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ϑ ϑ
M M M M
O2
PE X6-03 X6-02 X6-01 X7-03 X7-02 X7-01 PE
module
X5-01
min
Start
L
PE
L
N
PE
L
N
PE
N
L
N
PE
L
N
PE
H0-Start
Start
L
X8-03
L V1
PE L
V3
V2
SV
X5-02
min PE
M
L N
X8-02
ON/OFF V1
X5-03
3 L
2 OIL L
X8-01
L GAS L
INT L min.
P
max.
X9-03
GAS
P
LT
X4-01
OIL (CPI)
P
L
X9-02
RESET PE
PE IGNITION N
X4-02
N V1 L
X9-01
L V2 L
PE PV L
P
X4-03
N SV L
L (START)
X10-03
W-FM 200
ION
FSV/QRI
PE
FLAME
X10-02
N
X3-01 X3-02 X3-03
L MOTOR
L
L ALARM
Power QRI
P
QRB
L
L
FLANGE LINE
X10-01
N
L
G0
SAFETY 12VAC
G
L LOOP
X3-04
PE
L LINE
VOLTAGE
N
info esc
2
10 O 2 sensor 86
11 Frequency converter
11.1 Programming and display unit frequency
88
13 Maintenance
13.1 Safety information for maintenance
105
105
13.2 Maintenance plan 105
14 Technical data
14.1 Combustion manager W-FM
106
106
14.2 Servomotor SQM45.../48... 107
14.3 Flame guarding 108
14.4 Display and operating unit (ABE) 109
A Appendix
Notes 110
3
1 General information
These installation and operating instructions Hand-over and operating instructions
• are an integral part of the equipment and must be The contractor is responsible for passing the operating
kept permanently on site. instructions to the plant operator prior to hand-over. He
should also inform the plant operator that these instruc-
• are to be used by qualified personnel only. tions should be kept with the heating appliance. The
address and telephone number of the nearest service
• contain the relevant information for the safe assembly, centre should be entered on the reverse of the operating
commissioning and servicing of the equipment. instructions. The plant operator must note that an agent of
the contractor or other suitably qualified person must
• are for the attention of all personnel working with the inspect the plant at least once a year. To ensure regular
equipment. inspections, -weishaupt- recommends a service contract.
• in addition to this installation and operating manual, The contractor should instruct the plant operator in the use
the documentation for the relevant burner and the of the equipment prior to hand-over and inform him as and
type of frequency converter must be observed. when necessary of any further inspections that are required
before the plant can be used.
Abbreviations
Tab. Table
Ch. Chapter
4
2 Safety information 2
Dangers when using the equipment Electrical safety
Weishaupt products are manufactured in accordance with • Before starting work - isolate plant and protect against
the relevant existing standards and guidelines and the reactivation, check voltage is isolated, the unit is
recognised safety laws. However, improper use of the earthed, and protected from adjacent equipment that
equipment could endanger life of the user or a third party, might still be under voltage!
or result in damage to the plant. • Work on the electrical supply should be carried out by
a qualified electrician
To avoid unnecessary danger, the equipment is only to be • Electrical components should be checked during
used: servicing. Loose connections and heat damaged
• for its intended purpose cables should be dealt with immediately.
• under ideal safety conditions • The control panel should be locked at all times. Access
• with reference to all the information in the installation should be restricted to authorised button holder
and operating instructions personnel.
• in accordance with inspection and service work. • Should it be necessary to carry out work on live parts,
country specific safety regulations must be observed
Faults, which could affect the safe operation of the burner, and tools to EN 60900 must be used. A second
should be rectified immediately. person should be present to switch off the mains
supply in an emergency.
Personnel training
Only competent personnel may work on the appliance. Maintenance and fault rectification
Competent personnel according to this operating manual • Necessary installation, service and inspection work
are persons who are familiar with the installation, should be carried out at the specified time.
mounting, setting and commissioning of the product and • Inform the operator before beginning any service
have the necessary qualifications such as:- work.
• Training, instruction or authorisation to switch electrical • For all service, inspection and repair work, electrically
circuits and electrical devices on and off, to earth them isolate the equipment and ensure the mains switch
and to mark them in accordance with the safety cannot be accidentally switched back on. Cut off the
standards. fuel supply.
• Training, instruction or authorisation to carry out • Flame guarding devices, limit controls, correcting
installation, alteration and maintenance work on gas elements and all other safety devices must be
installations in buildings and on site. commissioned by, and may only be replaced by, the
manufacturer or an authorised agent.
• Following service work, all safety devices should be
Organisational measures tested to ensure they are functioning correctly.
• Everyone working on the plant should wear the
necessary protective clothing.
• All safety devices should be checked regularly. Alterations to the construction of the equipment
• No alterations to the equipment are to be made without
the approval of the manufacturer.
Informal safety measures All conversions require written confirmation from Max
• In addition to the installation and operating instructions, Weishaupt GmbH.
local codes of practice should also be adhered to. • Any parts not in perfect working order should be
Special attention should be paid to the relevant replaced immediately.
installation and safety guidelines given. • No additional components may be fitted, which have
• All safety and danger notices should be kept in a not been tested for use with the equipment.
legible condition. • Use only -weishaupt- replacement and connection
• Furthermore, all safety documentation and danger parts. Parts from other manufacturers are not
notes covering the frequency converter and burner guaranteed to be suitable to meet the necessary
must be observed. operational and safety requirements.
5
3 Technical description
The combustion manager W-FM contains all functions Functions
required for safe and efficient operation of multi-stage or • Burner control
modulating single fuel and dual fuel burners. • Electronic compound regulation for up to a max of
The display and programming unit shows the conditions 5 1 stepping motors
and allows programming via dial knob and function • Speed control
buttons. • O2 control
• Valve proving
• True dual fuel operation
• Integral load/ratings controller 2
• Flame guarding
• Separate ABE programmer
3.1 Function
Combustion manager Load controller 2
The combustion manager: The optional, integrated PID load controller can be used as
• controls the sequence of operation a temperature or pressure controller for multi-stage or
• guards the flame modulating burners, depending on the connection and
• communicates with the stepping motors parametering. Furthermore the load controller contains a
• controls and guards the frequency converter control reaction damper which protects the stepping
• carries out valve proving of the gas valves motors from unnecessary drive impulses, thus protecting
• has: – an integrated load controller 2 the stepping motors and increases their life span.
– Speed control 1 The load controller can be operated with one external
– O2 control 1 setting value or set point input, or with two internal set
points.
The internal set points can be selected using an external,
Operating elements potential free contact.
The system can be controlled by several operating units: Switchover from an external operation to the internal load
• a plug-in programmer ABE controller is via a contact.
• PC module for guard control A separate start up programme is incorporated for boiler
• Remote main control system (Building Management cold start if required.
System)
Speed control 1
Flame sensor The frequency converter of the fan motor is started by a set
Guards the flame during all phases of operation. If the point output (0/4 - 20 mA) and the speed is matched to
flame signal does not correspond to the sequence of the current burner rating required. The speed and the
operations, a safety lockout will occur. rotation are determined and guarded using an inductive
Flame sensors used: proximity switch in conjunction with an asymmetrical
• QRI for continuous or intermittent operation for oil, transmitter disc. In compound with the stepping motors
gas and dual fuel burners. the required combustion air is automatically adjusted and
• Ionisation electrode only for gas for continuous or the electrical consumption is reduced to a minimum.
intermittent operation. If the air supply fails or becomes insufficient, an air
pressure switch initiates lockout.
Stepping motors
Separate stepping motors (as appropriate) on: O2 Trim control 1
• Air damper The residual O2 content in the flue gas is determined by a
• Oil controller sensor, which compares it to the set points calculated
• Gas butterfly valve during commissioning. Depending on the control
• Mixing head deviations from the set points, the combustion manager
Providing precise, direct control of the correcting elements re-adjusts the air regulating devices and corrects the
in the compound. burner’s aeration.
Individual setting values are transmitted via CAN BUS from
the combustion manager to the stepping motors, the
stepping motors are electronically adjusted and the Low gas programme
combustion manager constantly guards their position If the control gas pressure falls below the setting of the low
return signals. gas pressure switch during operation, the combustion
manager starts a low gas programme.
If the gas pressure is below the set point prior to start, the
burner start is inhibited.
1
only W-FM 200
2
optional on W-FM 100
6
3
Valve proving (only on gas operation) Sequence diagram valve proving
Following each controlled shutdown, the combustion
1st. Test phase 2nd. Test phase
manager carries out a valve proving test of the gas
solenoid valves.
Following lockout or power failure, the valve proving test is Valve V1
carried out prior to the next burner start. 3 secs.
sek. 10
10sek.
secs. 3 secs.
sek. 10
10sek.
secs.
Valve V2
Function
1st. Test phase:
During a controlled shutdown valve V1 closes P between
V1 and V2
immediately, and valve V2 has a slight delay in closing
which permits the volume between the valve seats to Gas press.
depressurise. The section between V1 and V2 must switch VP
remain depressurised once the second valve has
closed.
Setting pressure gas pressure switch
2nd. Test phase:
Valve V1 opens and immediately closes again, PR + PV
allowing gas pressure build-up between V1 and V2 = setting pressure
valve seats. During the test phase, the pressure 2
between the valve seats must not fall below the
pressure setting of the gas pressure switch XX. PR = Control pressure into V1 (reduce impact pressure)
PV = Maximum pressure during pre-purge downstream of V2
Display
4 lines with scroll function
ESC button
Cancel or return
Info button
Return to operating display
Enter button
Execution
Scroll knob
Cursor control and value change
Contrast adjustment
To change the contrast of the display, press Enter button
and hold down whilst changing the contrast using the
scroll knob (+/–). (Only possible in menu Normal
operation, contrast adjustment with saving see Ch. 9.9.7).
7
4 Installation
4.1 Safety instructions for installation
Electrically isolate the plant Note Due to the frequency converters used it is
Prior to installation switch off the mains switch possible for some of the electrical
and the safety switch. components to continue to be energised
Failure to comply could cause death or following mains isolation. The waiting time
serious injury by electric shock. given must therefore be observed prior to
DANGER starting work.
External connections
Mains voltage carrying lines (230V; 50 Hz) should be
Display and programmer unit ABE flexible and have a minimum cross section of 0.75 mm. The
The installation of the ABE to the W-FM is carried out with PE terminals on the fixing plate of the W-FM should be
a special CAN-Bus cable. This cable supplies voltage to used for earth wire connection.
the ABE and transmits the BUS signals.
Flame sensor
The 1.8 m senor line to the flame sensor can be extended
by up to 100m if installed separately (i.e. for W-FM in a
separate control panel).
Ignition line
The ignition cables should be installed as close as
possible to the ignition electrodes. Ignition cables must
have an adequate spacing away from any other wiring.
8
4
Installation example: W-FM in burner housing Installation example: W-FM in a control panel
O2 module Jumper with Bus (only W-FM 200) O2-Modul Jumper with Bus (only W-FM 200)
connection connection
5 5
Burner Burner
SQM4... SQM4... SQM4... Frequency SQM4...
no Bus
SQM4...
no Bus
SQM4...
