme [ch. 3.1.2]
High pressure switch has reacted
22
0
1
50 … 67
#
Safety circuit / burner flange open
Safety circuit / burner flange open during
start-up
Internal fault
70
23
26
0
1
2
3
#
Load invalid
Modulating curve point undefined
Standby position undefined
Pre-purge position undefined
Post-purge position undefined
Ignition position undefined
Internal fault
–
23
26
Load invalid
Multi-stage curve points undefined
–
2
3
4
7
71
72
73
83250302 1/2018-08 La
Rectification
No flame signal in operating phase Ph44
No flame signal in operating phase Ph52
94-112
Check flame sensor (soiled, defective,
signal strength…)
Correct ignition load point
Check air pressure switch (setting,
connection)
Clean fan wheel and air guide
Check pressure and negative pressure
hoses
Check air pressure switch
Check flame sensor
Check flame sensor (soiled, defective,
signal strength…)
Check fuel supply
Check combustion
Duration of fuel values closed to flame failure.
Solution: 0.2 s (value 5 = 1 s)
Check valve proving pressure switch
[ch. 3.1.3]
Check solenoid valve
Check valve closing contact (function,
connection)
Check low pressure switch
Check fuel supply
Check gas supply
Check high pressure switch
Check fuel supply
Check safety devices
Replace combustion manager if fault
reoccurs
Set curve points for all actuators
Set special positions for all actuators
Replace combustion manager if fault
reoccurs
Set curve points for all actuators
Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
Fault code
76
Diagnostic
codes
1
2
4
16
#
80
1
75
2
Cause
Rectification
Current load incorrect
Target load incorrect
Target position incorrect
Different positions reached
Internal fault
–
–
–
Repeat standardisation
Replace combustion manager if fault
reoccurs
Combustion manager was unable to cor- Combustion manager has not been standrect speed deviations and has reached the ardised for this motor
lower regulating limit. Frequency converter
Repeat standardisation
speed to high.
The ramp times of the frequency converter
Combustion manager was unable to cor- are longer than those of the combustion
rect speed deviations and has reached the manager.
upper regulating limit. Frequency conCheck ramp times (parameter 522,
verter speed too low.
523).
The reference line of the frequency converter is not linear:
Adjust combustion manager/frequency
converter control signal (parameter
645).
81
1
83250302 1/2018-08 La
Interference impulses on sensor line
speed input
95-112
Frequency converter reacts too slowly:
Check frequency converter settings (inlet filter, slip compensation, fade-out of
different speeds).
Optimise EMC measures.
Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
Fault code
82
Diagnostic
codes
1
Cause
2
3
Repeat standardisation
Check the connection
Check distance speed sensor / transmitter disc.
Motor did not reach stable speed during The ramp times of the frequency converter
start.
are longer than those of the combustion
Frequency converter run-up time too long. manager.
Check ramp times (parameter 522,
Speed below minimum limit for standard523).
isation.
The reference line of the frequency converter is not linear:
Adjust combustion manager/frequency
converter control signal (parameter
645).
4
Rectification
Ramp time during run down during standardisation too short
Standardised speed not saved
No speed signal
Increase ramp time (parameter 523).
Frequency converter reacts too slowly:
Check frequency converter settings (inlet filter, slip compensation, fade-out of
different speeds).
5
6
7
15
20
21
22
23
24
128
255
83250302 1/2018-08 La
Speed of frequency converter is below the
minimum standardised speed (650 rpm)
Increase speed of frequency converter.
Incorrect rotation direction
Check rotation direction.
Check installation of transmitter disc.
Impulse pattern (60°, 120°, 180°) incorCheck the connection
rect, interference impulses on the sensor
Check distance speed sensor / transmitter disc.
line
Optimise EMC measures.
Standardised speed is not within the per- –
mitted range
Speed deviation between micro controlRepeat standardisation
ler 1 und micro controller 2
Standardisation in incorrect operating
Switch off heat demand and repeat
phase
standardisation.
