Combustion Manager W-FM / Installation and operating instruction. info. V esc SIEMENS LMV27.210A2WH W-FM5 VSD X64 AIR X56 VSD X74

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1 BC X56 VD X74 CO X92 FUEL X54 X53 AIR X64 VD V h mn s esc 1 nfo X75 X10-05 X10-06 X3-02 X5-03 X8-04 X8-02 X7-01 X3-04 E N L F A + X75 X10-05 X10-06 X3-02 X5-03 X8-0 X8-02 X7-01 L L N E E N L FUE 1 T6.3 IEC /V FUEL COUNTER U E ION QRB/ FLAME QRB/C- L QRA QRA L ON/OFF 3 2 L X3-0 + V2 V1 L E N L ar REET OERATION emens Buldng Technologes HVAC roducts GmbH Made n Germany CE-xxxxxxxxxxxxx DIN Rg.xxxxxxxxxxxxxx Refer to data sheet 7543 VDE Geräte-Nr.: AFETY LOO LINE VOLTAGE LMV27.210A2WH 230 VAC 50 or 60 Hz -20C to + 60C 1-4 F to +140 F Best.-Nr.: FM W-FM5 IEMEN L max max/oc E mn LT V3/V FLANGE IGNITION V MOTOR ALARM MOTO L mn E L LT E L N E L N E L N E L L L L X5-02 X5-01 X9-04 X7-02 X4-02 X6-03 X3-0 X3-03 X3-03 X3-05 X6-03 X4-02 X7-02 X9-04 X5-01 X5-02 Combuston Manager W-FM /

2 Combuston Manager W-FM 50 1 User nstructons Target group ymbols Guarantee and Lablty afety Desgnated applcaton When gas can be smelled afety measures Normal operaton Electrcal connecton Gas supply Alteratons to the constructon of the equpment Nose emsson Dsposal roduct descrpton Functon Burner Control Low gas programme Valve provng Varable speed drve Calculaton Data backup Referencng the actuator rogram sequence Operatng phase Gas drect gnton Gas wth gnton plot valve Fuel ol EL modulatng and mult-stage, heavy ol mult-stage Medum and heavy ol modulatng Inputs Voltage supply afety crcut Reset Ar pressure swtch Mnmum pressure swtch Max. pressure swtch Valve provng gas pressure swtch Heavy ol mmedate start Flame sensor Load controller analogue nput Load controller buldng management Load controller va contacts Fuel Meter Outputs Alarm Motor Ignton Frequency converter / La 2-112

3 Combuston Manager W-FM Analogue output Techncal data Electrcal data Ambent condtons Dmensons Installaton Electrcal connecton Operaton Operatng nterface Operatng panel Dsplay Dsplayng and adjustng parameters assword Manual load arameters assword level Info level ervce level Commssonng rerequste Adjustng the burner Adjustng gas sde Adjust modulaton ol sde Adjust mult-stage ol sde Check combuston Calculate gas throughput ervcng Notes on servcng ervce plan Troubleshootng rocedures for fault condtons Dsplay OFF Dsplay OFF Fault Lockout Fault hstory Rectfyng faults Techncal documentaton Frequency converter Frequency converter Nord sze I III Frequency converter Nord sze IV / La 3-112

4 Combuston Manager W-FM pares Notes Key word ndex / La 4-112

5 Combuston Manager W-FM 50 1 User nstructons Translaton of orgnal operatng nstructons 1 User nstructons Ths manual forms part of the equpment and must be kept on ste. Carefully read the manual pror to workng on the unt. 1.1 Target group The manual s ntended for the operator and qualfed personnel. They should be observed by all personnel workng wth the unt. Work on the unt must only be carred out by personnel who have the relevant tranng and nstructon. ersons wth lmted physcal, sensory or mental capabltes may only work on the unt f they are supervsed or have been traned by an authorsed person. Chldren must not play wth the unt. 1.2 ymbols DANGER WARNING CAUTION Immedate danger wth hgh rsk. Non observance can lead to serous njury or death. Danger wth medum rsk. Non observance can lead to envronmental damage, serous njury or death. Danger wth low rsk. Non observance can cause damage to the equpment and njury to personnel. Important nformaton Requres drect acton Result after an acton Itemsaton Range of values / La 5-112

6 1 User nstructons Combuston Manager W-FM Guarantee and Lablty Guarantee and lablty clams for personal and equpment damage are excluded, f they can be attrbuted to one or more of the followng causes: non approved applcaton, non-observance of the manual, operaton wth faulty safety equpment, contnual operaton despte a fault, mproper nstallaton, commssonng, operaton and servce, repars, whch have been carred out ncorrectly, the use of non orgnal Weshaupt parts, force majeure, unauthorsed modfcatons made to the unt, the nstallaton of addtonal components, whch have not been tested wth the unt, the nstallaton of combuston chamber nserts, whch mpede full flame formaton, unsutable fuels, defects n the nlet lnes / La 6-112

7 Combuston Manager W-FM 50 2 afety 2 afety 2.1 Desgnated applcaton The combuston manager W-FM 50 s sutable for use wth sngle fuel burners. Improper use could: endanger the health and safety of the user or thrd partes, cause damage to the unt or other materal assets. 2.2 When gas can be smelled Avod open flames and spark generaton, for example: do not operate lght swtches, do not operate electronc equpment, do not use moble telephones. Open doors and wndows. Close gas solatng valve. Warn the nhabtants, do not rng door bells. Leave the buldng. Inform the heatng contractor or gas suppler from outsde of the buldng. 2.3 afety measures afety relevant fault condtons must be elmnated mmedately. Components, whch show ncreased wear and tear or whose desgn lfespan s or wll be exceeded pror to the next servce should be replaced as a precauton. The desgn lfespan of the components s lsted n the servce plan [ch. 7.2] Normal operaton All labels on the unt must be kept n a legble condton. tpulated settngs, servce and nspecton work should be carred out at regular ntervals. Only operate the unt wth ts cover closed. Do not touch movng parts durng operaton. Do not touch the ol carryng parts of medum and heavy ol burners durng operaton Electrcal connecton For work carred out on lve components: Observe the accdent preventon nstructons DGUV Regulaton 3 and adhere to local drectves, tools n accordance wth EN should be used / La 7-112

8 2 afety Combuston Manager W-FM Gas supply Only the gas supply company or an approved agent may carry out nstallaton, alteraton and mantenance work on gas applances n buldngs and propertes. pework must be subject to a combned load and valve provng test and/or usablty testng relatve to the pressure range ntended, e. g. DVGW-TRGI, worksheet G 600. Inform the gas supply company about the type and sze of plant pror to nstallaton. Local regulatons and gudelnes must be observed durng nstallaton, e. g. DVGW-TRGI, worksheet G 600; TRF Band 1 and Band 2. The gas supply ppework should be sutable for the type and qualty of gas and should be desgned n such a way that t s not possble for lquds to form, e. g. condensate. Observe vaporsaton pressure and vaporsaton temperature of lqud petroleum gas. Use only tested and approved sealng materals, whlst observng all process nformaton. Re-commsson the applance when changng to a dfferent type of gas. Carry out soundness test after each servce and fault rectfcaton. 2.4 Alteratons to the constructon of the equpment All conversons requre wrtten approval from Max Weshaupt GmbH. No addtonal components may be ftted, whch have not been tested for use wth the equpment. Do not use combuston chamber nserts, whch hnder flame burnout. Use only orgnal Weshaupt replacement parts. 2.5 Nose emsson The nose emssons are determned by the acoustc behavour of all components ftted to the combuston system. rolonged exposure to hgh nose levels can lead to loss of hearng. rovde operatng personnel wth protectve equpment. Nose emssons can further be reduced wth a sound attenuator. 2.6 Dsposal Dspose of all materals and components n a safe and envronmentally frendly way at an authorsed locaton. Observe local regulatons / La 8-112

9 Combuston Manager W-FM 50 3 roduct descrpton 3 roduct descrpton 3.1 Functon Burner Control A burner control for ol and gas burners s ntegrated n the combuston manager. It controls the sequence of operaton, montors the flame and communcates wth all components Low gas programme The low gas pressure swtch montors the gas connecton pressure from operatng phase h22. If the gas pressure set at the low gas pressure swtch s not acheved, the combuston manager ntates a safety shutdown and starts the low gas programme. In the low gas programme the combuston manager carres out a safety shutdown and ntates a restart after the low gas watng tme (10 seconds). Ths low gas watng tme doubles after every unsuccessful start attempt. If the start attempts exceed the repetton lmt value (parameter 223) the combuston manager goes to lockout. The repetton counter and the low gas watng tme are automatcally reset when the burner starts / La 9-112

10 3 roduct descrpton Combuston Manager W-FM Valve provng The valve provng gas pressure swtch checks f the valves are tght. It sgnals the combuston manager f the pressure ncreases or decreases to an mpermssble level durng valve provng. Valve provng s carred out automatcally by the combuston manager: after every controlled shutdown, pror to burner start followng lockout or power outage. 1. Test phase (functon sequence for valve provng valve 1): Valve 1 remans closed, valve 2 opens, the gas escapes and the pressure between valve 1 and valve 2 reduces, valve 2 closes agan, both valves reman closed for 10 seconds. If the pressure ncreases to above the value set durng these 10 seconds, valve 1 s leakng. The combuston manager ntates a controlled shutdown. 2. Test phase (functon sequence for valve provng valve 2): Valve 1 opens, valve 2 remans closed, pressure between valve 1 and valve 2 ncreases, valve 1 closes agan, both valves reman closed for 10 seconds. If the pressure decreases to below the value set durng these 10 seconds, valve 2 s leakng. The combuston manager ntates a controlled shutdown. 3 s 10 s 3 s 10 s V1 V2 4 1 Valve 1 2 Valve 2 3 ressure between valve 1 and valve 2 4 Valve provng gas pressure swtch 5 Operatng phases Varable speed drve Va an analogue output, the W-FM controls the frequency converter of the fan motor and matches the speed to the burner capacty. Ths reduces electrcal consumpton. The speed and the rotaton drecton are montored by an nductve proxmty swtch and an asymmetrcal transmtter dsc / La

11 Combuston Manager W-FM 50 3 roduct descrpton Calculaton 1 2 A calculaton can be trggered n modulatng commssonng, f 1 and 9 are programmed. Durng a calculaton, a straght lne s generated from the operatng pont dsplayed to 1 or 9. The values on the straght are adopted as the new operatng ponts. Intate a calculaton after 9: ress and hold [+] key for 3 5 seconds. Intate a calculaton after 1: ress and hold [ ] key for 3 5 seconds. If durng commssonng only 1 and 9 are programmed, the combuston manager ntates an automatc calculaton when extng 1 and calculates 2 to Automatc calculaton 2 Calculaton from 5 to Data backup In the ABE, the settngs of the combuston manager can be saved va parameter 050 (Backup). If the unt needs to be replaced, or f the parameters have unntentonally been altered, the data can be transferred back to the combuston manager. Data transfer (Restore) from ABE to the combuston manager s only possble f the burner data s dentcal [ch. 5.3]. WARNING oot and CO formaton because no combuston analyss has been carred out. At heat demand, the burner starts automatcally approx. 30 seconds after the data transfer (Restore). Drectly followng the data transfer (Restore): Check sequence of operaton. Carry out a combuston analyss at all load pont. Only n conjuncton wth frequency converter Followng data transfer (Restore) a speed standardsaton wth subsequent adjustment must be carred out / La

12 3 roduct descrpton Combuston Manager W-FM Referencng the actuator In operatng phase h10 (Home Run) the combuston manager references the actuators, whereby the actuator drves over a reference marker. The actuator then drves back and determnes the nner edge of the reference marker. All settngs are referenced to ths poston. The combuston manager references the fuel actuators to the reference marker OEN and the ar actuator to the reference marker CLOED. The settng range of the ar damper shaft s lmted mechancally, therefore the ar actuator cannot drve to reference marker OEN. If the actuators have been mxed up, a reference fault s dentfed (fault code 85) Reference range CLOED 2 Reference marker CLOED (ar actuator) 3 Reference range OEN 4 Reference marker OEN (fuel actuator) / La

13 Combuston Manager W-FM 50 3 roduct descrpton rogram sequence Operatng phase h00 Lockout phase h02 afety phase h10 Home run h12 tandby h22 Fan / safety valve ON h24 re-purge poston h30 re-purge h36 Ignton poston h38 re-gnton h39 Test low gas pressure swtch (fuel valve 1 opens, only wth Gas) h40 Fuel release h42 Ignton OFF h44 Flame gnal h50 Flame stablsaton (only wth Gas wth plot gnton) h52 Ignton plot valve OFF (only wth Gas wth plot gnton) h60 Operatng settng 1 h62 Operatng settng 2 h70 ost burn tme h72 ost-purge poston h74 ost-purge h78 ost-purge h80 Ventng valve tran (only durng valve provng) h81 Test wthout pressure (only durng valve provng) h82 Fll valve tran (only durng valve provng) h83 Test wth operatng pressure (only durng valve provng) h90 Low gas watng tme / La

14 3 roduct descrpton Combuston Manager W-FM Gas drect gnton q w e X3-03:1, X3-04:1 X5-03:1 X10-05:2 X3-02:1 X5-01:2 X5-02:2 X9-04:2 X3-05:1 X4-02:3 X6-03:3 X8-02:1 X7-01:3 gnal at nput / output actuated No sgnal on nput Input wthout nfluence 1 Operatng phases 2 afety crcut 3 Heat demand controller 4 Flame gnal 5 Ar pressure swtch 6 Mnmum pressure swtch 7 Max. pressure swtch 8 Valve provng pressure swtch 9 Fan motor 0 Ignton unt q afety valve w Fuel valve 1 e Fuel valve / La

15 Combuston Manager W-FM 50 3 roduct descrpton Gas wth gnton plot valve q w e r X3-03:1, X3-04:1 X5-03:1 X10-05:2 X3-02:1 X5-01:2 X5-02:2 X9-04:2 X3-05:1 X4-02:3 X6-03:3 X8-02:1 X7-01:3 X7-02:3 gnal at nput / output actuated No sgnal on nput Input wthout nfluence 1 Operatng phases 2 afety crcut 3 Heat demand controller 4 Flame gnal 5 Ar pressure swtch 6 Mnmum pressure swtch 7 Max. pressure swtch 8 Valve provng pressure swtch 9 Fan motor 0 Ignton unt q afety valve w Fuel valve 1 e Fuel valve 2 r Ignton plot valve / La

16 Combuston Manager W-FM 50 3 roduct descrpton Fuel ol EL modulatng and mult-stage, heavy ol multstage X3-03:1, X3-04:1 X5-03:1 X10-05 X3-02:1 X5-01:2 X5-02: q w e X3-05:1 X4-02:3 X6-03:3 X8-02:1 X7-01:3 X7-02:3 (1 (2 (1 Only wth heavy ol and long pre-gnton phase (parameter 281). (2 Only wth operatng mode 12 (ol modulatng). gnal on nput / output actvated No sgnal on nput Input wthout nfluence 1 Operatng phases 2 afety crcut 3 Heat demand controller 4 Flame gnal 5 Ar pressure swtch 6 Mnmum pressure swtch 7 Max. pressure swtch 8 Fan motor 9 Ignton unt 0 afety valve q Fuel valve 1 w Fuel valve 2 e Fuel valve / La