no Bus
no Bus no Bus no Bus
con- con- con- converter 2 con- con- con-
ABE nection nection nection nection nection nection
2 AT
5 5 5
5 5
AC1 12V 4 AT
AC2 12V 4 AT
AC2 12V
AC1 12V
CANH
CANL
GND
GND
5 5
AC2 12V
AC1 12V
AC2 12V
AC1 12V
CANH
CANH
CANL
CANL
GND
GND
4 AT
4 AT
ABE
6,3 AT
5
W-FM
AC2 12V
AC1 12V
CANH
CANH
CANL
CANL
GND
GND
Netz
4 AT
4 AT
5
6,3 AT
(only W-FM 200)
W-FM
Frequency Frequency
converter
converter 1
Mains
Frequency
converter
9
10
T2 F10 S7 T1 Y9 F36 F35 Y7
X30-03 X30-02 1
4
3
2 4
P P< P>
12V
12V
2
1 P 2 3 1 2 3 1
3
2 (F10) X36 PE 2 3 1
X35 PE 2 3 1
2
12V
230V
1 1
X30-01
1
3
4
1
1
1
3
1
1
1
1
3
1
3
4
2
2
2
2
3
2
2
3
2
3
2
X10-01
X52
X3-02
X3-03
X4-02
X4-03
X5-01
X5-02
X6-02
L N L L PE N L L N PE PE L PE L PE N L
L PE N L L L L L N W-FM 200
2
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
1
1
2
1
X60
X61
X62
X63
0
0
0 2
FE
FE
FE 3
FE
X3-01
X3-04
X4-01
X5-03
X6-01
X7-03
X6-03
X8-01
0 - 10V
0 - 10V
4 - 20mA0
4 - 20mA0
4 - 20mA0
SX
Power Sensor
4.3 Electrical connection (principle drawing)
B3
X63
X62
Y10 Pt100
2 1 3
Pre-selection Gas
Pre-selection Oil
Burner on
ext. controller
contacts
P20W/P30W
Burner reset
B3 B3
= Set point
FX SX
PE
L
Burner lockout
Start release Oil
Residual oil immediate
start
Start release Gas
Gas operation
Oil operation
KX Pt/Ni1000
X60/X61 = actual value
FX
KX SX
operating type switchover load controller
Motor start
contactor
Safety circuit
230V 1/N/PE 50-60Hz N
Return signal motor
protection contact
Legend:
A1 Combustion manager
External connections B3 Appliance’s temperature/ pressure sensor
Additional connections F10 Air pressure switch
F35 Max. oil return pressure sensor
F36 Min. oil supply pressure sensor
S7 Burner flange limit switch
T1 Ignition unit
T2 Control transformer
Y7 Magnetic coupling
Y9 Solenoid valve on air pressure switch
Y10 Anti siphon fuel valve
FE certified earth
Y14
(U /2)
Y15
N (UN/2)
Y11 Y12 Y14
(U /2)
Y15
(U /2)
N N
Y11
1
2
3
4
1
2
3
1
2
3
1
2
3
1
2
3
4
X8-03
X7-01
X7-02
X7-01
X8-03
On multi stage
Light-oil burners
size 30 - 40
On modulating
Light-oil burners
sizes 30 - 70
PE N L
Y11 Y12
(UN/2) (UN/2)
Y14
(U /2)
Y15
N (UN/2)
(Option)
On multi stage
Heavy-oil burners
size 30 - 50
On modulating
Heavy-oil burners
sizes 30 - 70
1
2
3
1
2
3
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
X7-01
X7-02
X8-02
X8-03
X8-02
X8-03
PE N L PE N L L N PE L N PE L N PE L N PE
W-FM 200
11
12
B12
4
BU
BN
BK
B12
BN
BU
1
3
4
5
X70
W-FM 200
DC in
0/4-20
mA out
12-24V
1
2
3
4
1
2
3
4
1
2
3
4
5
6
X71
X72
X73
B20 B21
+24V
Start frequency converter
Lockout frequency converter
Set point
Earth
Screen
BN
BU
BN
BU
5
Connection
B20 B21 frequency converter
Legend:
B12 Proximity switch burner motor
B20 Fuel meter Gas (optional)
B21 Fuel meter Oil (optional)
A2 Y20 Y17 Y19 Y18
B1 QRB B1 1
3 5 M M M M
BK
BN
4/6 Bus interface
1
3
4
5
X10-02.1
5
7 5 5 5
X72
QRI B1 5 5
X70
4
7
2
8
3
braun
blue
black
1
3
4
5
1
3
4
5
1
2
6
2
6
2
4
5
6
X10-03
X10-02.2
X50
X51
L PE N
W-FM 200
2
1
4
1
3
2
4
3
2
1
X9-03
X9-02
X9-01
9
5
3
2
8
7
1
4
PE
Connection control panel
External signalling pressure switch (optional) 10
9
5
3
2
8
7
1
4
PE
2
1
1
1
3
2
4
3
2
1
2
1
4
3
2
Terminal box gas valve train Connection O2 module
X21-01
X21-02
X20-03
X20-02
X20-01
3
2
2
3
2
3
2
3
2
3
2
3
1
4
2
3
2
3
1
1
1
1
1
1
1
X22-01
X22-02
X22-03
X23-01
X23-02
X23-03
X24-01
X24-02
X24-03
2
1
Legend:
A2 Display unit/programmer
PE
L1
PE
L1
PE
L1
PE
N
PE
L1
N
L2
N
L2
N
L2
L1
L2
N
13
14
O2 sensor
Mains voltage QGO20
4
M
B1
U3
PE
B2
Q4
Q5
G2
3
6
5
4
3
2
1
6
2
5
4
3
1
3
2
1
3
2
1
3
2
1
3
2
1
X81
X89-01
X89-02
X82
X83
L N PE L N PE
O2 module
GND
GND
CANL
CANL
CANH
CANH
12VAC1
12VAC2
12VAC1
12VAC2
1
2
3
1
2
3
1
2
3
1
3
4
5
1
3
4
5
2
2
X88
X87
X86
X85
X84 5
Legend:
LOAD
3 Wire-PNP
X63
OUTPUT
0 4-20mA
PE X6-03 X6-02 X6-01 X7-03 X7-02 X7-01 PE
Reserve
P
FE
L
L
L
L
L
L
L
N
N
N
N
min
X70
N
PE
PE
PE
PE
PE
FE 0
X5-01
Start
Start
X8-03
Usensor 4-20mA
H0-Start
INPUT
2 Wire PE L
Pulse-IN 0-10V SET POINT
V2
V3
P
SV
M
3 Wire-PNP min
X62
PE
0
X5-02
OIL GAS OIL
X71
L N
FE FE
ON/OFF V1
X8-02
Usensor 0
2 Wire 3 L
Pulse-IN 4-20mA
X5-03
INPUT
3 Wire-PNP 2 OIL L
0 0-10V
TEMP./PRES.
X72
X8-01
L GAS L
X61
FE
Start-OUT
min.
P
INT L
12-24VDC Alarm in
TEMP.
max.
P
GAS
0/4-20mA Setpoint OUT
Pt100
LT
X9-03
P
OIL
Pt/Ni1000
(CPI)
X60
X4-01
L
X73
FE PE
RESET
FREQUENCY CONVERTER
X9-02
PE IGNITION N
N V1 L
X4-02
L V2 L
FE
X9-01
P
PE PV L
12VAC2
N SV L
M
X4-03
TRAFO
L (START)
X52
12VAC1
X10-03
ION
FSV/QRI
PE
BUS
N
FLAME
L MOTOR
W-FM
L GND
X10-02
L ALARM
Power QRI CANL
P
QRB CANH
L
L 12VAC2
FLANGE LINE
N 12VAC1
G0 Shield
X10-01
SAFETY 12VAC
G GND
L LOOP
CANL
PE
CANH
X3-04
L LINE
VOLTAGE 12VAC2
N
12VAC1
X50
Shield
BUS
15
5 Preparation for commissioning
5.1 Safety note
Check installation Safety notes on initial commissioning
All installation work must be completed and The initial commissioning must only be carried out by the
checked prior to commissioning. The burner supplier, manufacturer or their appointed agent. At this
must be mounted on the appliance, ready for time, all the control and safety equipment must be
operation and all control and safety devices checked to ensure correct operation and, if it can be
DANGER must be connected correctly. adjusted, it should be checked that it has been set
correctly.
❏ Burner mounted, including refractory as required Furthermore the correct fusing of the circuits and the
❏ Fuel supply complete measures for contact protection of electrical equipment
❏ Electrical connections and controls complete and of all wiring must be checked
1
W-FM 200 only when used with frequency converter
16
5
3. Carry out speed control standardisation 1 Speed standardisation
During speed control standardisation a set point signal of ➩ Ch. 9.11.1
95% is given. The speed is determined and saved in Parm + display
parameter Standardised Speed. If, during standardisation FC module
more than 50Hz is displayed, the motor-slip compensation Configuration
(=0) on the frequency converter has to be checked. Speed control
Standardisation
The rotational direction of the motor should be checked Standardisation
during speed standardisation. Curr: deactivated
New: activated
Note After each speed standardisation, or changes to the
saved values, the combustion quality needs to be
checked.
1
only W-FM 200 in connection with frequency
converter or O2 module
17
6 Commissioning - modulating
6.1 Set fuel and load limits on W-FM
Select fuel (only on dual fuel burners) Select fuel
Select the required fuel using the external fuel selection
switch. If an external fuel selection switch is not available, Operation ➩ Ch.9.3
fuel selection is made using the ABE or BMS. Fuel
Fuel selection or:
Note The external fuel selection switch takes priority. That Fuel selection Fuel selection
means the commissioning can only be carried out Curr: Oil switch on Oil
with the fuel set at this switch. New: Gas
18
6
6.2 Commissioning the burner
6.2.1 Set mixing pressure for ignition
Set Program stop 36 Program stop 36: Ignition position without ignition
Prior to the first ignition trial, the program stop must be set
to 36 IgnitionPos. After burner start the burner runs to the RatioControl ➩ Ch. 9.6.1
ignition position without actual ignition occurring. ProgramStop
ProgramStop
Note In its delivered condition the program stop has Curr: 36 IgnitionPos
already been factory pre-set to 36. New: 36 IgnitionPos
Open manual fuel shut off devices and the burner is Burner On
ready to start
After the fuel shut off devices have been opened the RatioControl ➩ Ch. 9.3
burner should be started in manual operation. Auto/Manual/Off
Auto/Manual/Off
Note For burner start all safety devices, pressure and Curr: Burner Off
temperature controllers should be in operating New: Burner ON
position.
Ensure sufficient heat requirement for the duration
of the commissioning procedures.
Set ignition position Ignition positions (example gas operation 3LN multiflam®)
Set the ignition positions whilst observing the mixing
pressure. RatioControl ➩ Ch. 9.6.1
The speed during ignition should not be less than 80% for GasSettings
oil and 70% for gas (only when using a frequency SpecialPositions
converter / W-FM200). IgnitionPos IgnitionPosGas
If the measured mixing pressure is too high, this can be IgnitionPosGas Curr: 10.5°
adjusted by reducing the air damper position. IgnitionPosAir New: 15°
IgnitionPosAux
The relevant ignition pre-settings should be taken from the IgnitionPosFC
installation and operating instructions of the burner or its IgnitionPosAir
test data sheet. Curr: 13°
New: 10°
Note The auxiliary motor position on 3LN burners
(multiflam®) in ignition position and during burner IgnitionPosAux
operation must be a minimum of 18°. Curr: 18°
New: 19°
IgnitionPosFC
Curr: 100%
New: 70%
19
6
6.2.2 Burner ignition
Set program stop 52 Program stop 52: ignition after safety time
To ignite the burner the program stop should be set from
36 to 52. Fuel is released following SpecialPositions ➩ Ch. 9.6.1
pre-ignition. The motors remain in the ignition positions ProgramStop
setting. ProgramStop
Curr: 36 IgnitionPos
New: 52 Interv 2
20
6
6.2.3 Set load point 1
Deactivate program stop Deactivate program stop
To continue with commissioning the program stop has to
be deactivated. If the program stop is not deactivated, the RatioControl ➩ Ch. 9.6.1
burner remains in the position set and setting of additional ProgramStop
load points is not possible. ProgramStop
Curr: 52 Interv 2
New: deactivated
Set load point 1 Take over Ignition load point as load point 1
In setting oil, the first load point has been programmed by
the factory. GasSettings ➩ Ch. 9.6.1
If the first load point has been deleted, the ignition load CurveParams
values will be taken over automatically as the first load Point Load :15.0
P Point Load :15.0
point just as with Setting Gas. Burn:15.0 : 1 Burn :15.0
In both cases the values should be matched and a ManualAir :10.0 O2 Air :10.0
combustion analysis should be carried out. Aux1 :19.0 4.9 Aux1 :19.0
FC :70.0 FC :70.0
At the first load point the fuel dependent minimum speed1 Change load point 1
should be aimed for whilst observing the combustion ➩ Ch. 9.6.1
quality and flame stability. Point Load: 10.5
Point I Point
Procedure: : 1 C
Change?
1. Drive up the air damper stepping motor until a residual Point Load:15.0 Point Load :15.0
O2 content in the flue gas of max. 8% has been 1 Burn:15.0 1 Burn:15.0
achieved (on 3LN burners multiflam® max. 7% residual O2 Air :10.0
A O2 Air :223.6
O2 content in the flue gas). 4.9 Aux1 :19.0 4.9 Aux1 :19.0
FC :70.0 FC 50.2
:5
2. Reduce speed1 (not below minimum speed). To
achieve minimum speed it may be necessary to repeat
steps 1 and 2. Point esc
save- >ENTER
3. Carry out combustion analysis and if necessary delete- >ESC
optimise combustion by adjusting the air damper
position.
Gas 50 % approx 25 Hz
1
only W-FM 200 with speed control
21
6
6.2.4 Start full load
Drive to full load via intermediate load points Increase load manually
Starting from the first load point, drive to full load via the
intermediate load points. Point Load:15.0 ➩ Ch. 9.6.1
Burn :15.0
Procedure: Hanual Air :23.6
M
1. Set cursor to Manual and press <ENTER>. Aux1 :19.0
Point esc
Save- >ENTER
enter->ESC
Point Load:100
:5 Burn:73.6
O2 Air :67.8
3.8 Aux1 :78.5
22
6
6.2.5 Optimising full load
Optimising full load
In the last load point (load = 100%) the exact fuel quantity
throughput for the required full load should be set.
Procedure:
1. Set fuel throughput
Optimising full load
Gas: At 65° to 70° gas butterfly setting, determine ➩ Ch. 9.6.1
gas throughput and adjust using the setting Point Load :100
screw on the pressure controller. 5 Burn 68.7
:6
O2 Air :67.8
Oil: Set pump pressure required, determine oil 4.5 Aux1 :78.5
throughput and adjust using stepping motor
setting of the oil controller (see burner test data
sheet: Indicator setting oil controller).
23
6
6.2.6 Re-define intermediate load points
Re-define load point 1 Drive to load point 1 and optimise combustion
To later allow O2 control across the whole ratings range,
point 1 must be a minimum 30% below the required partial Point Load :100
load (only when using an O2 module / W-FM 200). :5 Burn:68.7
O2 Air:76.2
Procedure: 3.8 Aux1 :78.2
1. Select point 1 with dial knob, press <ENTER>, confirm
Change point with <ENTER>, point 1 is started.
2. Check combustion quality, and optimise if necessary. Point Load :15.0 Point Point
Drive to combustion limit, note down and set excess air :1 Burn:15.0 : 1 c
vhange?
required for combustion limit. O2 Air :23.6 löschen?
