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Weishaupt W-FM 100, Installation And Operating Instruction

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Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200

3 Product description

83054802 1/2018-07 La

28-228

3.3.15 Flame sensor

If the flame signal from Phase 44 does not correspond to the value required, the
combustion manager initiates safety shutdown with restart. The number of safety
shutdowns set in parameter

 LossOfFlame 

 in sequence lead to lockout

[ch. 6.8.12]. 
Depending on parameter

 ReactionExtranL 

, a flame signal in Standby

(Phase 12) will lead to start prevention or lockout. 
A flame signal during pre-purge (Phases 30 to 36) or post-purge (Phase 76
and 78) leads to lockout after one repetition and repeated occurrence. 
The

 OperationalStat 

shows the current flame signal as a percentage value. 

QRB
POWER QRI
L
N
PE
QRI / FSV

2
3

X1

0-02

4
5
6

1

BN

BK

QRB…

The flame sensor QRB… (photo resistor) is connected to input X10-02:1/4. 
The flame sensor QRB is not suitable for continuous operation.

If the combustion manager is installed in a control panel, the sensor cable must be
routed separately (max 100 m).

Flame signal

Sensor current

Display

Minimum flame signal

DC 30 μA

approx. 35 %

Maximum flame signal

DC 70 μA

approx. 100 %

Extraneous light detection
from

DC 5 μA

-

QRB
POWER QRI
L
N
PE
QRI / FSV

2
3

X1

0-02

4
5
6

1

QRI

+

BN

BU

BK

QRI

The flame sensor QRI (infrared) is connected to input X10-02:2/4/6. 
The flame sensor QRI is suitable for continuous operation. The combustion man-
ager tests the flame sensor in cycles in operating position (Phase 60) by simulating
a flame failure. The voltage at output X10-02:2 is increased from 14 V to 21 V for
0.5 seconds. The signal voltage at the flame sensor therefore drops to 0 V and the
combustion manager receives the expected Off signal at input X10-02:6.

If the combustion manager is installed in a control panel, the sensor cable must be
routed separately (max 100 m).

Flame Signal

Display

Min. signal voltage: DC 3.5 V (X10-02:6)

approx. 50 %

Summary of Contents for W-FM 100

Page 1: ...Installation and operating instruction Combustion manager W FM 100 und W FM 200 83054802 1 2018 07 ...

Page 2: ...nitoring 14 3 2 7 Program sequence 15 3 2 7 1 Gas direct ignition 15 3 2 7 2 Gas with ignition pilot valve 16 3 2 7 3 Light oil direct ignition 18 3 2 7 4 Heavy oil direct ignition 20 3 2 7 5 Heavy oil with gas pilot ignition 22 3 3 Inputs 24 3 3 1 Voltage supply 24 3 3 2 Safety circuit 24 3 3 3 Reset 24 3 3 4 Air pressure switch 24 3 3 5 Fan contactor contact 25 3 3 6 Fuel selection 25 3 3 7 Mini...

Page 3: ...utput 41 3 4 11 Frequency converter 41 3 5 Technical data 42 3 5 1 Electrical data 42 3 5 2 Ambient conditions 43 3 5 3 Dimensions 44 4 Installation 46 4 1 Installing O2 sensor 46 5 Installation 48 5 1 Electrical connection 48 6 Operation 53 6 1 Operating interface 53 6 1 1 Operating panel 53 6 1 2 Display 54 6 2 Displaying and adjusting parameters 55 6 2 1 Password 56 6 3 Menu structure 57 6 4 Op...

Page 4: ... compound 84 6 9 1 Actuator ramps 84 6 9 2 Shutdown behaviour 84 6 9 3 Operating behaviour of frequency converter 85 6 9 4 SpecialPositions 86 6 9 5 Creating load points modulating operation 88 6 9 6 Operating and switch points multi stage operation 92 6 9 7 Load range 94 6 9 8 Load limit 96 6 9 9 Start point 96 6 10 O2 controller 97 6 10 1 O2 controller operating mode 98 6 10 2 O2 monitor 100 6 1...

Page 5: ...l variable calming 129 6 12 10 Fault signal suppression 129 6 12 11 Modulating switch differentials 130 6 12 12 Multi stage switch differentials and switch thresholds 131 6 12 12 1 Multi stage switch differentials 131 6 12 12 2 Multi stage switch threshold 132 6 12 12 3 Low impact start 132 6 12 13 Temperature sensor 133 6 12 14 Boiler cold start function 134 6 12 15 Adaption 137 6 13 Actuators 13...

Page 6: ...7 2 4 Adjust multi stage oil side 172 7 3 Load controller 176 7 3 1 Configure load controller 176 7 3 2 Adjust load controller 178 7 3 2 1 Modulating load control 178 7 3 2 2 Modulating load control 179 7 3 2 3 Boiler cold start function 180 7 4 O2 controller 182 7 4 1 Set O2 monitor 182 7 4 2 Set O2 trim 183 7 4 3 Check and optimise O2 trim 184 7 5 CO controller 186 7 5 1 Set measurement amplifie...

Page 7: ...Combustion manager W FM 100 und W FM 200 83054802 1 2018 07 La 7 228 10 Technical documentation 218 10 1 Frequency converter 218 10 1 1 Frequency converter Nord size I III 219 10 1 2 Frequency converter Nord size IV 220 11 Key word index 222 ...

Page 8: ...st only be carried out by personnel who have the relevant train ing and instruction Persons with limited physical sensory or mental capabilities may only work on the unit if they are supervised or have been trained by an authorised person Children must not play with the unit 1 2 Symbols DANGER Immediate danger with high risk Non observance can lead to serious injury or death WARNING Danger with me...

Page 9: ...tion non observance of the manual operation with faulty safety equipment continual operation despite a fault improper installation commissioning operation and service repairs which have been carried out incorrectly the use of non original Weishaupt parts force majeure unauthorised modifications made to the unit the installation of additional components which have not been tested with the unit the ...

Page 10: ...gas supplier from outside of the building 2 2 Safety measures Safety relevant fault conditions must be eliminated immediately Components which show increased wear and tear or whose design lifespan is or will be exceeded prior to the next service should be replaced as a precaution The design lifespan of the components is listed in the service plan ch 8 2 2 2 1 Normal operation All labels on the uni...

Page 11: ...uid petroleum gas Use only tested and approved sealing materials whilst observing all process in formation Re commission the appliance when changing to a different type of gas Chan ging from LPG to Natural Gas and visa versa requires a conversion Carry out soundness test after each service and fault rectification 2 3 Alterations to the construction of the equipment All conversions require written ...

Page 12: ...manager It controls the sequence of operation monitors the flame and communicates with all components 3 2 2 Low gas programme The low gas pressure switch monitors the gas connection pressure from phase 21 If the gas pressure set at the low gas pressure switch is not achieved the combus tion manager initiates a safety shutdown and starts the low gas programme In the low gas programme the combustion...

Page 13: ...d valve 2 reduces valve 2 closes again both valves remain closed for 10 seconds If the pressure increases to above the value set during these 10 seconds valve 1 is leaking The combustion manager initiates a controlled shutdown 2 Test phase function sequence for valve proving valve 2 Valve 1 opens valve 2 remains closed pressure between valve 1 and valve 2 increases valve 1 closes again both valves...

Page 14: ...2 5 Variable speed drive Only the W FM 200 is equipped with a frequency converter module for variable speed control Via an analogue output 0 4 20 mA the W FM 200 control the frequency con verter of the fan motor and matches the speed to the burner capacity This reduces electrical consumption The speed and the rotation direction are monitored by an inductive proximity switch and an asymmetrical tra...

Page 15: ...ime Post purge position Post purge Direct start Drain valve train Test without pressure Fill valve train System pressure test Valve proving Inputs Fuel selection Safety circuit Heat demand Flame Signal Air pressure switch Fan contactor contact Start release Gas Low gas pressure switch High gas pressure switch VP gas pressure switch Outputs Burner motor Fan Ignition Pressure switch release Start si...

Page 16: ... burn time Post purge position Post purge Direct start Drain valve train Test without pressure Fill valve train System pressure test Valve proving Inputs Fuel selection Safety circuit Heat demand Flame Signal Air pressure switch Fan contactor contact Start release Gas Low gas pressure switch High gas pressure switch VP gas pressure switch Outputs Burner motor Fan Ignition Pressure switch release S...

Page 17: ...200 3 Product description 83054802 1 2018 07 La 17 228 Signal on input output activated No signal on input Input without influence Signal optional or depending on parameter settings 1 Fuel actuator 2 Actuators air Aux1 Aux2 frequency converter 3 Actuator flue gas recirculation ...

Page 18: ...nal Partial load position Operating setting 1 Operating setting 2 Post burn time Post purge position Post purge Direct start Inputs Fuel selection Safety circuit Heat demand Flame Signal Air pressure switch Fan contactor contact Minimum oil pressure switch Max oil pressure switch Start release Oil Outputs Burner motor Fan Ignition Pressure switch release Start signal Anti syphon valve Fuel valve 1...

Page 19: ...200 3 Product description 83054802 1 2018 07 La 19 228 Signal on input output activated No signal on input Input without influence Signal optional or depending on parameter settings 1 Fuel actuator 2 Actuators air Aux1 Aux2 frequency converter 3 Actuator flue gas recirculation ...

Page 20: ...al load position Operating setting 1 Operating setting 2 Post burn time Post purge position Post purge Direct start Inputs Fuel selection Safety circuit Heat demand Flame Signal Air pressure switch Fan contactor contact Minimum oil pressure switch Max oil pressure switch Start release Oil Outputs Burner motor Fan Ignition Pressure switch release Start signal Anti syphon valve Fuel valve 1 Fuel val...

Page 21: ...200 3 Product description 83054802 1 2018 07 La 21 228 Signal on input output activated No signal on input Input without influence Signal optional or depending on parameter settings 1 Fuel actuator 2 Actuators air Aux1 Aux2 frequency converter 3 Actuator flue gas recirculation ...

Page 22: ...t burn time Post purge position Post purge Direct start Inputs Fuel selection Safety circuit Heat demand Flame Signal Air pressure switch Fan contactor contact Minimum oil pressure switch Max oil pressure switch Start release Oil Outputs Burner motor Fan Ignition Pressure switch release Start signal Anti siphon valve Oil Fuel valve 1 Oil Fuel valve 2 Oil Actuators Full load Pre purge position Post...

Page 23: ...200 3 Product description 83054802 1 2018 07 La 23 228 Signal on input output activated No signal on input Input without influence Signal optional or depending on parameter settings 1 Fuel actuator 2 Actuators air Aux1 Aux2 frequency converter 3 Actuator flue gas recirculation ...

Page 24: ...input X3 03 1 2 3 3 3 Reset 2 3 4 5 X3 04 PE N L L PE N L SAFETY LOOP LINE VOLTAGE 1 1 2 X3 01 L L MOTOR ALARM 2 3 4 X4 01 RESET OIL GAS 1 2 1 A reset button can be connected to input X4 01 4 Pressing this button in lockout will reset the combustion manager With lockout function 1 If the push button is also required for manual lockout it must be connected to mains input X3 04 5 L If the combustion...

Page 25: ... X5 01 On burners without minimum oil pressure switch the input is deactiv ated In oil operation the combustion manager expects a signal at input X5 01 2 from Phase 38 in Phase 44 with heavy oil with gas ignition device If the pressure falls below the value set the pressure switch contact opens and the combustion man ager initiates a lockout In Phase 38 in Phase 44 with heavy oil with gas ignition...