Safety circuit / burner flange open during
Repeat standardisation
standardisation.
Air actuator not referenced
Check actuator.
Frequency converter deactivated
Activate frequency converter and repeat
standardisation.
Standardisation started without valid operCheck operating mode (parameter
ating mode
201, 301) and repeat standardisation.
Frequency converter is activated, but is
Carry out standardisation.
not standardised.
Motor is rotating, but is not standardised
Carry out standardisation.
96-112
Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
Fault code
83
Diagnostic
codes
1
2 … 3
4… 7
8 … 15
Cause
Rectification
Speed not achieved, lower control limit
Rectification see error code 80.
was activated
Speed not achieved, upper control limit
Rectification see error code 80.
was activated
Aborted due to interference impulses on
Optimise EMC measures.
sensor line
Modulating operation: Curve gradient freCheck ramp times (parameter 522,
quency converter too steep (speed not
523).
achieved)
Depending on the ramp time (parameter
522, 523), the speed alteration between
two operating points must not exceed a
specific percentage.
84
16 … 31
10 % at 20 s
20 % at 10 s
40 % at 5 s
No speed signal
32 … 63
Speed deviation too high
1
Modulating operation: Curve gradient frequency converter too steep
Check the connection
Check distance speed sensor / transmitter disc.
Check ramp times (parameter 522,
523).
Check ramp times (parameter 522,
523).
Depending on the ramp time (parameter
522, 523), the speed alteration between
two operating points must not exceed a
specific percentage.
10 % at 20 s
20 % at 10 s
40 % at 5 s
2 … 3
85
86
Modulating operation: Curve gradient fuel
actuator too steep
4 … 7
Modulating operation: Curve gradient air
actuator too steep
0
Fuel actuator referencing error
1
Air actuator referencing error
128 … 255 Parameter settings of one actuator have
been changed.
0
Position error fuel actuator
1
Fuel actuator line break
8
16 … 255
83250302 1/2018-08 La
The position change between two operating points must not exceed maximum 31°:
Adjust operating points.
Check, if actuators have been mixed up.
Check, if actuator is blocked.
–
Check, if actuator is blocked.
min 0.5 V between Pin 5 and 2 or 6 and
2:
Check wiring
Modulating operation: Curve gradient fuel The position change between two operatactuator too steep
ing points must not exceed maximum 31°:
Adjust operating points.
Fuel actuator overloaded or mechanically
Check, if actuator is blocked.
twisted
97-112
Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
Fault code
87
Diagnostic
codes
0
1
Cause
Rectification
Position error air actuator
Air actuator line break
8
Modulating operation: Curve gradient air
actuator too steep
16 … 255
Check, if actuator is blocked.
min 0.5 V between Pin 5 and 2 or 6 and
2:
Check wiring
The position change between two operating points must not exceed maximum 31°:
Adjust operating points.
Check, if actuator is blocked.
90 … 91
#
Air actuator overloaded or mechanically
twisted
Internal fault
93
3
Flame sensor short circuit
95
#
3
4
5
6
#
3
4
5
6
External voltage relay contact (internal)
Ignition unit
Fuel valve 1
Fuel valve 2
Fuel valve 3
Relay contact fused (internal)
Ignition unit
Fuel valve 1
Fuel valve 2
Fuel valve 3
96
97
0
98
#
2
3
4
5
6
#
99 … 100
83250302 1/2018-08 La
Safety relay fused (internal) or external
voltage applied to safety relay
Relay does not activate (internal)
Safety valve
Ignition unit
Fuel valve 1
Fuel valve 2
Fuel valve 3
Internal fault relay activation
98-112
Replace combustion manager if fault
reoccurs
Check flame sensor
Check wiring
Check flame sensor
Check wiring
Check relay contact:
Apply voltage.
Output X3-05:1 must be de-energised.
Switch off voltage and unplug plug
X3-05.