17 Combuston Manager W-FM 50 3 roduct descrpton Medum and heavy ol modulatng X3-04:1 X5-03:1 X10-05 X3-02:1 X5-01:2 X5-02:2 X9-04:2 (1 9 0 q w e r X3-05:1 X4-02:2 X6-03:2 X8-02:1 X7-01:2 X7-02:2 (1 Only for evaluaton n operatng phase H38 H62 (parameter 286). gnal on nput / output actvated No sgnal on nput Input wthout nfluence 1 Operatng phases 2 afety crcut 3 Heat demand controller 4 Flame gnal 5 Ar pressure swtch 6 Mnmum pressure swtch 7 Max. pressure swtch 8 Heavy ol mmedate start 9 Fan motor 0 Ignton unt q afety valve w Fuel valve 1 e Fuel valve 2 r Fuel valve / La

18 3 roduct descrpton Combuston Manager W-FM Inputs L E N L X E N L Voltage supply The voltage supply s connected to nputs X3-04:3-5. The mans frequency s set n parameter 125. L E N L L X3-04 X afety crcut In the dagnostc code, the nputs X3-03:1/2 and X3-04:1/2 are combned as safety crcut. If one of the nputs s open the W-FM carres out at least one safety shutdown. If the repetton value s exceeded an open nput leads to lockout. The repetton value can be set n parameter 215. At nput X3-04:1/2 all external components of the safety crcut are swtched n sequence, these nclude: Emergency-Off swtch afety tme lmter (TL) Low water safety nterlock, etc. The burner flange lmt swtch s connected to nput X3-03:1/2. REET OERATION L E N L MOTOR ALARM MOTOR CONT X8-04 X3-04 X E N L Reset (1 (2 A reset button can be connected to nput X8-04:1. ressng ths button n lockout for 1 6 seconds wll reset the combuston manager. ressng the button for a longer or shorter perod wll be gnored by the combuston manager and therefore has no effect. Wth lockout functon (1 If the push button s also requred for manual lockout, t must be connected to mans nput X3-04:5 (L). If the combuston manager s n an operatng phase, pressng the push button for 1 to 6 seconds wll ntate a manual lockout. Wthout lockout functon (2 If the push button s not requred to carry out manual lockout t must be connected to alarm output X3-05: Ar pressure swtch L X The closng contact of the ar pressure swtch s connected nput X3-02. If the sgnal s mssng once the fan has started, the combuston manager ntates a lockout. The ar pressure swtch must have been deactvated, contact open, pror to the fan startng / La

19 Combuston Manager W-FM 50 3 roduct descrpton E mn L X Mnmum pressure swtch The closng contact of the mn. pressure swtch s connected to nput X5-01. For burners wthout mn. ol pressure swtch, a brdge has to be connected to termnal 2 and termnal 3. Low gas pressure swtch In gas operaton, the combuston manager expects a sgnal at nput X5-01:2 from operatng phase h22. If the pressure drops below the value set, the pressure swtch contact opens and the combuston manager starts the low gas programme [ch ]. Mnmum ol pressure swtch In ol operaton, the combuston manager expects a sgnal at nput X5-01:2 from operatng phase h38 or operatng phase h40 (dependng on parameter 276). If the pressure drops below the value set, the pressure swtch contact opens and the combuston manager ntates a lockout. Lockout occurs n operatng phase h38 (pre-gnton) after a delay of 30 seconds. In all subsequent phases, lockout occurs mmedately. E mn L X Max. pressure swtch The openng contact of the max. pressure swtch s connected to nput X5-02. For burners wthout max. ol pressure swtch, a brdge has to be connected to termnal 2 and termnal 3. Hgh gas pressure swtch The combuston manager expects a sgnal at nput X5-02:2 from operatng phase h40. If the value set at the pressure swtch s exceeded, the pressure swtch contact opens and the combuston manager ntates a lockout. Maxmum ol pressure swtch The combuston manager expects a sgnal at nput X5-02:2 from operatng phase h22. If the value set at the pressure swtch s exceeded, the pressure swtch contact opens and the combuston manager ntates a lockout. Lockout occurs n operatng phase h22 (fan ON) after a delay of 30 seconds. In all subsequent phases, lockout occurs mmedately / La

20 3 roduct descrpton Combuston Manager W-FM 50 E mn L X Valve provng gas pressure swtch The openng contact of the valve provng gas pressure swtch s connected to nput X9-04. Input X9-04 s only actvated durng valve provng [ch ]. The tme of valve provng can be set n parameter 241. If the pressure set s not acheved n operatng phase h81 (test wthout pressure), the contact closes. If the pressure set s exceeded n operatng phase h83 (test wth operatng pressure), the contact opens. E mn L X Heavy ol mmedate start The nput s only actvates for the return flow temperature sensor on heavy ol burners. The release contact of the return flow temperature sensor s connected to nput X9-04. In modulatng heavy ol operaton, the combuston manager carres out a nozzle crculaton for maxmum 45 seconds. If the sgnal s present at X9-04 before ths tme has elapsed, the nozzle crculaton s shortened accordngly. If the sgnal s mssng after ths tme has elapsed, the combuston manager ntates a home run wth subsequent repetton. Durng operaton, the sgnal s montored accordng to the settng of parameter / La

21 Combuston Manager W-FM 50 3 roduct descrpton Flame sensor If the flame sgnal n operatng phase h44 does not correspond to the value requred, the combuston manager ntates safety shutdown wth restart. If the flame sgnal durng operaton does not mantan the requred value, the combuston manager ntates a controlled shutdown wth restart. Two controlled shutdowns n sequence lead to lockout. A flame sgnal at heat demand (operatng phase h12) leads to start preventon. A flame sgnal durng pre-purge (operatng phase h30 h36) or post-purge (operatng phase h78) leads to lockout after one repetton and repeated occurrence. arameter 954 shows the current flame sgnal as a percentage value. QRA QRA QRA X BR + The flame sensor QRA (UV cell) s connected to nput X BU Flame sgnal arameter 954 Response lmt extraneous lght greater than 18 Operaton mn 24 Ionsaton electrode E ION QRB/C QRB/C-N X L 5 The onsaton electrode s connected to nput X10-05:2. Flame sgnal arameter 954 ensor current mn.: 4 μa approx. 30 ensor current max.: μa 100 QRB E ION QRB/C QRB/C-N X L 5 The flame sensor QRB (photo resstor) s connected to nput X10-05:3/4. Response lmt extraneous lght (resstance less than 400 kω) Flame sgnal arameter 954 approx. 10 Operaton (resstance less than 230 kω) approx. 16 hort crcut dentfcaton (resstance less than 0.5 kω) / La

22 Combuston Manager W-FM 50 3 roduct descrpton Load controller analogue nput ON/OFF L GND X5-03 X C The contact for heat demand s connected to nput X5-03:1 (burner ON/OFF). The analogue load sgnal s connected to termnals X64:1 (4 20 ma) and X64:2 (GND). A sgnal of less than 3 ma deactvates the analogue nput and the load pre-settng at nput X5-03:2/3 has prorty (parameter 942). If no load controller s connected to nput X5-03:2/3, the combuston manager remans at the current ratng untl heat demand s nterrupted. Modulatng operaton wth load controller In modulatng operaton, parameter 123 determnes the mnmum correctng element step. gnal on X64:1/2 Load W-FM 3 4 ma ma 100 Mult-stage operaton (fuel ol only) In mult-stage operaton a hysteress of 1 ma exsts between the operatng ponts, whch elmnates unnecessary load changes. Two stage: gnal on X64:1/2 Load W-FM ma tage ma tage 2 Three stage: gnal on X64:1/2 Load W-FM ma tage ma tage ma tage 3 ON/OFF L COM X5-03 X Interface Load controller buldng management A BU nterface for buldng management can be connected to nput COM X92: Modbus: Bus-Interface Modbus OCI (Order No.: ), ebu: Adapter MA ebu (Order No.: ). To ensure that load pre-settng s carred out by the buldng management system, nput X5-03:1 (burner ON/OFF) must be connected to voltage output X5-03:4 for burner start. The settngs requred for Bus communcaton are set n parameters 141 to / La

23 Combuston Manager W-FM 50 3 roduct descrpton ON/OFF L X C Load controller va contacts The contact for heat demand s connected to nput X5-03:1 (burner ON/OFF). The load control dstngushes between mult-stage and modulatng operaton. The operatng mode s set n parameter 201. Modulatng operaton wth load controller If nput X5-03:2 (CLOED) s actvated, the burner capacty reduces. If nput X5-03:3 (OEN) s actvated, the burner capacty ncreases. If none of the two nputs s actvated, the burner capacty remans unchanged. Operatng mode sldng two stage wth thermostat ON/OFF L ON/OFF L X5-03 X If thermostats or pressure regulators are connected to nputs X5-03, the modulatng fuel can only be operated n sldng two stage operaton. At heat demand nput X5-03:2 (CLOED) s actvated and the burner drves to partal load. If the temperature drops below the value set, nput X5-03:3 (OEN) s actvated and the burner drves to full load. If a sgnal s appled to nput X5-03:3, nput X5-03:2 s gnored. ON/OFF L X C Mult-stage operaton (fuel ol only) Two and three stage: Input Operatng mode two stage three stage X5-03:1 tage 1 tage 1 X5-03:2 tage 1 tage 2 X5-03:3 tage 2 tage 3 ON/OFF L ON/OFF L X5-03 X If nput X5-03:3 s actvated durng three stage operaton, the burner drves to stage 3, the sgnal from stage 2 s no longer relevant. Low mpact start: At heat demand and wth the brdge between termnal 1 and 2 the burner gntes n stage 1 and then automatcally drves to stage 2. If nput X5-03:3 s also actvated the burner drves to stage 3. Change-over release: A brdge connects termnals 2 and 3. At heat demand the burner drves to stage 1. If nputs X5-03:2/3 are then actvated smultaneously the burner drves va stage 2 to stage 3. X Fuel Meter It s possble to connect a fuel meter wth Reed contact to nput X75. A prerequste for ths s that no frequency nverter s connected and actvated. The meter pulses per unt volume must be set n parameter 128. The mpulse frequency must not exceed 300 Hz / La

24 Combuston Manager W-FM 50 3 roduct descrpton 3.3 Outputs Alarm MOTOR ALARM MOTOR CONT X A mans voltage sgnal s gven at alarm output X3-05:2 n lockout (operatng phase h00). In addton, start preventon can also be sgnaled. To do ths, parameter 210 should be set to Motor MOTOR ALARM MOTOR CONT X L M N Normal operaton The fan motor s connected to output X3-05:1 va contactor or star delta swtchng. Contnuous operaton MOTOR ALARM MOTOR CONT X M The fan motor s connected to output X3-05:3 va contactor or star delta swtchng. If an ar pressure swtch s ftted, contnuous runnng fan s only possble va pressure swtch relef. To do ths, a vent valve has to be ftted to the ar pressure swtch and connected to output X3-05:1. L N Ignton E N L X The gnton unt s connected to output X4-02. Ignton behavour Gas re-gnton n operatng phase h38 can be adjusted n parameter 226. Ignton behavour Ol In parameter 281,the swtch-on pont of gnton (operatng phase h22 or h38) s determned. re-gnton n operatng phase h38 can be adjusted n parameter Frequency converter 24 V 1 The frequency converter and the speed sensor are connected at output X Frequency converter 4 10 V 5 Termnal Functon V X74 X74:1 24 V nput; supply from frequency converter X74:2 gnal acquston X74:3 peed setpont sgnal (parameter 645) peed measurement Termnal Functon X74:4 peed return sgnal (nput actual speed) X74:5 10 V; suppled by combuston manager / La

25 Combuston Manager W-FM 50 3 roduct descrpton Analogue output 24 V Instead of the frequency converter, a load dependent analogue sgnal can be emtted at output X74:3. rerequste s an external 24 V DC voltage source at nput X74:1/2. 4 The values gven relate to an analogue sgnal of 0 10 V, f a sgnal of 2 10 V 10 V 5 or 0/2 10 V s set n parameter 645 the voltages lsted wll change. Converson: (orgnal value x 0.8) + 2 =new value V X74 Modulatng operaton Ratng Curve pont Analogue sgnal Off 0 V Ignton load 0 1 V artal load (20 ) 1 2 V Full load (100 ) 9 10 V Two stage operaton Ratng Curve pont Analogue sgnal Off 0 V tage V tage V Three stage operaton Ratng Curve pont Analogue sgnal Off 0 V tage V tage V tage V / La

26 Combuston Manager W-FM 50 3 roduct descrpton 3.4 Techncal data Electrcal data Combuston Manager Mans voltage / Mans frequency 230 V / Hz Consumpton max 30 W Internal unt fuse T6.3H, IEC 127-2/5 External fuse max 16 AB Type of protecton I 00 Dsplay and operatng unt (ABE) Mans voltage DC 5 V Consumpton max 50 mw Type of protecton (front) Type of protecton (rear) I54 to IEC 529 I00 to IEC 529 rotecton class II to DIN EN Actuator TE Nm Mans voltage DC/AC 24 V / HZ TE 50 3 Nm DC/AC 24 V / HZ Consumpton max 7.5 W max 10 W Torque 1.2 Nm 3 Nm ettng tme 5 s / 90 4 s / 90 Type of protecton I 54 I 54 rotecton class II II Ambent condtons Temperature n operaton C Temperature durng transport / storage C relatve humdty max 95, no dew pont / La

27 Combuston Manager W-FM 50 3 roduct descrpton Dmensons Combuston manager 230 mm 60 mm 217 mm 135 mm 122 mm Dsplay and operatng unt (ABE) Recess dmenson: 127 x 91 mm ± 0.5 mm 17 mm 96 mm 18 mm 90,6 mm 132 mm 126,4 mm F VD V h mn s esc A - + nfo / La

28 4 Installaton Combuston Manager W-FM 50 4 Installaton 4.1 Electrcal connecton DANGER WARNING Rsk of electrc shock Workng on the devce when voltage s appled can lead to electrc shock. Isolate the devce from the power supply pror to startng any work. afeguard aganst accdental restart. Electrc shock despte dsconnecton from the voltage supply It s possble that electrcal components on burners wth frequency converters contnue to carry voltage and cause electrc shock even after the voltage supply has been dsconnected. Wat approx. 5 mnutes before commencng work. Electrc voltage has dsspated. The electrcal connecton must only be carred out by qualfed electrcans. Observe local regulatons. Connect combuston manager Use cable entry grommets on the housng. Connect wrng to wrng dagram enclosed. Control crcuts, whch are taken drectly va a 16 AB fuse from a 3 phase or sngle phase alternatng current supply, must only be connected between a phase conductor and earth potental neutral conductor. On mans supply, whch does not have a neutral, the control voltage must be suppled va an solatng transformer. The pole of the transformer, whch s to be used as the neutral conductor, must be earthed. hase L must not be mxed up wth the neutral conductor N. Contact protecton wll otherwse no longer be gven. Malfunctons, whch endanger operatonal safety could occur. The cable cross secton of the voltage supply must be sutable for the nomnal current of the external fuse (maxmum 16 AB). All other cable connectons must be sutable for the relevant nternal unt fuse (T6.3H). Earthng and neutral conductor must conform to local regulatons. The followng apples for cable length: Dsplay and operatng unt, load controller, safety nterlock crcut, burner flange, reset key - maxmum 20 m (100 pf/m). BCI nterface maxmum 20 m (100 pf/m). Connectng the burner motor The motor must be protected aganst thermal overload and short crcut. Weshaupt recommend the use of a motor protecton swtch. Open termnal box on motor. Connect voltage supply to wrng dagram enclosed, observe motor rotaton / La