Page 26: ...aximum 45 seconds If the signal is present at input X6 01 3 before this time has elapsed the nozzle circulation is shortened accordingly If the signal is missing after this time has elapsed the combustion manager initiates a home run with sub sequent repetition Depending on the burner nozzle circulation is carried out in phase 38 with direct ignition 44 with gas ignition device If the signal fails...

Page 27: ...d lockouts caused by pressure fluctuations when the valves open the input reacts time delayed in Phase 40 42 and 50 The time delay can be adjusted in parameter PressSigReactTime see ch 6 8 1 3 3 14 Low gas pressure switch L 2 3 X9 03 max min 4 1 P P P LT CPI P The input is activated in gas operation and in heavy oil operation with gas ignition device The closing contact of the low gas pressure swi...

Page 28: ...2 1 4 The flame sensor QRB is not suitable for continuous operation If the combustion manager is installed in a control panel the sensor cable must be routed separately max 100 m Flame signal Sensor current Display Minimum flame signal DC 30 μA approx 35 Maximum flame signal DC 70 μA approx 100 Extraneous light detection from DC 5 μA QRB POWER QRI L N PE QRI FSV 2 3 X10 02 4 5 6 1 QRI BN BU BK QRI...

Page 29: ...t the flame sensor therefore drops to 0 nbsp V and the combustion manager receives the expected Off signal at input X10 02 6 If the combustion manager is installed in a control panel the connection must be divided into 2 lines after the AGM23 plug and routed separately max 100 m Supply line Core 1 2 and PE L N PE Signal line screened Core 3 4 and 5 POWER QRI N QRI Flame Signal Display Min signal v...

Page 30: ...can only be operated in sliding two stage operation At heat demand input X5 03 2 CLOSED is activated and the burner drives to par tial load If the temperature drops below the value set input X5 03 3 OPEN is ac tivated and the burner drives to full load Multi stage operation fuel oil only 2 3 4 X5 03 ON OFF 1 3 2 L Two and three stage Input Operating mode two stage three stage X5 03 1 Stage 1 Stage...

Page 31: ...n In modulating operation parameter MinActuatorStep determines the minimum correcting element step ch 6 12 9 Signal on X62 Load W FM 3 4 mA 20 20 mA 100 Multi stage operation fuel oil only In multi stage operation a hysteresis of 1 mA exists between the operating points which eliminates unnecessary load changes Two stage Signal on X62 Load W FM 3 5 12 mA Stage 1 13 15 20 mA Stage 2 Three stage Sig...

Page 32: ...t for the internal load controller via the analogue input In parameter Ext Inp X62 U I the input has to be matched to the analogue signal ch 6 12 4 Parameters Ext Setpoint min max can be used to limit the external setpoint ch 6 12 6 The contact is used to switch from the external setpoint to the internal setpoint W1 If a voltage signal is present at input X62 2 the voltage signal has to be separat...

Page 33: ...irTempX60PT1000 OEM level must be set to activated The internal temperature monitor function is only possible with temperature sensor on input X60 If there is no external safety temperature limiter available in the safety circuit two temperature sensors Pt100 Pt1000 or Pt100 Ni1000 must be con nected for the internal temperature monitor function With different cable resistances in the three wire c...

Page 34: ... is connected to the O2 module input X86 access ory The sensor has to be configured in parameter FlueGasTempSens see ch 6 10 9 Alternatively the flue gas temperature sensor can be used as FGR temperature sensor flue gas recirculation In parameter FGR sensor X86PtNi1000 must then be defined as FGR temperature sensor ch 6 15 3 3 3 24 Combustion air sensor CO resistance circuit board 2 3 X87 1 Pt Ni ...

Page 35: ... O2 module cable length maximum 10 m Connect separate cable 3 x 0 75 mm2 for the sensor heating to output X89 2 Q4 Q5 The O2 sensor has to be configured in parameter O2 Sensor see ch 6 10 7 Terminal Function B1 M Nernst voltage depending on the current O2 content ch 6 10 16 B2 M Thermo element of the O2 sensor 0 33 mV 700 C equal to approx 29 1 mV Current operating temperature ch 6 10 20 G2 Voltag...

Page 36: ...an is only possible via pres sure switch relief To do this a vent valve has to be fitted and connected to out put X4 03 3 4 3 Oil pump magnetic coupling 1 2 X6 02 3 PE N L M Either the magnetic coupling a separate oil pump or the anti syphon valve are con nected to output X6 02 The type of oil pump coupling is set in parameter OilPumpCoupling see ch 6 8 4 Magnetic coupling separate oil pump On dua...

Page 37: ...se 79 The output is not controlled in phase 21 and 79 the air pressure switch de energises via the open vent valve and the signal at input X3 02 1 corresponds to the program sequence 3 4 5 Ignition 1 2 X4 02 3 PE N L IGNITION The ignition unit is connected to output X4 02 Ignition behaviour Gas In gas operation the output is controlled in phase 38 and 40 The pre ignition time in phase 38 can be ad...

Page 38: ...nnected to out put X6 03 X6 02 or X3 01 Output X6 03 Dual fuel burners with magnetic coupling between burner motor and oil pump Oil and dual fuel burners with separately driven oil pump Output X6 02 Oil burners with oil pump coupled directly to the burner motor without continu ous running fan Output X3 01 Dual fuel burners with oil pump coupled directly to the burner motor without continuous runni...

Page 39: ... solenoid valve Nozzle circulation via output X8 03 is not possible on three stage heavy oil burners as the combustion manager controls outputs X8 02 and X8 03 simultaneously The solenoid valve for nozzle circulation is connected to output X4 02 ignition and parameter IgnOilPumpStart must be set to on in Ph22 long pre ignition ch 6 8 4 1 2 X7 01 3 PE N L V2 L 1 2 X8 02 3 4 N PE V1 MS EL L 1 2 X8 0...

Page 40: ...witches monitor the valve lift and are switched in sequence with the voltage supply of actuator V2 At burner start the limit switches are bridged via a timer relay for approx 25 seconds If both limit switches are closed once this time has elapsed valve V2 re mains open If a valve does not maintain the minimum lift the relevant limit switch opens and in terrupts the voltage from actuator V2 Valve V...

Page 41: ...lti stage operation Burner capacity OFF Stage 1 Stage 2 Stage 3 Analogue signal 4 mA 5 mA 10 mA 15 mA 3 4 11 Frequency converter FE 1 2 X73 3 4 6 5 Start OUT 0 U1 WH BN GN YE GY The frequency converter is connected to output X73 using a screened cable W FM 200 only The screen must be connected to ground on both sides Terminal W FM 200 Function X73 1 2 Enable contact The enable contact for the freq...

Page 42: ...ressure switch relief output X4 03 0 5 A Magnetic coupling output X6 02 1 6 2 A Oil fuel valves 1 6 1 A Fuel valves Gas 1 6 2 A Display and operating unit ABE Mains voltage AC 24 V Consumption max 50 mW Type of protection front Type of protection rear IP54 to ICE 529 IP00 to ICE 529 Transformer Mains voltage Mains frequency 120 230 V 50 60 Hz Secondary 1 AC 12 V Secondary 2 2 x AC 12 V Actuator SQ...

Page 43: ... AB Type of protection IP 44 O2 sensor Mains voltage Mains frequency 120 230 V 50 60 Hz Consumption max 90 W Type of protection IP 44 Permissible flue gas velocity 1 10 m s Flue gas temperature max 300 C Permissible fuels QGO 20 Natural and Liquid Petro leum Gas Fuel oil EL QGO 21 Natural and Liquid Petro leum Gas Fuel oil EL Heavy oil to DIN 51603 3 and DIN 51603 5 3 5 2 Ambient conditions Temper...

Page 44: ... W FM 100 und W FM 200 3 Product description 83054802 1 2018 07 La 44 228 3 5 3 Dimensions Combustion Manager 82 mm 260 mm 232 mm 200 mm 182 mm 250 mm Display and operating unit ABE Recess dimension 127 x 91 mm 0 5 mm 19 24 49 mm 96 mm 90 2 mm 135 8 mm 126 mm ...

Page 45: ...allation and operating instruction Combustion manager W FM 100 und W FM 200 3 Product description 83054802 1 2018 07 La 45 228 Transformer 79 5 mm 102 5 mm 120 mm 10 5 mm 40 5 mm 55 5 mm 9 mm 87 mm 66 5 mm ...

Page 46: ...e The distance between O2 sensor and O2 module must be no more than 10 m Flange dimensions 90 mm 51 mm 180 260 mm 53 5 mm 48 mm QGO 21 QGO 20 Prerequisite CAUTION Damage to the O2 sensor caused by overheating Flue gas temperature above 300 C can damage the O2 sensor Avoid flue gas temperatures above 300 C at the O2 sensor Install O2 sensor only with the corresponding flange It must not be possible...

Page 47: ...tal part of the flue gas pipe QGO 20 vertically from above or at an angle of 45 QGO 21 horizontal Sensor in the vertical part of the flue gas pipe With a downward inclination of approx 5 45 45 5 QGO 21 QGO 20 min 1 x Ø Ø Installation Weld flange gastight to flue gas pipe 1 with QGO 20 observe the position of the flue gas outlet openings 4 Install O2 sensor 2 ensuring correct alignment of the seal ...

Page 48: ... the housing Connect wiring to wiring diagram enclosed Control circuits which are taken directly via a 16 AB fuse from a 3 phase or single phase alternating current supply must only be connected between a phase conductor and earth potential neutral conductor On mains supply which does not have a neutral the control voltage must be sup plied via an isolating transformer The pole of the transformer ...

Page 49: ...be terminated with a bus termination resistor The bus termination is permanently installed in the ABE On the last actuator or at the O2 module the bus termination must be set via a jumper Bus termination must be deactivated for all other participants The screen of the bus line must be terminated at both ends 12V 12V U N 12V X10 01 G G0 L N X52 FE 12AC2 M 12AC1 GND 12AC2 12AC1 Shield X51 X51 CANL C...

Page 50: ...s CAN X70 CAN Bus connection to the combustion manager COM 1 X71 RS 232 for PC connection COM 2 X72 RJ45 connection building management system via Bus interface The COM interfaces can not be used at the same time 1 2 3 4 5 6 7 8 9 1 8 CAN X70 COM 2 X72 1 2 3 4 5 6 7 8 9 COM 1 X71 PIN CAN X70 COM 1 X71 COM 2 X72 1 TXD 2 CAN L RXD 3 GND TXD RXD 4 VAC 2 GND 5 GND U 1 6 GND 7 CAN H U 2 8 VAC 1 ...

Page 51: ...he frequency con verter is not screened If the frequency converter is separate the control line and the motor connection must be screened Apply screen to the screen clamp on frequency converter Use screen cable glands metal on the burner Connect gas valve train Observe wiring diagram supplied Connect double gas valve plug K32 Solenoid coil on W MF or DMV Actuator on VGD Connect limit switch for va...

Page 52: ...ed to the O2 module accessory Connect the signal cable 3 x 2 x 0 25 mm2 twisted in pairs to X81 Connect the screen to one side of the creen clamp of the O2 module cable length maximum 10 m Connect separate cable 3 x 0 75 mm2 for the sensor heating to output X89 2 Q4 Q5 2 3 X81 4 5 6 1 QGO B1 M B2 M G2 U3 GND 2 3 X89 2 1 QGO PE N L Q5 Q4 Q5 Q4 G2 M M B1 U3 B2 PLL QGO ...