No ohmic connection must exist
between output X3-05:1 and input
X3-04:4 (N).
If a criteria is not met:
Replace combustion manager
Rectification see error code 96.
Replace combustion manager if fault
reoccurs
Replace combustion manager if fault
reoccurs
Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
Fault code
Diagnostic
codes
105
#
0
1
2
3
4
5
6
7
8
9
10
11
12
13
106 … 110 #
Cause
Rectification
Internal fault contact interrogation
Minimum pressure switch
Max. pressure switch
Valve proving pressure switch
Air pressure switch
Load controller OPEN
Load controller ON / OFF
Load controller CLOSED
Safety circuit / burner flange
Safety valve
Ignition unit
Fuel valve 1
Fuel valve 2
Fuel valve 3
Reset
Internal fault
Can be caused by capacitive loads or direct current feed at the inputs. The input, at
which the fault occurred is displayed with
diagnostic code.
111
#
112
#
113 … 115 #
Mains frequency too low
Voltage return
Internal fault
116
117
120
121 … 124
Operating cycle lifespan exceeded
Lifespan exceeded
Interference impulses on fuel meter input
Internal fault
–
No fault
Replace combustion manager if fault
reoccurs
Replace combustion manager
Replace combustion manager
Optimise EMC measures.
Reset parameters or reset data using
Restore.
Replace combustion manager if fault
reoccurs
Reset parameters.
Replace combustion manager if fault
reoccurs
Reset parameters or reset data using
Restore.
Replace combustion manager if fault
reoccurs
Replace combustion manager if fault
reoccurs
Reset parameters.
Replace combustion manager if fault
reoccurs
Replace combustion manager if fault
reoccurs
Reset parameters.
Replace combustion manager if fault
reoccurs
No fault
#
#
0
#
125 … 126 #
Internal fault
127
#
Internal fault
128
0
Internal fault
129 … 131 #
Internal fault
132
#
Internal fault
133 … 135 #
Internal fault
136
Restore started
1
83250302 1/2018-08 La
99-112
Replace combustion manager if fault
reoccurs
Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
Fault code
137
Diagnostic
codes
255 (-1)
254
253
252
251
(-2)
(-3)
(-4)
(-5)
250 (-6)
249 (-7)
248 (-8)
247 (-9)
246 (-10)
245 (-11)
244 (-12)
243 (-13)
242 (-14)
241 (-15)
240 (-16)
239 (-17)
157 (-99)
146
150
1
2
1 (-1)
2 (-2)
3 (-3)
4 (-4)
5 (-5)
165 … 166 #
83250302 1/2018-08 La
Cause
Rectification
Aborted due to Time-out during Backup /
Restore or ABE does not have this function.
Aborted due to transfers error
Restore cannot be carried out at present
Restore incomplete
No burner identification
Backup data set invalid, Restore not possible
Backup has unsuitable burner identification and must not be uploaded.
Restore cannot be carried out at present
Backup data set invalid, Restore not possible
Aborted due to Time-out during Restore
Access error Restore
Software version and Backup data set not
compatible, Restore not possible
Backup data comparison between the micro controllers incorrect
Backup is incorrect and cannot not reloaded
Backup contains unsuitable ASN and
must not be uploaded
No Backup in ABE
Backup memory in ABE faulty
Restore successful, however Backup data
less than in current system
Modbus Time-out
eBUS Time-out
TÜV test in invalid operating phase
Check the connection
Repeat Backup / Restore.
Replace ABE.
Repeat Backup / Restore.
Define burner identification (parameter
113).
–
–
Repeat Backup / Restore.
–
Repeat Backup / Restore.
–
Repeat Backup / Restore.
–
–
–
Repeat Backup / Restore.
–
–
–
Start TÜV test in operating phase
Ph60
Adjust load and repeat TÜV Test.