29 Combuston Manager W-FM 50 4 Installaton Varable speed drve (optonal) If the frequency converter s located on the motor, the cable to the frequency converter s not screened. If the frequency converter s separate the control lne and the motor connecton must be screened. Apply screen to the screen clamp on frequency converter. Use screen cable glands (metal) on the burner. Connect gas valve tran Observe wrng dagram suppled. Connect double gas valve (plug K32). olenod col on W-MF or DMV Actuator on VGD. Connect lmt swtch for valve lft montorng (plug 33 / 35), only wth VGD. Connect gnton gas valve (plug K31). Connect low gas pressure swtch (plug B31). Connect valve provng gas pressure swtch (plug B32). If requred, connect hgh gas pressure swtch (plug B33) / La

30 5 Operaton Combuston Manager W-FM 50 5 Operaton 5.1 Operatng nterface Operatng panel Dsplay and operatng unt (ABE) 1 VD V h mn s esc nfo 5 F A [Enter] back-up of value changes; entry to parameter and values [nfo] call up nformaton press for approx. 3 seconds: Info level press for approx. 5 seconds: ervce level 2 [+] navgaton through parameter structure; 3 [ ] changng values 2 and 3 [+] and [ ] press smultaneously: return/cancel 4 [A] Ar selects the damper poston 5 [F] Fuel selects the fuel supply 4 and 5 [F] and [A] press smultaneously: selects the frequency converter (optonal) OFF functon ress [ENTER] and any other key smultaneously. Immedate lockout / La

31 Combuston Manager W-FM 50 5 Operaton Dsplay The black cursor n the dsplay shows the status of the nputs and outputs, the unt of values and the actve level u z t V h mn s r e w q Heat demand by the boler control (start) 2 Burner motor 3 Ignton 4 Fuel valves 5 Flame sgnal on 6 Flame falure or lockout 7 Degree of angle settng 8 ercentage value 9 econd 0 Mnute q Hour (together wth volume = V/h) w Volume (m 3, l, ft 3, gal) e Actuator OEN r Actuator CLOED t ervce level z Info level u arameter level (engneer level) / La

32 Combuston Manager W-FM 50 5 Operaton Dsplay OFF The parameter settng s mssng, ncomplete or has been deleted. No heat demand from controller (nput X5-03:1). afety crcut not closed at heat demand (nput X3-03:1/2 and X3-04:1/2). Dsplay h The combuston manager s n an operatng phase and wats for sgnals or actvates outputs dependng on the program sequence. The combuston manager s n an operatng phase and shows the remanng run tme programmed (example: pre-purge). Dsplay Op The combuston manager s n modulatng operaton and shows the current load n percent. The combuston manager s n mult-stage operaton and shows the current fuel stage. When the fuel stage s changed, the addtonal dsplay on or of ndcates the swtchng of the relevant fuel valve. Dsplay flashes Manual load s actvated. The combuston manager s n manual load default. Deactvate manual load: ress and hold [esc] key for 5 seconds. Fault dsplay Durng a fault condton, the dsplay alternately shows the error code C and dagnostc code D [ch. 8.3]. The combuston manager s n lockout. Once the fault has been rectfed, the combuston manager has to be reset [ch ]. The combuston manager ntates a safety shutdown. The burner restarts automatcally once the fault condton has been rectfed. The combuston manager shows an occurrence, whch does not lead to a shutdown / La

33 Combuston Manager W-FM 50 5 Operaton assword level (engneer level) call up level 5.2 Dsplayng and adjustng parameters ress [F] and [A] keys smultaneously and then enter the password [ch ]. Info-/ervce level The Info or ervce level can only be called up from the standard dsplay. ress [Enter]. For Info level 1 3 s For ervce level 3 5 s Next parameter revous parameter ress [+] key. ress [ ] key. ress [+] key. or Brefly press [Enter]. ress [ ] key. One level lower ress [Enter]. ress [Enter] 1 3 s. One level hgher ress [esc]. ress [Enter] 3 5 s. or Brefly press [esc] key. Change value ress [+] or [ ] key. not possble ave value ress [Enter]. not possble / La

34 5 Operaton Combuston Manager W-FM assword Enter password ress [F] and [A] smultaneously for approx. 2 seconds. The dsplay shows CodE. Enter the frst dgt usng [+] or [ ] and confrm wth [ENTER]. Repeat procedure untl the password has been entered. Ext password entry usng [ENTER]. The dsplay shows ArA (parameter level) for a short tme and then changes over to 400: Et (setup). V h mn s V h mn s V h mn s V h mn s Deactvatng password If no key s actvated for 30 mnutes, the combuston manager automatcally deactvates the password and blocks the level. In the password level, the password can be aborted early: ress [esc] key untl the dsplay shows CLr CodE. Let go of the [esc] key. The combuston manager blocks the password level and changes to the operatng dsplay. V h mn s 3 s V h mn s V h mn s / La

35 Combuston Manager W-FM 50 5 Operaton Load default Manual load If a sgnal s appled to nput X5-03:1 (burner ON), each load settng wthn the load lmt can be selected manually. If manual load s actvated, the current load flashng n the operatng dsplay. Manual load can be actvated usng a key combnaton or parameter 121. If manual load s set va parameter 121 addtonal functons are avalable. Functon arameter 121 Key combnaton ---- Manual load deactvated not possble Manual OFF, remans actve even after fuel changeover Intate gnton poston (mult stage operaton only) Intate load settng wthn the load lmts. Values outsde of the load lmts can be adjusted, but not ntated. If the load lmts are extended durng actve manual load, the burner reacts accordngly. not possble not possble Intate load settng wthn the load lmts. Only values wthn the load lmts can be adjusted. For the duraton of commssonng (400 et), manual load s gnored. Wth the excepton of Manual OFF, manual load s deactvated durng fuel changeover. Manual load va key combnaton Actvate manual load: ress and hold [F] key. The dsplay shows LoAd. et manual load usng [+] or [-] key. The manual load set flashes. Manual load burner OFF: Drve to mnmum load poston and release [F] and [-] keys. ress [F] and [-] keys agan. Deactvate manual load: ress and hold [esc] key for approx. 5 seconds. V h mn s V h mn s V h mn s 5 s V h mn s Manual load va parameter 121 Enter password [ch ]. elect parameter 121. ress [Enter]. et manual load usng [+] or [-] key. ress [Enter]. Manual load s ntated / La

36 Combuston Manager W-FM 50 5 Operaton 5.3 arameters arameter Functon 050 Data backup [ch ] assword level Internal parameter (000: Int) Transfer of data sets between W-FM and ABE wth dentcal burner dentfcaton (parameter 113). If the backup or restore s ncorrect, a negatve value s dsplayed. The cause of the error s descrbed n error code 137 see. ave from W-FM to ABE (Backup): ress [Enter]. The dsplay shows bac_up. ress [Enter]. et 1 usng [+] key and confrm wth [Enter]. Followng successful executon the dsplay s reset to 0. ave from ABE to W-FM (Restore): ress [Enter]. The dsplay shows bac_up. ress [+] key. The dsplay shows retore. et 1 usng [+] key and confrm wth [Enter]. Followng successful executon the dsplay s reset to Burner dentfcaton of data backup (read only). 056 AN excerpts of data backup (read only). 057 oftware verson when creatng backup (read only). arameter Functon 102 Date of manufacture DD.MM.YY 103 roducton number General parameters (100: ArA) 104 arameter default settng: Customer code 105 arameter default settng: Verson 107 oftware verson 108 oftware varaton 111 AN excerpt for comparson wth data backup (parameter 056) 113 Burner dentfcaton: Identcal to the burner seral number (name plate). The burner dentfcaton has to be reset f the combuston manager has been replaced. 121 Manual load 123 Mnmum settng step n percent Only load changes, whch exceed the value set are ntated, ths avods unnecessary settng movements n modulatng operaton : Load default from buldng management : Analogue load controller on X : Load controller contact on X / La

37 Combuston Manager W-FM 50 5 Operaton arameter Functon 124 Flame falure test (TÜV test) The flame falure test can only be carred out n operatng settng 1 (operatng phase h60). The flame falure test closes the fuel valves and calculates the tme up to flame falure. The calculated tme s dsplayed n the dagnostc code n multples of 0.2 seconds (example Loc.D: 8 = 1.6 seconds). For the flame falure test the burner drves to the load defned under parameter 133. If no load s defned n parameter 133, the flame falure test s carred out at the current load. 125 Mans frequency 0: 50 Hz 1: 60 Hz ress [Enter]. et value 1 usng [+] key and confrm wth [Enter]. Followng successful executon, the dsplay alternately shows the error code Loc.c: 7 and dagnostc code Loc.d: x. 126 Dsplay llumnaton 128 Fuel meter The value must correspond to the number of mpulses per unt of volume (l, m³) of the fuel meter. If the value s set to 0, the fuel meter stops. 130 Delete error hstory [ch. 8.1] 133 Load for flame falure test 141 Operatng mode buldng management 0: OFF 1: Modbus, the combuston manager operates as lave, the RTU transfer mode s used (Remote Termnal Unt) 2: ebu 142 Recurrence tme f communcaton s nterrupted (settng range: s) If communcaton to the buldng management system fals, the next load controller accordng to prorty wll be actvated once ths tme has elapsed. If no other load controller s connected, the burner remans at the current load or t drves to the load defned n parameter 148. rorty 1: Load controller buldng management rorty 2: Load controller on analogue nput X64 rorty 3: Load controller on nput X Unt address of combuston manager as ebu partcpant 1: Address 03 2: Address 13 3: Address 33 4: Address 73 5: Address F3 6: Address 1F 7: Address 3F 8: Address 7F 144 end cycle n seconds for the ebu 05 and Unt address of combuston manager as Modbus partcpant 146 Baud rate Modbus The Baud rate of the combuston manager and the buldng management system must be dentcal. 0: : arty Modbus The party of the combuston manager and the buldng management system must be dentcal. 0: no arty bt 1: odd arty bt 2: even arty bt / La

38 Combuston Manager W-FM 50 5 Operaton arameter Functon 148 Replacement load (settng range: ) Load default for communcaton falure wth buldng management system. : no replacement load : burner OFF 161 Number of lockouts 162 Operatng hours snce last reset Reset: ress [Enter]. ress [ ] key. The dsplay shows 0, operatng hours have been reset. 163 Total operatng hours (voltage appled to combuston manager) 164 tart-ups snce last reset Reset: ress [Enter]. ress [ ] key. The dsplay shows 0, start-ups have been reset. 166 Total start-ups 167 Fuel volume snce last reset Reset: ress [Enter]. ress [ ] key. The dsplay shows 0, the fuel volume has been reset. 190 oston of actuators at lockout not used 0: tandby poston 1: ost-purge poston 195 Repetton counter for heavy ol mmedate start Number of heavy ol start attempts wth mssng sgnal at nput X9-04 untl lockout / La

39 Combuston Manager W-FM 50 5 Operaton arameter Functon 201 Operatng mode 204 not used Burner control (200: Ar0) : not defned (delete curves) 1: Gas drect gnton 2: Gas plot gnton 5: fuel ol EL, M and two stage Z 6: fuel ol EL, M and three stage T 12: fuel ol EL modulatng 23: fuel ol M and modulatng Other settngs wthout functon (3, 4, 7 11, und 24 27). 208 rogram stop 0: deactvated 1: re-purge poston (operatng phase h24) 2: gnton poston (operatng phase h36) 3: nterval tme 1 (operatng phase h44) 4: nterval tme 2 (operatng phase h52) 210 Alarm at start preventon Determnes whether a sgnal s gven at output X3-05:2 durng start preventon. 0: no alarm (no sgnal at output X3-05:2) 1: Alarm (sgnal at output X3-05:2) 211 Fan run-up tme (settng range: s) Tme from fan start to start of actuators. 212 wtch off behavour / max. tme to partal load (settng range: s.) If heat demand s no longer present, the burner drves as far as possble to partal load n a predetermned tme and then swtches off. The burner takes approx. 32 seconds to drve from 100 load to 20 (partal load). 215 Repetton counter safety crcut (settng range: 1 16) Number of safety shutdowns by the safety crcut before lockout occurs [ch ]. 221 Flame sensor Gas 0: QRC 1: onsaton electrode/qra 222 re-purge Gas When usng a valve provng system and two Class A fuel valves pre-purge followng a controlled shutdown can be omtted (to EN 676). 0: OFF 1: ON (pre-purge phase parameter 225) 223 Repetton counter low gas pressure swtch (settng range: 1 16) Number of safety shutdowns by the low gas pressure swtch before lockout occurs [ch ]. 225 re-purge tme Gas n operatng phase h30 (settng range: s) Once the pre-purge postons have been reached, the combuston manager remans n h30 for the duraton of the tme set. 226 re-gnton Gas (settng range: s) Duraton of pre-gnton tme n operatng phase h Interval tme 1 Gas The nterval tme 1 n operatng phase h44 acts as stablsaton tme followng flame formaton. 232 Interval tme 2 Gas The nterval tme 2 n operatng phase h52 acts as stablsaton tme followng flame formaton / La

40 Combuston Manager W-FM 50 5 Operaton arameter Functon 233 ost burn tme Gas (settng range: s) The combuston manager remans n operatng phase h70 for the duraton of the tme set, the flame sensor s gnored durng ths tme. 234 ost-purge tme Gas (settng range: s) Once the post-purge poston has been reached, the combuston manager remans n operatng phase h74 for the duraton of the tme set, the flame sensor s gnored durng ths tme. 236 Low gas pressure swtch nput / nstallaton poston 0: OFF 1: Low gas pressure swtch ftted upstream of valve 1 (factory settng) 2: Low gas pressure swtch ftted between valve 1 and valve 2, valve provng va low gas pressure swtch 237 Hgh gas pressure swtch If a hgh gas pressure swtch s ftted, set parameter to 1. 0: OFF 1: hgh gas pressure swtch 2: valve closng contact 239 Wth forced ntermttent actvated, a controlled shutdown wth subsequent restart s ntated after 23 hours and 45 mnutes unnterrupted burner operaton. 0: OFF 1: forced ntermttent actvated 241 Valve provng In accordance wth DIN EN 676 valve provng s not necessary f pre-purge s actvated and the burner ratng s less than 1200 kw. 0: valve provng OFF (only wth capacty < 1200 kw, parameter 222 must be set to 1: ON) 1: valve provng at stat-up 2: valve provng at shutdown (factory settng) 3: valve provng at stat-up and shutdown 248 ost-purge tme 3 Gas (settng range: s) The combuston manager remans n operatng phase h78 for the duraton of the tme set except f a new heat demand nterrupts the post-purge tme 3 n operatng phase h Flame sensor Ol 0: QRB 1: QRA 265 re-purge tme Ol n operatng phase h30 (settng range: s) Once the pre-purge postons have been reached, the combuston manager remans n operatng phase h30 for the duraton of the tme set. 266 re-gnton tme Ol (settng range: s) Once the gnton postons have been reached, the combuston manager remans n operatng phase h38 for the duraton of the tme set. 270 Interval tme 1 Ol 272 not used The nterval tme 1 n operatng phase h44 acts as stablsaton tme followng flame formaton. 273 ost-burn tme Ol (settng range: s) The combuston manager remans n operatng phase h70 for the duraton of the tme set, the flame sensor s gnored durng ths tme. 274 ost-purge tme Ol (settng range: s) Once the post-purge poston has been reached, the combuston manager remans n operatng phaseh74 for the duraton of the tme set, the flame sensor s gnored durng ths tme / La