Page 53: ...n 6 1 Operating interface 6 1 1 Operating panel Display and operating unit ABE 4 3 2 1 1 Dial knob navigation through parameter structure chan ging values 2 Enter select 3 esc return cancel 4 info return to operating display OFF function Press ENTER and esc simultaneously Immediate lockout The lockout is stored in the fault history ...

Page 54: ...splay menu The esc key is used to return the display to the menu point previously used Menu level 1 Operating display Operation Manual operation Param Display The esc key is used to leave any position and to go back all the way to menu level 1 ch 6 3 Fault display During a fault condition the display alternately shows the shutdown behaviour and the fault diagnosed as a plain text display Lockout A...

Page 55: ...oints the display scrolls up and down One level lower Operating display Operation Manual operation Param Display Boiler setpoint User Maxload Fuel Date Time Press ENTER One level higher Boiler setpoint User Maxload Fuel Date Time Operating display Operation Manual operation Param Display Press esc key Change value Auto Manuel Off Time SwitchOffBeh ProgramStop Program stop Curr deactivated New 36 I...

Page 56: ... password with Enter Display changes to menu level 1 Enter PW TÜV Test Manual operation Param Display Updating Enter PW Access without PW Access with HE Access with OEM Access with SBT Enter Password 9876 Deactivating password If no key is activated for 120 minutes the combustion manager automatically deac tivates the password and blocks the password level Select Deactivate PW in menu level 1 and ...

Page 57: ...tion Boiler setpoint Setpoint W1 Setpoint W2 Load limitAB UserMaxLoadMod 100 UserMaxLoadStg S3 Fuel CurrentFuel FuelSelect Date Time Display the clock Date Time Weekday Set the clock Date Time Weekday Hours run Gas operation OilStage1 Mod OilStage2 OilStage3 TotalHoursReset TotalHours SystemOnPower StartCounter GasStartCount OilStartCount TotalStartCountR TotalStartCount Fuel meter 1 Curr Flow Rat...

Page 58: ...ic Param Display Burner Control Times 2 TimeStartup1 MinTimeStartRel 1 s FanRunUpTme 2 s PrepurgeTmeGas 20 s PrepurgeTmeOil 15 s PrepurgeSafeGas 20 s PrepurgeSafeOil 15 s PrepurgePtl1Gas 0 2 s PrpurgePt3Gas 0 2 s PrepurgePt1Oil 0 2 s PrepurgePt3Oil 0 2 s PreIgnTime_Gas 2 s PreIgnTime_Oil 2 s MinOnTime Oil pump 1 s TimeStartup2 Interval1Gas 2 s Interval1Oil 2 s Interval2Gas 2 s Interval2Oil 2 s Pre...

Page 59: ...Intermit activated Skip PrepurgeGas deactivated ContinuousPurge deactivated ConfigIn output 2 RotSpeed PS on 1 80 RotSpeed PS off 1 50 Config X5 03 LMV5x hrs Start PS Valve ConfigFlamDet ReacExtranLight Startblock FlameSignal RepetCounter 2 LossOfFlame 2 HeavyOil 3 StartRelease 10 SafetyLoop 16 ProductID ASN ProductionDate SerialNumber ParamSet Code ParamSet Vers SW Version Ratio control SettingGa...

Page 60: ...ed O2Contr Alarm 1 Gas Oil settings Operating mode 2 O2 trim 2 O2 monitor 2 O2 Alarm O2 MaxValue 15 NumMinUntilDeact 1 Controller parameter PI LowFireAdaptPtNo 2 2 O2CtrlThreshold 2 0 LoadCtrlSuspend 2 5 O2ModOffset 2 0 Type Air Change 2 like theory O2MaxManVariable 2 35 O2MinManVariable 2 35 Startmode O2InitOffset 2 0 NoTauSuspend 2 10 Adjust Temp O2 20 C Type of Fuel 2 Fuel user def 2 V_LNmin V_...

Page 61: ...Off 10 Sd_Stage2Off 8 Sd_Stage3Off 6 ThreshStage2On 300 ThreshStage3On 600 TempLimiter 2 TL_ThreshOff 95 C TL_SD_On 5 Cold start ColdStartOn 2 deactivated ThresholdOn 2 20 StageLoad 2 15 StageSetp_Mod 2 5 StageSetp_Stage 2 5 MaxTmeMod 2 3 min MaxTmeStage 2 3 min ThresholdOff 2 80 AdditionalSens 2 deactivated Temp ColdStart SetpAddSensor 2 Release Stages 2 Release Configuration LC_OptgMode Int LR S...

Page 62: ...ion AdaptionLoad 100 SW Version ABE Times Sum WinterTime Automatic Time EU US Language DateFormat PhysicalUnits eBUS Address 1 SendCycleBU 30 s Modbus Address 1 Baud rate 19200 bit s Parity none Timeout 30 s Local Remote Remote Mode W3 Display contrast ProductID ASN ProductionDate SerialNumber ParamSet Code ParamSet Vers SW Version Actuators Addressing 2 1 AirActuator 2 GasActuator Oil 3 OilActuat...

Page 63: ...iguration Releasecontct VSD 2 closed Speed Num Puls per R 2 3 Standardisation 2 StandardisedSp 2 Absolute Speed Setpoint Output 2 4 20 mA Fuel meter 2 PulseValueGas 1 PulseValueOil 1 Process data Max Stat Dev Max Dyn Dev NumDev 0 3 NumDev 0 5 Absolute Speed Product identification ASN Production date SerialNumber ParamSet Code ParamSet Vers SW Version O2 module 1 Configuration 2 O2 Sensor no sensor...

Page 64: ...r X86PtNi1000 actTmpFGR sensor ThresholdFGR Gas ThresholdFGR Gas 300 s FGR Factor Gas 100 Operating temp Gas ThresholdFGR Oil ThresholdFGR Oil 300 s Factor FGR Oil 100 Operation TempOil FGR MinPos 0 FGR MaxPos Fact 10 SystemConfig LC_OptgMode IntLC Ext Inp X62 U I 2 4 20 mA TempLimiter 2 TL_Thresh_Off 95 C TL_SD_On 5 Sensor Select Pt100 MeasureRangePtNi 150 C 302 F O2Ctrl LimitrGas 2 man deact O2C...

Page 65: ...t OilStartCount TotalStartCountR Fuel meter Curr Flow Rate Volume Gas Volume Oil Volume Gas R Volume Oil R Reset DateGas Reset DateOil Updating ParamBackup Backup info Date TimeOfDay BU included AZL included LC included SA1 included SA2 included SA3 included SA4 included SA5 included SA6 included VSD included O2 included LMV5x AZL 2 AZL LMV5x 2 Load SW from PC 2 Enter PW Deactivate PW 2 TÜV Test L...

Page 66: ... position display shows the following information Actuator positions Speed O2 content Burner capacity 6 4 2 Fuel selection Operation Fuel Current fuel Fuel selection Current fuel The fuel selected is shown in parameter CurrentFuel read only Fuel selection With dual fuel burners you can switch between oil and gas operation A fuel change during operation will initiate a restart Fuel selection is pos...

Page 67: ...otalHoursReset Total operating hours can be reset TotalHours Total operating hours read only can not be reset SystemOnPower Operating hours with voltage applied to device read only can not be reset Reset Reset only possible under Param Display HoursRun 6 4 4 Start up counter Operation StartCounter or Param Display StartCounter Access in menu Operation StartCounter is read only The individual start...

Page 68: ...ceed 300 Hz In partial load the impulse frequency must be minimum 0 1 Hz If the fuel meter does not supply a signal for 10 seconds no fuel throughput is detected Example Gas meter 100 impulses m3 Full load throughput 300 m3 h Partial load throughput 50 m3 h Full load frequency 100 Imp m3 x 300 m3 h 30000 Imp h 30000 Imp h 3600 s 8 333 Hz Partial load frequency 100 Imp m3 x 50 m3 h 5000 Imp h 5000 ...

Page 69: ... Control ProductID or Param Display AZL ProductID or Param Display Actuators ProductID or Param Display VSD module ProductID or Param Display O2 module ProductID In menu ProductID the following information is displayed for all components selected ASN type description Production date Identification number Customer code parameters Version parameters 6 4 9 Software version Param Display Burner Contro...

Page 70: ... The parameter BurnerID shows the burner specific serial number The burner identification serves as copy protection Burner specific data in the memory of the ABE can not be transferred to another W FM If a W FM is delivered without burner identification and the backup copy from the ABE is installed the W FM adopts the burner identification of the backup copy ch 6 16 1 ...

Page 71: ...ern Europe 1 English German French Italian Spanish Por tuguese Western Europe 2 English Dutch Danish Swedish Norwegian Finnish Eastern Europe 1 English Polish Hungarian Czech Croatian Slove nian Eastern Europe 2 English German Russian Bulgarian Turkish Ru manian 6 5 2 Set contrast Param Display AZL Display Contrast The contrast of the display can be changed and saved using parameter Display Contra...

Page 72: ...ter time Param Display AZL Times Sum WinterTime Time EU US Parameter Sum WinterTime is used to select manual or automatic changeover from summertime to wintertime Parameter Time EU US is used to select the European or American summer time or wintertime Date format Param Display AZL DateFormat Parameter DateFormat is used to select the date format DD MM YY or YY MM DD 6 5 4 Units Param Display AZL ...

Page 73: ...activated until the esc key is used to exit from parameter In terfacePC Interface for building management system COM 2 The building management system can be connected to the ABE using an external Bus interface allowing it to access the W FM Activating the interface Select parameter Gateway BMS on and confirm with Enter The interface in the display and operating unit ABE has been activated and the ...

Page 74: ...Modbus protocol The RTU Modus is used for transfer Modbus address Parameter Address determines the Modbus address of the display and operat ing unit ABE Baud rate Parameter Baudrate determines the transfer speed The Baud rate of the dis play and operating unit ABE and the Modbus participant connected must be identical Parity Parameter Parity determines the type of parity protocols The parity of th...

Page 75: ...into local mode When communication is restored the mode has to be set to remote either via the ABE or via Modbus signal Remote mode Parameter Remote mode is read only the setting is made via Modbus building management system Setting Function Auto Setpoint W3 is determined by the building management system On Load is determined by the building management system Off The internal load controller take...

Page 76: ...tomatic The burner starts if there is a heat demand at in put X5 03 1 The load controller determines the burner capacity Manuel The burner starts if there is a heat demand at input X5 03 1 Parameter SetLoad determines the burner capacity Burner Off Burner drives to or remains in Standby Phase 12 A message that the W FM is set to Burner Off in manual operation does not appear Target load Load to wh...

Page 77: ... in phase 34 or at least for the duration set under Pre purgeTimeTl3 PrepurgeSafeGas PrepurgeSafeOil Pre purge time after the following occurrences Lockout or safety shutdown Power failure Standby longer than 24h PrepurgePt1Gas PrepurgePt1Oil For the duration of this time auxiliary actuator 3 FGR re mains in phase 30 and the fuel actuators remain in standby position The air determining actuators r...

Page 78: ... the anti siphon valve at out put X6 03 closes and the actuators for air and fuel drive to post purge position Post purge time PostpurgeT1Gas PostpurgeT1Oil Residence time in phase 74 Post purge time 1 in phase 74 is always executed Once this time has elapsed the auxiliary actuator 3 FGR drives to post purge position Post purgeT3Gas Post purgeT3Oil Residence time in phase 78 Post purge time 3 in p...