Point Load:15.0
Excess air: • without O2 control approx. 15% to 20% 6.4 Aux1 :19.0 11.9
: 1 Burn:1
• with O2 control approx. 20% to 25% O2 Air :2 22.2
6.3 Aux: 18.6
Please observe the minimum speed and the mixing FC 50.0
:5
pressure required.
Procedure;
Select Point 2 with dial knob, press <ENTER>, confirm
Delete point with <ENTER>, point 2 is deleted and the Point Load:19.8 Point Point
setting values for the next intermediate load point : 2 Burn :19.3 : 2 change?
below point 2 appear automatically. O2 Air :25.5 Manual d
lelete?
Repeat procedure, until full load settings appear under 5.9 Aux1 :23.2 Point Load :449.6
point 2. : 2 Burn: 35.9
Do not delete the full load point (Load: 100) and point Manual Air: 47.3
1. 47.1 Aux1 :444.2
Check
Select point 3 with dial knob. If all intermediate load
points have been deleted, no values are defined in
point 3 and the following display is shown.
Point Load: 100
:2 Burn: 68.7
Point Load :XXXX O2 Air :76.2
: 3 Burn: XXXX 3.8 Aux1 :78.2
Manual Air :XXXX
Aux1 :XXXX
24
6
Set new intermediate load points and carry out ratings Reduce rating and optimise combustion
distribution in percentages
For burner operation 5 load points are required, this means Point Load: 100 ➩ Ch. 9.6.1
at least 3 intermediate load points must be set. Burn :68.7
depending on the installation, more intermediate load Hanual Air :76.2
M
points may be required (maximum 15 load points). Aux1 :78.2
To maintain an even speed reference line, the speed Point Load :100
should not be adjusted after this process if at all : 3 Burn :68.7
possible (only when using a frequency converter / W- O2 air :76.2
FM 200). 4.0 Aux1 :78.2
4. Determine fuel quantity throughput, calculate rating esc
and carry out ratings distribution.
P
Point Load :89.7
Burn :62.0
5. Leave point using <ESC> and save with <ENTER>.
HAnd Air :68.8
Aux1 :70.7
6. Repeat procedure for all curve points.
FC :84.2
Gas:
305 m3/h
Rating [%] = • 100 = 89.7 %
340 m3/h
Oil:
260 kg/h
Rating [%] = • 100 = 89.7 %
290 kg/h
Point .
Load:90.0 Punkt Load 89.7
:8
: 3 Burn:62.0 : 3 Burn :62.0
O2 Air :68.8 O2 Air :68.8
4.0 Aux1 :70.7 4.0 Aux1 :70.7
25
6
6.3 O2 functions modulating
The settings for the O2 trim control must only be carried
out if a W-FM 200 with O2 trim control is to be used.
Determine O2 value of combustion limit and note it: Determine combustion limit
1. Select the point to be set using the dial knob and
confirm with <ENTER>. Point:1
: 13.9% ➩ Ch. 9.7.1
:9
Point:9 100%
2. Select P air manual using dial knob and confirm with Point:9 100% Point:9 100%
<ENTER>. 02-Setpoint: 3.8 02-Setpoint: 0.7
P-AirHand: 0.0. 10.4 .
P-AirMan:1
3. Turn dial knob to the right. The air rating is reduced on
the curve flow line in relation to the ratings setting of P
air manual. The fuel quantity throughput remains
unchanged.
Reduce air rating until the combustion limit (CO or O2 graph
soot) has been reached. 8
5
5. Enter O2 min value in the graph on the right.
4
3
2
1
0
0 10 20 30 40 50 60 70 80 90 100
26
6.3.2 Set O2 trim control
6
For subsequent O2 trim settings, a standardisation has to O2 trim
be carried out at each point.
Param Display ➩ Ch. 9.7.1
O2Ctlr/Guard
Setting ...
O2 trim
Procedure: Standardisation
1. Select point to be set using the dial knob and confirm
with <ENTER>. Point:2
: 21.1% ➩ Ch. 9.7.1
02-Verbund
: :xxxx
Point:2 21.1% Point :221.1%
2. As soon as the O2 value is stabilised confirm with 02-Sollwert:xxxx
O2 RatioCon: 6.0 O2 RatioCon: 6.0
<ENTER>. Normierert :xxxx
If the value is stable O2 SetPoint:3.9
continue with ENTER StandardVal:11.3
.
3. Turn dial knob to the right. The air rating is reduced on
the curve flow line in relation to the ratings setting of
Point esc
standardisation value. The fuel quantity throughput
remains unchanged. save- >ENTER
The standardised O2 value should be 1 to 1.5% points delete->ESC
above the combustion limit (O2 min value of guard
function) and minimum of 1 % point below the O2 ratio.
4. Leave setting level with <ESC> and save the O2 value delay time is
using <ENTER>. measured O2 Actual
value: 4.2
Note At point 2 and with 100% the time (Tau) between Measurem success
the air quantity change and its recognition at the O2 ControlParam has
sensor is determined. This results in the controller been determined
parameters for subsequent O2 control. continiue with ESC
trol
5
O2 S
4 etP
oint
3 O2 G
Control limit uard
At burner ratings in the lower load range, the flue gas 2
velocity at the O2 sensor may not be sufficient for correct 1
and problem free control. In this case the O2 control limit
0
must be increased accordingly. 0 10 20 30 40 50 60 70 80 90 100
QB · 0,0046 T+273
General formula: v = 2 ·
d 273
27
6
6.3.3 Set O2 controlling functions
The O2 trim control function is set using OptgMode. O2 operating mode
O2 controller
The O2 controller and O2 guard are active.
Start-up only when the operating temperature of the
sensor has been reached.
If the O2 guard reacts, or if an error is detected during
measuring, lockout occurs, if there is no possibility of
repetition.
conAutoDeact
The O2 controller and O2 guard are active.
Start-up before operating temperature of the sensor has
been reached.
If the O2 guard reacts, or if an error is detected during
measuring the function auto deact is initiated.
conAutoDeact.
The burner remains in operation, however without O2
control and O2 guard.
6.3.4 Check and optimise O2 control
Check O2 control If the O2 sensor has reached its operating temperature,
Procedure: and the controller’s damping time (10 x Tau in partial load)
1. Re-start burner in automatic operation. The start has elapsed, pre-control starts and the O2 value goes
behaviour can be checked again. close to the set point. If within the delay time (approx. 2 x
Tau in full load) no load changes occur, control goes to the
2. Change rating with external signal, so that the O2 value O2 set point. The actual O2 value should then be equal to
can be checked on the display of the ABE • i.e. the O2 set point.
connect a 3 pole switch to X5-03 and change over the
LC operating type to ExtLC X5-03. When a load change occurs the O2 controller is locked at
the existing value, and the air motors are re-adjusted with
3. In menu “OperationalStat” select “NormalOperation” the pre-control starting from the previous differential value
and change over to the second display using setting. This means that the O2 set point is almost
<ENTER>. maintained even during pre-control.
4. Carry out various load changes across the whole Note The O2 control can also be guarded using
ratings range whilst observing the O2 controller’s recording software.
behaviour.
28
6
6.3.5 Optimise O2 control
Depending on site specific requirements it may be O2 control parameters
necessary to adjust the O2 control parameters in the
SERV level. Param + Display ➩ Ch. 9.7.1
O2Ctlr/Guard
Setting ...
ControllerParams
LoadCtrlSuspend increase
FilterTmeLoad reduce
LoadCtrlSuspend increase
O2Offset increase
29
6
6.4 Concluding work following commissioning
6.4.1 Lower load limit (partial load)
Observing the instructions given in the installation and Set lower load limit
operating instructions of the burner and the instructions
given by the appliance manufacturer, partial load and the GasSettings ➩ Ch. 9.6.1
control range should be set in menu Load limits. Here, LoadLimits
partial load is defined with parameter MinLoad. MinLoadGas
MinLoadGas
Curr: 0.0%
New: 22.8%
Flue gas temperature limit value Set flue gas temperature limit values
If the limit value is exceeded the warning Flue gas
temperature too high is given. A prerequisite for this is a Param + Display ➩ Ch. 9.12.1
configured flue gas temperature sensor on the O2 module O2 Module
(only W-FM 200). Configuration
The limit value should be set approx. 20% above the flue MaxTempFlueGas
gas temperature at nominal load.
ATTENTION
30
6
6.4.2 Concluding work on the burner
Following commissioning the following, concluding work
has to be carried out on the burner.
• Set air pressure switch.
• Set gas and oil pressure switches.
• Remove measuring devices,
• etc ...
31
7 Commissioning multi-stage
Prior to commissioning the preparations necessary for
commissioning (Ch. 5) must be completed.
32
7
7.2 Adjust burner
7.2.1 Preset curve parameter
For commissioning the fan speed1 and air damper setting Call up stepping motor positions
of each operating point as well as the On/Off switch points ➩ Ch. 9.6.1
must be checked and if necessary adjusted. Param + Display
RatioControl
Procedure; Oil Settings
1. Call up stepping motor positions. CurveParams
Curve Settings
2. Select option Without start Stepping motor
positions
3. Call up operating, the on and off stage switch points With start
one by one using the dial knob and compare air damper Without start
setting (air stepping motor) and fan speed1 (FC) with
table values. If they deviate, overwrite the parameter
by Activate option ‘without start’
• calling up operating, on and off switch points with
<ENTER>, ➩ Ch. 9.6.1
• selecting parameter using dial knob and confirming Stepping motor Point Air :40.0
with <ENTER>, positions ::BS1 FC :80.0
• inputting parameter value (dial knob +/-) and saving With start O2
with <ENTER>. W
Without start xxxx
• Continue procedure until all parameters are the same
as the table values.
Call up operating, on and off switch points
1
two Air damper [°<] Speed [%] ➩ Ch. 9.6.1
operating stages Air PC Point Air :40.0 Point Air :40.0
::BS1 FC :80.0 ES2 FC
::E :90.0
Operating point BS1 40 80 O2 O2
Switch on point ES2 xxxx xxxx
Switch off point AS2 70 100
Operating point BS2
Overwrite parameters
Exit level
1
Only W-FM200 in connection with frequency
converter
33
7
7.2.2 Burner ignition
Set programme stop 36 Programme stop 36: Ignition position without ignition
Prior to first ignition the programme stop has to be set to
36 IgnitionPos. After burner start, the burner then drives to SpecialPositions ➩ Ch. 9.6.1
ignition position without igniting (with long pre-ignition, ProgramStop
ignition is carried out without fuel release). ProgramStop
Curr: 36 IgnitionPos
Note In its delivered condition the programme stop has New: 36 IgnitionPos
already been factory pre-set to 36.
Setting ignition position Set air damper fan speed and ignition position
The fan speed and the ignition position of the air damper
should be set whilst observing the mixing pressure. The RatioControl ➩ Ch. 9.6.1
ignition speed1 should not be below 80%. Depending on OIlSettings
the burner, the mixing pressure for ignition should be SpecialPositions
between 3 and 5 mbar. The mixing pressure can be IgnitionPos
adjusted with the air damper and diffuser positions. * The IgnitionPosOil does
IgnitionPosOil* not need to be set for
It is recommended to note down the IgnitionPos set IgnitionPosAir multi-stage operation, as
values.. IgnitionPosAux no oil throughput regu-
IgnitionPosFC lator valve and thus no
stepping motor is fitted.
Set programme stop 44 Programme stop 44: ignition position after safety time
To be able to ignite the burner the programme stop has to
be set from 36 to 44. Once the pre-ignition time has SpecialPositions ➩ Ch. 9.6.1
elapsed fuel is released. The stepping motors remain in the ProgramStop
ignition position setting. Programmstopp
Curr: 36 IgnitionPos
New: 44 Interv 1
1
only W-FM 200 in connection with frequency
converter
34
7
7.2.3 Start full load
Activate option “With start” Activate option “With start”
In stepping motor positions activate the option “With start”
by pressing <ENTER>. CurveParams ➩ Ch. 9.6.1
Curve Settings
Stepping motor Point Air :40.0
Note Operation of the switch off points should be positions ::BS1 FC :80.0
avoided during commissioning, as this can lead to With start O2
excessive air deficiency. Without start xxxx
Pre-set operating point S1 Pre-set operating point and set switch on point
1. Select operating point S1 using the dial knob and
confirm with <ENTER>. Point Air :40.0 ➩ Ch. 9.6.1
2. Call up parameter values using the dial knob and ::BS1 FC :80.0
<ENTER> and adjust operating point BS1 whilst O2
observing the combustion quality. xxxx
1
only W-FM 200 in connection with frequency
converter 35
7
7.2.4 Set switch off point(s)
Change over to option “Without start” Activate option “Without start”
Exit option With start in stepping motor positions with
<ESC> and re-enter Curve setting to select option Curve Settings ➩ Ch. 9.6.1
Without start and activate with <ENTER>. Stepping motor Point Air :33.0
positions ::BS1 FC :63.0
With start O2
W
Without start xxxx
esc
Carry out combustion check Note With 3-stage operation an additional combustion
• activate option With start. quality check for stage 2 (operating point BS2) is
required.
• Drive to operating point BS1 and check combustion
quality.
36
7
7.2.6 Check start behaviour
Procedure: Programme stop
1. Set ProgramStop to phase 44.
SpecialPositions ➩ Ch. 9.6.1
2. Re-start burner in manual operation. ProgramStop
ProgramStop
3. Check start behaviour and if necessary correct ignition Curr: deactivated
load setting. New: 44 Interv 1
Note If the ignition load setting has been altered, the start
behaviour has to be rechecked.