41 Combuston Manager W-FM 50 5 Operaton arameter Functon 276 Mnmum ol pressure swtch 0: OFF 1: actve from operatng phase h38 2: actve from operatng phase h40 wth solenod valve upstream of pressure swtch (e.g. pump wth valve) 277 Max. ol pressure swtch If a max. ol pressure swtch s ftted set parameter to 1. 0: OFF 1: ol pressure swtch 2: valve closng contact 279 Wth forced ntermttent actvated, a controlled shutdown wth subsequent restart s ntated after 23 hours and 45 mnutes unnterrupted burner operaton. 0: OFF 1: forced ntermttent actvated 281 ont of gnton Ol 0: gnton on n operatng phase h38 (short pre-gnton) 1: gnton on n operatng phase h22 (long pre-gnton at fan start) 284 ost-purge tme 3 Ol (settng range: s) The combuston manager remans n operatng phase h78 for the duraton of the tme set except f a new heat demand nterrupts the post-purge tme 3 n operatng phase h Evaluaton of heavy ol mmedate start If the sgnal s mssng durng the operatng phase set, the W-FM ntates a shutdown wth a subsequent restart (repetton). The number of repettons can be set n parameter : sgnal only requred n operatng phase h38 1: sgnal requred n operatng phases H38 H Maxmum watng tme for sgnal for heavy ol mmedate start n operatng phase H38 (settng range: 1 45 s) arameter Functon 501 pecal postons fuel actuator Commssonng parameter (400: Et) arameter set 400 s used to adjust the fuel ar compound regulaton (see Ch. 6). Compound (500: ArA) : standby poston (s actvated n operatng phases h10, h12 and h00 ) : re-purge poston (s only actvated n operatng phase h24 ) : ost-purge poston (s actvated n operatng phase h72 ) 502 pecal poston ar actuator : standby poston (s actvated n operatng phases h10, h12 and h00 ) : re-purge poston (s actvated n operatng phase h24 ) : ost-purge poston (s actvated n operatng phase h72 ) 503 pecal postons frequency converter : standby poston (s actvated n operatng phases h10, h12 and h00 ) : pre-purge poston (s actvated n operatng phase h24 ) : ost-purge poston (s actvated n operatng phase h72 ) 522 Drve up ramp (settng range: 5 20 s) The ramp should be at least 20 slower than that of the frequency converter. 523 Drve up ramp (settng range: 5 20 s) The ramp should be at least 20 slower than that of the frequency converter / La

42 Combuston Manager W-FM 50 5 Operaton arameter Functon 542 Actvaton of frequency converter 0: not actvated 1: actvated 544 Operatng ramp modulatng Tme for the actuators to drve from low load to hgh load. Recommended factory settng: 32 s 545 Lower load lmt (settng range: ) Defnes the lower modulatng lmt (partal load). If no lmt has been defned, the lower load lmt n operaton s automatcally set to 20. : no load lmt defned (20 ) 546 Upper load lmt (settng lmt: ) Defnes the upper modulatng lmt (full load). If no lmt has been defned, the upper load lmt n operaton s automatcally set to 100. : no load lmt defned (100 ) arameter Functon Confguraton of actuators : fuel actuator : ar actuator 641 peed standardsaton Actuators (600: ACtr) Durng speed standardsaton, a setpont sgnal of 95 (9.5 V) s sent to the frequency converter. The speed acheved s saved as 100 value, whch means that a reserve of 5 s avalable durng operaton. The maxmum frequency at the frequency converter must therefore be 52.6 Hz. If the frequency converter s ftted to the burner, the maxmum frequency has been factory preset. If the frequency converter s external, the maxmum frequency has to be set to ths value. tartng standardsaton: ress [Enter]. et value 1 usng [+] key and confrm wth [Enter]. The fan motor starts wth the ar damper open. Followng successful executon the dsplay s reset to 0. If a negatve value appears (-X), the normalsaton has faled. The combuston values must be checked after every speed standardsaton. 642 tandardsed speed Durng speed standardsaton a 95 sgnal s sgnalled to the frequency converter and the speed acheved s saved as the standard speed : tandard speed saved from mcro controller : tandard speed saved from mcro controller 2. The speeds of the two mcro controllers may vary by up to Analogue output X74 Ths output can be used to sgnal a load dependent analogue sgnal [ch ] or to actvate a frequency converter [ch ]. In conjuncton wth a frequency converter the voltage at output X74 and and at setpont nput of the frequency converter must be set dentcally. 0: DC 0 10 V 1: DC 2 10 V 2: DC 0/2 10 V / La

43 Combuston Manager W-FM 50 5 Operaton arameter Functon 652 Actvaton of the frequency converter wth safety crcut open 0: no actvaton 1: frequency converter s actvated wth peed montorng n standby, standby speed 0 0: no speed montorng 1: speed montorng actvated arameter Functon 903 Current capacty : Fuel : Ar 922 Actuator step poston : fuel actuator : ar actuator 935 Absolute speed Fault hstory (700: HIt) arameter set 700 s used to localse and correct faults [ch. 8.2]. rocess data (900: data) Current actual speed (recorded by transmtter dsc on motor) 936 tandardsed speed Current speed sgnal n percent. 942 Actve load source (load controller) The parameter shows the load source currently actve. If more than one load source s avalable, the combuston manager prortses to the sequence lsted below. The prorty cannot be altered. 1: load by curve settng 2: manual load 3: load controller va buldng management 4: external load controller va analogue nput X64 termnal 1 / termnal 2 5: external load controller va contacts X5-03 termnal 2 / termnal Contact nterrogaton W-FM (bt coded output) : nputs 1: mn. pressure swtch 2: max. pressure swtch 4: nternal fuel selecton 8: ar pressure swtch 16: load controller OEN 32: load controller ON 64: load controller CLOED 128: safety crcut : outputs 1: safety valve 2: gnton 4: fuel valve 1 8: fuel valve 2 16: fuel valve 3 / plot valve 32: nternal fuel selecton Contact return sgnal network meter / La

44 Combuston Manager W-FM 50 5 Operaton arameter Functon 950 Relay nomnal condton (Bt coded output) 1: alarm 2: safety valve 4: gnton 8: fuel valve 1 16: fuel valve 2 32: fuel valve 3 / plot valve 951 Mans voltage (standardsed) Value dsplayed x factor = current voltage Factor 230 V: Factor 120 V: Current flame sgnal n percent [ch ] 960 Current fuel throughput 961 Current operatng phase [ch ] 981 Fault hstory: fault codes 982 Fault hstory: dagnostc codes 992 Fault flags arameters Functon 167 Fuel volume snce last reset Info level 162 Operatng hours snce last reset 164 tart-ups snce last reset In the Info level, parameter values can be dsplayed but not altered. elect parameter usng [+] or [-] key. ress [Enter] 1 3 s. arameter value appears. 163 Total operatng hours (voltage appled to combuston manager) 166 Total start-ups 113 Burner dentfcaton: dentcal to the burner seral number (name plate) 107 oftware verson 108 oftware varaton 102 Date of manufacture DD.MM.YY 103 roducton number 104 arameter default settng: Customer code 105 arameter default settng: Verson 143 Unt address of combuston manager as ebu partcpant / La

45 Combuston Manager W-FM 50 5 Operaton arameters Functon ervce level In the servce level, parameter values can be dsplayed but not altered. elect parameter usng [+] or [-] key. ress [Enter] 1 3 s. arameter value appears. 954 Current flame sgnal n percent [ch ] 960 Current fuel throughput 121 Manual load 922 Actuator step poston : fuel actuator : ar actuator 936 tandardsed speed Current speed sgnal n percent 161 Number of lockouts FaultHstory [ch ] / La

46 6 Commssonng Combuston Manager W-FM 50 6 Commssonng 6.1 rerequste Commssonng must only be carred out by qualfed personnel. Only correctly carred out commssonng ensures the operatonal safety. Observe the prerequstes for commssonng n the nstallaton and operatng manual of the burner. Ths manual contans detaled nformaton about: general nstallaton regulatons, nozzle selecton, connectng measurng devces, replacng flter nserts, checkng the gas connecton pressure, carryng out soundness test, ventng the gas valve tran, settng the gas pressure regulator, pre-settng the pressure swtch. 6.2 Adjustng the burner In addton to ths chapter, the nformaton about adjustment n nstallaton and operatng manual of the burner should be observed. Ths manual contans detaled nformaton about: speeds (n n conjuncton wth frequency converter), pump pressure, flow and return pressure, default settngs, mxng pressure / La

47 Combuston Manager W-FM 50 6 Commssonng Adjustng gas sde rerequste Open gas solatng valve. ressure n gas valve tran ncreases. Close solatng valve. wtch on voltage supply. The dsplay shows ether OFF Ur or OFF. V h mn s V h mn s OFF Ur OFF burner off and not programmed burner off 1. Enter password ress [F] and [A] smultaneously for approx. 2 seconds. The dsplay shows CodE. Enter the frst dgt usng [+] or [ ] and confrm wth [ENTER]. Repeat procedure untl the password has been entered. Ext password entry usng [ENTER]. The dsplay shows ArA (parameter level) for a short tme and then changes over to 400: Et (setup). V h mn s V h mn s V h mn s V h mn s 2. wtch on burner Ensure there s a demand for heat. A black dash appears below the symbol (start). A heat demand from the boler controller s requred for the duraton of commssonng, that means sgnal on nput X5-03:1. V h mn s / La

48 6 Commssonng Combuston Manager W-FM tart setup ress [ENTER]. If the combuston manager has been pre-programmed, the dsplay shows run 1. elect type of settng (from step 9). If the combuston manager has not been programmed, the dsplay shows parameter Defne parameters 201, 542 and 641 and set 0 (from step 4). 201: Operatng mode 542: Actvaton of frequency converter 641: peed standardsaton 1 V h mn s V h mn s 2 V h mn s 4. et operatng mode The followng steps must only be carred out f the combuston manager s not programmed. If the combuston manager has been pre-programmed, proceed wth step 9. ress [ENTER]. The dsplay shows only the parameter value. et operatng mode usng [+] or [ ] keys and confrm wth [Enter]. 1: drect gnton 2: plot gnton Ext entry usng [esc]. The dsplay shows parameter 201 wth the current operatng mode. V h mn s V h mn s V h mn s / La

49 Combuston Manager W-FM 50 6 Commssonng 5. Actvate/deactvate frequency converter ress [+] key. The dsplay shows parameter 542. ress [Enter]. The dsplay shows only the parameter value. Actvate or deactvate the frequency converter usng [+] or [ ] and confrm wth [ENTER]. 0: wthout frequency converter 1: wth frequency converter Ext entry usng [esc]. The dsplay shows parameter 542 wth the current settng. V h mn s V h mn s V h mn s 6. Carry out speed standardsaton peed standardsaton must only be carred out n conjuncton wth a frequency converter. If no frequency converter s ftted, skp speed standardsaton 641 usng the [+] key. ress [+] key. The dsplay shows parameter 641. ress [ENTER]. et value to 1 usng the [+] and start speed standardsaton by pressng [ENTER]. Check rotaton drecton of burner motor The fan motor starts wth open ar damper settng. Once standardsaton s complete, the dsplay changes form 1 to 0. Ext speed standardsaton usng [esc]. The standardsed speed can be read n parameter 642. V h mn s m 3 m 3 /h l l/h V h mn s V h mn s V h mn s / La

50 6 Commssonng Combuston Manager W-FM reset gnton load pont ress [+] key. The dsplay shows the gnton load pont 0. press and hold [A] and usng [+]/[ ] set ar damper settng ress and hold [F] and set gas butterfly valve settng usng [+]/[ ]. Only n conjuncton wth frequency converter The gnton speed must not be less than 70. ress and hold [A] and [F] (VD) smultaneously and set speed usng [+]/[ ]. V h mn s V h mn s V h mn s h mn s V h mn s 8. reset full load pont ress [+] key. The dsplay shows the full load pont 9. ress and hold [A] and usng [+]/[ ] set ar damper settng from settng dagram. ress and hold [F] and set gas butterfly valve settng usng [+]/[ ]. Only n conjuncton wth frequency converter ress and hold [A] and [F] (VD) smultaneously and set speed to 100 usng [+]/[ ]. ress [+] key. Ext pre-settng. The dsplay changes to run. V h mn s V h mn s V h mn s V h mn s V h mn s V h mn s / La

51 Combuston Manager W-FM 50 6 Commssonng 9. elect type of settng The followng can be selected as type of settng: Adjustment wth flame re-settng wthout flame re-settng wthout flame s only used, f the operatng ponts are known, for example f the combuston manager s exchanged. Adjustment wth flame 1 ress [Enter]. Check rotaton drecton of burner motor The burner starts pre-purge h12 and stops n gnton poston h36 wthout flame formaton. The dsplay shows the gnton load pont 0. et mxng pressure n gnton poston (from step 11). re-settng wthout flame 2 Brefly press [esc] key. The dsplay shows the gnton load pont 0. The black dash below the symbol dsappears. re-set operatng ponts wthout flame (from step 10). 1 V h mn s V h mn s 2 V h mn s V h mn s / La

52 6 Commssonng Combuston Manager W-FM re-set ponts wthout flame Ths step must only be carred out, f the type of settng wthout flame has been selected prevously. The adjustment wth flame (from step 11) s not replaced by ths process. ress [+] key. The dsplay shows the operatng pont 1. ress and hold [A] and pre-set ar damper settng usng [+]/[ ]. ress and hold [F] and pre-set gas butterfly valve settng usng [+]/[ ]. Only n conjuncton wth frequency converter ress and hold [A] and [F] (VD) smultaneously and pre-set speed usng [+]/ [ ]. V h mn s V h mn s V h mn s V h mn s V h mn s ress [+] key. The dsplay shows CALC. The combuston manager starts the calculaton. The dsplay then shows the operatng pont 2. et poston ar damper settng [A] and gas butterfly valve [F], wth optonal frequency converter also set speed [A] and [F] (VD). Usng the [+] key select and pre-set ponts 3 to 9 n sequence. V h mn s V h mn s V h mn s V h mn s V h mn s V h mn s V h mn s / La

53 Combuston Manager W-FM 50 6 Commssonng Ext pre-settng usng [esc]. The dsplay shows 400 Et. ress [ENTER]. The dsplay shows run. ress [ENTER]. Check rotaton drecton of burner motor The burner starts pre-purge and stops n gnton poston wthout flame formaton. The dsplay shows the gnton load pont 0. V h mn s V h mn s V h mn s 11. Check mxng pressure n gnton poston The mxng pressure n gnton poston must be mbar above the combuston chamber pressure. If necessary, adjust mxng pressure va ar damper settng: Only n conjuncton wth frequency converter The gnton speed must not be less than 70. ress and hold [A] and [F] (VD) smultaneously and set speed usng [+]/[ ]. V h mn s V h mn s V h mn s V h mn s / La

54 6 Commssonng Combuston Manager W-FM Check gas valves ress [+] key and ensure that the valves open and close correctly. The burner attempts to gnte. The low gas pressure swtch reacts. After the nterrupton, the dsplay shows OFF Ur. Open gas solatng valve. ress [ENTER], untl the burner starts agan. The dsplay shows 0 agan wth the values set for mxng pressure n gnton poston. 13. Igntng the burner ress [+] key. The burner starts and stops n gnton poston. The dsplay shows the followng operatng phases: H 38: Ignton ON H 40: Fuel valve h 42: Ignton OFF H 44: Flame n gnton poston V h V h V h V h mn l V h mn s 14. Adjust settng pressure on pressure regulator Check the settng pressure at the pressure regulator and f necessary adjust. 15. Check combuston Determne combuston values at gnton poston. et O2 content approx. 4 5 above gas butterfly valve settng / La