Load during TÜV test less than lower load
limit (parameter 545)
Load during TÜV test higher then upper
load limit (parameter 546)
Manual abort TÜV test
No fault
No flame failure after fuel valves have shut
Check for extraneous light.
down
Check wiring
Check soundness of valves.
Internal fault
–
100-112
Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting
Fault code
Cause
Rectification
Manual lockout by contact
Manual lockout by ABE
Manual lockout by PC-Tool
Communication between W-FM and ABE
was interrupted during curve setting
Communication between W-FM and PCTool was interrupted during curve setting
Reset attempt by PC-Tool
Internal fault
No fault
–
System fault free
No operating mode selected
No fuel supply defined
No curves defined
Standardised speed undefined
Backup / Restore was not possible
Internal fault operating mode setting
–
–
–
–
–
–
202
#
1
2 … 3
4 … 7
8 … 15
16 … 31
#
203
#
Internal fault operating mode setting
204
24 … 52
Program stop is activated. Operating
phase is shown in diagnostic code.
205
#
Internal fault
206
0
Impermissible unit combination (combus- –
tion manager - ABE)
Combustion manager version too old
–
ABE version too old
–
Internal fault
Replace combustion manager if fault
reoccurs
Impermissible operating mode
Redefine operating mode (parameter
201).
Internal fault
Replace combustion manager if fault
reoccurs
167
Diagnostic
codes
1
2
3
8
9
33
168 … 171 #
200
201
207
0
1
208 … 209 #
210
0
240 … 250 #
83250302 1/2018-08 La
101-112
–
–
–
Replace combustion manager if fault
reoccurs
Redefine operating mode (parameter
201).
Redefine operating mode (parameter
201).
Replace combustion manager if fault
reoccurs
Deactivate program stop (parameter
208).
Replace combustion manager if fault
reoccurs
Installation and operating instruction
Combustion Manager W-FM 50
9 Technical documentation
9 Technical documentation
9.1 Frequency converter
Detailed information see Frequency converter CD.
The construction and arrangement of diagnostic LEDs is dependent on the size of
the frequency converter.
9.1.1 Frequency converter Nord size I … III
1
2
3
1
2
3
1 2
ON
1 Interfaces
2 DIP switches
3 Diagnostic LED's
Interface
The interface is used to access the frequency converter via a PC.
The Software required can be found on the Frequency Converter CD.
A connection cable RJ12 to SUB-D9 is required for the connection (Order No. 743
361). A readily available USB interfaces converter USB to RS232 is also required
for the connection to the USB port.
DIP switches
The analogue inputs AIN1 and AIN2 are configured via setting of the DIP switches.
Factory setting (2 … 10 V):
Switch 1: OFF
Switch 2: OFF
83250302 1/2018-08 La
102-112
Installation and operating instruction
Combustion Manager W-FM 50
9 Technical documentation
Diagnostic LED's
LED
1 (BUS-S)
2 (BUS-E)
3 (DS)
Signal
–
–
OFF
Green
Flashing green
0.5 Hz(1
4 Hz(1
Flashing red/green 4 Hz(1
1 … 25 Hz(1
Flashing red
Number ≙ flashing codes
(1
1 Hz ≙ once per second
83250302 1/2018-08 La
103-112
Description
System bus status (not used)
System bus fault (not used)
No mains voltage and no control voltage
Operation, FC operating
Ready for operation
Start blocked
Warning
Intensity overload
Fault, flashing codes see Frequency
converter CD
Installation and operating instruction
Combustion Manager W-FM 50
9 Technical documentation
9.1.2 Frequency converter Nord size IV
1
2
3
2 3
4
1
9 0
8
5
7 6
B
A
1 Interfaces
2 Diagnostic LED's
3 Status LED's
Interface
The interface is used to access the frequency converter via a PC.
The Software required can be found on the Frequency Converter CD.
A connection cable RJ12 to SUB-D9 is required for the connection (Order No. 743
361). A readily available USB interfaces converter USB to RS232 is also required
for the connection to the USB port.