Page 79: ...ed faults are also recognised as start prevention in Standby and are displayed in the ABE 6 8 3 Normal or direct start Param Display Burner Control Configuration ConfigGeneral NormDirectStart Start prevention at heat demand during shutdown in phase 78 Normal start If NormalStart is activated the fan switches off and the burner only starts after a home run in phase 10 Direct start If DirectStart is...

Page 80: ...t coupl The long pre ignition on in Ph22 is automatically activated in parameter IgnOilPumpStart 6 8 5 Forced intermittent Param Display Burner Control Configuration ConfigGeneral ForcedIntermit With ForcedIntermit activated the W FM initiates a controlled shutdown with sub sequent restart after 23 h 50 min uninterrupted burner operation If the burner is not suitable for continuous operation force...

Page 81: ...equency converter are al ways activated even if the safety circuit burner flange are open off Sloop Output X3 01 1 fan and the frequency converter are al ways activated except if the safety circuit burner flange are open deact VSD SL In phases 00 to 21 output X3 01 1 fan is not activated In Phase 00 to 21 the frequency converter is controlled with the idle speed HomePosVSD set except if the safety...

Page 82: ...er Config X5 03 input X5 03 can be used to deactivate O2 trim or to trigger a stop function For this setting parameter LC_OptgMode must not be set to ExtLC X5 03 Input Function Pin 2 X5 03 Mains voltage input at X5 03 2 deactivates O2 trim and the W FM 200 operates to the compound curves The function O2 alarm remains activated Pin 3 X5 03 If no mains voltage is applied to input X5 03 3 the burner ...

Page 83: ...nt in Standby Phase 12 Setting Function Lockout Flame signal in phase 12 triggers a lockout Startblock A flame signal in phase 12 leads to start prevention 6 8 12 Repetition counter Param Display Burner Control Configuration RepetitCounter The parameters in menu RepetitCounter determine the number of safety shutdowns until shutdown with lockout is initiated Changes in the repetition counter are on...

Page 84: ...ge operation for phases 60 and 62 In operating position all actuators operate at this speed Ramp Ramp time outside the operating position for modulating and multi stage operation All actuators operate at this speed in pre purge ignition post purge and standby po sition Only in conjunction with frequency converter The ramp time of the frequency converter must be less than the ramp time set in the W...

Page 85: ...the frequency converter The operating behaviour can be set individually for each fuel Setting Function deactivated No frequency converter available The inputs and outputs for variable speed drive are not activated activated Only in conjunction with a frequency converter The inputs and outputs for variable speed drive are activ ated air influen Only in conjunction with a frequency converter The inp...

Page 86: ...dampers PosAux1 Adjustable mixing head PosAux2 Auxiliary actuator for special applications W FM 200 only PosAux3 Auxiliary actuator for special applications damper for flue gas recirculation W FM 200 only PosVSD VSD only in conjunction with frequency converter W FM 200 Standby positions Parameter StandbyPos determines the positions for phases 00 to 22 Pre purge position Parameter PrepurgePos deter...

Page 87: ...ram stop Using parameter ProgramStop the program sequence can be stopped in defined phases Parameter ProgramStop can also be called up in menu Param Display RatioControl Setting Function deactivated No program stop 24 PrePurgP Stop in phase 24 pre purge position 32 PrePFGR Stop in phase 32 auxiliary actuator3 in pre purge position 36 IgnitPos Stop in phase 36 ignition position 44 Interv 1 Stop in ...

Page 88: ...ual Air 15 0 Aux1 0 0 2 1 During initial commissioning set load points up to full load Once full load has been regulated optimise combustion in load point 1 Load point 1 must be within the ca pacity graph and below below partial load Now delete all load points between point 1 and full load Starting at point 1 set new load points until full load is achieved Optimise combustion in the current point ...

Page 89: ...r 23 8 Aux1 5 0 O2 XXXX Editing load points Select Point and confirm with ENTER Select load point using dial knob and confirm with ENTER key Confirm query Change point with ENTER Confirm query With start with ENTER The curve points can be changed and the actuators are synchronised Select actuator using the dial knob and press Enter Change values using the dial knob and confirm with ENTER Once comb...

Page 90: ... confirm with Enter Load point is deleted Load points above this will be renumbered The display shows the next higher load point in the current numbering If the last load point was deleted the actu ator positions show XXXX Point Load 0 0 Fuel 0 0 Air 23 8 Aux1 5 0 Manual Point 1 Load 10 0 Fuel 10 0 Air 20 0 Aux1 0 0 O2 XXXX Point 2 Load 15 0 Fuel 14 4 Air 23 8 Aux1 5 0 O2 XXXX Point 2 Change point...

Page 91: ...ial knob and confirm with ENTER key Confirm query Change point with ENTER Confirm query With start with ENTER Confirm line Load with Enter Calculate actual load Set load using dial knob and confirm with Enter Exit point using esc and save with ENTER Point Load 15 0 Fuel 14 4 Air 23 8 Aux1 5 0 Manual Point 1 Load 10 0 Fuel 10 0 Air 20 0 Aux1 0 0 O2 XXXX Point 2 Load 15 0 Fuel 14 4 Air 23 8 Aux1 5 0...

Page 92: ...nt is exceeded the solenoid valve of the next stage opens If the switch on point is activated directly the solenoid valve remains closed only the air influencing actuators drive to the switch on position and the flame stability can be checked prior to the change over Switch off points AS2 AS3 1 In the switch off point the air quantity for the change over process into the next lower stage is set If...

Page 93: ...quency converter following Pre setting values see in stallation and operating manual of burner Setting operating and switch points Select menu CurveSet and confirm with Enter Choose appropriate option with the dial knob and confirm with Enter With start Optimise operating stages and switch on points Without start Pre set values and optimise switch off points Select operating stage or switch point ...

Page 94: ...limits restrict the load range within the compound curves programmed On dual fuel burners the load limits for each fuel can be set separately Minimum load Parameter MinLoad_ limits the load range downward partial load Minimum load can not be set below load point 1 in conjunction with O2 trim not below load point 2 Maximum load Parameter MaxLoad_ limits the load range upwards full load 0 100 P1 1 3...

Page 95: ...ot started directly The burner drives from the bottom to the lower limit and passes through the partial range only when the load setpoint reached the upper limit From the upper range the burner remains at the upper limit and drives through the partial range only when the load setpoint has reached the lower limit Lower limit partial range Parameter LoadMaskLowLimit determines the lower limit The lo...

Page 96: ...Further restricts full load within the load limits ch 6 9 7 User MaxLoadStg Load limit for multi stage operation The burner drives only to the stage set 6 9 9 Start point Param Display RatioControl GasSettings OilSettings StartPointOp Parameter StartPointOp determines the load point for partial load position in phase 54 In phase 54 the burner drives to the load point set when the load point is rea...

Page 97: ... 100 2 1 3 4 5 6 1 Burner capacity 2 O2 content in the flue gas 3 O2 residual content at the combustion limit 4 Minimum O2 value for O2 monitor 5 O2 setpoint for O2 trim 6 O2 compound excess air in the load points 20 to 25 With frequency converter On burners with frequency converter parameter VSD can be used to determine if the frequency converter is to be included in O2 trim ch 6 9 3 Pre control ...

Page 98: ...rameter O2Control activates the O2 controller and O2 monitor If the O2 sensor has not reached the operating temperature at burner start a start prevention is initiated If the O2 monitor is triggered or if an O2 fault occurs the W FM initiates a controlled shutdown with single repetition then lockout occurs Automatically deactivate control conAutoDeac Parameter conAutoDeac activates the O2 controll...

Page 99: ... mode Parameter auto deact is automatically activated when a fault occurs in operat ing mode conAutoDeac The O2 controller is deactivated and the burner oper ates to the compound curves A fault message appears in the display If the operat ing mode is changed over the fault message disappears ch 6 10 23 The O2 controller can also be deactivated via a signal at input X5 03 2 ch 6 8 9 ...

Page 100: ... has to be defined as the lower limit in each load point The O2 MinValue results from the O2 content in the flue gas at the combustion limit The O2 MinValue can be entered direct at each load point or can be determ ined by reducing the air rating Select menu O2 Alarm and confirm with Enter Select load point using dial knob and confirm with ENTER key Select entry type 1 or 2 Operating mode O2 trim ...

Page 101: ...1 Press ENTER to accept the O2 actual value The display shows the value determined as O2 MinValue Exit entry using esc Point 9 100 O2 MinValue 0 7 P Air manual Point 9 100 O2 MinValue XXXX P Air manual Point 9 100 O2 MinValue 3 8 P Air manual 0 0 Point 9 100 O2 MinValue 0 7 P Air manual 10 4 Point 9 100 O2 MinValue 0 7 P Air manual 10 4 O2 maximum monitor Parameter O2 MaxValue determines the upper...

Page 102: ...mined up to full load and the O2 setpoint is determined During standardisation the air influencing actuators drive open on the compound curve according to the standardised value and reduce the air quantity the fuel quantity remains unchanged No standardisation is carried out in load point 1 the reference line between load point 1 and load point 2 only serves to reduce air To ensure O2 trim is poss...

Page 103: ...X O2 setpoint XXXX Standard val XXXX Point 9 O2 compound 3 8 If value is stable continue w ENTER Point 9 O2 compound 3 8 O2 setpoint 3 8 Standard val XXXX Point 9 O2 compound 3 8 O2 setpoint 1 7 Standard val 10 2 Point 9 O2 compound 3 8 O2 setpoint 1 7 Standard val 10 2 Save point ENTER cancel ESC Delay time is measured O2 actual value 2 6 Point 9 100 O2 compound 3 8 O2 setpoint 1 7 Standard val 1...

Page 104: ...ontroller tends to over oscillate I Low Fire I High Fire Integral part of O2 trim The smaller the value set the faster the regulation will commence If the value is set too small the controller tends to oscillate Tau Low Fire The flue gas reaction time measured during standardisa tion in the point set under LowFireAdaptPtNo Tau High Fire The flue gas reaction time measured during standardisa tion a...

Page 105: ...s very slowly to changes in the O2 content in the flue gas In this case increase the O2 regulating limit accordingly Flue gas velocity v min 1 m s max 10 m s Formula Rule of thumb v QB L λ t 273 273 d2 0 785 3600 v QB 0 0046 d2 t 273 273 A A v Flue gas velocity m s QB Fuel throughput kg h m3 h L Stoichiometric air requirement m3 kg m3 m3 λ Air number tA Flue gas temperature C d Flue gas pipe diame...

Page 106: ...actuators operate and increase the O2 content by the value set then the fuel actuator operates In conjunction with CO trim the W FM increases the O2 setpoint by O2 offset if the CO limit value has been exceeded Pre control Type Air Change Parameter Type Air Change influences the calculation procedure of the pre control ch 6 10 Parameters Function like theory Recommended for fuel gas Temperature an...

Page 107: ...tion and deactivated O2 controller The burner oper ates to the compound curves The control variable limit results from the maximum expected temperature or air pressure fluctuations based on the conditions at the time of commissioning If the control variable is set too low this will lead to a safety shutdown if climatic fluctu ations are too great The control variable limit can be determined using ...

Page 108: ...se 60 After the block time the W FM initialises the O2 regulator and releases O2 trim after a further 4 x Tau Low Fire As the two possible O2 sensors differ in reaction and settling time Number TauSuspend depends on the sensor used O2 sensor Recommended NumberTauSuspend QGO 20 approx 10 20 QGO 21 greater than 40 The block time also applies to the function CO monitor and CO controller ch 6 11 At bu...