55 Combuston Manager W-FM 50 6 Commssonng 16. re-set operatng pont 1 ress [+] key. The dsplay shows the operatng pont 1. re-set gas throughput [F] and ar quantty [A] whlst observng combuston values. Operatng pont 1 must le below the partal load requred and wthn the capacty graph. Only n conjuncton wth frequency converter elect speed n operatng pont 1 as low as possble, but not less than 50. Observe flame stablty. lowly reduce speed usng [F] and [A] (VD), whlst openng ar damper settng alternately usng the [A] key. ress [+] key. The dsplay shows operatng pont 2. If no other ponts have been defned, the combuston manager carres out a calculaton and calculates all mssng ponts up to 9, the dsplay brefly shows CALC. V h mn s V h mn s V h mn s m V h mn s V h mn s V h mn s m l l/h V h mn s / La

56 6 Commssonng Combuston Manager W-FM Drve to full load Usng the [+] key, drve to the ponts n sequence up to 9. Check combuston values at each pont and f necessary correct va the gas butterfly valve settng [F]. V h mn s V h mn s V h mn s V h mn s V h mn s 18. Adjust full load When adjustng, the ratngs data gven by the boler manufacturer and the capacty graph of the burner should be observed. Only n conjuncton wth frequency converter elect speed at full load as low as possble, but not less than 80. Observe flame stablty. Calculate gas throughput (operatng volume VB) requred [ch. 6.4]. et gas butterfly settng [F] n full load pont to approx Adjust settng pressure at the pressure regulator untl gas throughput (VB) s acheved. Check combuston values Determne combuston lmt and set excess ar [ch. 6.3]. Determne gas throughput agan. If necessary adjust settng pressure at pressure regulator and reset excess ar. The settng pressure must not be altered once ths work has been completed. V h mn s V h mn s V h mn s V h mn s V h mn s / La

57 Combuston Manager W-FM 50 6 Commssonng 19. Re-defne pont 1 (only for ZMI) Ths step should only be carred out on burners n verson ZMI. On burners of dfferent verson, skp ths step and proceed wth step 20. Drve to 1 usng the [ ] key. Reduce gas butterfly valve settng [F] untl mnmum burner ratng has been acheved. Check combuston values and f necessary adjust whlst observng the mnmum ar damper settng [A]. Mnmum ar damper settng [A] Combuston head CLOED Combuston head OEN Natural Gas Wthout varable speed drve 0 3 wth VD 5 8 Lqud etroleum Gas Wthout varable speed drve 0 8 wth VD 5 13 V h mn s V h mn s V h mn s V h mn s To acheve a constant operatng behavour, t s necessary to ntate a calculaton from 9 to 1. Drve to 9 usng the [+] key. ress [ ] for approx. 4 seconds. The dsplay shows CALC. Release [ ] key. The combuston manager starts the calculaton. The dsplay then shows the operatng pont 8. V h mn s V h mn s V h mn s Contnue wth Adjustng operatng ponts (step 21) / La

58 6 Commssonng Combuston Manager W-FM Intate a calculaton To acheve a constant operatng behavour, t s necessary to ntate a calculaton from 9 to 1. ress [ ] for approx. 4 seconds. The dsplay shows CALC. Release [ ] key. The combuston manager starts the calculaton. The dsplay then shows the operatng pont 8. V h mn s V h mn s V h mn s 21. Adjustng the operatng ponts If the [ ] key s pressed agan for more than 4 seconds, a calculaton s started from the pont shown to 1. Brefly press [ ] key, to ensure ponts calculated or set are not overwrtten. The operatng ponts should only be adjusted va the fuel supply [F]. Changes to the ar quantty nfluence the lnearty, whch has a negatve effect on the load control and VD. Check combuston values ress and hold [F] key and usng [+]/[ ] optmse combuston values. Optmse combuston values at each operatng pont, untl 1 has been reached. V h mn s V h mn s V h mn s V h mn s V h mn s / La

59 Combuston Manager W-FM 50 6 Commssonng 22. Defne upper load lmt (full load) Full load can be lmted va parameter 546. Ext settng mode usng [esc]. The dsplay shows 546. Full load has not been defned, that means full load 9 (100 load assgnment). If full load s to be lmted: ress [Enter]. The dsplay shows only the parameter value. et load lmt usng [+] or [ ] and confrm wth [ENTER]. Burner drves to value set. Ext entry usng [esc]. The dsplay shows 546 wth the current upper load lmt. V h mn s V h mn s V h mn s 23. Defne lower load lmt (partal load) artal load can be lmted va parameter 545. When adjustng, the ratngs data gven by the boler manufacturer and the capacty graph of the burner should be observed. ress [+] key. The dsplay shows 545. artal load has not been defned, that means partal load 1. ress [Enter]. The dsplay shows only the parameter value. et load lmt usng [+] or [ ] and confrm wth [ENTER]. Burner drves to value set. Determne fuel throughput and f necessary adjust load lmt. Ext entry usng [esc]. The dsplay shows 545 wth the current lower load lmt. V h mn s V h mn s V h mn s / La

60 6 Commssonng Combuston Manager W-FM ave ponts Ext level usng [esc]. The dsplay shows 400 Et. Ext entry usng [esc]. The dsplay shows o (Operate) wth the current ratng. V h mn s V h mn s V h mn s 25. Check start behavour wtch off and restart burner. Check start behavour and f necessary correct gnton poston. If the gnton poston has been altered: Re-check start behavour. 26. Carry out data backup ress keys [F] and [A] smultaneously. elect 000: Int usng [-] key and confrm wth [ENTER]. The dsplay shows parameter : 0 ress [Enter]. The dsplay shows bac_up. ress [Enter]. et 1 usng [+] key and confrm wth [ENTER]. Followng successful data backup the dsplay s reset to 0. The values have been backed up from the combuston manager to the ABE. Ext levels usng [esc]. 27. et pressure swtch and carry out concludng work For further detals see burner nstallaton and operatng manual / La

61 Combuston Manager W-FM 50 6 Commssonng Adjust modulaton ol sde rerequste Open ol shut off devces. wtch on voltage supply. The dsplay shows ether OFF Ur or OFF. V h mn s V h mn s OFF Ur OFF burner off and not programmed burner off 1. Enter password ress [F] and [A] smultaneously for approx. 2 seconds. The dsplay shows CodE. Enter the frst dgt usng [+] or [ ] and confrm wth [ENTER]. Repeat procedure untl the password has been entered. Ext password entry usng [ENTER]. The dsplay shows ArA (parameter level) for a short tme and then changes over to 400: Et (setup). V h mn s V h mn s V h mn s V h mn s 2. wtch on burner Ensure there s a demand for heat. A black dash appears below the symbol (start). A heat demand from the boler controller s requred for the duraton of commssonng, that means sgnal on nput X5-03:1. V h mn s / La

62 6 Commssonng Combuston Manager W-FM tart setup ress [ENTER]. If the combuston manager has been pre-programmed, the dsplay shows run 1. elect type of settng (from step 9). If the combuston manager has not been programmed, the dsplay shows parameter Defne parameters 201, 542 and 641 and set 0 (from step 4). 201: Operatng mode 542: Actvaton of frequency converter 641: peed standardsaton 1 V h mn s V h mn s 2 V h mn s 4. et operatng mode The followng steps must only be carred out f the combuston manager s not programmed. If the combuston manager has been pre-programmed, proceed wth step 9. ress [ENTER]. The dsplay shows only the parameter value. et operatng mode usng [+] or [ ] keys and confrm wth [Enter]. 12: fuel ol EL modulatng 23: medum and heavy ol modulatng Ext entry usng [esc]. The dsplay shows parameter 201 wth the current operatng mode. V h mn s V h mn s V h mn s / La

63 Combuston Manager W-FM 50 6 Commssonng 5. Actvate/deactvate frequency converter ress [+] key. The dsplay shows parameter 542. ress [Enter]. The dsplay shows only the parameter value. Actvate or deactvate the frequency converter usng [+] or [ ] and confrm wth [ENTER]. 0: wthout frequency converter 1: wth frequency converter Ext entry usng [esc]. The dsplay shows parameter 542 wth the current settng. V h mn s V h mn s V h mn s 6. Carry out speed standardsaton peed standardsaton must only be carred out n conjuncton wth a frequency converter. If no frequency converter s ftted, skp speed standardsaton 641 usng the [+] key. ress [+] key. The dsplay shows parameter 641. ress [ENTER]. et value to 1 usng the [+] and start speed standardsaton by pressng [ENTER]. Check rotaton drecton of burner motor The fan motor starts wth open ar damper settng. Once standardsaton s complete, the dsplay changes form 1 to 0. Ext speed standardsaton usng [esc]. The standardsed speed can be read n parameter 642. V h mn s m 3 m 3 /h l l/h V h mn s V h mn s V h mn s / La

64 6 Commssonng Combuston Manager W-FM reset gnton load pont ress [+] key. The dsplay shows the gnton load pont 0. The gnton load pont 0 s factory preset, see burner data sheet. If values are avalable proceed wth step 8. If the combuston manager s not programmed (e. g.. f t has been replaced) the ar damper poston and the poston of the ol quantty regulator must be enter ress and hold [A] and usng [+]/[ ] set ar damper settng. ress and hold [F] and usng [+]/[ ] set poston of ol quantty regulator. Only n conjuncton wth frequency converter The gnton speed should be 100. ress and hold [A] and [F] (VD) smultaneously and set speed to 100 usng [+]/[ ] key. V h mn s V h mn s V h mn s h mn s V h mn s / La

65 Combuston Manager W-FM 50 6 Commssonng 8. reset full load pont ress [+] key. The dsplay shows the full load pont 9. ress and hold [A] and usng [+]/[ ] set ar damper settng from settng dagram, see burner nstallaton and operatng manual. Determne the poston of the ol quantty regulator from the burner data sheet. ress and hold [F] and set value usng [+]/[ ] key. Only n conjuncton wth frequency converter ress and hold [A] and [F] (VD) smultaneously and set speed to 100 usng [+]/[ ]. ress [+] key. Ext pre-settng. The dsplay changes to run. V h mn s V h mn s V h mn s V h mn s V h mn s V h mn s / La

66 Combuston Manager W-FM 50 6 Commssonng 9. elect type of settng The followng can be selected as type of settng: Adjustment wth flame re-settng wthout flame re-settng wthout flame s only used, f the operatng ponts are known, for example f the combuston manager s exchanged. Adjustment wth flame 1 ress [Enter]. Check rotaton drecton of burner motor The burner starts pre-purge h12 and stops n gnton poston h36 wthout flame formaton. The dsplay shows the gnton load pont 0. et mxng pressure n gnton poston (from step 11). re-settng wthout flame 2 Brefly press [esc] key. The dsplay shows the gnton load pont 0. The black dash below the symbol dsappears. re-set operatng ponts wthout flame (from step 10). 1 V h mn s V h mn s 2 V h mn s V h mn s / La

67 Combuston Manager W-FM 50 6 Commssonng 10. re-set ponts wthout flame Ths step must only be carred out, f the type of settng wthout flame has been selected prevously. The adjustment wth flame (from step 11) s not replaced by ths process. ress [+] key. The dsplay shows the operatng pont 1. ress and hold [A] and pre-set ar damper settng usng [+]/[ ]. ress and hold [F] key and usng [+]/[ ] key preset poston of ol quantty regulator. Only n conjuncton wth frequency converter ress and hold [A] and [F] (VD) smultaneously and pre-set speed usng [+]/ [ ]. V h mn s V h mn s V h mn s V h mn s V h mn s ress [+] key. The dsplay shows CALC. The combuston manager starts the calculaton. The dsplay then shows the operatng pont 2. et poston ar damper settng [A] and ol quantty regulator [F], wth optonal frequency converter also set speed [A] and [F] (VD). Usng the [+] key select and pre-set ponts 3 to 9 n sequence. V h mn s V h mn s V h mn s V h mn s V h mn s V h mn s V h mn s / La

68 6 Commssonng Combuston Manager W-FM 50 Ext pre-settng usng [esc]. The dsplay shows 400 Et. ress [ENTER]. The dsplay shows run. ress [ENTER]. Check rotaton drecton of burner motor The burner starts pre-purge and stops n gnton poston wthout flame formaton. The dsplay shows the gnton load pont 0. V h mn s V h mn s V h mn s 11. Check mxng pressure n gnton poston The mxng pressure n gnton poston must be 2 5 mbar above the combuston chamber pressure. If necessary, adjust mxng pressure va ar damper settng: Only n conjuncton wth frequency converter The gnton speed should be 100. ress and hold [A] and [F] (VD) smultaneously and set speed to 100 usng [+]/[ ] key. V h mn s V h mn s V h mn s V h mn s / La

69 + Combuston Manager W-FM 50 6 Commssonng 12. Check pump pressure The pump pressure n gnton poston must be approx. 1 2 bar less than that of the full load pressure, see burner data sheet. Check pump pressure at pressure gauge. Remove closng cap 1 (types T and TA only). Undo locknut 2 (types T and TA only). et pump pressure usng pressure regulatng screw 3. ncrease pressure: clockwse rotaton, decrease pressure: antclockwse rotaton Igntng the burner ress [+] key. The burner starts and stops n gnton poston. The dsplay shows the followng operatng phases: H 38: Ignton ON H 40: Fuel valve h 42: Ignton OFF H 44: Flame n gnton poston V h V h V h V h mn l V h mn s 14. Check combuston Determne combuston values at gnton poston. et O2 content of approx. 4 5 by postonng the ol quantty regulator [F] whlst observng the return pressure. Fuel ol EL: mn 6 8 bar Heavy ol: mn 12 bar / La

70 6 Commssonng Combuston Manager W-FM re-set operatng pont 1 Only n conjuncton wth frequency converter In ol operaton, the speed should only be reduced so far, that the pump pressure set at full load does not fall by more than 15. ress [+] key. The dsplay shows the operatng pont 1. Check combuston values and correct f necessary. ress [+] key. The dsplay shows operatng pont 2. If no other ponts have been defned, the combuston manager carres out a calculaton and calculates all mssng ponts up to 9, the dsplay brefly shows CALC. V h mn s V h mn s V h mn s m V h mn s V h mn s V h mn s m l l/h V h mn s 16. Drve to full load Usng the [+] key, drve to the ponts n sequence up to 9. Check combuston values at each pont and correct va the poston of the ol quantty regulator [F]. V h mn s V h mn s V h mn s V h mn s V h mn s / La

71 Combuston Manager W-FM 50 6 Commssonng 17. Adjust full load When adjustng, the ratngs data gven by the boler manufacturer and the capacty graph of the burner should be observed. Only n conjuncton wth frequency converter elect speed at full load as low as possble, but not less than 80. Observe flame stablty. The burner has been factory pre-szed for a specfc ol throughput, see burner data sheet. et pump pressure and ol quantty regulator poston to the data gven on the burner data sheet. Determne ol throughput, f necessary adjust poston of ol quantty regulator [F] untl the ol throughput requred s acheved. Check combuston values Determne combuston lmt and set excess ar [ch. 6.3]. V h mn s V h mn s V h mn s V h mn s The pump pressure must not be altered once ths work has been completed. 18. Intate a calculaton To acheve a constant operatng behavour, t s necessary to ntate a calculaton from 9 to 1. ress [ ] for approx. 4 seconds. The dsplay shows CALC. Release [ ] key. The combuston manager starts the calculaton. The dsplay then shows the operatng pont 8. V h mn s V h mn s V h mn s / La