Diagnostic LED's
LED
1 (DOUT1 )
Signal
yellow
2 (DOUT2)
3 (BRAKE)
4 (TEMP)
5 (DIN4)
6 (DIN3)
7 (DIN2)
8 (DIN1)
yellow
yellow
yellow
yellow
yellow
yellow
yellow
9 (BUS-S)
OFF
Green
Flashing green
OFF
Flashing red
red
0 (BUS-E)
83250302 1/2018-08 La
Description
Alarm from frequency converter (digital
output 1)
Signal at digital output 2
Mechanical brake
Excess temperature at motor
Signal at digital input 4
Signal at digital input 3
Signal at digital input 3
Frequency converter start release (digital
input 1)
No Bus communication (system bus)
Bus communication
Bus warning
System bus is operating correctly
Monitoring fault
No system bus
104-112
Installation and operating instruction
Combustion Manager W-FM 50
9 Technical documentation
Status LED's
LED
A (AS-i)
B (DS)
Signal
–
OFF
Green
Green ON +
red flashing
0.5 Hz(1
4 Hz(1
Flashing red/green 4 Hz(1
1 … 25 Hz(1
Flashing red
Number ≙ flashing codes
Flashing green
(1
1 Hz ≙ once per second
83250302 1/2018-08 La
105-112
Description
Status AS interface (not used)
No mains voltage and no control voltage
Operation, FC operating
Frequency converter not ready for operation,
control voltage applied but no mains
voltage
Ready for operation
Start blocked
Warning
Intensity overload
Fault, flashing codes see Frequency
converter CD
Installation and operating instruction
Combustion Manager W-FM 50
10 Spares
10 Spares
1.01
1.03
1.04
1.02
83250302 1/2018-08 La
106-112
Installation and operating instruction
Combustion Manager W-FM 50
10 Spares
Pos.
1.01
1.02
1.03
1.04
83250302 1/2018-08 La
Description
ABE for W-FM 50/54
Plug cable ABE-W-FM 50
–2m
– 10 m
Combustion manager W-FM50 230 V 50/60 Hz
W-FM plug
– X3-02 Air pressure switch
– X3-03 Limit switch burner flange
– X3-04 Mains and safety circuit
– X3-05 Fan, alarm
– X4-02 Ignition unit
– X5-01 Min. oil pressure switch
– X5-02 Max. oil pressure switch
– X5-03 Control circuit
– X6-03 Safety valve
– X7-01 Oil valve stage 2
– X7-02 Oil valve stage 3
– X8-02 Oil valve stage 1
– X8-04 Operation Reset 50
– X9-04 Valve proving pressure switch
– X10-05 Flame sensor QRB, QRD, ionisation
– X10-06 Flame sensor QRA
– X64 Reserve 4-20mA
– X74 Frequency converter connection
– X75 Fuel meter
107-112
Order No.