Page 109: ...combustion efficiency User defined fuel values The fuel values have to be defined in menu Fuel user def if parameter Type of Fuel is set to user def V_LNmin Stoichiometric air requirement Lambda 1 m3 Air per m3 Gas or kg Oil V_afNmin Flue gas volume wet in stoichiometric combustion Lambda 1 m3 Flue gas wet per m3 Gas or kg Oil V_atrNmin Flue gas volume dry in stoichiometric combustion Lambda 1 m3 ...

Page 110: ...n with QGO 21 the factor has to be set to minimum 40 in parameter NumberTauSuspend see ch 6 10 5 6 10 8 Service interval for O2 sensor Param Display O2 module Configuration O2SensServTim O2SensServTimRes Setting the service interval Parameter O2SensServTim stipulates the service interval in days for the the O2 sensor The interval is deactivated if the setting is 0 The interval is compared with the...

Page 111: ... gas temperature sensor has to be fitted for this function ch 3 3 23 The threshold is determined separately for oil and gas Set the threshold approx 20 above the maximum flue gas temperature measured during commissioning ch 6 10 19 CAUTION Damage to the O2 sensor caused by overheating Flue gas temperature above 300 C can damage the O2 sensor Avoid flue gas temperatures above 300 C at the O2 sensor...

Page 112: ...tus O2 controller Param Display O2Ctrl Limit Process Data Status O2 Ctrl Parameter Status O2 Ctrl shows the current status of the O2 controller deactivated The O2 controller is deactivated The burner operates to the compound curves locked The O2 controller is blocked sensor testing partial load not achieved LockTStart Blocked time in partial load elapses Tau Low Fire x NumberTauSuspend InitContr I...

Page 113: ...urrently measured in the flue gas Depending on the O2 content in the flue gas and the temperature in the measuring cell the O2 sensor generates Nernst voltage The O2 module calculates the O2 con tent using the Nernst voltage and the sensor temperature It is possible for implausible values to be displayed whilst the sensor is being heated up to operating temperature 700 C The sensor will only opera...

Page 114: ...ction with CO monitoring the parameter shows the status of the CO switching threshold ch 3 3 24 6 10 19 Flue gas temperature Param Display O2 module Process Data Flue gas temperature or Operation O2 module Flue gas temperature If a flue gas temperature sensor is connected to the O2 module parameter Flue gas temperature shows the current flue gas temperature ch 3 3 23 6 10 20 O2 sensor temperature ...

Page 115: ...ance shows the internal resistance of the O2 sensor The internal resistance changes during the course of the operation With an internal resistance of less than 5 Ω or greater than 150 Ω the sensor is subject to aging If the parameter shows an internal resistance of 0 Ω the W FM has not yet carried out the sensor test Sensor test The W FM carries out a sensor test every 23 hours The O2 content must...

Page 116: ...l output 3 Out3 of the measurement ampli fier is connected via a resistance board at the input of the combustion air sensor in the O2 module ch 3 3 24 Digital output 3 Out3 is evaluated via the resistance board In this case the ABE shows the switching status of the measurement amplifier via the combustion air temperature Display Description approx 730 C CO limit value exceeded Digital output 3 Out...

Page 117: ...h repetition Following the release of O2 trim the digital output is permanently interrogated ch 6 10 5 If the CO content exceeds the limit value the digital output in the measurement amplifier opens and the value of the resistance board changes to approx 3 6 kΩ The W FM recognises that the limit has been exceeded and increases the O2 set point by the O2ModOffset set ch 6 10 4 O2 trim is suspended ...

Page 118: ...nly the CO monitor is activated COx control CO controller and CO monitor are activated 6 11 2 Time delay limit value exceeded Param Display O2Ctrl Limit COx Time COx Alarm Parameter Time COx Alarm determines the time delay until a safety shutdown with repetition is carried out if the CO limit value is exceeded If the number of re petitions is exceeded the W FM initiates a lockout The number of rep...

Page 119: ...al 6 12 1 Setpoint Operation BoilerSetpoint SetpointW1 SetpointW2 or Param Display LoadController ControlParam SetpointW1 SetpointW2 Two setpoints W1 W2 can be specified for the internal load controller using parameters Setpoint The setpoints can not be set via the temperature monitor TL_Thresh_Off see ch 6 12 13 A potential free contact at input X62 can be used to switch between the setpoints W1 ...

Page 120: ...er is used and which source specifies the setpoint External load controller Setting Function ExtLC X5 03 External load controller at input X5 03 ch 3 3 16 ExtLC X62 External load controller with analogue load signal at input X62 ch 3 3 17 In put X62 must be matched to the analogue signal in parameter Ext Inp X62 U I see ch 6 12 4 The internal load controller converts the analogue signal into a dig...

Page 121: ...ched to the analogue signal in parameter Ext Inp X62 U I see ch 6 12 4 The setpoint range results from the selected measuring range for the temperature sensor in parameter Meas range PtNi ch 6 12 5 Parameters Ext Min MaxSetpoint can be used to limit the setpoint range ch 6 12 6 A contact at terminals X62 1 2 can be used to switch to the internal setpoint W1 ch 3 3 19 Changing over operating mode t...

Page 122: ... 1 2 4 Pt1000 1 Pt1000 sensor at terminal X60 3 4 Ni1000 1 Ni1000 sensor at terminal X60 3 4 Pt100Pt1000 1 Pt100 sensor at terminals X60 1 2 4 for temperature reg ulator function Pt1000 sensor at terminals X60 3 4 for temperature mon itor function Pt100Ni1000 1 Pt100 sensor at terminals X60 1 2 4 for temperature reg ulator function Ni1000 sensor at terminals X60 3 4 for temperature mon itor functi...

Page 123: ...nt signal with load monitoring 0 20 mA Current signal without load monitoring 2 10 V Voltage signal with load monitoring 0 10 V Voltage signal without load monitoring Input X62 Param Display LoadController Configuration Ext Inp X62 U I or Param Display SystemConfig Ext Inp X62 U I If an analogue setpoint or load signal is present at input X62 the input must be matched to the analogue signal in par...

Page 124: ...r RangePtNi can be used to restrict the end of the measuring range as required Prerequisite is that the value in parameter Meas ureRangePtNi is set to 850 C 1562 F The scaling of the resistance curve does not change Values approx 10 above the end of measuring range are interpreted as sensor short circuit Only required in conjunction with flue gas recirculation If the sensor is used as FGR temperat...

Page 125: ...al in percentage to the measurement range ch 6 12 5 set for the actual value sensor and generates the setpoint for the load control Measurement range set MeasureRangePtNi Analogue signal Ext Inp X62 U I Setpoint load controller Current Voltage 0 150 C 0 4 mA 0 2 V 0 C 20 mA 10 V 150 C 0 400 C 0 4 mA 0 2 V 0 C 20 mA 10 V 400 C 0 850 C 0 4 mA 0 2 V 0 C 20 mA 10 V 850 C 0 XX 1 C bar 0 4 mA 0 2 V 0 C ...

Page 126: ...tipulates the value that is output as a current signal at output X63 Setting Function Load 1 Load 0 Load signal from internal load controller O2 Residual oxygen content in flue gas Pos Air Pos fuel Pos Aux Position of the relevant actuator Speed VSD Setpoint speed Flame Flame Signal Temp Pt Temp Ni1000 Temperature sensor input X60 Temp X61 Press X61 Temperature pressure sensor input X61 1 Current ...

Page 127: ...0mA temp Temperature at input X60 X61 0 2000 C at 20 mA valid for Temp Pt1000 Temp Ni1000 Temp Pt100 Temp X61 Press X61 Pressure sensor at input X61 0 99 9 bar at 20 mA valid for Press X61 Scale20mA angle Actuator position in degree of angle 0 90 at 20 mA valid for Pos Air Pos fuel Pos Aux Scaling Scale 0 4mA Parameter Scale 0 4mA defines the internal value for the lower current limit Depending on...

Page 128: ...r is set in menu ControlParamList Under StandardParam one of five standard parameter sets or the PID para meter set from the adaption can be selected Parameter set StandardParam P Part Xp I Part Tn s D Part Tv s Adaption Values determined during adaption ch 6 12 15 very fast 42 5 68 12 fast 14 5 77 14 normal 6 4 136 24 slow 4 7 250 44 very slow 3 4 273 48 Adapting control parameters The PID parame...

Page 129: ...ol variable is maintained The actuators are less stressed due to the reduced drive impulses If the control variable calming is too great the control becomes inaccurate or be gins to oscillate 6 12 10 Fault signal suppression Param Display LoadController ControlParam SW_FilterTmeCon Parameter SW_FilterTmeCon weakens actual value fault signals Actual value fault signals mainly affect the D part If t...

Page 130: ...controller for mod ulating operation Parameters Function Sd_ModOn Switch on point controller ON Sd_ModOFF Switch off point controller OFF The on and off switch points are given as a percentage value and relate to the cur rent setpoint Example On and off switch points at setpoint W 70 C Sd_ModOn 10 of 70 C 7 C Sd_ModOff 5 of 70 C 3 5 C Controller ON 70 7 63 C Controller OFF 70 3 5 73 5 C With a pos...

Page 131: ..._Stage3Off Switch off point stage 3 The on and off switch points are given as a percentage value and relate to the cur rent setpoint Example On and off switch points at setpoint W 70 C Sd_Stage1On 10 of 70 C 7 C Sd_Stage1Off 5 of 70 C 3 5 C Sd_Stage2Off 2 of 70 C 1 4 C Sd_Stage3Off 1 of 70 C 0 7 C Stage 1 controller ON 70 7 63 C Stage 1 controller OFF 70 3 5 73 5 C Stage 2 OFF 70 1 4 71 4 C Stage ...

Page 132: ...viation x time When the value reaches ThreshStage2On Q2 stage 2 switches If the value reaches ThreshStage3On Q3 before Sd_Stage1On is not achieved stage 3 switches Q2 Q2 Q3 Sd_Stage1Off Sd_Stage2Off Sd_Stage3Off Setpoint W Sd_Stage1On Stage 1 controller ON Stage 2 Stage 3 6 12 12 3 Low impact start If a three stage burner is to be operated two stage with low impact start Set parameter Sd_Stage2Off...

Page 133: ...sensors Pt100 Pt1000 or Ni1000 see ch 6 12 3 Parameter TL_ThreshOff stipulates the switch threshold for the temperature monitor Parameter TL_SD_On stipulates the switch on hysteresis The switch on hyster esis is given as a percentage value and relates to the switch threshold for the tem perature monitor Example TL_ThreshOff 80 C If the temperature exceeds the threshold the W FM initiates a shutdow...

Page 134: ...he boiler cold start function at burner start the W FM carries out a cold start sequence The burner starts with the lowest burner ca pacity The capacity is increased either after the residence time set or when the boiler temperature exceeds the next setpoint step When the boiler temperature reaches the switch off threshold set the W FM stops the cold start sequence and the load control is activate...

Page 135: ...late the step for the setpoint increase Parameters Function StageSetp_Mod Setpoint step for modulating operation StageSetp_Stage Setpoint step for multi stage operation The setpoint step is given as a percentage value and relates to to current set point W1 or W2 If an additional sensor is connected to input X60 the switch on threshold relates to the setpoint set under Setp AddSensor When the boile...

Page 136: ...ionalSens If the additional sensor has been defined the setpoint set under Setp AddSensor is deemed as the reference value for the boiler cold start function Temperature at additional sensor Temp ColdStart Parameter Temp ColdStart shows the current temperature at the additional sensor Setpoint for additional sensor Setp AddSensor Parameter Setp AddSensor stipulates the setpoint for the boiler cold...