Restart burner
4. Deactivate programme stop.
Auto/Maual/Off ➩ Ch. 9.4
Auto/Manual/Off
Curr: Burner Off
New: Burner Off
Auto/Manual/Off
Curr: Burner On
New: Burner On
37
8 Load controller
The controller has to be configured relevant to the
installation to ensure safe and reliable load control. On the
W-FM100 the load controller is optional.
38
8
8.2 Configure sensors
Sensors used Configure sensors
Sensor selection has to be configured depending on
whether the actual value is determined by a temperature Param + Display ➩ Ch. 9.8.4
sensor (input X60) or a temperature or pressure sensor LoadController
(input X61). Configuration
Sensor selection
PT 100 PT 100 sensor on terminal X60:1/2/4, Sensor selection
temperature limit (TL) function is active. Curr: PT 100
New: PT 100
PT 1000 PT 1000 sensor on terminal X60:3/4,
temperature limit (TL) function is active.
39
8
8.3 Set point (external)
External load / set point signal Define analogue signal at input X62
If a load controller is connected to input X62 (Ext LC X62),
or if the set point signal for the internal load controller (Int Param + Display ➩ Ch. 9.8.4
LC X62) is given by this input, the type of analogue signal LoadController
must be defined. Configuration
Ext Inp X62 U/I
Ext LC X62 (load signal) : 4 to 20 mA or 2 to 10 V Ext Inp X62 U/I
Curr: 4 ... 20 mA
Int LC X62 (set point signal) : 4 to 20 mA or o to 10 V New: 0 ... 10V
Set limit values for external set point Set limit values
The set point signal for the internal load controller (Int LC
X62) can be limited in parameter Ext MinSetPoint and Ext Param + Display ➩ Ch. 9.8.4
MaxSetPoint. LoadController
The percentages given for the limit relate to the value set Configuration
under MeasureRange PtNi. Ext MinSetPoint Ext MaxSetPoint
Ext MinSetPoint Ext MaxSetPoint
Example: Curr: 0% Curr: 100%
New: 33% New 5 3%
Upper set point limit required = 80°C
Calculation
80°C
• 100 ≈ 53,3%
150°C
40
8
8.4 Set point (internal)
Internal set points (W1 / W2) Internal set points (W1 / W2)
Two internal set points can be stipulated.
Switchover is with potential free contact on the terminals Param + Display ➩ Ch. 9.8.1
X62:1/2. LoadController
The set points cannot be set above the temperature limit ControlParam
value already entered. ContParamList
Setpoint W1
Setpoint W2
Setpoint W1
Curr: 80°C
New: 70°C
41
8
8.5 Modulating load control
8.5.1 Parametering internal load control
Adaption Filter time
During adaption, the internal load controller recognises the
control section and calculates the PID parameter. Param + Display ➩ Ch. 9.8.1
Adaption can be started in manual or automatic operation LC-OptgMode
independent of the operating phase (standby or Regelparameter
operation). SW-FilterTmeCon
During adaption, the parameter SW-FilterTmeCon should SW-FilterTmeCon
be between 2 and 4 seconds. If the value selected is too Curr: 3 s
high, this can stop the adaption or lead to insufficient New: 3 s
control parameters.
• Start-up (heating)
The direction of the actual value during the heat up
phase is determined.
Adaption complete
• calculation of control parameter (Adaption ok)
Using the measured values of the stabilising phase, Adaption ok Adaption ok
the heat input and reaction times and the PID P-content (Xp) P-content (Tu)
parameter are calculated. 11.2% 53s
The values calculated can be called up using the dial continue with <> continue with <>
knob.
43
8
8.6 Multi-stage load control
Switching differentials Switching differentials
The switching differentials are formed in percentages
depending on the current set point. Param + Display ➩ Ch. 9.8.1
LC-OptgMode
SD_SStage1On: ControllerParam
At this switching differential the control circuit is closed SD_Stage1On SD_Stage1On
and the burner is switched on. SD_Stage1Off Curr: 1.0%
SD_Stage2Off New: 1.0%
SD_SStage1Off: SD_Stage3Off
As this switching differential is exceeded the control circuit
is opened and the burner is switched off.
SD_SStage2Off:
As this switching differential is exceeded the system is
switched from stage 2 to stage 1.
SD_SStage3Off:
As this switching differential is exceeded the system is
switched from stage 3 to stage 2.
ThresholdStage3On:
Switch criteria for the release of third stage.
44
8
8.7 Cold start function
Activate cold start function Activate cold start function
In order to avoid the appliance operating at its maximum
loading before the required minimum appliance Param + Display ➩ Ch. 9.8.3
temperature or pressure has been reached, the cold start LC-OptgMode
function has to be activated. LC OptgMode Cold start On
Curr: deactivated
New: activate
45
9 Parameters and functions
9.1 Menu structure (ABE)
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
OperationalStat NornalOperation
esc
Status/Reset
FaultHistory
LockoutHistory
Alarm Act/deact
Fuel CurrentFuel
esc
FuelSelect
SetClock Date
esc
TimeOfDay
Weekday
HoursRun GasFiring
esc
OilStage1/Mod
OiStage2
OilStage3
TotalHoursreset
TotalHours
SystemOnPower
StartCounter GasStartCount
esc
OilStartCount
TotalStartCountR
TotalstartCount
LockoutCounter
BurnerID
OptgModeSelect InterfacePC
esc
GatewayBASon
GatewayBASoff
Type of Gateway
O2Ctr Activate
only W-FM200
ManualOperation SetLoad
esc
Auto/Manual/Off
End user: Access without password
Engineer: Access with SERV password
46
9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
Param & Display BurnerControl Times Times Startup1 FanRunup Tme
esc esc esc esc Prepurge TmeGas
Prepurge TmeOil
TimesStartup2 Interval1Gas
esc
Interval1Oil
Interval2Gas
Interval2Oil
TimesShutdown MaxTmeLowFire
esc
Postpurge3Gas
Postpurge3Oil
TimesGeneral AlarmDelay
esc
DelayStartPrev
ProductID ASN
esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW version
CurveParams
LoadLimits MinLoadGas
esc
MaxLoadGas
LoadLimits MinLoadOil
esc
MaxLoadOil
Auto/Manual/Off
Times OperatRampMod
esc
OperatRampStage
DriveRamp
ShutdownBehav
O2CtrlThreshold
Type of fuel
OptgMode
O2 Control
O2 Guard
OilSettings OptgMode
esc esc
O2 Control
O2 Guard
O2CtrlThreshold
Type of fuel
O2 OffsetOil
LoadCtrlSuspend
Filter TimeLoad
MinActuatorStep
SW_FilterTmeCon
SetpointW1
SetpointW2
SD_ModOn
SD_ModOff
SD_Stage1On
SD_Stage1Off
SD_Stage2Off
SD_Stage3Off
ThreshStage2On
ThreshStage3On
TempLimiter TL_ThreshOff
esc
TL_SD_On
ColdStart ColdStartOn
esc
ThresholdOn
StageLoad
StageSetp_Mod
StageSetp_Stage
MaxTmeMod
MaxTmeStage
ThresholdOff
AdditionalSens
Setp AddSensor
Release Stages
Configuration LC_OptgMode
esc
Sensor Select
MeasureRangePtNi
Ext Inp X61 U/I
MRange TempSens
MRange PressSens
Ext Inp X62 U/I
Ext MinSetpoint
Ext MaxSetpoint
Adaption StartAdaption
esc
AdaptionLoad
SW version
Language
DateFormat
PhysicalUnits UnitTemperature
esc
UnitPressure
eBus Address
esc
SendCycleBU
ModBus Address
esc
Baudrate
Parity
Timeout
Local/Remote
Remote Mode
W3
Display Contrast
ProductID ASN
esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW Version
5 Auxiliary ASN
esc
Actuator 2 ProductionDate
(only on W-FM 200) SerialNumber
ParamSet Code
ParamSet Vers
5 Auxiliary ASN
esc
Actuator 3 ProductionDate
(only on W-FM 200) SerialNumber
ParamSet Code
ParamSet Vers
SW Version 1 AirActuator
esc
2 GasActuat(Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2
6 AuxActuator3
ProductID ASN
esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW Version
ProductID ASN
esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW Version
SystemConfig LC_OptgMode
esc
Inp3Config..I/U
TempLimiter TL_Thresh_Off
esc
TL_SD_On
Sensor Select
MeasureRangePtNi
O2Ctrl/LimitrGas
O2Ctrl/LimitrOil
Reset GasFiring
esc
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
StartCounter GasStartCount
esc
OilStartCount
TotalStartCountR
TotalStartCount
Reset GasStartCount
esc
OilStartCount
TotalStartCountR
PW Login Load_SW_from_PC
PW Logout
SafetyCheckFunct LossFlameTest
esc
SLT Test
NormalOperation FaultHistory
Status/Reset LockoutHistroy
If a lockout is present at display “NormalOperation”, this Memory of the last 9 faults, which caused lockout.
can only be reset using parameter “Status/Reset”. Display of:
The display alternates between displaying fault information • Date and time when lockout occurred
and clear text description of the fault. The display is exited • Fault and diagnostic codes (C/D) ☞ see Ch. 12
using ESC and the plant can be reset by pressing ENTER. • Phase, in which lockout occurred (P)
• Load position and fuel
Alarm act/deact
9.3 Operation
BoilerSetpoint
Two set points (W1/W2) can be entered for the internal Set point switchover W1/W2
load controller. The set points cannot be set using the
current guarding temperature (optional on W-FM 100).
Fuel
Fuel determination with “CurrentFuel” (read only) External fuel selection switch
Pre-selection
If an external fuel selection switch is not fitted, or if this Oil
2
switch has been set to W-FM internal the current fuel can Pre-selection
1
be changed with the ABE using “FuelSelect”. Gas
W-FM internal
012
Date/TimeOfDay
In this menu the date, time and weekday are shown and
can be adjusted if required.
54
9
HoursRun BurnerID
HoursRun is read only. Reset of the individual counters is Here, the burner specific serial number is saved at the
only possible in level Param & Display in menu HoursRun factory. Using the serial number it is possible to replace a
(see Ch. 9.14). failed unit with one that has the same factory pre-settings.
BurnerID also acts as copy protection; this means burner
specific data in the memory of the ABE cannot be
transferred to another W-FM.
StartCounter
The burner starts are read only. Reset of the individual start
counters is only possible in level Param & Display in menu OptgModeSelect
StartCounter (see Ch. 9.15).
Here, the operating mode of ABE for serial interface is set.
InterfacePC
Fuel meter The ABE acts as PC interface. The W-FM is set using a
PC and software.
see Ch. 9.16 Param & Display - fuel meter
GatewayBASon
Access by building management (BMS) to the W-FM
LockoutCounter using the ABE. The ABE remains functioning.
Total number of lockouts since commissioning (cannot be GatewayBASoff
reset). Operation without building management. Access to the
W-FM only with ABE.
CombEfficiency
Type of Gateway
Display of the current efficiency during burner operation Stipulated by the relevant bus protocol (eBus or Modbus).
(see Ch. 9.7.1).
0-100%
Load started in manual operation (burner On). if not
specified, partial load is started.
S1-S3
Highest stage which can be started in manual operation
(burner On).
Automatic
The burner is regulated by an external or the internal load
controller to set point. Regulation can be two stage, three
stage or modulating.
Manual On
The burner starts and is switched of by the external or
internal temperature guard. Prerequisite is a closed control
circuit or bridge at input X5-03 terminals 1 and 4.
Manual Off
Burner switches off. Even if the switch on hysteresis is not
reached, the burner remains off.
55
9
9.5 Burner control
Depending on the password entry the relevant parameter
for the operator or the engineer is displayed.
9.5.1 Times
Time shutdown
MaxTime_LowFire
If the burner is shut down, or if fuel change over is initiated,
the shutdown program starts at the latest after completion
of this time. If low fire is reached prior to this time elapsing,
the shutdown program starts when low fire is reached.
Post-purge time 3
Duration of post-purge.
9.5.2 Configuration
ForcedIntermit
With ForcedIntermit active, a controlled shutdown with
immediate restart is carried out after 23 h 50 mins.
Product ID SW version
The “ProductID” gives information about: The “SW Version” gives information about the software
• Type description (LMV...) version of the burner control.
• Production date
• Serial number
• Parameter set codes
• Parameter set version
56
9
9.6 Ratio control
The setting parameters in menu “RatioControl” can only be
accessed with the password for the engineer.
SpecialPositions
The special positions are fuel specific and can be entered Ignition positions
individually for oil and gas. This parameter is used to set the stepping motor positions
and speed for ignition. Ignition (phase 38) is only carried
Home positions out when all motors have reached their ignition positions.
This parameter is used to set the stepping motor positions
or speed control in Standby.
HomePosFC = 0 Frequency converter deactivated IIgnPosGas : Ignition must be carried out with excess
HomePosFC > 0 Start release frequency converter air. The gas pressure has to be set to the
Fan motor starts with relevant instructions given in the installation and
speed set (in %). operating instructions of the burner.
Gas butterfly opening during ignition:
Pre-purge positions – with ignition pilot 10 to 20°<)
This parameter is used to set the air determining stepping – without ignition pilot approx. 10°<)
motor positions or the motor speed for pre-purge.