600 408
400 406
600 407
600 402
716 301
716 302
716 303
716 410
716 305
716 307
716 308
716 309
716 312
716 313
716 314
716 317
716 411
716 418
716 413
716 414
716 416
716 417
716 415
Installation and operating instruction
Combustion Manager W-FM 50
11 Notes
11 Notes
83250302 1/2018-08 La
108-112
Installation and operating instruction
Combustion Manager W-FM 50
12 Key word index
12 Key word index
Extraneous light ................................................................... 21
A
ABE ........................................................................................ 26
Actuator................................................................................. 43
Air actuator ........................................................................... 41
Air number ............................................................................ 86
Air pressure .......................................................................... 87
Air pressure switch............................................................. 18
Alarm.............................................................................. 24, 39
Ambient conditions............................................................. 26
Analogue input..................................................................... 22
Analogue signal........................................................... 22, 25
Atomising pressure..................................................... 69, 81
B
Backup .................................................... 11, 36, 60, 74, 85
Baud rate .............................................................................. 37
Building management ................................................ 22, 37
Burner control (200: PAr0)............................................... 39
Burner flange limit switch.................................................. 18
Burner identification ........................................................... 36
Burner motor ........................................................................ 24
Burner ON .................................................................... 22, 23
Bus interface........................................................................ 22
C
Calculation............................................................................ 11
Change-over release.......................................................... 23
CO content .......................................................................... 86
Combustion control............................................................ 86
Combustion limit ................................................................. 86
Combustion Manager ........................................................ 26
Commissioning..................................................... 46, 47, 61
Compound............................................................................ 41
Condensate............................................................................ 8
Connection pressure ........................................................... 9
Consumption........................................................................ 26
Contact interrogation ......................................................... 43
Continuous ventilation ....................................................... 24
Conversion factor ............................................................... 87
D
Data backup ........................................... 11, 36, 60, 74, 85
Data set ................................................................................. 36
Design lifespan ............................................................... 7, 88
Diagnostic code ............................................................... 101
Dimensions........................................................................... 27
Direct ignition....................................................................... 39
Display ............................................................. 30, 31, 33, 37
Display and operating unit ................................. 26, 30, 90
Display illumination ............................................................. 37
Disposal .................................................................................. 8
E
eBUS ..................................................................................... 37
Electrical connection.......................................................... 28
Emergency-Off .................................................................... 18
Engineer level....................................................................... 33
Excess air.............................................................................. 86
Exchanging the unit ............................................................ 91
83250302 1/2018-08 La
F
Fan motor.............................................................................. 24
Fan run-up time ................................................................... 39
Fault ....................................................................................... 90
Fault code.......................................................................... 101
Fault history .......................................................................... 43
Flame failure test ................................................................. 37
Flame sensor......................................................... 21, 39, 40
Flame signal ......................................................................... 21
Flame stabilisation time ..................................................... 39
Flashing ......................................................................... 32, 35
Flue gas losses.................................................................... 86
Flue gas measurement....................................................... 86
Flue gas temperature ......................................................... 86
Frequency ............................................................................. 37
Frequency converter ........... 24, 41, 42, 49, 63, 77, 102
Fuel meter..................................................................... 23, 37
Fuel stage ............................................................................. 32
Fuel valve ........................................................ 14, 15, 16, 17
Fuel volume .......................................................................... 38
Full load ............................................ 42, 56, 59, 71, 72, 83
Fuse ....................................................................................... 26
G
Gas connection pressure.................................................... 9
Gas temperature ................................................................. 87
Gas throughput ................................................................... 87
Guarantee............................................................................... 6
H
Heat demand ............................................................... 22, 23
Heavy oil intermediate start .............................................. 20
High gas pressure switch ................................................. 40
Humidity ................................................................................ 26
I
Ignition load point ................................................ 50, 64, 78
Ignition pilot valve................................................................ 15
Ignition position ................................................................... 50
Ignition speed .............................................................. 50, 53
Ignition unit ............................................. 14, 15, 16, 17, 24
Illumination............................................................................ 37
Impulse frequency............................................................... 23
Info level ................................................................................ 33
Input COM X92................................................................... 22
Input X10-05.......................................... 14, 15, 16, 17, 21
Input X10-06........................................................................ 21
Input X3-02 ............................................ 14, 15, 16, 17, 18
Input X3-03 .................................................... 14, 15, 16, 18
Input X3-04 ............................................ 14, 15, 16, 17, 18
Input X5-01 ............................................ 14, 15, 16, 17, 19
Input X5-02 .......................................................................... 19
Input X5-03 ............................................ 14, 15, 16, 17, 23
Input X9-04 ............................................ 14, 15, 16, 17, 20
Input X75 .............................................................................. 23
Input X8-04 .......................................................................... 18
Interface ................................................................... 102, 104
109-112
Installation and operating instruction
Combustion Manager W-FM 50
12 Key word index
Ionisation electrode ............................................................ 21
L
Liability..................................................................................... 6
Lifespan............................................................................ 7, 88
Limit switch........................................................................... 18
Load change ........................................................................ 36
Load controller............................................................. 22, 23