Page 137: ...ression must be 2 4 seconds ch 6 12 10 Automatic adaption passes through 4 phases Phase Function Temp setback Reduces actual value to 5 below setpoint Stabilisation phase The course of the actual value is evaluated for 5 minutes If severe fluctuations occur the time increases to 10 minutes Heating The course of the actual value during heat up phase is determined Adaption ok Adaption completed succ...

Page 138: ...e actuator cover In menu Param Display Actuator select parameter Addressing and confirm with Enter Select the relevant actuator using the dial knob 1 AirActuator Air damper 2 GasActuator Oil Gas butterfly valve 3 OilActuator Oil quantity regulator 4 AuxActuator Mixing head 5 AuxActuator2 Auxiliary actuator for special applications 6 AuxActuator3 Auxiliary actuator for special applications Confirm ...

Page 139: ...tuator changes to continually ON 6 13 2 Delete curves Param Display Actuators Rotational direction DeleteCurves Parameter DeleteCurves deletes the compound curves of all actuators is re quired to change the rotation direction in the OEM level 6 13 3 Position control Param Display SystemConfig Allowed Pot diff Each actuator transmits two independent position signals to the W FM The W FM compares th...

Page 140: ...tion at input X70 ch 3 3 21 6 14 3 Speed standardisation Param Display VSD module Configuration Speed Standardisation StandardisedSp Speed standardisation Standardisation Parameter Standardisation starts the automatic speed standardisation to do this set parameter to activated As a prerequisite for speed standardisation the pre purge position of the air influ encing actuators must be set to 90 ch ...

Page 141: ...ust be matched to the frequency converter Setting Function 4 20 mA Current signal with load monitoring standard 0 20 mA Current signal without load monitoring 6 14 6 Speed deviation Param Display VSD module Process Data The process data can be found in the volatile memory and are reset during reset or power failure Parameters Function Max Stat Dev Shows the maximum speed deviation when changing a ...

Page 142: ...cial positions 6 15 1 FGR function 6 15 1 1 Fan on burner Through a pipeline the fan draws the flue gas from the flue gas pipe A flue gas damper FGR damper 1 in the pipeline meters the recirculated flue gas quantity The FGR damper is driven load dependent in compound by the actuator Aux3 The recirculated flue gas quantity dependents on the position of the FGR damper 1 the negative pressure in the ...

Page 143: ... 5 Example Actuator Change Reaction FGR damper OPEN more recirculated flue gas Air damper CLOSED decreased combustion air increased negative pressure more recirculated flue gas Speed Increase increased combustion air increased negative pressure more recirculated flue gas The position of the mixing head has little influence on the amount of recirculated flue gas ...

Page 144: ...pressure in the FGR suction chamber 2 and the flue gas pressure at the extraction point 5 With sufficient negative pressure the FGR damper operates up to an opening angle of approx 60 above this the recirculated flue gas quantity increases marginally If the recirculated flue gas quantity is insuffi cient to reach the NOX content the negative pressure in the FGR suction chamber has to be increased ...

Page 145: ...er Air on the burner and the position of the mixing head Aux1 have little influence on the amount of recirculated flue gas Initial commissioning without FGR To ensure sufficient negative pressure for flue gas recirculation slightly close the air dampers in front of the FGR connector housing at each load point during the ini tial commissioning without FGR Once the combustion limit is determined and...

Page 146: ...int If during operation the FGR temperature differs from the saved temperature the W FM recalculates the position for actuator Auxs3 Deviating from the compound curve the actuator drives to the calculated position and compensates the temper ature deviation How much the temperature deviation affects the actuator position can be set in parameter FactorFGR The FGR minimum position is always maintaine...

Page 147: ... shows the current temperature at the FGR tem perature sensor 6 15 5 FGR release Param Display Flue Gas Recircula tion ThresholdFGR DelaytimeFGR The parameters stipulate when the FGR function is released After entering phase 60 operating position 1 actuator Aux3 initially remains in igni tion position if the release criteria is met Aux3 drives on the compound curve Depending on the FGR operating m...

Page 148: ...amper based on a fictitious flue gas temperature of 0 C If the FGR temperature deviates form the saved value during operation the W FM recalculates the position for the FGR damper If the FGR temperature exceeds the value saved the FGR damper opens further The opening angle is stipulated by parameter FGR MaxPos Fact see ch 6 15 8 If the FGR temperature drops below the value saved the FGR damper clo...

Page 149: ...city 1 Setpoint temperature at FGR sensor 2 Maximum FGR position FGR MaxPos Fact ch 6 15 8 3 Flue gas damper FGR damper compound curve 4 5 Zero curve setting range with factor 100 6 7 Zero curve setting range with factor 50 Example Flue gas damper FGR damper setting in full load Temperature deviation at FGR sensor 30 C 0 C 15 C 30 C Zero curve 100 45 42 38 33 Zero curve 50 45 42 29 16 5 ...

Page 150: ...mpensated operating modes Temp comp TCautoDeact FGR minimum position Param Display Flue Gas Recircula tion FGR MinPos Parameter FGR MinPos limits the closing angle and ensures a minimum flow The minimum position is an absolute value degree of angle and applies to the whole load range The FGR damper drives to minimum position if the W FM calculates a smaller closing angles for the temperature compe...

Page 151: ...uded Shows the actuators connected during the last data back up VSD included Indicates whether a frequency converter module was saved in the backup copy O2 included Indicates whether an O2 module was saved in the backup copy Creating a backup copy Parameter LMV5x AZL creates a backup copy of the W FM in the display and operating unit ABE The existing data is overwritten The data from the W FM can ...

Page 152: ...g the esc key The W FM goes to lockout and displays the reason for the lockout Exit display using the esc key Reset burner using the ENTER key Param Display Updating Enter PW Deactivate PW Param backup Load SW from PC Parameters being updated Abort with ESC Backup Restore running Backup Info LMV5x AZL AZL LMV5x AZL LMV5x Start process with ENTER Abort with ESC Parameters Backup Restore Backup Rest...

Page 153: ...rupts the flame signal and it is possible to check if the W FM initiates a lockout 6 17 2 Safety temperature limiter TÜV Test SLT Test SLT Testload Mod SLT Testload Stg These parameters can be used to check if the safety temperature limiter STL re sponds Parameter SLT Test generates a heat demand deactivates the internal temper ature monitor and the burner drives to the load or stage set under SLT...

Page 154: ...egulator pre setting the pressure switch 7 1 1 Adapting the motor to the frequency converter Frequency converter fitted to burner If the frequency converter is fitted to the burner motor the parameters have been matched to the motor and motor adaption is therefore not required Separate frequency converter On burners with separate frequency converter the automatic motor adaptation must be carried o...

Page 155: ...eavy oil Switch on voltage supply 1 Switch off burner The ABE is in OperationalStat in the sub menu NormalOperation and dis plays current values Exit level using the esc key Select ManualOperation Select Autom Manual Off Set Burner Off The burner switches off Exit level using the esc key 2 Enter password Select Param Display Select Access with HE password for heating engineer Enter HE password usi...

Page 156: ...d via external fuel selection switch the display and operating unit ABE building management system BMS The fuel selector switch has priority over fuel selection via the display and operating unit ABE or building management system BMS Select fuel via ABE Select Operation Select Fuel Select FuelSelect Select Fuel using the dial knob and confirm with ENTER Exit level using the esc key ...

Page 157: ...nverter ch 6 14 3 On dual fuel burner standardisation should only be carried out during the commis sioning of the first fuel The burner requires re commissioning after each standard isation Skip this step on burners without frequency converter Select Param Display Select VSD module Select Configuration Select Speed Select Standardisation Select activated using the dial knob and confirm with ENTER ...

Page 158: ...g esc 2 Check O2 sensor temperature Monitor sensor temperature regularly during heat up phase Select Process Data Select parameter QGO SensorTemp and check sensor temperature ch 6 10 20 Operating temperature 700 15 C Exit level O2 Module press esc twice 3 Deactivating O2 trim Deactivate the O2 trim prior to commissioning the compound curves Deactivate the O2 trim for both fuels oil and gas ch 6 10...

Page 159: ...ulation Skip this step on burners without flue gas recirculation Deactivate flue gas recirculation prior to commissioning the compound curves ch 6 15 2 Select Param Display Select Flue Gas Recirc Select FGR Mode Select deactMinpos using dial knob and confirm with ENTER Exit level FGR Modeusing esc Select FGR MinPos Set 0 using dial knob and confirm with ENTER Exit level Flue Gas Recirc press esc t...

Page 160: ... to the display LoadLimits 2 Check ignition position Select Special positions Select IgnitionPos Select IgnitionPosGas gas butterfly valve setting in ignition position Check IgnPosGas pre setting values see installation and operating manual of burner Only in conjunction with adjustable mixing head Select IgnitionPosAux1 auxiliary motor setting in ignition position Check IgnitionPosAux1 Standard 0 ...

Page 161: ...ect SpecialPositions Select IgnitionPos Select IgnitionPosGas and adjust Use esc key to return to the display IgnitionPos 4 Check gas valves Set new program stop without ignition gas 44 Interv 1 with ignition gas 52 Interv 2 Ensure that the valves open and close correctly The burner attempts to ignite The low gas pressure switch reacts 5 Ignition Open gas isolating valve The burner restarts the se...

Page 162: ... and adjust via air damper setting Air Minimum speed see table must be main tained Burner version Minimum speed NR 40 LN 1LN 1SF 3LN 4LN 50 Exit point 1 using esc key and save with ENTER key Press esc key The menu displays Point Manual and the current actuator positions In menu Point all load points can be adjusted In menu point Manual the current burner capacity can be adjusted manually Select Ma...

Page 163: ...he pressure regulator until gas throughput VB is achieved Check combustion values Determine combustion limit and set excess air ch 7 9 Only in conjunction with flue gas recirculation If the burner is later operated with flue gas recirculation the recirculated flue gas reduces the excess air Set excess air 25 30 above the combustion limit to ensure sufficient com bustion air during the commissionin...

Page 164: ...maximum of 15 load points can be programmed A minimum of 5 load points are required for modulating operation Only in conjunction with frequency converter To ensure an even speed characteristic curve the speed of the new load points should not be altered Increase burner rating in menu Manual whilst observing combustion values Set new intermediate load point using ENTER key Optimise combustion at in...

Page 165: ...l Off Set Automatic Exit level using the esc key If necessary set load controller and O2 trim 15 Carry out data backup Exit level using the esc key The display shows Create parameter backup Start data backup by pressing ENTER key The display shows Parameters are being updated and the Para meters have been saved The values have been backed up from the combustion manager to the ABE Exit level using ...

Page 166: ...d set setpoints only in conjunction with oil preheater type WEV Commission oil preheater 1 Check load limits Select RatioControl Select OilSettings Select LoadLimits Select MinLoadOil and set 0 0 Select MaxLoadOil and set 100 Use esc key to return to the display LoadLimits 2 Check ignition position The setting of the oil quantity regulator in ignition position is pre set when supplied see burner d...

Page 167: ...nPosGas and adjust Use esc key to return to the display IgnitionPos 4 Check pump pressure The pump pressure in ignition position must be approx 1 4 bar less than that of the full load pressure see burner data sheet On light oil burners with magnetic coupling between burner motor and oil pump or with separate oil pump the pump pressure can only be set in the next step during ignition Check pump pre...

Page 168: ...in conjunction with frequency converter Reduce speed VSD step by step whilst observing the combustion values and adjust via air damper setting Air Minimum speed see table must be main tained Burner version Minimum speed Pump driven separately Pump on burner motor NR 50 70 LN 1LN 3LN 60 Exit point 1 using esc key and save with ENTER key Press esc key The menu displays Point Manual and the current a...