Pre-purge only starts once all motors have reached their IgnPosOil : Position of the oil controller. The ignition
pre-purge positions. position for oil can be found on the burner
test data sheet. The indicator position
Post-purge positions given is the same as the data given for the
The parameter PostpurgePos allows separate setting of degree of angle. If an oil controller is not
the individual stepping motors. fitted (multi-stage) the ignition position of
Pre-set values have been entered at the factory. Generally, oil has no influence.
setting values are required, which ensure sufficient cooling
of the mixing head whilst still maintaining adequate heat in IgnPosAir : When the fuel is ignited a pressure
the heat exchanger. increase occurs in the combustion
The speed of the frequency converter must not be set chamber. The burner must create a
below 10%. resistance against this to avoid a back
flow of flue gases. Therefore ignition with
Program stop open air damper and matching of the
In menu, ProgramStop the start of the burner can be mixing pressure by speed only is not
stopped at 7 defined positions and adjustments to the possible. A setting of approx. 30°<) for the
burner settings can be made. air damper is recommended. The actual
air damper opening will be determined
24 PrePurgPos : Nominal load pre-purge position later by the mixing pressure measurement.
32 PreP FGR : Nominal load pre-purge for FGR
36 IgnitPos : Ignition position without ignition IgnPosAux : The position of the adjustable mixing head
44 Interv 1 : End of first safety time can be found in the installation and
52 Interv 2 : End of second safety time operating instructions of the burner. If an
72 PostPPos : Air damper in post-purge position adjustable mixing head is not fitted, the
(shutdown) fixed sleeve or the adjustable flame head
76 PostPFGR : Air damper in post-purge position must be pre-set to the operating points in
for FGR the capacity graph.
Note: In its delivered condition a provisional ignition IgnPosFC : The ignition speed depends on the fuel
position has been set, for fuel oil also the program and should not be below 70% for gas and
point P1 (these values are needed for burner 80% for oil. If the mixing pressure for
testing). ignition is outside of the limit, correction
To ensure that the burner does not start at the must be made using the air damper or
installation, a program has been set in phase 36. mixing head position (only in connection
with a frequency converter / W-FM 200).
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9
Curve parameters (modulating)
Speed %
W-FM suggests the ignition position as load point 1. 80 90
10 10
Once the new load point has been saved, a new reference P1
line is created. The reference lines are drawn between the 0 0
previous and the new load point and are further extra- 0 10 20 30 40 50 60 70 80 90 100
polated. in manual load increase, the stepping motors are Rating %
now driven on the basis of the new reference lines.
This procedure is repeated until full load has been Curve lines after saving P2
reached.
90 100
Motor positions °<)
Speed %
80 90
Optimising full load
The required nominal load in full load has to be set with the 80
70
fuel throughput.
4 70
60
Gas: Due to the control characteristic of the gas butterfly
60
this should be set to 65° to 70°. The gas throughput 50
has to be determined and adjusted using the setting 50
screw on the pressure controller. 40
40
Oil: Set required pump pressure in accordance with the 30 3
30
information given in the installation and operating
instructions or the burner test data sheet. Determine 20 2
20
oil throughput and adjust using the setting of the oil 1 P2
controller’s stepping motor. 10 10
P1
0 0
Determine combustion limit at full load and set excess air. 0 10 20 30 40 50 60 70 80 90 100
Rating %
Excess air:
• without O2 control approx. 15 to 20%
• with O2 control approx. 20 to 25% Drive to full load and optimise
For the air quantity setting this means, that the speed is set 90 100
Motor positions °<)
Speed %
20 2
20
1 P2
10 10
P1
0 0
0 10 20 30 40 50 60 70 80 90 100
Rating %
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9
Deleting points Delete intermediate load points
If a curve point is deleted, the numbering is automatically
90 100
changed to the next point. The reference line will then run
Speed %
linear with the neighbouring points. 80 90
80
70
Insert load points
4 70
If a new load point is inserted, its number is always the 60
P4
number of existing load points plus one. In setting P5 60
“Manual” the load is set with the burner in operation to the 50
value at which the load point is required (recommendation: P3 50
P4
all 10%). 40
40
Carry out combustion optimisation and once the fuel
throughput has been determined, carry out load 30
3 30
P2
apportionment. To achieve an even speed curve line, the P3
20 2
speed should not be adjusted during combustion 20
1
optimisation. P2
10 10
P1
When saving the intermediate load point, an automatic “re- 0 0
sorting” of the load points is carried out according to the 0 10 20 30 40 50 60 70 80 90 100
load. Rating %
This means: The new point 8 now becomes point 7,
point 7 becomes point 8.
Enter intermediate load points
It is possible to optimise ratio control with up to 15 points.
90 100
Motor positions °<)
Speed %
Note: If O2 control is used, point P2 forms the minimum 90
80
O2 control load.
For loads below P2, the O2 control is deactivated 80
70
and the burner runs on the normal ratio control
curve. 60
4 70
Point P1 is important for the air ratings reduction of P7
P8 60
the O2 control. This must have sufficient distance 50
to P2. 50
Recommendation: P1 minimum 30% below P2 40
P8 40
P7
30 P6
3 30
Load assignment P5
Once the curve points have been saved, they automatically 20
2
P4 20
sort themselves according to the load assigned to them. 1 P3
250 m3/h
Load [%] = ––––––––––––––––––––––––––––––– x 73,5%
340 m3/h
59
9
Curve parameter (multi-stage)
The operating mode “multi-stage” is only possible in oil On and off switch point - 2 stage operation
operation. Depending on burner version two or three stage
operation is available. A three stage burner can also BS2
operate in two stage mode with low impact start.
With start-up
By pressing the ENTER button the point called up is
started and the motors follow the current settings made
with the dial knob.
The on and off switch points are also started, however the
valve does not yet switched at the on and off switch point.
This procedure is required to optimise the air quantity to
the fuel quantity.
Operating points
BS1: Stipulates the air quantity for fuel quantity for
stage 1 (excess air approx. 20 to 25%).
Switch on point
Only once the switch on point has been exceeded will the
solenoid valve for the next stage open. This means the
solenoid valve of the next stage remains closed at the
direct start of the point. This allows the flame stability can
be checked prior to switching to the next stage.
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9
Load limits
Using the parameter min and max load, the burner can be
limited fuel specific in its load range within the
programmed curve lines.
MinLoad_Gas/Oil
Limits the load range downwards (low fire).
The min load cannot be set below point 1 and if used with
O2 control not below point 2.
MaxLoad_Gas/Oil
Limits the load range upwards (full load).
9.6.2 Times
The duration of the slowest motor across a setting section
of 90° is important for parametering the drive times.
OptgRampMod DriveRamp
Gives the run time of the motors in modulating operation. Gives the run time of the motors during the operating
phase without flame.
OptgRampStage
SM stopped HomePos
The stepping motors remain in the position at the time of At lockout the motors drive to the given home positions.
lockout.
Post purge
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9
9.7 O2 control and guarding
Here, the relevant parameters for the operator or the
engineer are displayed depending on the password
entered (only W-FM 200).
Operating mode
auto deact O2 controller
Is activated automatically, if the O2 control is switched off The O2 controller and guard are active. The same data
in operating mode “RegAuto deact”. applies as for O2 guard.
O2 controller and guard are deactivated and ratio control
drives on the curve lines programmed. At the same time a conAutodeact
warning message appears in the display. Manual activation The O2 controller and guard are active. Start-up is carried
of operating mode is not recommended. out prior to the operating temperature of the O2 sensor
being reached. Activation of the O2 control in operation is
man deact only carried out once the operating temperature has been
O2 controller and guard are deactivated. The systems reached and the sensor test has been successful.
drives on the parametered ration control curve lines. The
burner starts with cold sensor (only for commissioning, not If the O2 guard reacts, or if a fault occurs in connection
recommended for normal operation). with the O2 measurement, the O2 module, the O2 sensor
or the sensor test, the O2 controller and O2 guard are
O2 guard deactivated automatically.
Only the O2 guard is active.
If the O2 sensor has not reached operating temperature, The system drives to the O2 ratio control setting. The
start is prevented. operating mode is set to “auto deact”. The ABE displays
If the O2 guard reacts, or if a fault occurs in connection the note about the automatic deactivation. The fault code
with the O2 measurement, the O2 module or the O2 sensor, remains until the operating mode is changed.
a safety shutdown is initiated. If repetition is not possible
lockout occurs.
O2 control
Using this parameter an O2 set point standardisation has
to be carried out at each point.
The air determining stepping motors are driven down on
the programmed ration control curve lines in line with the
standard values given. The air load this reduced, but the
fuel quantity remains unchanged.
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9
O2 Guard
Using this parameter, an O2 limit value has to be set for O2 min limit
each point (CO/soot).
If during operation, the O2 min limit is not reached for 3,0
3 secs. this leads to either a safety shutdown or an
automatic deactivation of the O2 control / guarding 2,5
function, depending on the operating mode selected.
2,0
O2 content [%]
The O2 min limit can be entered directly if the combustion
limit has already be determined, or it can be determined by 1,5
reducing the air load.
1,0
Direct input:
If the O2 values on the combustion limit are already known
these can be assigned as O2 min value for the Guard 0,5
function.
0
Determination: 0 10 20 30 40 50 60 70 80 90 100
Burner rating [%]
Using P-Air manual reduce air load until the combustion
limit (CO/soot) has been reached and save the O2 actual O2 min limit for guard function
value displayed as limit value. Increased O2 min value with steep CO increase at the
combustion limit (+0.2 to 0.3 % points)
Note If the CO increases sharply at the combustion limit,
the O2 min value for the guard function can be
selected 0.2 to 0.3% points higher.
Control parameter
The O2 control is supported by the pre-control function. O2 control behaviour
If equal ambient conditions are present, the pre-control
calculates the air load reduction for the total load range. If O2 Currual value
O2 content [%]
the load signal changes, a setting size alteration (air) of the O2 set point
ratio control is carried out by the pre-control. This means,
the O2 control only has to adjust deviations in ambient
conditions (temperature, air pressure, ...).
O2 Offset Gas/Oil
Increase of O2 content before a load increase is carried
out.
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9
O2 control limit
For burner ratings below the set value, the O2 control is
deactivated and the system drives on the programmed
curve lines of the ratio control. If the burner rating
increases to 5% points above the control limit, the O2
control is reactivated.
Type of Fuel
To calculate the combustion efficiency the fuel currently The values
used must be set. V_Lnmin = Air volume under normal conditions at λ 1
V_afNmin = Flue gas volume wet under normal cond. λ 1
If the fuel is not available, its fuel values can be entered V_atrNmin = Flue gas volume dry under normal cond. λ 1
under FuelUseDef. are required for converting O2 wet to O2 dry
In parameter FuelUseDef the calculation values for the
combustion efficiency will be displayed. A2 = Adjustable constancies for ηF
B/1000 = Adjustable constancies for ηF
are constancies depending on the fuel.
LoadContLock
Limit value of the load difference from which the O2 control
is locked.
FilterTimeLoad
Lock time after which a load change in the size of the
LoadContLock can be made.
O2 Offset gas/Oil
Increase of O2 content before a load increase is carried
out.
64
9
9.8 LoadController
Here, the relevant parameters for the operator or the
engineer are displayed depending on the password
entered.
On W-FM 100 the load controller is optional.
ReglerParam Wahl
Under (StandardParam) 5 standard parameter sets and Adapt control parameters
the adaption PID values can be accessed. Each one of
these parameter sets can be copied direct into the PID Xp too small Xp too large
memory, the existing values will be overwritten.
MinActuatorStep
The smallest possible correcting element step is used for
setting value damping.
If the difference between the new calculated setting size
and the current setting size is smaller than
MinActuatorStep, the current setting size is maintained.
SW FilterTmeCon
Using the filter time actual value fault signals, which
predominantly affect the D content, can be weakened.
However, if the filter time is too long this influences the
actual value determination and has a negative effect on the
control accuracy.
SD_S
Stage On/Off
Switch difference in percent for modulating operation.
With positive SD_Stage1On the switch difference is
above the set point, with negative below.
ThresholdStage... On
If control deviations occur an integral is created over the Switch ThresholdStage... On
time.
Actual
If the integral drops below the ThresholdStage...On the value
next stage is switched. This can influence the switching
Set point
frequency of the individual stages.
SD_Stage
1 On
Stage 2
Q2 Q2
Stage 3
Q3
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9
9.8.3 Cold start
Threshold
Threshold On Off
Step load
Step Setpoint m/s
Low fire
Stipulates the cold start set point increase.
If the boiler temperature reaches the current cold start set
MaxTmeMod
point, this is increased by the given value.
MaxTimeStage:
Time after which the next stage is released. Pre-requisite is Stage 1
that Release Stages is activated.
ThresholdOff MaxTmeStage
Setpoint AddSens
If the additional sensor has been activated this set point is
the reference size for the on and off switch threshold of the
cold function.
67
9
9.8.4 Configuration load controller
LC operating mode
The load controller setting (internal/external) in
SystemConfig has priority. This means that if an external
load controller has been activated in SystemConfig,
operating mode selection is not possible.
X5-03
°C
3 Stage 2 Open
int LC
4
Activates the internal load controller. Set point (W1/W2) L
X62
4…20 mA
3
0…10 V
2
int LC Bus ext. switch contact Int LC
1
The building management system stipulates the set point
for the internal load controller. Signal switchover is carried
out by the ABE and an additional eBus interface. For this
the gateway has to be activated in menu Operation,
parameter Select operating mode (Ch. 9.3) and the Bus External set point / load input via Bus
protocol (Gateway type) has to be entered. If the Gateway
type ModBus has been selected, the ModBus must be set
to local in menu AZL(ABE) (Ch. 9.9.6).