72 6 Commssonng Combuston Manager W-FM Adjustng the operatng ponts If the [ ] key s pressed agan for more than 4 seconds, a calculaton s started from the pont shown to 1. Brefly press [ ] key, to ensure ponts calculated or set are not overwrtten. The operatng ponts should only be adjusted va the fuel supply [F]. Changes to the ar quantty nfluence the lnearty, whch has a negatve effect on the load control and VD. Check combuston values ress and hold [F] key and usng [+]/[ ] optmse combuston values. Optmse combuston values at each operatng pont, untl 1 has been reached. V h mn s V h mn s V h mn s V h mn s V h mn s 20. Defne upper load lmt (full load) Full load can be lmted va parameter 546. Ext settng mode usng [esc]. The dsplay shows 546. Full load has not been defned, that means full load 9 (100 load assgnment). If full load s to be lmted: ress [Enter]. The dsplay shows only the parameter value. et load lmt usng [+] or [ ] and confrm wth [ENTER]. Burner drves to value set. Ext entry usng [esc]. The dsplay shows 546 wth the current upper load lmt. V h mn s V h mn s V h mn s / La

73 Combuston Manager W-FM 50 6 Commssonng 21. Defne lower load lmt (partal load) artal load can be lmted va parameter 545. When adjustng, the ratngs data gven by the boler manufacturer and the capacty graph of the burner should be observed. ress [+] key. The dsplay shows 545. artal load has not been defned, that means partal load 1. ress [Enter]. The dsplay shows only the parameter value. et load lmt usng [+] or [ ] and confrm wth [ENTER]. Burner drves to value set. Determne fuel throughput and f necessary adjust load lmt. Ext entry usng [esc]. The dsplay shows 545 wth the current lower load lmt. V h mn s V h mn s V h mn s 22. ave ponts Ext level usng [esc]. The dsplay shows 400 Et. Ext entry usng [esc]. The dsplay shows o (Operate) wth the current ratng. V h mn s V h mn s V h mn s 23. Check start behavour wtch off and restart burner. Check start behavour and f necessary: correct gnton poston, ncrease ol temperature at ol preheater. If the gnton poston has been altered: Re-check start behavour. If the ol temperature has been altered: Re-check start behavour. Restart each pont and check combuston values / La

74 6 Commssonng Combuston Manager W-FM Carry out data backup ress keys [F] and [A] smultaneously. elect 000: Int usng [-] key and confrm wth [ENTER]. The dsplay shows parameter : 0 ress [Enter]. The dsplay shows bac_up. ress [Enter]. et 1 usng [+] key and confrm wth [ENTER]. Followng successful data backup the dsplay s reset to 0. The values have been backed up from the combuston manager to the ABE. Ext levels usng [esc]. 25. et pressure swtch and carry out concludng work For further detals see burner nstallaton and operatng manual / La

75 Combuston Manager W-FM 50 6 Commssonng Adjust mult-stage ol sde Only n conjuncton wth frequency converter When usng a frequency converter please note: Ignton speed and speed n full load should be 100. It s recommended that the speed at the on and off swtch ponts s 100. peed at the operatng ponts below full load must only be reduced so far as to ensure safe operatng behavour whlst: mantanng speed at 60, mantanng mnmum pump pressure, see nstallaton and operatng manual of burner. rerequste Open ol shut off devces. wtch on voltage supply. The dsplay shows ether OFF Ur or OFF. V h mn s V h mn s OFF Ur OFF burner off and not programmed burner off 1. Enter password ress [F] and [A] smultaneously for approx. 2 seconds. The dsplay shows CodE. Enter the frst dgt usng [+] or [ ] and confrm wth [ENTER]. Repeat procedure untl the password has been entered. Ext password entry usng [ENTER]. The dsplay shows ArA (parameter level) for a short tme and then changes over to 400: Et (setup). V h mn s V h mn s V h mn s V h mn s 2. wtch on burner Ensure there s a demand for heat. A black dash appears below the symbol (start). A heat demand from the boler controller s requred for the duraton of commssonng, that means sgnal on nput X5-03:1. V h mn s / La

76 6 Commssonng Combuston Manager W-FM tart setup ress [ENTER]. If the combuston manager has been pre-programmed, the dsplay shows run 1. elect type of settng (from step 9). If the combuston manager has not been programmed, the dsplay shows parameter Defne parameters 201, 542 and 641 and set 0 (from step 4). 201: Operatng mode 542: Actvaton of frequency converter 641: peed standardsaton 1 V h mn s V h mn s 2 V h mn s 4. et operatng mode The followng steps must only be carred out f the combuston manager s not programmed. If the combuston manager has been pre-programmed, proceed wth step 9. ress [ENTER]. The dsplay shows only the parameter value. et operatng mode usng [+] or [ ] keys and confrm wth [Enter]. 5: two stage 6: three stage Ext entry usng [esc]. The dsplay shows parameter 201 wth the current operatng mode. V h mn s V h mn s V h mn s / La

77 Combuston Manager W-FM 50 6 Commssonng 5. Actvate/deactvate frequency converter ress [+] key. The dsplay shows parameter 542. ress [Enter]. The dsplay shows only the parameter value. Actvate or deactvate the frequency converter usng [+] or [ ] and confrm wth [ENTER]. 0: wthout frequency converter 1: wth frequency converter Ext entry usng [esc]. The dsplay shows parameter 542 wth the current settng. V h mn s V h mn s V h mn s 6. Carry out speed standardsaton peed standardsaton must only be carred out n conjuncton wth a frequency converter. If no frequency converter s ftted, skp speed standardsaton 641 usng the [+] key. ress [+] key. The dsplay shows parameter 641. ress [ENTER]. et value to 1 usng the [+] and start speed standardsaton by pressng [ENTER]. Check rotaton drecton of burner motor The fan motor starts wth open ar damper settng. Once standardsaton s complete, the dsplay changes form 1 to 0. Ext speed standardsaton usng [esc]. The standardsed speed can be read n parameter 642. V h mn s m 3 m 3 /h l l/h V h mn s V h mn s V h mn s / La

78 6 Commssonng Combuston Manager W-FM reset gnton load pont Only n conjuncton wth frequency converter The gnton speed should be 100. ress and hold [A] and [F] (VD) smultaneously and set speed to 100 usng [+]/[ ] key. ress [+] key. The dsplay shows the gnton load pont 0. ress and hold [A] and usng [+]/[ ] set ar damper settng, see burner nstallaton and operatng manual. ress [+] key. Ext gnton load pont pre-settng. The dsplay changes to run. V h mn s V h mn s V h mn s V h mn s V h mn s / La

79 Combuston Manager W-FM 50 6 Commssonng 8. elect type of settng The followng can be selected as type of settng: Adjustment wth flame re-settng wthout flame re-settng wthout flame s only used, f the operatng ponts are known, for example f the combuston manager s exchanged. Adjustment wth flame 1 ress [Enter]. Check rotaton drecton of burner motor The burner starts pre-purge h12 and stops n gnton poston h36 wthout flame formaton. The dsplay shows the gnton load pont 0. et mxng pressure n gnton poston (from step 10). re-settng wthout flame 2 Brefly press [esc] key. The dsplay shows the gnton load pont 0. The black dash below the symbol dsappears. re-set operatng ponts wthout flame (from step 9). 1 V h mn s V h mn s 2 V h mn s V h mn s / La

80 Combuston Manager W-FM 50 6 Commssonng 9. re-set ponts wthout flame Ths step must only be carred out, f the type of settng wthout flame has been selected prevously. The adjustment wth flame (from step 10) s not replaced by ths process. Usng [+] key select and pre-set the followng ponts n sequence: 1 ont 1 (gnton stage) 2on wtch pont from 1 to 2 2 Operatng pont 2 3on wtch pont from 2 to 3 (only wth three stage operaton) 3 Operatng pont 3 (only wth three stage operaton) ress and hold [A] and pre-set ar damper settng usng [+]/[ ]. V h mn s V h mn s V h mn s V h mn s Usng [ ] key select and pre-set the followng ponts: 3oF 2oF wtch pont from 3 to 2 wtch pont from 2 to 1 ress and hold [A] and pre-set ar damper settng usng [+]/[ ]. Ext pre-settng usng [esc]. The dsplay shows 400 Et. ress [Enter]. The dsplay shows run. ress [Enter]. The burner starts pre-purge and stops n gnton poston wthout flame formaton. The dsplay shows the gnton load pont 0. V h mn s V h mn s V h mn s V h mn s / La

81 + Combuston Manager W-FM 50 6 Commssonng 10. Check mxng pressure n gnton poston The mxng pressure n gnton poston must be 2 5 mbar above the combuston chamber pressure. If necessary, adjust mxng pressure va ar damper settng: V h mn s V h mn s V h mn s V h mn s 11. Check pump pressure The pump pressure must be set accordng to the nozzle selected. Check pump pressure at pressure gauge. Remove closng cap 1 (types T and TA only). Undo locknut 2 (types T and TA only). et pump pressure usng pressure regulatng screw 3. ncrease pressure: clockwse rotaton, decrease pressure: antclockwse rotaton / La

82 6 Commssonng Combuston Manager W-FM Igntng the burner ress [+] key. The burner starts and stops n gnton poston. The dsplay shows the followng operatng phases: H 38: Ignton ON H 40: Fuel valve h 42: Ignton OFF H 44: Flame n gnton poston Check pump pressure. Check combuston values tandard: approx. 5 O2 content 3LN (multflam): approx O2 content If necessary adjust ar damper settng whlst observng the mxng pressure. V h V h V h V h mn l V h mn s 13. Adjustng operatng pont 1 ress [+] key. The dsplay shows pont 1. If 1 has not been pre-set, the values from 0 are adopted for 1. re-set ar damper settng [A] whlst observng the combuston values. V h l l/h m 3 m h mn s V h mn s 14. Determne swtch pont 2on ress [+] key. The dsplay shows 2on. Valve operatng pont 2 remans closed. If 2on has not been pre-set, the values from 1 are adopted for 2on. et excess ar (O2 content approx. 7 ) va ar damper settng [A] whlst observng flame stablty. V h l l/h m 3 mh mn s V h mn s / La

83 Combuston Manager W-FM 50 6 Commssonng 15. et pre-set pont 2_d ress [+] key. The dsplay shows the pre-set pont 2_d. Valve operatng pont 2 remans closed. re-set ar damper settng [A] expected for the operatng pont 2. The value s not actvated yet. The pre-set pont reduces nsuffcent ar durng the actvaton of operatng pont 2. V h l l/h m 3 m h mn s V h mn s 16. Actvate operatng pont 2 ress [+] key. The dsplay shows 2. Valve operatng pont 2 opens. The preset ar damper settng from 2_d s actvated. re-set ar damper settng [A] whlst observng the combuston values. V h l l/h m 3 mh mn s V h mn s 17. Adjust full load When adjustng, the ratngs data gven by the boler manufacturer and the capacty graph of the burner should be observed. Repeat procedure for three stage operaton: swtch pont 3on (step 14), pre-set pont 3_d (step 15), operatng pont 3 (step 16). V h mn s V h mn s V h mn s Determne fuel throughput and f necessary adjust pump pressure. Check combuston values Determne combuston lmt and set excess ar [ch. 6.3]. The pump pressure must not be altered once ths work has been completed / La

84 6 Commssonng Combuston Manager W-FM Intate partal load ress [ ] key. The dsplay shows swtch pont 3oF. The swtch pont determnes, at whch ar damper settng the valve of the stage above closes. The pont tself can not be actvated. Adapt ar damper settng [A]. The swtch pont must le mnmum 5 above the swtch pont of the respectve stage. ress [ ] key and observe swtch off behavour. Check combuston values n operatng pont 2. et excess ar va ar damper settng [A], do not alter fuel pressure n the process. Repeat procedure for operatng pont 1. V h l l/h m 3 m h mn s V h mn s V h mn s V h mn s 19. Check operatng behavour Actvate operatng ponts several tmes usng the [+] and [ ] keys and observe the swtch-over behavour. If the flame s unstable or a pressure surge occurs: Decrease ar damper settng [A] n the change-over pont. If soot or CO s formed: Increase ar damper settng [A] n the change-over pont. 20. ave ponts The operatng pont 1 must be actvated once, otherwse the dsplay shows OFF Ur when extng commssonng and the combuston manager remans unprogrammed. Actvate operatng pont 1. ress [esc] twce. The dsplay shows o (Operate) and an operatng pont. V h mn s V h mn s V h mn s / La

85 Combuston Manager W-FM 50 6 Commssonng 21. Check start behavour wtch off and restart burner. Check start behavour and f necessary: correct gnton poston, ncrease ol temperature at ol preheater. If the gnton poston has been altered: Re-check start behavour. If the ol temperature has been altered: Re-check start behavour. Restart each pont and check combuston values. 22. Carry out data backup ress keys [F] and [A] smultaneously. elect 000: Int usng [-] key and confrm wth [ENTER]. The dsplay shows parameter : 0 ress [Enter]. The dsplay shows bac_up. ress [Enter]. et 1 usng [+] key and confrm wth [ENTER]. Followng successful data backup the dsplay s reset to 0. The values have been backed up from the combuston manager to the ABE. Ext levels usng [esc]. 23. et pressure swtch and carry out concludng work For further detals see burner nstallaton and operatng manual / La

86 Combuston Manager W-FM 50 6 Commssonng 6.3 Check combuston Determne excess ar lowly close ar damper(s) n the relevant operatng pont, untl the combuston lmt s reached (CO content approx. 100 ppm or smoke number approx. 1). Measure and document O2 content. Read ar number (λ). Increase ar number to ensure suffcent excess ar: by (equates to excess ar), by more than 0.2 for more dffcult condtons, such as: drty combuston ar, fluctuatng ntake temperature, fluctuatng chmney draught. Example λ = λ* et ar number (λ*), do not exceed CO content of 50 ppm. Measure and document O2 content. Check flue gas temperature Check flue gas temperature. Ensure that the flue gas temperature comples wth the data provded by the boler manufacturer. If necessary adjust flue gas temperature, e g.: Increase burner capacty n partal load to avod condensaton n the flue gas ducts, except on condensng unts. Reduce burner capacty n full load to mprove effcency. Adjust heat exchanger to the data provded by the manufacturer. Determne flue gas losses Drve to full load. Measure combuston ar temperature (tl) near the ar damper(s). Measure oxygen content (O2) and flue gas temperature (ta) at the same tme at one pont. Determne flue gas losses usng the followng formula: q A = (t A - t L ) ( A O 2 ) + B qa Flue gas losses [] ta Flue gas temperature [ C] tl Combuston ar temperature [ C] O2 Volumetrc content of oxygen n dry flue gas [] Fuel factors Natural Gas Lqud etroleum Gas Fuel ol A B / La

87 Combuston Manager W-FM 50 6 Commssonng 6.4 Calculate gas throughput Formula symbol Explanaton Example values VB VN Operatng volume [m 3 /h] Volume measured at gas meter at current pressure and temperature (gas throughput). tandard volume [m 3 /h] Volume ganed by gas at 1013 mbar and 0 C. f Converson factor QN Heat ratng [kw] 6000 kw η Boler effcency (e. g ) 0.92 H Calorfc value [kwh/m 3 ] at 0 C and 1013 mbar kw/m 3 (Natural Gas E) tgas Gas temperature at gas meter [ C] 10 C Gas ressure at gas meter [mbar] 250 mbar Baro Barometrc ar pressure [mbar], see table 500 m 955 mbar VG Gas throughput determned at gas meter 18.2 m³ TM Measurng tme [seconds] 120 seconds Calculate normal volume Calculate the normal volume (VN) usng the followng formula. V N = Q N η H V N = 6000 kw kw/m³ = m³/h Heght above sea level [m] Baro [mbar] Calculate converson factor Determne gas temperature (tgas) and pressure (Gas) at gas meter. Determne barometrc ar pressure (Baro) from table Calculate converson factor (f) usng the followng formula. f= Baro + Gas f= t Gas = Calculate operatng volume (gas throughput) requred V B = V N f m³/h V B = = m³/h Determne current operatng volume (gas throughput) Measure gas throughput (VG) at gas meter, measurng tme (TM) should be a mnmum of 60 seconds. Calculate operatng volume (VB) usng the followng formula. V B = 3600 V G T M V B = m³ 120 s =546.0 m³/h / La