Page 169: ...the speed FC Check combustion values Determine combustion limit and set excess air ch 7 9 Only in conjunction with flue gas recirculation If the burner is later operated with flue gas recirculation the recirculated flue gas reduces the excess air Set excess air 25 30 above the combustion limit to ensure sufficient com bustion air during the commissioning of the flue gas recirculation On burners wi...

Page 170: ...crease burner rating in menu Manual whilst observing combustion values Set new intermediate load point using ENTER key Optimise combustion at intermediate load point via air damper setting Air If the burner is equipped with an adjustable mixing head the combustion can be optimised by utilising the interaction between air damper Air and Mixing head Aux1 Carry out load apportionment ch 7 11 Repeat s...

Page 171: ...l Off Set Automatic Exit level using the esc key If necessary set load controller and O2 trim 14 Carry out data backup Exit level using the esc key The display shows Create parameter backup Start data backup by pressing ENTER key The display shows Parameters are being updated and the Para meters have been saved The values have been backed up from the combustion manager to the ABE Exit level using ...

Page 172: ...e burns if touched Do not touch the components Observe the enclosed installation and operating manual for the oil preheater Print No 18 Prior to adjusting ensure that the oil supply is vented all oil shut off devices are open the oil supply has been preheated ring main pressure and oil flow is available Configure parameter C118 at the temperature regulator DR100 to wiring dia gram specification an...

Page 173: ... Select IgnitionPosGas and adjust Use esc key to return to the display IgnitionPos 4 Check pump pressure The pump pressure must be set according to the nozzle selected On light oil burners with magnetic coupling between burner motor and oil pump or with separate oil pump the pump pressure can only be set in the next step during ignition Check pump pressure at pressure gauge Remove closing cap 1 ty...

Page 174: ...ss air O2 content approx 7 whilst observing flame stability For two stage burners only Two stage burners do not have a switch on point ES3 and no operating point BS3 Operating point BS2 is full load and should be adjusted as full loaf point BS3 full load 9 Pre set operating point BS2 Select BS2 Valve for nozzle 2 opens Check combustion values and if necessary adjust via air damper setting Air 10 P...

Page 175: ...behaviour If necessary optimise operating behaviour Adjust switch off point in menu Without start whilst increasing the air damper setting to avoid soot and CO formation Adjust switch on points in menu With start 15 Check start behaviour Switch off and restart burner Check start behaviour and if necessary correct ignition position If the ignition position has been altered Re check start behaviour ...

Page 176: ...ller and temperature monitor function the connected sensors must be defined ch 3 3 20 Select Sensor Select Define connected sensor with the dial knob and confirm with Enter ch 6 12 3 Use esc to return to the display Sensor Select To ensure the actual value is entered correctly the measuring range of the sensors must be defined ch 6 12 5 Select menu for the sensor defined and confirm with Enter Sen...

Page 177: ...t for the operating mode with internal load controller ch 6 12 1 Select LoadController Select ControlParam Select SetpointW1 Set setpoint using the dial knob and confirm with Enter Use esc to return to the display ControlParam If the second setpoint W2 is required Repeat procedure for SetpointW2 7 Set temperature sensor function With an activated temperature monitor the switch threshold and switch...

Page 178: ...es the controlled system and forms the PID parameters ch 6 12 15 One PID parameter set can be selected from five standard parameter sets ch 6 12 8 Identifying the controlled system via adaption Select ControlParam Select SW_FilterTmeCon using the dial knob and confirm with Enter The filter time must be 2 4 seconds ch 6 12 10 Use esc to return to the display ControlParam Select Adaption Select Adap...

Page 179: ... on point controller ON Select ControlParam Select Sd_Stage1On Set switch differential using the dial knob and confirm with Enter Use esc to return to the display Sd_Stage1On Set switch off point stage 1 controller OFF Select Sd_Stage1Off Set switch differential using the dial knob and confirm with Enter Use esc to return to the display Sd_Stage1Off Set switch off point stage 2 Select Sd_Stage2Off...

Page 180: ... with the dial knob and confirm with Enter Use esc to return to the display AdditionalSens Select Setp AddSensor Set setpoint using the dial knob and confirm with Enter Use esc to return to the display Setp AddSensor 3 Set switch thresholds The switch thresholds relate to the current setpoint or if an additional sensor is connected to Setp AddSensor ON threshold Select ThresholdOn Set threshold us...

Page 181: ...geSetp_Stage 6 Set residence time For modulating operation Select MaxTmeMod Set setpoint step using the dial knob and confirm with Enter Use esc to return to the display MaxTmeMod For multi stage operation Select MaxTmeStage Set setpoint step using the dial knob and confirm with Enter Use esc to return to the display MaxTmeStage 7 Carry out data backup Exit level using the esc key The display show...

Page 182: ...t O2 Alarm and confirm with ENTER 2 Set O2 minimum monitor An O2 MinValue has to be defined as the lower limit in each load point either by driving to combustion limit and take over the value determined direct input only possible if the O2 minimum value at the combustion limit is known Driving to combustion limit and take over the value determined Select O2 Alarm Select load point using dial knob ...

Page 183: ...ct O2 Control and confirm with ENTER Select load point using dial knob and confirm with ENTER key Burner drives to load point Once the O2 content has stabilised confirm with ENTER Turn dial knob to the right The air determining actuators drive open on the compound curve reduce the air quantity and thus the O2 content The O2 Setpoint should be approx 0 5 1 points above the 02 Min Value at the combu...

Page 184: ...onfirm with ENTER Use esc to return to the display Autom Manual Off Use info to return to OperationalStat Select NormalOperation 4 Check O2 trim Close control circuit and drive to full load via 3 pole switch Check control behaviour whilst monitoring O2 value in the display and operating unit The burner drives on the compound curves to full load Once the O2 sensor has reached operating temperature ...

Page 185: ...t ch 6 10 4 O2 trim remains suspended despite a prolonged period of constant load Check status of O2 controller ch 6 10 13 Increase parameter LoadCtrlSus pend see ch 6 10 4 O2 monitor reacts to load change Check setting of O2 monitor ch 7 4 1 Increase parameter O2ModOffset 5 Set flue gas temperature warning threshold Drive to full load Check flue gas temperature Select O2 Module Select Configurati...

Page 186: ...3 For detailed information see instructions Lambda Transmitter LT3 and combination sensor KS1 D Setting the language Select language in main menu F3 Enter password Select Enter Password in main menu F3 Enter password 8F3W and confirm Set CO limit value Select Config LimitValue in main menu F3 Select Config LimitValue 1 Select LV fuel 1 Select Config fixed value and set 100 ppm Return to main menu ...

Page 187: ...lue gas temperature warning threshold SelectMaxTempFlueGas Set 850 C using dial knob and confirm with Enter Use esc to return to the display O2 Module On dual fuel burners set both MaxTempFlGasGas and MaxTempFlGasOil 3 Set blocking time To ensure that an increased CO content during burner start does not initiate a safety shutdown the factor for the blocking time must be set to a minimum of 10 ch 6...

Page 188: ...e display Flue Gas Recirc 4 Editing load points Select CurveParams Press ENTER The menu displays Point Manual and the current actuator positions Select Point and confirm with ENTER Select load point using dial knob and confirm with ENTER key Confirm query Change point with ENTER Confirm query With start with ENTER 5 Set NOX required Select Aux3 using dial knob and confirm with Enter The display sh...

Page 189: ...lect Aux3 using dial knob and confirm with Enter Open flue gas damper Aux3 using the dial knob and reduce NOX by approx 2 ppm Check operating behaviour If the temperature deviates greatly from the value noted down Exit point using esc and save with ENTER Current temperature is saved in the point If the temperature deviates only minimally from the value noted down Exit point without saving press es...

Page 190: ...mining actuat ors To determine the lowest differential pressure the burner must drive to the com bustion limit in point 2 On dual fuel burners the setting should be carried out with fuel Gas Call up function O2 Alarm see ch 6 10 2 Select menu O2 Alarm and confirm with Enter Select load point 2 using dial knob and confirm with Enter key Select parameter P Air Manual and confirm with Enter The displ...

Page 191: ...lue gas temperature Check flue gas temperature Ensure that the flue gas temperature complies with the data provided by the boiler manufacturer If necessary adjust flue gas temperature e g Increase burner capacity in partial load to avoid condensation in the flue gas ducts except on condensing units Reduce burner capacity in full load to improve efficiency Adjust heat exchanger to the data provided...

Page 192: ... TM Measuring time seconds 120 seconds Calculate normal volume Calculate the normal volume VN using the following formula VN QN η Hi VN 6000 kW 0 92 10 35 kW m 630 1 m h Calculate conversion factor Determine gas temperature tGas and pressure PGas at gas meter Determine barometric air pressure PBaro from table Height above sea level m 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 PBaro ...

Page 193: ...tings apportionment The load points are automatically assigned relative to the capacity Incorrect load distribution can cause operating problems during the load control Assign capacity in for load point using the following formula Enter the calculated capacity for load point in Load Load Throughput load point Throughput full load 100 ...

Page 194: ...lead to burns Allow components to cool Servicing must only be carried out by qualified personnel The combustion plant should be serviced annually Depending on site conditions more frequent checks may be required Components which show increased wear and tear or whose design lifespan is or will be exceeded prior to the next service should be replaced as a precaution The design lifespan of the compon...

Page 195: ...mixing head ignition flame monitoring gas carrying components gas connection pressure and setting pressure oil pump pump pressure and suction resistance pressure switch safety interlock circuit Check combustion values if necessary re adjust the burner Enter combustion values and settings in the commissioning record and or test sheet 8 2 Service plan For detailed information see installation and op...

Page 196: ...tely shows the shutdown behaviour and the fault diagnosed as a plain text display WARNING Damage resulting from incorrect fault repair Incorrect fault repair can cause damage to the equipment and injure personnel Do not carry out more than 2 lockout resets successively Faults must be rectified by qualified personnel If the ABE displays a fault Exit display using the esc key Reset burner using the ...

Page 197: ...ubleshooting 83054802 1 2018 07 La 197 228 9 1 1 Deactivating an alarm OperationalStat Alarm act deact Parameter Alarm act deact deactivates or activates the alarm output X3 01 2 A reset or a burner start automatically resets the deactivation and the alarm output is ready for use again ...

Page 198: ...or diagnostic display ch 9 4 Select History using dial knob and confirm with Enter Browse history with the dial knob The display changes every 5 seconds between plain text and diagnostic display The Enter key can be used to manually change the display Exit History using esc key Normal operation Status Reset Fault history Lockout history Safety loop is open 1 Class 00 Oil Code 21 Phase 24 Diag 00 L...

Page 199: ...or diagnostic display ch 9 4 Select History using dial knob and confirm with Enter Browse history with the dial knob The display changes every 5 seconds between plain text and diagnostic display The Enter key can be used to manually change the display Exit History using esc key Normal operation Status Reset Fault history Lockout history Air pressure is off 1 01 04 15 13 22 C 28 D 00 P 62 Start No ...

Page 200: ...nt at the corresponding output This could be triggered by reverse voltage caused by an operating signal e g during a lamp test 02 Fan contactor contact 03 Fuel selection Oil 04 Fuel selection Gas 05 Reset 06 Max oil pressure switch 07 Minimum oil pressure switch 08 Valve proving gas pressure switch 09 Anti syphon valve safety valve Oil SV return signal X6 03 0A Fuel valve Oil V1 return signal X8 0...