BMS
int LC X62
The building management system stipulates an analogue
signal as set point for the internal load controller. The
setting range automatically matches itself to the
parametered measuring range of the sensor
(MeasureRange PtNI). Additionally, it is possible to limit
the set point range both up and down (Ext SetPoint ...). eBus
Interface
W-FM 200
ext LC X62
The building management system stipulates an analogue
load signal (tab. External load input). The W-FM converts
the signal and starts the relevant motors or the frequency
converter.
Load signal output - only with internal load controller -
0
signal Low fire High fire Stage 1 Stage 2 Stage 3 2
4…20 mA
1
I (mA) 4 20 5 10 15
For the operating modes with internal load controller a load
U (V) 2 10 2,5 5 7,5 signal of 4 to 20 mA is given to output X63:1/2.
X60
3
PT 1000 sensor on terminal X60:3/4
2
➔ temperature limiting function is active.
1
Ni 1000
Ni 1000 sensor on terminal X60:3/4
➔ temperature switch function is active.
PT100 PT1000
PT 100 sensor on terminal X60:1/2/4 (three core switching)
for temperature switch function.
PT1000 sensor on terminal X60:3/4 for temperature
limitng function.
PT100 Ni 1000
PT 100 sensor on terminal X60:1/2/4 (three core switching)
for temperature switch function.
Ni 1000 sensor on terminal X60:3/4 for temperature
limiting function.
none
No sensor connected to W-FM (i.e. external ratings input
without temperature guarding function).
69
9
MeasureRange TempSens / PressSens
The measuring range of the temperature or pressure sensor
can be parametered freely within the preset limits.
Example 1 (set point signal in mA): Example 2 (set point signal in Volt):
Upper set point limit required = 80° C Lower set point limit required = 50° C
Calculation Calculation:
80°C 50°C
• 100 ≈ 53,3% • 100 = 12,5%
150°C 400°C
16 mA 10 V
• 80°C + 4mAOffset ≈ 12,53 mA • 50°C = 1,25 V
150°C 400°C
70
9
9.8.5 Adaption
Start adaption
The adaption allows the load controller to automatically
identify the control section and to create the PID
parameter from the data determined. Adaption is available
for both temperature and pressure control. The adaption
can be started in manual or automatic operation; the
installation can be in operation or standby.
Adaption is not possible in multi-stage operation.
Adaption Load
With this parameter, the adaption load can be reduced by
up to 40%. This could be necessary, if the heat demand
during adaption for full load (100%) is insufficient and the
installation switches off during the adaption process.
If the adaption load is selected so low that the set
temperature is not reached this leads to interruption of the
adaption.
9.8.6 SW version
The “SW Version” supplies details about the software
version of the load controller.
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9
9.9 ABE
9.9.1 Times
9.9.2 Language
Six languages are available for selection.
If the required language is not available the language
group can be overwritten with PC software. A total of 4
language groups, each with 6 languages, are available in
the software.
9.9.5 eBus
72
9
9.9.6 Modbus
Timeout
This time stipulates, after what time the ABE automatically
switches from remote to local if Modbus communication
fails.
This means the building management system is
deactivated and the internal load controller of the W-FM
takes over control.
Product ID SW Version
The “Product ID” gives information about: The “SW Version” gives information about the software
• Type description (ABE) version of the display and operating unit (ABE).
• Production date
• Serial number
• Parameter set code
• parameter set version
73
9
9.10 Stepping motors (Actuators)
9.10.1 Addressing
If only one stepping motor is changed the addressing and Addressing stepping motor
the rotational direction will remain the same. If more than
one stepping motor is changed, a new address has to be
entered for each new motor.
Bus connection
If the stepping motor is the last unit in the bus line,
a bus connection has to be made using a jumper. The bus
connection on all other units must be deactivated (the ABE
has a fixed bus connection).
Delete address
If a wrong address has been entered, this can be deleted
by pressing the push button on the stepping motor for 10
seconds, if necessary disconnect the mains voltage whilst
holding down the button. The LED will return to continuous without bus with bus
illumination. connection connection
Flashing codes
Air stepping motor 1 impulse
Gas stepping motor (Oil) 2 impulses LED continuous illumination = no address
Oil stepping motor 3 impulses
Auxiliary motor 4 impulses
Auxiliary motor 2 5 impulses
Auxiliary motor 3 6 impulses LED continuous flashing = addressing in progress
DeleteCurves
Deletes curve lines of all stepping motors, only required to
change the rotation direction in menu level OEM.
Product ID SW Version
The “Product ID” gives information about: The “SW Version” gives information about the software
• Type description (stepping motor) version of the stepping motor.
• Production date
• Serial number
• Parameter set code
• Parameter set version
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9
9.11 FC-Modul
Depending on the password entered this displays the
parameters for the operator or the engineer (only W-
FM200).
9.11.1 Configuration
Speed
Number of impulses per rotation Set point output
Speed determination is carried out with an asymmetrical The output signal (0/4 to 20 mA) at terminal X73 of the
transmitter (3 impulses per rotation) at input X70. The W-FM and the input signal of the frequency converter must
asymmetrical transmitter construction (60°, 120°, 180°) is have been matched to one another.
used for recognising the rotation direction, motor start with To guard the signal line, the setting 4 to 20 mA should be
the wrong direction is therefore not possible. selected on the W-FM and frequency converter.
Standardisation
During standardisation a set point signal of 95% is given
at open air or auxiliary stepping motor. This means that Speed determination
there is a shortfall of 5% of the max. frequency set at the 180°
transformer (52.5 Hz x 0.95 = 50 Hz). The speed reached 60°
1 10 V DC
at the standardised 50 Hz is saved in parameter 2 core
Standardised Speed as 100% value for the speed control. 2 Pulse
3 core PNP
X70
If more than 50 Hz is shown during standardisation, the 3 GND
120°
motor slip adjustment (=0) on the frequency converter has 4 Reserve
to be checked. 5 Screen Pulse sequence: 60°, 120°, 180°
If the standardised speed is not reached during operation
at 100%, a reserve of 5% is available to the system.
Connection Frequency converter
Note Following speed standardisation or changes to the
speed saved, the combustion values should be 24 V
checked. 1 FC
2 Start FC
12…24 V DC in (Alarm)
X73
Standardised speed 3
The speed determined during standardisation is saved in 4 0/4…20 mA out (Setpoint)
this parameter and can be altered if necessary (not 5 GND
recommended). 6 Screen
Fuel meter
Fuel meters with Namur or Reed output and Open Impulse value Gas
Collector (pnp) can be used. Depending on the type of gas meter, m3 or ft3 can be
The system continually calculates the current fuel selected.
throughput for the fuel selected. Calculation time
is dynamic and is between 1 and 10 seconds. Impulse value Oil
If the meter does not supply an impulse for 10 seconds, Depending on the type of oil meter, l or gal can be
throughput “Zero” is displayed. This means that the selected.
transmitter should have a minimum impulse frequency of
0.1 Hz at minimum throughput.
At maximum throughput the maximum frequency is 300 Hz. Fuel meters
Gas 10 V DC Fuel meter
1
2 core
Example: Pulse Oil
X71
2
Data on gas meter: 250 impulses per m3 3 core PNP
3 GND
Throughput full load: 20 m3/h ^
= 5000 Imp./h ^
= 1,388Hz 4 Screen
Throughput partial load: 4 m3/h ^
= 1000 Imp./h ^
= 0,277Hz
2
3 core PNP
3 GND
4 Screen
75
9
9.11.2 Process data
The process data is located in the volatile memory and is
reset automatically following lockout.
Product ID SW Version
The “Product ID” gives information about: The “SW Version” gives information about the software
• Type description (FC module) version of the FC module.
• Production data
• Serial number
• Parameter set code
• Parameter set version
76
9
9.12 O2-Module
Depending on the password entered this displays
the parameters for the operator or the engineer (only
W-FM200).
9.12.1 Configuration
Heating Load:
Flue gas temperature Start heat load up to 100° C ______________approx. 13%
Flue gas temperature measured by the Pt/Ni sensor. Used Heat up process approx. 60%
to determine combustion efficiency. Operating temperature ______________approx. 15 to 25%
QGO Resistance
The internal resistance is a measure for the function ability
QGO SensorTemp of the sensor. It changes during the operating time.
Current operating temperature of the O2 sensor. If the internal resistance is < 5 Ω or > 150 Ω the sensor is
ageing.
Product ID SW Version
The “Product ID” gives information about: The “SW Version” gives details about the software version
• Type description (O2 module) of the O2 module.
• production date
• Serial number
• Parameter set code
• Parameter set version
77
9
9.13 SystemConfig
LC operating mode TempLimit
The configuration of the load controller operating mode is The configuration of the TL_ThresholdOff and TL_SD_Off
identical to that in menu LoadController (Ch. 9.8.4). is identical to that in menu LoadController (Ch. 9.8.2).
However, the setting in SystemConfig has priority.
This means that if an external load controller is selected in The configuration for SensSelect and for MeasureRange
menu SystemConfig you cannot change over to internal is identical to that in menu LoadController (Ch. 9.8.4).
operating mode in menu LoadController.
78
9
9.15 Start counter
Start counter Gas TotalStartCounterR
Burner starts with fuel gas since last reset. Total burner starts with fuel oil and gas since last reset.
Reset
Here all parameters, which can be reset, can be set to
“Zero”.
Displays the current throughput for gas in m3/h or oil in l/h. Fuel throughput for gas in m3 since last reset. Reset by
pressing the ENTER button.
Volume Gas
Reset date gas
Total gas throughput in m3.
This value cannot be reset. Date of last reset for fuel gas.
Volume Gas R
Fuel throughput for oil in litres since last reset. Reset by
pressing ENTER button.
79
9
9.17 Updating
9.17.1 Parameter backup
9.18 Password
PW login Deactivate PW (PW Logout)
After entering the engineer’s password additional access Using this parameter the password protected level can be
to the engineer’s level is available. The password is protected at an earlier stage.
deactivated 120 minutes after the last input.