88 7 ervcng Combuston Manager W-FM 50 7 ervcng 7.1 Notes on servcng DANGER DANGER WARNING Rsk of exploson due to leakng gas Improper servce work can lead to escapng gas and exploson. Close fuel shut off devces pror to startng work. Care should be taken when dsmantlng and assemblng gas carryng components. Close the screws on the test ponts ensurng the tests ponts are sealed. Rsk of electrc shock Workng on the devce when voltage s appled can lead to electrc shock. Isolate the devce from the power supply pror to startng any work. afeguard aganst accdental restart. Danger of gettng burned on hot components Hot components can lead to burns. Allow components to cool. ervcng must only be carred out by qualfed personnel. The combuston plant should be servced annually. Dependng on ste condtons more frequent checks may be requred. Components, whch show ncreased wear and tear or whose desgn lfespan s or wll be exceeded pror to the next servce should be replaced as a precauton. The desgn lfespan of the components s lsted n the servce plan [ch. 7.2]. Weshaupt recommends a servce contract s entered nto to ensure regular nspectons. The followng components must only be replaced and must not be repared: combuston manager flame sensor actuator gas valve ol solenod valve nozzle head (shut off needle), pressure regulator pressure swtch ror to every servcng Inform the operator about the extent of servce work to be carred out. wtch off mans swtch of nstallaton and safeguard aganst accdental reactvaton. Close fuel shut off devces / La

89 Combuston Manager W-FM 50 7 ervcng Followng servcng Check tghtness of ol and gas carryng components. Check functon of: adjustable mxng head, gnton, flame montorng, gas carryng components (gas connecton pressure and settng pressure), ol pump (pump pressure and sucton resstance), pressure swtch Check control and safety devces. Check combuston values, f necessary re-adjust the burner. Enter combuston values and settngs n the commssonng record and/or test sheet. 7.2 ervce plan For detaled nformaton see nstallaton and operatng manual of burner / La

90 Combuston Manager W-FM 50 8 Troubleshootng 8 Troubleshootng 8.1 rocedures for fault condtons Check prerequstes for operaton: Voltage supply avalable. Heatng swtch s set to On. The combuston manager recognses rregulartes of the burner and dsplays these on the dsplay and operatng unt (ABE). The followng condtons can occur: Dsplay OFF [ch ] Dsplay OFF [ch ] Fault [ch ] Lockout [ch ] Dsplay OFF The followng faults may be corrected by the operator: Fault Cause Rectfcaton Burner not operatng Temperature regulator or pressure regulator on heat exchanger has been set ncorrectly Boler or heatng crcut control s not functonng or has not been set correctly Adjust temperature regulator or pressure regulator on heat exchanger. Check functon and settng of boler or heatng crcut control Dsplay OFF The followng faults may be corrected by the operator: Fault Cause Rectfcaton afety crcut open Temperature lmter or pressure lmter on heat exchanger has trggered (1 Low water safety nterlock on heat exchanger has trggered (1 Reset temperature lmter or pressure lmter on heat exchanger. Top up water. Reset low water safety nterlock on heat exchanger. (1 Notfy your heatng contractor or Weshaupt Customer ervce f the problem occurs repeatedly / La

91 Combuston Manager W-FM 50 8 Troubleshootng Example Fault If a fault occurs, the combuston manager ntates a controlled shutdown. The dsplay and operatng unt alternates between Err.c: (error code) and Err.d: (dagnostc code). The burner restarts automatcally as soon as the fault condton has been rectfed. Faults must only be rectfed by qualfed personnel. Read the fault code and proceed accordng to the fault message [ch. 8.3]. Example Lockout If a lockout condton occurs, the combuston manager ntates a fault shutdown and burner lockout. The dsplay and operatng unt alternates between Loc.c: (error code) and Loc.d: (dagnostc code). Once the fault has been rectfed, the combuston manager has to be reset for restart. Lockouts must only be rectfed by qualfed personnel. Read the fault code and proceed accordng to the fault message [ch. 8.3]. Resettng WARNING Damage resultng from ncorrect fault repar Incorrect fault repar can cause damage to the equpment and njure personnel. Do not carry out more than 2 lockout resets successvely. Faults must be rectfed by qualfed personnel. If the ABE dsplays a fault: ress [Enter] for approx. 2 seconds. reet s dsplayed. Release key. The burner has been reset. Exchangng the unt If the combuston manager or the ABE are replaced: elect and check fault hstory and lockout hstory and nclude a copy when returnng the unt for exchange / La

92 Combuston Manager W-FM 50 8 Troubleshootng 8.2 Fault hstory The combuston manager stores the last 25 faults and lockouts n the fault hstory (parameter 700), 701 s the fault, whch occurred last. The fault hstory can be called up n the servce level or password level. Dsplay faults elect servce level or password level [ch. 5.2] elect parameter 700 usng the [+] key and confrm wth [Enter] (password level only). elect faults n sequence usng [+] or [ ] key. press [Enter] (press servce level 1 3 s). Fault level flashes. elect fault level n sequence usng [+] or [ ] key. If fault levels 05 and 06 show - - n the dsplay: press [Enter] (press servce level 1 3 s). Value s dsplayed. V h mn s V h mn s V h mn s V h mn s V h mn s arameters Level Fault codes 02 Dagnostc code 03 Fault class (arranges faults by prorty) Defnton 0: Lockout, hghest prorty 1: afety shut down wth software reset 2: Low voltage 3: afety shut down n safety phase 4: afety shutdown start preventon 5: afety shutdown shutdown 6: gnal wthout swtch off reacton 04 Operatng phase Operatng phase at tme of fault [ch ]. 05 tart-up counter Number of start-ups at tme of fault. ress [Enter] to dsplay. 06 Ratng Load at tme of fault. ress [Enter] to dsplay / La

93 Combuston Manager W-FM 50 8 Troubleshootng Delete faults Only the fault hstory n the servce level can be deleted. The fault hstory n the password level s not affected by the deletng process. Enter password [ch ]. elect parameter 130. ress [Enter]. The dsplay shows value 0. et value to 1 wthn 3 seconds usng [+] key, confrm wth [Enter] key, then set value to 2 and confrm agan wth [Enter] key. When the dsplay changes to 0 the delete process has been completed. If the dsplay shows -1 the duraton of 3 seconds was exceeded and the delete process was aborted. V h mn s V h mn s V h mn s 3 s V h mn s V h mn s / La

94 8 Troubleshootng Combuston Manager W-FM 50 Fault code Dagnostc codes 8.3 Rectfyng faults Cause Rectfcaton 2 1 No flame sgnal n operatng phase h44 Check flame sensor (soled, defectve, 2 No flame sgnal n operatng phase h52 sgnal strength ) Correct gnton load pont 3 0 No ar pressure swtch sgnal from operatng phase H24 1 Ar pressure swtch sgnal pror to operatng phase h22 4 Ar pressure swtch sgnal pror to start-up Check ar pressure swtch (settng, connecton) Clean fan wheel and ar gude Check pressure and negatve pressure hoses Check ar pressure swtch 4 0 Flame sgnal durng pre-purge Check flame sensor 1 Flame sgnal durng shutdown 2 Flame sgnal durng start-up 7 0 Loss of flame Check flame sensor (soled, defectve, sgnal strength ) Check fuel supply Check combuston Flame falure due to TÜV test Duraton of fuel values closed to flame falure. oluton: 0.2 s (value 5 = 1 s) Valve provng V1 leakng Check valve provng pressure swtch 83 Valve provng V2 leakng [ch ] Check solenod valve 14 0 OC open Check valve closng contact (functon, 1 OC closed connecton) 64 OC open pror to start-up 20 0 Low pressure swtch has reacted Check low pressure swtch Check fuel supply 1 Low gas programme [ch ] Check gas supply 21 0 Hgh pressure swtch has reacted Check hgh pressure swtch Check fuel supply 22 0 afety crcut / burner flange open Check safety devces 1 afety crcut / burner flange open durng start-up # Internal fault Replace combuston manager f fault reoccurs Load nvald 26 Modulatng curve pont undefned et curve ponts for all actuators 71 0 tandby poston undefned et specal postons for all actuators 1 re-purge poston undefned 2 ost-purge poston undefned 3 Ignton poston undefned 72 # Internal fault Replace combuston manager f fault reoccurs Load nvald 26 Mult-stage curve ponts undefned et curve ponts for all actuators / La

95 Combuston Manager W-FM 50 8 Troubleshootng Fault code Dagnostc codes Cause 75 1 Current load ncorrect 2 Target load ncorrect 4 Target poston ncorrect Rectfcaton 16 Dfferent postons reached Repeat standardsaton 76 # Internal fault Replace combuston manager f fault reoccurs 80 1 Combuston manager was unable to correct speed devatons and has reached the lower regulatng lmt. Frequency converter speed to hgh. 2 Combuston manager was unable to correct speed devatons and has reached the upper regulatng lmt. Frequency converter speed too low Interference mpulses on sensor lne speed nput Combuston manager has not been standardsed for ths motor Repeat standardsaton The ramp tmes of the frequency converter are longer than those of the combuston manager. Check ramp tmes (parameter 522, 523). The reference lne of the frequency converter s not lnear: Adjust combuston manager/frequency converter control sgnal (parameter 645). Frequency converter reacts too slowly: Check frequency converter settngs (nlet flter, slp compensaton, fade-out of dfferent speeds). Optmse EMC measures / La

96 Combuston Manager W-FM 50 8 Troubleshootng Fault code Dagnostc codes Cause 82 1 Ramp tme durng run down durng standardsaton too short Rectfcaton Increase ramp tme (parameter 523). 2 tandardsed speed not saved Repeat standardsaton 3 No speed sgnal Check the connecton Check dstance speed sensor / transmtter dsc. 4 Motor dd not reach stable speed durng start. Frequency converter run-up tme too long. peed below mnmum lmt for standardsaton. The ramp tmes of the frequency converter are longer than those of the combuston manager. Check ramp tmes (parameter 522, 523). The reference lne of the frequency converter s not lnear: Adjust combuston manager/frequency converter control sgnal (parameter 645). Frequency converter reacts too slowly: Check frequency converter settngs (nlet flter, slp compensaton, fade-out of dfferent speeds). peed of frequency converter s below the mnmum standardsed speed (650 rpm) Increase speed of frequency converter. 5 Incorrect rotaton drecton Check rotaton drecton. Check nstallaton of transmtter dsc. 6 Impulse pattern (60, 120, 180 ) ncorrect, nterference mpulses on the sensor lne 7 tandardsed speed s not wthn the permtted range 15 peed devaton between mcro controller 1 und mcro controller 2 20 tandardsaton n ncorrect operatng phase 21 afety crcut / burner flange open durng standardsaton. Check the connecton Check dstance speed sensor / transmtter dsc. Optmse EMC measures. Repeat standardsaton wtch off heat demand and repeat standardsaton. Repeat standardsaton 22 Ar actuator not referenced Check actuator. 23 Frequency converter deactvated Actvate frequency converter and repeat standardsaton. 24 tandardsaton started wthout vald operatng mode 128 Frequency converter s actvated, but s not standardsed. Check operatng mode (parameter 201, 301) and repeat standardsaton. Carry out standardsaton. 255 Motor s rotatng, but s not standardsed Carry out standardsaton / La

97 Combuston Manager W-FM 50 8 Troubleshootng Fault code Dagnostc codes Cause 83 1 peed not acheved, lower control lmt was actvated 2 3 peed not acheved, upper control lmt was actvated 4 7 Aborted due to nterference mpulses on sensor lne 8 15 Modulatng operaton: Curve gradent frequency converter too steep (speed not acheved) Dependng on the ramp tme (parameter 522, 523), the speed alteraton between two operatng ponts must not exceed a specfc percentage. 10 at 20 s 20 at 10 s 40 at 5 s Rectfcaton Rectfcaton see error code 80. Rectfcaton see error code 80. Optmse EMC measures. Check ramp tmes (parameter 522, 523) No speed sgnal Check the connecton Check dstance speed sensor / transmtter dsc peed devaton too hgh Check ramp tmes (parameter 522, 523) Modulatng operaton: Curve gradent frequency converter too steep Dependng on the ramp tme (parameter 522, 523), the speed alteraton between two operatng ponts must not exceed a specfc percentage. 10 at 20 s 20 at 10 s 40 at 5 s Check ramp tmes (parameter 522, 523). 2 3 Modulatng operaton: Curve gradent fuel actuator too steep 4 7 Modulatng operaton: Curve gradent ar actuator too steep The poston change between two operatng ponts must not exceed maxmum 31 : Adjust operatng ponts Fuel actuator referencng error Check, f actuators have been mxed up. 1 Ar actuator referencng error Check, f actuator s blocked arameter settngs of one actuator have been changed oston error fuel actuator Check, f actuator s blocked. 1 Fuel actuator lne break mn 0.5 V between n 5 and 2 or 6 and 2: Check wrng 8 Modulatng operaton: Curve gradent fuel actuator too steep Fuel actuator overloaded or mechancally twsted The poston change between two operatng ponts must not exceed maxmum 31 : Adjust operatng ponts. Check, f actuator s blocked / La

98 8 Troubleshootng Combuston Manager W-FM 50 Fault code Dagnostc codes Cause Rectfcaton 87 0 oston error ar actuator Check, f actuator s blocked. 1 Ar actuator lne break mn 0.5 V between n 5 and 2 or 6 and 2: Check wrng 8 Modulatng operaton: Curve gradent ar actuator too steep Ar actuator overloaded or mechancally twsted The poston change between two operatng ponts must not exceed maxmum 31 : Adjust operatng ponts. Check, f actuator s blocked # Internal fault Replace combuston manager f fault reoccurs 93 3 Flame sensor short crcut Check flame sensor Check wrng 95 # External voltage relay contact (nternal) Check flame sensor 3 Ignton unt Check wrng 4 Fuel valve 1 5 Fuel valve 2 6 Fuel valve 3 96 # Relay contact fused (nternal) Check relay contact: 3 Ignton unt Apply voltage. Output X3-05:1 must be de-energsed. 4 Fuel valve 1 wtch off voltage and unplug plug 5 Fuel valve 2 X Fuel valve 3 No ohmc connecton must exst between output X3-05:1 and nput X3-04:4 (N) afety relay fused (nternal) or external voltage appled to safety relay If a crtera s not met: Replace combuston manager Rectfcaton see error code # Relay does not actvate (nternal) Replace combuston manager f fault 2 afety valve reoccurs 3 Ignton unt 4 Fuel valve 1 5 Fuel valve 2 6 Fuel valve # Internal fault relay actvaton Replace combuston manager f fault reoccurs / La

99 Combuston Manager W-FM 50 8 Troubleshootng Fault code Dagnostc codes Cause Rectfcaton 105 # Internal fault contact nterrogaton Can be caused by capactve loads or drect current feed at the nputs. The nput, at 0 Mnmum pressure swtch whch the fault occurred s dsplayed wth 1 Max. pressure swtch dagnostc code. 2 Valve provng pressure swtch 3 Ar pressure swtch 4 Load controller OEN 5 Load controller ON / OFF 6 Load controller CLOED 7 afety crcut / burner flange 8 afety valve 9 Ignton unt 10 Fuel valve 1 11 Fuel valve 2 12 Fuel valve 3 13 Reset # Internal fault Replace combuston manager f fault reoccurs 111 # Mans frequency too low 112 # Voltage return No fault # Internal fault Replace combuston manager f fault reoccurs 116 # Operatng cycle lfespan exceeded Replace combuston manager 117 # Lfespan exceeded Replace combuston manager Interference mpulses on fuel meter nput Optmse EMC measures # Internal fault Reset parameters or reset data usng Restore. Replace combuston manager f fault reoccurs # Internal fault Reset parameters. Replace combuston manager f fault reoccurs 127 # Internal fault Reset parameters or reset data usng Restore. Replace combuston manager f fault reoccurs Internal fault Replace combuston manager f fault reoccurs # Internal fault Reset parameters. Replace combuston manager f fault reoccurs 132 # Internal fault Replace combuston manager f fault reoccurs # Internal fault Reset parameters. Replace combuston manager f fault reoccurs Restore started No fault / La