Load limit............................................................................... 42
Load signal ........................................................................... 22
Lockout.......................................................................... 18, 90
Low gas pressure switch ...................................... 9, 19, 40
Low gas programme ............................................................ 9
Low impact start.................................................................. 23
M
Mains frequency .......................................................... 26, 37
Mains voltage ............................................................... 18, 26
Manual load .................................................................. 35, 36
Manual OFF.......................................................................... 35
Max. oil pressure switch .................................................... 19
Max. pressure switch ......................................................... 19
Min. oil pressure switch..................................................... 19
Min. pressure switch .......................................................... 19
Modbus ................................................................................. 37
Modulating.................................................................... 22, 39
Modulation limit ................................................................... 42
Motor.............................................................................. 24, 28
Multi-stage.................................................................... 22, 23
Point of ignition.................................................................... 41
Post burn time ..................................................................... 40
Post-purge position............................................................ 41
Post-purge time................................................................... 40
Pre-ignition phase................................................ 16, 17, 24
Pre-purge.............................................................................. 39
Pre-purge position...................................................... 39, 41
Pre-purge position ............................................................. 41
Pre-purge time..................................................................... 39
Pressure regulating screw ........................................ 69, 81
Pressure regulator .............................................................. 23
Pressure switch relief......................................................... 24
Program stop ....................................................................... 39
Programme sequence......................................... 14, 15, 16
Pump pressure ............................................................ 69, 81
R
Ramp time............................................................................. 41
Referencing .......................................................................... 12
Repetition counter ............................................................. 39
Reset.............................................................................. 18, 91
Restore.................................................................................. 36
S
OFF function ........................................................................ 30
Oil throughput...................................................................... 71
Operating mode .......................................................... 22, 23
Operating phase ................................... 13, 14, 15, 16, 17
Operating point ................................................................... 11
Operating setting ................................................................ 13
Operating stage 1............................................................... 84
Operating unit...................................................................... 30
Operating volume ............................................................... 87
Output X3-05 ........................................ 14, 15, 16, 17, 24
Output X4-02 ........................................ 14, 15, 16, 17, 24
Output X6-03 ................................................ 14, 15, 16, 17
Output X7-01 ................................................ 14, 15, 16, 17
Output X7-02 ................................................ 14, 15, 16, 17
Output X3-05 ...................................................................... 24
Output X74 .................................................................. 24, 25
Safety circuit ................................... 14, 15, 16, 17, 18, 39
Safety measures.................................................................... 7
Safety shutdown ................................................................. 32
Safety time limiter................................................................ 18
Safety valve .................................................... 14, 15, 16, 17
Save ........................................................................ 11, 33, 36
Service................................................................................... 88
Service contract .................................................................. 88
Service interval .................................................................... 88
Service level ......................................................................... 33
Setting step.......................................................................... 36
Setting time .......................................................................... 26
Smell of gas ........................................................................... 7
Software version ......................................................... 36, 44
Spares ................................................................................ 107
Special positions................................................................. 41
Speed alteration.................................................................. 97
Speed measurement.......................................................... 24
Speed standardisation................................. 42, 49, 63, 77
Stabilisation time................................................................. 39
Standard volume ................................................................. 87
Standby position ................................................................. 41
Start prevention........................................................... 24, 39
Start-up ................................................................................. 38
STL ......................................................................................... 18
Storage.................................................................................. 26
Switch off behaviour........................................................... 39
P
T
Parameter ........................................ 36, 38, 41, 42, 43, 44
Parity ...................................................................................... 37
Partial load...................................................... 42, 59, 73, 84
Password ........................................................ 34, 47, 61, 75
Password level..................................................................... 33
Photo resistor....................................................................... 21
Pilot ignition.......................................................................... 39
Temperature ......................................................................... 26
Thermostat............................................................................ 23
Three stage .......................................................................... 39
Throughput ........................................................................... 71
Torque ................................................................................... 26
Transport............................................................................... 26
Tree stage............................................................................. 22
N
Nozzle circulation ................................................................ 20
O
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Installation and operating instruction
Combustion Manager W-FM 50
12 Key word index
Two stage ..................................................................... 22, 39
Type of operation ................................................................ 39
Type of protection............................................................... 26
U
Unit address......................................................................... 37
UV cell ................................................................................... 21
V
Valve proving................................................................ 10, 20
Valve proving gas pressure switch ................................. 20
Valve proving pressure switch ......................................... 20
Voltage supply ..................................................................... 18
VSD........................................................................................ 43
X
X5-02..................................................................................... 17
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Max Weishaupt GmbH · 88475 Schwendi
Weishaupt close by? Addresses, telephone numbers etc. can be found
at www.weishaupt.de
We reserve the right to make changes. All rights reserved.