80
Start up Operation Shutdown Valve proving
tv TSA1 TSA2
ON
Safety
Standby
Fuel valve
Home run
Pre-purge
Fan = ON
Press test
Safety fuel
Post purge
relay = ON
Direct start
valve = ON
Pre-ignition
Ignition OFF
Safety phase
Fill valve train
Test no press
Interval time 2
Lockout phase
ignition position
Ignition position
Low fire position
Flame signal ON
After burner time
Empty valve train
Stepping motor in
pre-purge position
Flame stabilisation
Operating phase 1
Operating phase 2
post purge position
tn3 5
6
V1 = Closed, V2 = Closed
V1 = Closed, V2 = Closed
Operating phase 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79 80 81 82 83
Timer-Event- Link und und or and
Timer 1 t0 t10 t21 t22 t30 t34 t38 t42 t44 t52 t62 t70 t74 t78 t80 t81 t82 t83
Timer 2 9 tv TSA
Times
Timer 3 = Phase max. time t01 tmx1 tmx1 tmx2 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx2
Fuel switch GAS X4-01: 1 C B B B B B B B B B F F F F G B
Safety circuit X3-04: 1 C B B B B B B B B B D D D D D D D D E B w D D D D
Sequence diagram gas with direct ignition
Gas + Oil
BrnFan motor aux-contact X4-01: 3 e A/c A/c 9 C A A A A A A A A A A A A A A A A A A A A A A
Inputs
or FGR- Fan-PS X4-01: 3 A/c A/c c C A A A A A A A A A A A A A A A c A A A A
CPI or VP-PS X9-03: 2 C A A A A A A A A A a a A A A A A
Low gas press.sw. LGPS X9-03: 4 3t G B B B B B B B D D D D D D D D H w D D D D
Release Gas X7-03: 1 3w G B B B B B B B D D D D D D D D H w D D D D
Gas
Lockout HGPS. X9-03: 3 3 A A A A A A A A
Gas pressure switch GPSVP X9-03: 2 A a
Burner motor / Fan X3-01: 1 9/0 9 9 9 9 N N N N N N N N N N N N N N N N N N N N N N N N N
Ignition X4-02 N N
3-way solenoid X4-03 u 49 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 N 4 4 4 4
Alarm X3-01: 2 i N 8
Gas + Oil
Safety relay internal X3-04: 1/2 N N N N N N N N N N N N N N N N N N N N N N N N N N N
Output
Safety relay Gas X9-01: 1 N N N N N N N N N N N N N N N N N N N N N
Valve pilot ignition Gas X9-01: 2
Gas
Fuel valve 1 Gas X9-01: 4 N N N N N N N N N
Fuel valve 2 Gas X9-01: 3 N N N N N N N N N
Fuel
Partial load
Ignition position
Standby position
Actuators
90° (Full load)
Pre-purge position
Post-purge position
Air
Partial load
Ignition position
Standby position
9
81
82
Start up Operation Shutdown Valve proving
tv TSA1 TSA2
9
ON
Safety
Standby
Fuel valve
Home run
Pre-purge
Fan = ON
Press test
Safety fuel
Post purge
relay = ON
Direct start
valve = ON
Pre-ignition
Ignition OFF
Safety phase
Fill valve train
Test no press
Lockout phase
ignition position
Ignition position
Low fire position
Flame signal ON
After burner time
Empty valve train
pre-purge position
Flame stabilisation
Operating phase 1
Operating phase 2
Stepping motors in
post purge position
Air stepping motor in
tn3 5
6
V1 = Closed, V2 = Closed
V1 = Closed, V2 = Closed
Operating phase 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79 80 81 82 83
Timer-Event- Link und und or and
Timer 1 t0 t10 t21 t22 t30 t34 t38 t42 t44 t52 t62 t70 t74 t78 t80 t81 t82 t83
Timer 2 9 tv TSA
Times
Timer 3 = Phase max. time t01 tmx1 tmx1 tmx2 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx2
Fuel switch GAS X4-01: 1 C B B B B B B B B B F F F F G B
Sequence diagram gas with pilot ignition
Gas + Oil
BrnFan motor aux-contact X4-01: 3 e A/c A/c 9 C A A A A A A A A A A A A A A A A A A A A A A
Inputs
Or FGR-Fan-PS X4-01: 3 A/c A/c c C A A A A A A A A A A A A A A A c A A A A
CPI or VP-PS X9-03: 2 C A A A A A A A A A a a A A A A A
Low gas press. sw. LGPS X9-03: 4 3t H B B B B B B B D D D D D D D D H w D D D D
Release Gas X7-03: 1 3w H B B B B B B B D D D D D D D D H w D D D D
Gas
Lockout HGPS. X9-03: 3 3 A A A A A A A A
Gas press. switch GPSVP X9-03: 2 A a
Burner fan motor X3-01: 1 9/0 9 9 9 9 N N N N N N N N N N N N N N N N N N N N N N N N N
Ignition X4-02 N N
3-way solenoid valve X4-03 u 49 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 N 4 4 4 4
Alarm X3-01: 2 i N 8
Gas + Oil
Safety relay internal X3-04: 1/2 N N N N N N N N N N N N N N N N N N N N N N N N N N N
Output
Safety relay Gas X9-01: 1 N N N N N N N N N N N N N N N N N N N N N
Valve pilot ignition Gas X9-01: 2 N N N N
Gas
Fuel valve 1 Gas X9-01: 4 N N N N N N N N N
Fuel valve 2 Gas X9-01: 3 N N N N N N
Fuel
Partial load
Ignition position
Standby position
Actuators
90° (Full load)
Pre-purge position
Post-purge position
Air
Partial load
Ignition position
Standby position
Start up Operation Shutdown
tv TSA1 TSA2
ON
Safety
Standby
Fuel valve
Home run
Pre-purge
Fan = ON
Safety fuel
Post purge
relay = ON
Direct start
valve = ON
Pre-ignition
Ignition OFF
Safety phase
Interval time 2
Lockout phase
ignition position
Ignition position
Low fire position
Flame signal ON
After burner time
pre-purge position
Flame stabilisation
Operating phase 1
Operating phase 2
Stepping motors in
post purge position
Air stepping motor in
Operating phase 00 01 10 12 20 21 22 24 36 38 40 30 32 34 42 44 50 52 54 60 62 70 72 74 76 78 79
Timer-Event-Link und und und und or and
Timer 1 t10 t21 t22 t30 t34 t36 t38 t42 t44 t52 t62 t70 t74 t78 tmx1
Timer 2 9 tv TSA1
Times
Timer-Event- Link t01 tmx1 tmx1 tmx2 tmx1 tmx1 tmx1 tmx3 tmx1 tmx1 tmx1 tmx1 tmx1 tmx2
Fuel switch OIL X4-01: 2 C B B B B B B B B B D D D D G B
Sequence diagram oil with direct ignition
Gas + Oil
BrnFan motor aux-contact X4-01: 3 e A/c A/c 9 C A A A A A A A A A A A A A A A A A A
Inputs
or FGR-Fan-PS X4-01: 3 A/c A/c c C A A A A A A A A A A A A A A A c
CPI or VP-PS X9-03: 2 C A A A A A A A A A A A A A A A A A A A A A A A
Low oil press. sw. LOPS X5-02: 1 3 r C A A A A A A A A
High oil press. sw. HOPS X5-02: 2 3
Oil
C A A A A A A A A A A A A A A A
Start release Oil X6-01: 1 3 H B B B B B B B D D D D D D D D H
Burner fan motor X3-01: 1 9/0 9 9 9 9 N N N N N N N N N N N N N N N N N N N N N
Ignition X4-02 2 2 2 2 2 2 N N
3-way solenoid on APS X4-03 49 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 N
Alarm X3-01.2 u N 8
Gas + Oil
Safety relay internal X3-01: 1/2 i N N N N N N N 2
N N N N N N N N N N N N N N N N
Safety relay Oil X6-03: 3 N N N N N N N N N N N N N N N N N N
Output
Fuel valve 1 Oil X8-02/-03 N N N N N N N N
Oil
Fuel valve 2 Oil X7-01 N
Fuel valve 3 Oil X7-02 N
Magnetic clutch/sep. Pump X6-02: 3 z 2 2 2 2 2 2 N N N N N N N N N
Fuel
Partial load
Ignition position
Standby position
Actuators
90° (Full load)
Pre-purge position
Post-purge position
Air
Partial load
Ignition position
Standby position
9
83
9
Legend for the sequence diagrams
Signal “ON” Signal “OFF” Reaction if relevant signal to sequence diagram is not given
6 Follow on phase 24
e With normal venting: Check for ON in phase 10, stop until completion of phase max. time, then jump to phase 01
With continuous running fan: Check for ON in phase 10 and 12, stop until completion of phase max. time, then jump to
phase 01
r If the min. oil pressure switch input has been parametered to “Act from ts” no check is carried out prior to completion of
TSA 1 time
t If the low gas pressure switch input has been parametered to “deactOgp” no check is carried out with oil with gas pilot
ignition
z If the output is parametered to “DirectCoupl”, the safety valve Oil has to be connected. The output is driven together
with the fan and stops 15 s after the fan in time delay.
u If the output is parametered to “PS relief”, this (output PS relief valve) is inverted logically
i The alarm output can be temporarily deactivated for the current fault
84
9
Assignment times:
Time Description
Actuators
In Standby:
The SA can be moved within the permitted
position range, will however, always be driven
to the standby position, and must be in
standby for phase change.
Abbreviations
FGR Flue gas recirculation
CPI Closed position indicator
PS Pressure switch
VP Valve proving
BrnFan Auxiliary contact burner fan contactor
PL or LF Low fire position
AD Air damper
APS Air pressure switch
PP Post-purge position / post-purge
S Standby
SR Safety relay
STB Safety temperature limiter
TL Temperature guard
PV Pre-purge position / pre-purge
Z Ignition position
85
10 O2 sensor
Installing the O2 sensor
• The O2 sensor must only be fitted with the relevant Sensor position
flanges and to the enclosed drawing.
Air
up to 45°
Installation instruction
do not insulate
86
10
Electrical connection
Connection to O2 module
O2 module
Mains
X10
L (Q4)
N (Q5)
PE 1
Q5
Q4
GND
U3 U3
G2 G2
M
M B2
X1
B2 M
B1
M
B1 1
L, N, PE: Supply voltage sensor heating 230V pulsed Nernst voltage at 700° C sensor temperature
(N switching)
700°C
U3 : Temperature compensation 1 µA/K relating to 120
absolute zero, i.e. 273 µA corresponds to a
sensor temperature of 0° C 100
Nernst voltage [mV]
0
0,05 0,1 0,2 0,5 1 2 5 10 20
O2 content [%]
87
11 Frequency converter
If the W-FM 200 is used in connection with a frequency Further information and details relating to the frequency
converter VLT 2800 or VLT 5000 (Danfoss),the converter can be found in the manufacturers
parametering of the frequency converter has to be documentation.
checked and if necessary adjusted.
+/- Buttons
Selection of parameters and value changes
Quick-Menu
Call up menu or return without changes
Change Data
Confirm value changes
LED display of operating conditions
Stop/Reset
Stop motor / reset lockout
Start
Starts the frequency converter
88
11
Programme and display unit VLT 5000
50.0 Hz
Menu
Call up of menus for all parameters Operation
Quick-Menu
Call up of all parameters in the quick menu
Display/Status
Selection of display/change to display mode DISPLAY MENU
OK STATUS
Confirmation of value changes
Cancel
Cancel value changes
Change Data
Changes the parameter selected CANCEL OK
+/- Buttons
Selection of parameters and value changes
Arrow buttons
Selection of parameter groups and value changes
Stop/Reset
Stop motor/reset lockout STOP FWD. START
JOG RESET JOG REV.
Activate fixed speed / deactivating (parameter 15)
FWD./REV.
Change of rotation direction (parameter 16)
Start
Starts the frequency converter
89
11
11.2 parametering the VLT 2800
In connection with the W-FM 200, certain parameters on
the frequency converter have to be checked and set if
necessary.
123 Frequency stop function 2 Hz activation motor free run if not reached
207 Ramp time Open 1 81/152/283 sec. acceleration time from 0 Hz to nominal frequency
208 Ramp time From 1 81/152/283 sec. delay time from nominal frequency to 0 Hz
211 Ramp time Jog 81/152/283 sec. acceleration/delay time fixed speed
212 Ramp time From Quick Stop 81/152/283 sec. delay time quick stop
1 up to size 50
2 on sizes 60 to 70
3 WK burners
90
11
No. Description Value Unit Meaning
314 Input 60 analogue 1 - set point signal from W-FM200 terminal X73:4
314 Input 60 min. scaling 4.0 m Alower set point signal min.
91
11
11.3 Parametriering VLT 5000
In connection with the W-FM 200 certain parameters on
the frequency converter have to be checked and set if
necessary.
013 Setp. Local Mode BLOCKED Set point input only with digital inputs from W-FM
019 Mains ON mode AUTO RESTART Automatic restart when mains switch on
100 Configuration WITH SLIP COMP. Speed control with slippage adjustment
106 Motor nom. speed Set nominal speed as per name plate
113 Load adjust. low 80% Load compensation in lower speed range
114 Load adjust. high 80% Load compensation in upper speed range
123 Freq. stop function 2Hz activates motor free run if not reached
127 DC br. start freq. 2Hz activates motor free run brake if exceeded
1 up to size 50
2 on sizes 60 to 70
3 WK burners
92
11
No. Display Data Meaning
302 Input 18 digital STARTS tart signal from W-FM 200 contact X73:1/2
314 Input 60 analogue SETPOINT Set point signal from W-FM 200
315 Input 60 scale min 4.0 m Alower set point signal min.
316 Input 60 scale max 20.0 m Aupper set point signal max.
93
12 Cause and rectification of faults (fault list)
Faults are displayed alternating as codes and clear text Display - Fault history
information. The following fault possibilities are listed in
order of fault code and diagnostic code. Operating mode
Fault history
Fault rectification: 1 18.06.99 10:35 Stepping motor
• Call up fault history - analyse last fault C:15 D:1 P:81 fault from ECR
• Determine cause, determine reason Start No: 123456
• Rectify fault Load:25.0 Gas
• If necessary, record fault
C: = Fault code
D: = Diagnostic code
P: = Phase
Fault list
01 01 ROM Fault • 1)
02 01…07 RAM Fault • 1)
03 01…44 Fault at internal data comparison • 1)
04 – Synchronisation fault • 1)
05 01,02 Fault flame signal booster test • 1)
• Replace flame sensor
06 01…04 Fault internal hardware test • 1)
10 01…1B Fault inputs / outputs The number of the diagnostic codes shows
which input is faulty.
01 Load controller on/off • Neutral conductor may be missing, (or not zero V)
02 Fan contact
03 Oil operation selection • The fault could be caused by capacitance loads,
04 Gas operation selection causing longer than 10 ms to reduce the voltage
05 Reset to 0 Volts before the relay switches off.
06 Pressure switch Oil maximum
07 Pressure switch Oil minimum
08 Pressure switch valve proving • Check control wiring
09 Safety valve Oil return signal
0A Fuel valve 1 Oil return signal • 1)
0B Fuel valve 2 Oil return signal
0C Fuel valve 3 Oil return signal
0D Safety valve Gas return signal
0E Fuel valve 1 Gas return signal
0F Fuel valve 2 Gas return signal
10 Fuel valve 3 Gas return signal
11 Safety circuit burner flange
12 Safety relay return signal
13 Pressure switch Gas minimum
14 Pressure switch Gas maximum
15 Ignition transformer return signal
16 Fan pressure switch
17 Start release Oil
18 Residual oil immediate start
19 Load controller open
1A Load controller closed
1B Start release Gas
94
12
Fault Fault Cause Recommended measures
list code
95
12
Fault Diagnostic Cause Recommended measures
code code
19 01…2F Fault at comparison pot channel A to B. The diagnostic value is made up of the faults listed
The diagnostic code shows which motor or their combination. The individual diagnostic codes
is faulty. are added hexadecimal.
01 Air stepping motor faulty at comparison • With sporadic occurrences, improve EMC
pot channel A to B measures.
02 Active fuel stepping motor faulty • With permanent occurrence, replace relevant
at comparison pot channel A to B steppingmotors (see diagnostic code).
04 Auxiliary stepping motor 1 faulty
at comparison pot channel A to B
08 Auxiliary stepping motor 2 faulty
at comparison pot channel A to B
20 Auxiliary stepping motor 3 faulty
at comparison pot channel A to B
1A 01 The curve gradient of a partial Max. gradient between two support points:
curve section is too high - 3.6° per 0.1 % (30s ramp)
- 1.8° per 0.1 % (60s ramp)
- 0.9° per 0.1 % (120s ramp)
Alter load matching of the support point until
the conditions are met.