100 Combuston Manager W-FM 50 8 Troubleshootng Fault code Dagnostc codes Cause (-1) Aborted due to Tme-out durng Backup / Restore or ABE does not have ths functon. Rectfcaton Check the connecton Repeat Backup / Restore. Replace ABE. 254 (-2) Aborted due to transfers error Repeat Backup / Restore. 253 (-3) Restore cannot be carred out at present 252 (-4) Restore ncomplete 251 (-5) No burner dentfcaton Defne burner dentfcaton (parameter 113). 250 (-6) Backup data set nvald, Restore not possble 249 (-7) Backup has unsutable burner dentfcaton and must not be uploaded. 248 (-8) Restore cannot be carred out at present Repeat Backup / Restore. 247 (-9) Backup data set nvald, Restore not possble 246 (-10) Aborted due to Tme-out durng Restore Repeat Backup / Restore. 245 (-11) Access error Restore 244 (-12) oftware verson and Backup data set not compatble, Restore not possble 243 (-13) Backup data comparson between the mcro controllers ncorrect 242 (-14) Backup s ncorrect and cannot not reloaded 241 (-15) Backup contans unsutable AN and must not be uploaded 240 (-16) No Backup n ABE Repeat Backup / Restore. 239 (-17) Backup memory n ABE faulty Repeat Backup / Restore. 157 (-99) Restore successful, however Backup data less than n current system Modbus Tme-out 2 ebu Tme-out (-1) TÜV test n nvald operatng phase tart TÜV test n operatng phase h60 2 (-2) Load durng TÜV test less than lower load lmt (parameter 545) 3 (-3) Load durng TÜV test hgher then upper load lmt (parameter 546) 4 (-4) Manual abort TÜV test No fault 5 (-5) No flame falure after fuel valves have shut down # Internal fault Adjust load and repeat TÜV Test. Check for extraneous lght. Check wrng Check soundness of valves / La

101 Combuston Manager W-FM 50 8 Troubleshootng Fault code Dagnostc codes Cause Rectfcaton Manual lockout by contact No fault 2 Manual lockout by ABE 3 Manual lockout by C-Tool 8 Communcaton between W-FM and ABE was nterrupted durng curve settng 9 Communcaton between W-FM and C- Tool was nterrupted durng curve settng 33 Reset attempt by C-Tool # Internal fault Replace combuston manager f fault reoccurs 200 # ystem fault free No operatng mode selected 2 3 No fuel supply defned 4 7 No curves defned 8 15 tandardsed speed undefned Backup / Restore was not possble 202 # Internal fault operatng mode settng Redefne operatng mode (parameter 201). 203 # Internal fault operatng mode settng Redefne operatng mode (parameter 201). Replace combuston manager f fault reoccurs rogram stop s actvated. Operatng phase s shown n dagnostc code. Deactvate program stop (parameter 208). 205 # Internal fault Replace combuston manager f fault reoccurs Impermssble unt combnaton (combuston manager - ABE) Combuston manager verson too old 1 ABE verson too old # Internal fault Replace combuston manager f fault reoccurs Impermssble operatng mode Redefne operatng mode (parameter 201) # Internal fault Replace combuston manager f fault reoccurs / La

102 9 Techncal documentaton Combuston Manager W-FM 50 9 Techncal documentaton 9.1 Frequency converter Detaled nformaton see Frequency converter CD. The constructon and arrangement of dagnostc LEDs s dependent on the sze of the frequency converter Frequency converter Nord sze I III ON Interfaces 2 DI swtches 3 Dagnostc LED's Interface The nterface s used to access the frequency converter va a C. The oftware requred can be found on the Frequency Converter CD. A connecton cable RJ12 to UB-D9 s requred for the connecton (Order No ). A readly avalable UB nterfaces converter UB to R232 s also requred for the connecton to the UB port. DI swtches The analogue nputs AIN1 and AIN2 are confgured va settng of the DI swtches. Factory settng (2 10 V): wtch 1: OFF wtch 2: OFF / La

103 Combuston Manager W-FM 50 9 Techncal documentaton Dagnostc LED's LED gnal Descrpton 1 (BU-) ystem bus status (not used) 2 (BU-E) ystem bus fault (not used) 3 (D) OFF No mans voltage and no control voltage (1 1 Hz once per second Green Operaton, FC operatng Flashng green 0.5 Hz (1 Ready for operaton 4 Hz (1 tart blocked Flashng red/green 4 Hz (1 Warnng Flashng red Number flashng codes 1 25 Hz (1 Intensty overload Fault, flashng codes see Frequency converter CD / La

104 9 Techncal documentaton Combuston Manager W-FM Frequency converter Nord sze IV B A Interfaces 2 Dagnostc LED's 3 tatus LED's Interface The nterface s used to access the frequency converter va a C. The oftware requred can be found on the Frequency Converter CD. A connecton cable RJ12 to UB-D9 s requred for the connecton (Order No ). A readly avalable UB nterfaces converter UB to R232 s also requred for the connecton to the UB port. Dagnostc LED's LED gnal Descrpton 1 (DOUT1 ) yellow Alarm from frequency converter (dgtal output 1) 2 (DOUT2) yellow gnal at dgtal output 2 3 (BRAKE) yellow Mechancal brake 4 (TEM) yellow Excess temperature at motor 5 (DIN4) yellow gnal at dgtal nput 4 6 (DIN3) yellow gnal at dgtal nput 3 7 (DIN2) yellow gnal at dgtal nput 3 8 (DIN1) yellow Frequency converter start release (dgtal nput 1) 9 (BU-) OFF No Bus communcaton (system bus) Green Flashng green Bus communcaton Bus warnng 0 (BU-E) OFF ystem bus s operatng correctly Flashng red red Montorng fault No system bus / La

105 Combuston Manager W-FM 50 9 Techncal documentaton tatus LED's LED gnal Descrpton A (A-) tatus A nterface (not used) B (D) OFF No mans voltage and no control voltage (1 1 Hz once per second Green Green ON + red flashng Operaton, FC operatng Flashng green 0.5 Hz (1 Ready for operaton 4 Hz (1 tart blocked Flashng red/green 4 Hz (1 Warnng Flashng red Number flashng codes 1 25 Hz (1 Intensty overload Frequency converter not ready for operaton, control voltage appled but no mans voltage Fault, flashng codes see Frequency converter CD / La

106 10 pares Combuston Manager W-FM pares / La

107 Combuston Manager W-FM pares os. Descrpton Order No ABE for W-FM 50/ lug cable ABE-W-FM 50 2 m m Combuston manager W-FM V 50/60 Hz W-FM plug X3-02 Ar pressure swtch X3-03 Lmt swtch burner flange X3-04 Mans and safety crcut X3-05 Fan, alarm X4-02 Ignton unt X5-01 Mn. ol pressure swtch X5-02 Max. ol pressure swtch X5-03 Control crcut X6-03 afety valve X7-01 Ol valve stage X7-02 Ol valve stage X8-02 Ol valve stage X8-04 Operaton Reset X9-04 Valve provng pressure swtch X10-05 Flame sensor QRB, QRD, onsaton X10-06 Flame sensor QRA X64 Reserve 4-20mA X74 Frequency converter connecton X75 Fuel meter / La

108 11 Notes Combuston Manager W-FM Notes / La

109 12 Key word ndex Combuston Manager W-FM Key word ndex A ABE Actuator Ar actuator Ar number Ar pressure Ar pressure swtch Alarm... 24, 39 Ambent condtons Analogue nput Analogue sgnal... 22, 25 Atomsng pressure... 69, 81 B Backup... 11, 36, 60, 74, 85 Baud rate Buldng management... 22, 37 Burner control (200: Ar0) Burner flange lmt swtch Burner dentfcaton Burner motor Burner ON... 22, 23 Bus nterface C Calculaton Change-over release CO content Combuston control Combuston lmt Combuston Manager Commssonng... 46, 47, 61 Compound Condensate... 8 Connecton pressure... 9 Consumpton Contact nterrogaton Contnuous ventlaton Converson factor D Data backup... 11, 36, 60, 74, 85 Data set Desgn lfespan... 7, 88 Dagnostc code Dmensons Drect gnton Dsplay... 30, 31, 33, 37 Dsplay and operatng unt... 26, 30, 90 Dsplay llumnaton Dsposal... 8 E ebu Electrcal connecton Emergency-Off Engneer level Excess ar Exchangng the unt Extraneous lght F Fan motor Fan run-up tme Fault Fault code Fault hstory Flame falure test Flame sensor... 21, 39, 40 Flame sgnal Flame stablsaton tme Flashng... 32, 35 Flue gas losses Flue gas measurement Flue gas temperature Frequency Frequency converter... 24, 41, 42, 49, 63, 77, 102 Fuel meter... 23, 37 Fuel stage Fuel valve... 14, 15, 16, 17 Fuel volume Full load... 42, 56, 59, 71, 72, 83 Fuse G Gas connecton pressure... 9 Gas temperature Gas throughput Guarantee... 6 H Heat demand... 22, 23 Heavy ol ntermedate start Hgh gas pressure swtch Humdty I Ignton load pont... 50, 64, 78 Ignton plot valve Ignton poston Ignton speed... 50, 53 Ignton unt... 14, 15, 16, 17, 24 Illumnaton Impulse frequency Info level Input COM X Input X , 15, 16, 17, 21 Input X Input X , 15, 16, 17, 18 Input X , 15, 16, 18 Input X , 15, 16, 17, 18 Input X , 15, 16, 17, 19 Input X Input X , 15, 16, 17, 23 Input X , 15, 16, 17, 20 Input X Input X Interface , / La

110 12 Key word ndex Combuston Manager W-FM 50 Ionsaton electrode L Lablty... 6 Lfespan... 7, 88 Lmt swtch Load change Load controller... 22, 23 Load lmt Load sgnal Lockout... 18, 90 Low gas pressure swtch... 9, 19, 40 Low gas programme... 9 Low mpact start M Mans frequency... 26, 37 Mans voltage... 18, 26 Manual load... 35, 36 Manual OFF Max. ol pressure swtch Max. pressure swtch Mn. ol pressure swtch Mn. pressure swtch Modbus Modulatng... 22, 39 Modulaton lmt Motor... 24, 28 Mult-stage... 22, 23 N Nozzle crculaton O OFF functon Ol throughput Operatng mode... 22, 23 Operatng phase... 13, 14, 15, 16, 17 Operatng pont Operatng settng Operatng stage Operatng unt Operatng volume Output X , 15, 16, 17, 24 Output X , 15, 16, 17, 24 Output X , 15, 16, 17 Output X , 15, 16, 17 Output X , 15, 16, 17 Output X Output X , 25 arameter... 36, 38, 41, 42, 43, 44 arty artal load... 42, 59, 73, 84 assword... 34, 47, 61, 75 assword level hoto resstor lot gnton ont of gnton ost burn tme ost-purge poston ost-purge tme re-gnton phase... 16, 17, 24 re-purge re-purge poston... 39, 41 re-purge poston re-purge tme ressure regulatng screw... 69, 81 ressure regulator ressure swtch relef rogram stop rogramme sequence... 14, 15, 16 ump pressure... 69, 81 R Ramp tme Referencng Repetton counter Reset... 18, 91 Restore afety crcut... 14, 15, 16, 17, 18, 39 afety measures... 7 afety shutdown afety tme lmter afety valve... 14, 15, 16, 17 ave... 11, 33, 36 ervce ervce contract ervce nterval ervce level ettng step ettng tme mell of gas... 7 oftware verson... 36, 44 pares pecal postons peed alteraton peed measurement peed standardsaton... 42, 49, 63, 77 tablsaton tme tandard volume tandby poston tart preventon... 24, 39 tart-up TL torage wtch off behavour T Temperature Thermostat Three stage Throughput Torque Transport Tree stage / La

111 Combuston Manager W-FM Key word ndex Two stage... 22, 39 Type of operaton Type of protecton U Unt address UV cell V Valve provng... 10, 20 Valve provng gas pressure swtch Valve provng pressure swtch Voltage supply VD X X / La

112 Max Weshaupt GmbH chwend Weshaupt close by? Addresses, telephone numbers etc. can be found at We reserve the rght to make changes. All rghts reserved. The complete program: Relable technology and prompt, professonal servce W Burners up to 570 kw The compact burners, proven mllons of tmes over, are economcal and relable. Avalable as gas, ol and dual fuel burners for domestc and commercal applcatons. The purflam burner verson wth specal mxng head gves almost soot-free combuston of ol wth greatly reduced NOx emssons. Wall-hung condensng bolers for gas up to 240 kw The wall-hung condensng bolers WTC-GW have been developed to meet the hghest demands n ease of operaton and effcency. Modulatng operaton means these unts operate quetly and economcally. monarch WM Burners and Industral Burners up to 11,700 kw Floor-standng condensng bolers for ol and gas up to 1,200 kw These legendary ndustral burners are durable and versatle. Numerous varatons of ol, gas and dual fuel burners meet a wde range of applcatons and capacty requrements. The floor-standng condensng bolers WTC-GB (up to 300 kw) and WTC-OB (up to 45 kw) are effcent, low n pollutants and versatle n use. Even the largest capactes can be covered by cascadng up to four gas condensng bolers. WKmono 80 Brenner up to 17,000 kw olar systems The WKmono 80 burners are the most powerful monoblock burners from Weshaupt. They are avalable as ol, gas or dual fuel burners and are desgned for tough ndustral applcaton. The stylsh flat-plate collectors are the deal complement for any Weshaupt heatng system. They are sutable for solar water heatng and for combned heatng support. Wth versons for on-roof, n-roof and flat roof nstallatons, solar energy can be utlsed on almost any roof. WK Burners up to 32,000 kw Water heaters/energy storage These ndustral burners of modular constructon are adaptable, robust and powerful. Even on the toughest ndustral applcatons these ol, gas and dual fuel burners operate relably. The dverse program of potable water and energy storage for varous heat sources ncludes storage volumes of 70 to 3,000 ltres. In order to mnmze storage losses, potable water cylnders from 140 to 500 ltres are avalable wth hghly effcent nsulaton usng vacuum nsulaton panels. MCR Technology / Buldng Automaton from Neuberger From control panels to complete buldng management systems - at Weshaupt you can fnd the entre spectrum of modern control technology. Future orentated, economcal and flexble. Heat pumps up to 180 kw The heat pump range offers solutons for the utlsaton of heat from the ar, the sol or ground water. ome systems are also sutable for coolng buldngs. ervce Weshaupt customers can be assured that specalst knowledge and tools are avalable whenever they are needed. Our servce engneers are fully qualfed and have extensve product knowledge, be t for burners, heat pumps, condensng bolers or solar collectors. Geothermal probe drllng Wth ts daughter company, BauGrund üd, Weshaupt also offers geothermal probe and well drllng. Wth the experence of more than 10,000 systems and more than 2 mllon meters of drllng, BauGrund üd offers a comprehensve servce program / La

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