Page 201: ...xiliary actuator2 04 Fault compound curve auxiliary actuator3 05 Fault compound curve frequency converter 0A P part outside of permissible range Check O2 control parameters if necessary adjust ch 6 10 4 0B I part outside of permissible range 0C Tau outside of permissible range 0D O2 setpoint outside of permissible range Check values if necessary readjust O2 trim ch 6 10 2 0E O2 min value outside o...

Page 202: ... compound curves due to lack of heat de mand Set compound curves in Manual oper ating mode ch 6 7 Prevents shutdown by the load controller Shutdown only occurs if the temperature monitor responds The current load point being adjusted can still be saved 1C 01 3F Ignition position for the relevant actuator is missing If several faults occur the diagnosis codes are add up 01 Air actuator ignition pos...

Page 203: ...urement ch 3 3 21 Check speed standardisation ch 6 14 3 1F 01 Internal test of frequency converter module failed Internal fault 1 02 Rotational direction of fan incorrect Check rotation direction of motor Check transmitter disc for speed measurement ch 3 3 21 Check rotational direction of frequency converter 03 Impulse fault during speed measurement Check transmitter disc and proximity switch for ...

Page 204: ...de 02 No flame flame sensor QR 03 No flame flame sensor QR and ionisation electrode 27 Impermissible ON signal from air pressure switch Check air pressure switch ch 3 3 4 Check pressure switch release ch 3 4 4 28 Impermissible OFF signal from air pressure switch 29 Impermissible ON signal from fan contactor contact Check electrical connection and fan con tactor contact ch 3 3 5 Supply for contacto...

Page 205: ...ck electrical connection at output Depending on the operating phase an imper missible voltage signal is present at the cor responding output This could be triggered by reverse voltage caused by an operating signal e g during a lamp test 02 Fuel valve Oil V1 X8 02 X8 03 04 Fuel valve Oil V2 X7 01 08 Fuel valve Oil V3 X7 02 10 External solenoid valve Gas safety valve Gas SV X9 01 1 20 Fuel valve Gas...

Page 206: ... longer required ch 6 9 4 01 Stop in phase 24 pre purge position 02 Stop in phase 32 auxiliary actuator3 in pre purge position 03 Stop in phase 36 ignition position 04 Stop in phase 44 flame signal 05 Stop in phase 52 ignition pilot valve OFF 06 Stop in phase 72 post purge position 07 Stop in phase 76 auxiliary actuator3 in post purge position 47 Signal start release Gas input X7 03 2 miss ing 48 ...

Page 207: ...de or Config X5 03 see ch 6 8 9 0D Prohibited setting HT FG RedCo Change setting OEM level 0E Prohibited setting in COx OptgMode COx Gas and OptgMode COx Oil are deactivated unequally Change setting ch 6 11 1 Function is only available for type LMV52 4 58 Parameter set is corrupted Reset W FM see ch 9 1 If the error occurred during a parameter change Check parameter that was last changed for plaus...

Page 208: ...uator2 86 01 03 Prohibited condition internal load controller Internal fault 1 87 01 03 Prohibited condition ABE Check CAN Bus and Bus connection ch 5 1 Internal fault 1 88 01 Plausibility fault actuators Internal fault 1 02 Plausibility fault load controller 03 Plausibility fault ABE 04 Plausibility fault frequency converter module 05 Plausibility fault O2 module 90 ROM CRC error auxiliary actuat...

Page 209: ... converter 12 Error during analogue to digital conversion 13 Actuator position outside of permissible range 0 90 Check actuator position if necessary turn back mechanically 15 CAN Bus connection error Check CAN Bus connection ch 5 1 16 CRC error of parameter page 17 Page was open too long Reset W FM see ch 9 1 If the error occurred during a parameter change Check parameter that was last changed fo...

Page 210: ...r fault Internal fault 1 A6 40 Page was open too long Reset W FM see ch 9 1 If the error occurred during a parameter change Check parameter that was last changed for plausibility If the reset does not achieve a fault free con dition Load data from the ABE ch 6 16 1 If none of the actions listed leads to a fault free condition Replace W FM A6 41 43 Internal load controller fault Internal fault 1 A6...

Page 211: ...nput X60 1 4 Check electrical connection Check signal ripple voltage 71 Signal fluctuation input X60 2 4 72 Signal fluctuation input X60 3 4 73 Signal fluctuation PWM 74 Signal fluctuation U input X61 2 75 Signal fluctuation I input X61 3 76 Signal fluctuation U input X62 2 4 77 Signal fluctuation I input X62 3 4 A6 78 7F Load controller input signals too great or in correct polarity The diagnosti...

Page 212: ... parameters failed 0D OilSettings was selected in the menu the fuel selection is set to Gas Select fuel Gas ch 6 4 2 0E GasSettings was selected in the menu the fuel selection is set to Oil Select fuel Oil ch 6 4 2 15 1A Internal fault ABE Internal fault 1 1B Error during data backup Reset W FM see ch 9 1 Repeat data backup ch 6 16 1 1C 28 Internal fault ABE 30 Bus communication error Check connec...

Page 213: ...cy converter Carry out speed standardisation ch 7 2 1 1 The burner requires re commissioning after each standardisation 0E Error internal speed calculation Internal fault 1 15 CAN Bus connection error Check CAN Bus and Bus connection ch 5 1 16 CRC error of parameter page Reset W FM see ch 9 1 If the error occurred during a parameter change Check parameter that was last changed for plausibility If ...

Page 214: ...n test Internal fault 1 23 Internal resistance of O2 sensor less than 5 Ω or greater than 150 Ω Check electrical connection ch 3 3 25 Replace O2 sensor ch 6 10 22 24 Reaction time of O2 sensor greater than 5 seconds Check installation position of O2 sensor ch 4 1 Clean O2 sensor Replace O2 sensor sensor ageing If necessary increase O2 control limit 25 Error during sensor test ch 6 10 22 O2 value f...

Page 215: ...n full load ch 6 10 4 Repeat standardisation in the relevant load point ch 6 10 3 09 Test time for O2 monitor missing Change setting OEM level 0A Internal W FM fault in conjunction with O2 trim Internal fault 1 B6 01 CO signal outside of the permissible range ch 6 11 Check CO resistance circuit board connection ch 3 3 24 02 Prohibited setting Time COx Alarm Check setting ch 6 11 2 03 Flue gas reac...

Page 216: ... achieve a fault free con dition Carry out software update of ABE Replace relevant component 02 Load controller software version in the W FM not current 04 ABE software version not current 08 Actuator software version not current 10 Frequency converter module software version in the W FM not current 20 Software version of O2module not current D1 01 03 Prohibited condition of frequency converter mo...

Page 217: ...O 21 in sufficient Increase factor NumberTauSuspend see ch 6 10 5 08 O2 value above 135 during controller initial isation in phase 60 Check O2 sensor malfunction secondary air Increase factor NumberTauSuspend see ch 6 10 5 F4 01 Connection error CAN Bus between W FM and O2 module Check CAN Bus connection ch 5 1 15 Temperature combustion air sensor outside of permissible range 20 800 C Check electr...

Page 218: ...d W FM 200 10 Technical documentation 83054802 1 2018 07 La 218 228 10 Technical documentation 10 1 Frequency converter Detailed information see Frequency converter CD The construction and arrangement of diagnostic LEDs is dependent on the size of the frequency converter ...

Page 219: ... readily available USB interfaces converter USB to RS232 is also required for the connection to the USB port DIP switches The analogue inputs AIN1 and AIN2 are configured via setting of the DIP switches Factory setting 4 20 mA Switch 1 ON Switch 2 ON Diagnostic LED s LED Signal Description 1 BUS S System bus status not used 2 BUS E System bus fault not used 3 DS OFF No mains voltage and no control...

Page 220: ...ailable USB interfaces converter USB to RS232 is also required for the connection to the USB port Diagnostic LED s LED Signal Description 1 DOUT1 yellow Alarm from frequency converter digital output 1 2 DOUT2 yellow Signal at digital output 2 3 BRAKE yellow Mechanical brake 4 TEMP yellow Excess temperature at motor 5 DIN4 yellow Signal at digital input 4 6 DIN3 yellow Signal at digital input 3 7 D...

Page 221: ...FF No mains voltage and no control voltage Green Operation FC operating Green ON red flashing Frequency converter not ready for oper ation control voltage applied but no mains voltage Flashing green 0 5 Hz 1 Ready for operation 4 Hz 1 Start blocked Flashing red green 4 Hz 1 Warning 1 25 Hz 1 Intensity overload Flashing red Number flashing codes Fault flashing codes see Frequency converter CD 1 1 H...

Page 222: ...e over release 30 Changing over operation mode 121 Check O2 trim 184 Circulation time 77 CO content 191 CO control blocking time 187 CO controller 116 CO function 111 118 CO limit value 186 CO limit value exceeded 118 CO measurement amplifier 116 186 CO monitor 116 CO resistance board 116 CO resistance circuit board 34 CO switching threshold 114 Cold start 61 134 180 COM interface 50 Combustion ai...

Page 223: ...124 Flue gas recirculation FGR 64 142 188 Flue gas temperature 43 58 111 114 191 Flue gas temperature sensor 34 111 Flue gas velocity 43 105 Forced intermittent 59 80 Frequency converter 14 25 60 63 85 97 140 154 218 Fuel 66 Fuel meter 34 57 63 65 68 Fuel selection 25 57 66 Fuel values 109 Fuel valve 39 Fuel valves 40 Full load 94 163 169 Fuse 42 G Gas connection pressure 12 Gas meter 34 68 Gas pr...

Page 224: ...or adaption 154 Multi stage 30 31 39 82 N Nernst voltage 113 Normal operation 57 66 Normal start 79 Nozzle circulation 26 39 77 Number of lockouts 69 O O2 adaption point 104 O2 alarm 100 O2 block time 108 O2 content 113 O2 control parameters 104 O2 control variable limit 107 O2 controller 58 98 115 O2 controller manipulated variable 112 O2 maximum value 101 O2 minimum value 100 O2 module 14 63 O2 ...

Page 225: ...set start counter 67 Resetting operating hours 67 Residence time 135 Resistance board 116 Resistance circuit board 34 Restore 152 Restoring 152 Rotation direction 62 S Safety circuit 24 Safety measures 10 Safety shutdown 54 Safety temperature limiter 65 153 Safety time limiter 24 Scaling 127 Send cycle 62 74 Sensor 124 Sensor current 28 29 Sensor Select 122 Sensor short circuit 124 Sensor temperat...

Page 226: ...ure limiter 61 64 Temperature monitor 33 133 Temperature sensor 33 122 124 Temperature sensor flue gas recirculation 147 Test O2 sensor 115 Thermostat 30 Throughput 34 68 169 Time 57 72 Time constant Tau 102 104 Time delay 118 Time out 74 Timeout 62 Times 77 84 Torque 42 Transport 43 Tree stage 31 TÜV Test 65 Two stage 31 Type description 69 Type of Fuel 109 Type of protection 42 U Unit 62 Units 7...

Page 227: ...83054802 1 2018 07 La ...

Page 228: ...Weishaupt GmbH 88475 Schwendi Weishaupt close by Addresses telephone numbers etc can be found at www weishaupt de We reserve the right to make changes All rights reserved Water heaters Energy storage The diverse program of potable water and energy storage for various heat sources includes storage volumes of 70 to 3 000 litres In order to minimize storage losses potable water cylinders from 140 to ...

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