1B – The programming mode remains active Curve parametering should be carried out in manual
in phase 62 and the set positions operation to avoid shutting down the load controller.
(normal operation) have not been However, if the TL reacts this can lead to shutdown.
reached The value (curve point) currently being changed
can however be locked in Standby or lockout
1C 01…3F The relevant ignition positions The diagnostic value is made up of the faults listed
have not been parametered. or their combination. The individual diagnostic
codes are added hexadecimal.
01 Ignition pos. air stepping motor not param. Set ignition position
02 Ignition pos. of active fuel stepping motor
not parametered
04 Ign. pos. auxiliary stepping motor 1 not param.
08 Ign. pos. auxiliary stepping motor 2 not param.
10 Ignition pos. FC not parametered
20 Ign. pos. auxiliary stepping motor 3 not param.
1D 01…3F Run time fault stepping motors / The diagnostic value is made up of the faults listed
frequency converter or their combination. The individual diagnostic
codes are added hexadecimal.
01 Run time fault air stepping motor • Check motor for mechanical overload.
02 Run time fault current fuel stepping motor • Check supply voltage and fuses.
04 Run time fault auxiliary stepping motor 1 • Drive ramp of the stepping motor must be ≤
08 Run time fault auxiliary stepping motor 2 parametered ramp.
10 Run time fault frequency converter • Ramp of the frequency converter must be smaller than the
20 Run time fault auxiliary stepping motor 3 ramp parameter in the WM-F. Recommendation 20%.
1E 01…3F The base unit has detected, that one The diagnostic value is made up of the faults listed
or more stepping motors (incl. FC) have or their combination. The individual diagnostic
not reached the special position codes are added hexadecimal.
required for the phase.
01 Special pos. air stepping motor not reached • Check motor for mechanical overload.
02 Special pos. current fuel stepping motor • Check supply voltage and fuses.
not reached
04 Spec. pos. auxiliary stepping motor 1 not reached
08 Spec. pos. auxiliary stepping motor 2 not reached
10 Spec. pos. FC (speed) not reached
20 Spec. pos. auxiliary stepping motor 3 not reached
96
12
Fault Diagnostic Cause Recommended measures
code code
97
12
Fault Diagnostic Cause Recommended measures
code code
42 01…FF Contact setting fault of internal The diagnostic value is made up of the faults listed
fuel valve relays or their combination. The individual diagnostic codes
are added hexadecimal.
01 Safety valve - Oil Check wiring of output
02 Fuel valve V1 - Oil
04 Fuel valve V2 - Oil
08 Fuel valve V3 - Oil
10 Safety valve - Gas
20 Fuel valve V1 - Gas
40 Fuel valve V2 - Gas
80 Fuel valve V3 - Gas
43 01…0D Fault during plausibility check
01 No fuel selected
02 No def. fuel train parametered
03 Variable “train” not defined
04 Variable “fuel” not defined
05 Undefined mode of operation with LC
06 Pre-purge time gas too short
07 Pre-purge time oil too short
08 Oil Safety time 1 too long
09 Gas Safety time 1 too long
0A Ignition - Off - Time > ts1 Gas
0B Ignition - Off - Time > ts1 Oil
0C Oil Safety time 2 too long
0D Gas Safety time 2 too long
44 01…0A Deactivated inputs connected
01 Controller input to X62 Activate input or connect nothing
02 Air pressure switch input X3-02
03 Brn Fan / FGR air pressure switch X4-01:3
04 Low gas pressure switch terminal X9-03:4
05 High gas pressure switch terminal X9-03:3
06 Low oil pressure switch terminal X5-01
07 High oil pressure switch terminal X5-02
08 Start signal Oil input X6-01:1/2
09 Residual Oil immediate start input X6-01:3/4
0A Start signal Gas input X7-03
45 – At STB test activated a controlled
shutdown was carried out
46 01…07 A programme stop has been activated
01 Phase 24: Pre-purge If the programme stop (see Ch. 9.6.1) is no longer
02 Phase 32: Pre-purge for FGR required, deactivate it.
03 Phase 36: Ignition positions
04 Phase 44: End first safety time
05 Phase 52: End second safety time
06 Phase 72: Post-purge position
07 Phase 76: Post-purge position FGR
47 – Start release Gas = Off
48 – 1 sensor operation parametered,
but 2 flame signals present
98
12
Fault Diagnostic Cause Recommended measures
code code
99
12
Fault Diagnostic Cause Recommended measures
code code
A0 01…1F Auxiliary stepping motor3 has signalled fault With sporadic occurrences,
A1 01…1F Air stepping motor has signalled fault improve EMC measures.
A2 01…1F Gas stepping motor has signalled fault With permanent occurrence,
A3 01…1F Oil stepping motor has signalled fault replace the relevant motor.
A4 01…1F Auxiliary stepping motor1 has signalled fault
A5 01…1F Auxiliary stepping motor2 has signalled fault
01 CRC fault at ROM test
02 CRC fault at RAM test
04 Fault in button value test
05 Time block overrun
07 Sync fault or CRC fault
08 Revolution counter
09 Fault at stack test
0C Temperature warning and shutdown Check housing temperature (max. 60° C)
0D Wrong rotation direction
0E Ramp time for stretch too small • Match ramp time to slowest motor
• Reduce spanning between special positions
10 Timeout at AD change
11 Fault at ADC test
12 Fault at AD change
13 Stepping motor is outside of the valid Check setting range (0-90°)
degree of angle (0-90°)
15 CAN fault Check CAN wiring
16 CRC fault of one parameter section
17 Section was opened too long Reset unit
18 Section is damaged If this fault occurred during parametering:
19 Invalid access to parameter check parameter last changed for plausibility.
1B Fault at copying parameter section If reset does not achieve faultless condition:
Restore parameters from ABE
Otherwise, replace defective base unit.
1E Invalid setting in drive order Check special positions are within valid range
1F Plausibility fault internal
A6 10…FF Internal LC has signalled fault Type of fault: see diagnostic code
10 No actual value increase 1)
12 Invalid XP identified
13 Invalid TN identified
14 TV larger than identification time
15 Invalid TV identified
16 Timeout during observation time
17 Cold start thermal shock protection is active
18 Timeout during adaption load
22 Temp controller Set point larger limit value
30…32 Internal fault load controller
33 Invalid CRC when reading a section Reset unit, poss. repeat Backup Restore
34…3B Internal fault load controller 1)
40 Section open too long Reset unit. If this fault occurred during parametering:
check parameter last changed for plausibility.
If reset does not achieve faultless condition:
Restore parameters from ABE.
Otherwise, replace defective base unit.
41…43 Internal fault load controller 1)
100
12
Fault Diagnostic Cause Recommended measures
code code
A7 01…8A The ABE signals faults. With sporadic occurrences, improve EMC measures.
Type of fault, see diagnostic code
With permanent occurrence, replace ABE
01 …08 Internal fault ABE
09 Fault signal Emergency-Off Function ABE
0A Internal fault ABE
0B Service message through burner starts Carry out service, reset start counter
0C Fault parameter backup
0D Fuel changeover from oil to gas Change to menu “Settings Gas”
0E Fuel change over from gas to oil Change to menu “Settings Oil”
15 …1A Internal fault ABE
1B Fault during copying parameter section Reset unit, if necessary repeat parameter backup
1C…28 Interner Fehler ABE
30 Fault during eBus communication
38 Interface mode could not be stopped
40 Parameter fault PC Tool
88…8A Internal fault ABE
A9 01…1F FC module has signalled a fault
01…09 Internal fault FC module 1)
0A Poss. fault on line to speed • Check cabling, use screened
transmitter • 1)
0C Frequency converter has initiated fault Read fault codes of frequency converter
0D FC module could not control speed • Check if current interfaces on frequency converter
difference within its control limit and FC module are set the same (0/4 to 20 mA).
• Carry out speed standardisation incl.
burner adjustment (fuel / air ratio)
0E Fault during speed calculation test 1)
15 F Interrupted CAN Bus transmission • With sporadic occurrence check CAN Bus wiring,
improve EMC measures
• Check closed resistance, correct if necessary
16 CRC fault of a parameter section Reset unit
17 Section was open too long If this fault occurred during parametering:
18 Section has been destroyed check parameter last changed for plausibility.
19 Invalid access to parameter If reset does not achieve faultless condition:
1B Fault during copying parameter section Restore parameters from ABE
Otherwise, replace defective base unit.
1E Invalid entries in drive order Check special positions for valid range
1F Plausibility fault internal 1)
AB 01…3F O2 module has signalled a fault
01…0A Internal fault O2 module 2)
10 Nernst voltage QGO sensor (B1/M) Check connection (poling, short circuit, break)
12 Voltage thermo element (B2/M)
13 Voltage compensation element (G2/U3)
15 Supply air sensor out of range • Check connection (short circuit, break)
16 Flue gas sensor out of range • Check ambient temperature (-20° C to +400° C)
17…1B Internal fault O2 module during test phase 2)
20 Temperature of O2 sensor too low Check heating start up O2 sensor (Q4/Q5)
21 Temperature of O2 sensor too high Check QGO temperature
22 Fault during calculation test 2)
23 Internal resistance of sensor is smaller • Check connection (poling, short circuit)
5 Ohm or larger 150 Ohm • Replace O2 sensor
1) With sporadic occurrences, improve EMC measures. 2) With sporadic occurrences, improve EMC measures.
With permanent occurrence, replace W-FM With permanent occurrence, replace W-FM
102
12
Fault Diagnostic Cause Recommended measures
code code
1) With sporadic occurrences, improve EMC measures. 2) With sporadic occurrences, improve EMC measures.
With permanent occurrence, replace W-FM With permanent occurrence, replace W-FM
103
12
Fault Diagnostic Cause Recommended measures
code code
104
13 Maintenance 13
13.1 Safety information for maintenance
Failure to carry out maintenance and service Endangering operational safety
work properly can have severe consequen- Maintenance work on the following parts may only be
ces, including the loss of life. Pay close carried out by the manufacturer or their appointed agent
attention to the following safety notes. on the individual components.
DANGER • Combustion manager
• Stepping motors
Detailed information and instructions for maintenance can • Flame sensor
be found in the installation and operating instructions of • Gas pressure switch
the burner. • Air pressure switch
• Oil pressure switch
Qualified personnel • Solenoid valves
Only qualified and experienced personnel must carry out
maintenance and service work.
105
14 Technical data
14.1 Combustion manager W-FM
Mains voltage AC 230V -15% / +10% Ambient conditions for all components:
Mains pre-fusing (external)max. 16 AT Dew point, freezing, water ingress not permitted
Unit fusing (internal) 6.3 AT (IEC 127 2 / 5)
CE Conformity To the guidelines of the EU
Mains supply input currentinstallation specific Electromagnetic compatibility
EMC 89 / 336 EU incl. 92 / 31 EU
Individual contact loading:
Nominal voltage AC 230V + 10% / - 15%, 50-60 Hz Interference transmission To EN 55022
- Fan motor contactor max. 1 A
- Ignition transformer 2A Interference fastness To IEC 1000-4-3
- Fuel valves Gas 2A
- Fuel valves oil 1A
- Oil pump / solenoid valve max. 2 A
- LP test valve max. 0.5 A Housing dimension
- Alarm output 1A
- Ratings factor cosϕ > 0.4
UeMaxUmains + 10%
UeMinUmains - 15%
200
The cable diameters of the mains supply (L, N, PE) and the
safety circuit (STB, low water, etc.) must be selected for
the nominal currents relative to the selected external pre-
fusing.
The cable diameters of the remaining conductors should
be dimensioned in relative to the internal unit fusing (max.
6.3 AT).
Low-voltage transformer
When the W-FM is fitted into a control panel, the burner
must also be fitted with a low-volt transformer for the
control voltage to the stepping motors.
106
14
14.2 Stepping motors SQM45.../48...
Supply voltage AC 2 x 12 V Cable connection
The connection of the screened Bus cable is via plug
Protection class Install low voltage cables with safe screw terminal Rast 3.5. The two connection sockets
separation from mains voltages (x1, X2) on the stepping motor have the same value.
Dimensions
90
,4
15 116 76 ø5
2
12
ø1
0 +0
,0 6
0 5
41
+0,1
3N9
33
2,5 0
ø10 h8
ø16
SQM 45
Groove for
25
Woodruff key
3 x 3.7 DIN 6888
122
137
87
50
Prepared for
self tapping screws
+0,1
6 0 M5, 10mm deep,
to DIN 7500
7814m01
25,5
47 2 x M16x1,5
+0,1
0
P9
5
1,9
key 5 x 28
36
SQM 48 39
2 28
ø14 h8
107
14
14.3 Flame supervision
QRI QRI flame sensor
The infrared flame sensor QRI... has the following
characteristics:
• Infrared flame sensor with IR sensitive sensor for gas
and oil flames
• Integrated flame signal amplifier
• Self checking of flame signal for continuous run
• For front or side (90°) viewing
• Fitted to burner body with flange and clamp
Ionisation electrode
Flame supervision with ionisation electrode for gas
operation is suitable for continuous run.
108
14
14.4 Display and operating unit (ABE)
Supply voltage via Bus cable AC 12 V Dimensions
Installation optional
109
A Notizen
110
A
111
Weishaupt products Max Weishaupt GmbH
D-88475 Schwendi