The complete program:
Reliable technology and prompt, professional service
W Burners
up to 570 kW
The compact burners, proven millions of times
over, are economical and reliable. Available as
gas, oil and dual fuel burners for domestic and
commercial applications.
The purflam® burner version with special
mixing head gives almost soot-free combustion
of oil with greatly reduced NOx emissions.
The wall-hung condensing boilers WTC-GW
have been developed to meet the highest
demands in ease of operation and efficiency.
Modulating operation means these units
operate quietly and economically.
monarch® WM Burners
and Industrial Burners
Floor-standing condensing boilers
for oil and gas
up to 1,200 kW
up to 11,700 kW
These legendary industrial burners are durable
and versatile.
Numerous variations of oil, gas and dual fuel
burners meet a wide range of applications and
capacity requirements.
The floor-standing condensing boilers
WTC-GB (up to 300 kW) and WTC-OB
(up to 45 kW) are efficient, low in pollutants
and versatile in use.
Even the largest capacities can be covered by
cascading up to four gas condensing boilers.
WKmono 80 Brenner
Solar systems
up to 17,000 kW
The WKmono 80 burners are the most
powerful monoblock burners from Weishaupt.
They are available as oil, gas or dual fuel
burners and are designed for tough industrial
application.
The stylish flat-plate collectors are the ideal
complement for any Weishaupt heating
system. They are suitable for solar water
heating and for combined heating support.
With versions for on-roof, in-roof and flat roof
installations, solar energy can be utilised on
almost any roof.
WK Burners
Water heaters/Energy storage
up to 32,000 kW
These industrial burners of modular
construction are adaptable, robust and
powerful.
Even on the toughest industrial applications
these oil, gas and dual fuel burners operate
reliably.
The diverse program of potable water and
energy storage for various heat sources
includes storage volumes of 70 to 3,000 litres.
In order to minimize storage losses, potable
water cylinders from 140 to 500 litres are
available with highly efficient insulation using
vacuum insulation panels.
MCR Technology / Building Automation
from Neuberger
Heat pumps
From control panels to complete building management systems - at Weishaupt you can find
the entire spectrum of modern control
technology. Future orientated, economical and
flexible.
83250302 1/2018-08 La
Wall-hung condensing boilers
for gas
up to 240 kW
up to 180 kW
The heat pump range offers solutions for the
utilisation of heat from the air, the soil or
ground water.
Some systems are also suitable for cooling
buildings.
Service
Geothermal probe drilling
Weishaupt customers can be assured that
specialist knowledge and tools are available
whenever they are needed. Our service
engineers are fully qualified and have
extensive product knowledge, be it for burners,
heat pumps, condensing boilers or solar
collectors.
With its daughter company, BauGrund Süd,
Weishaupt also offers geothermal probe and
well drilling. With the experience of more than
10,000 systems and more than 2 million meters
of drilling, BauGrund Süd offers a
comprehensive service program.