Weishaupt W-FM 100 User guide

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200 83054802 1/2018-07

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
83054802 1/2018-07 La 2-228
1 User instructions..............................................................................................................8
1.1  Target group.................................................................................................................. 8
1.2  Symbols.......................................................................................................................... 8
1.3  Guarantee and Liability............................................................................................... 9
2 Safety .................................................................................................................................. 10
2.1  When gas can be smelled.......................................................................................10
2.2  Safety measures.........................................................................................................10
2.2.1  Normal operation................................................................................................ 10
2.2.2  Electrical connection......................................................................................... 10
2.2.3  Gas supply........................................................................................................... 11
2.3  Alterations to the construction of the equipment ...............................................11
2.4  Noise emission ...........................................................................................................11
2.5  Disposal .......................................................................................................................11
3 Product description ..................................................................................................... 12
3.1  Variations .....................................................................................................................12
3.2  Function........................................................................................................................12
3.2.1  Burner Control.................................................................................................... 12
3.2.2  Low gas programme.......................................................................................... 12
3.2.3  Valve proving....................................................................................................... 13
3.2.4  Load controller.................................................................................................... 14
3.2.5  Variable speed drive.......................................................................................... 14
3.2.6  O2 trim / monitoring .......................................................................................... 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  Minimum oil pressure switch ........................................................................... 25
3.3.8  Max. oil pressure switch ................................................................................... 25
3.3.9  Start release Oil.................................................................................................. 26
3.3.10  Heavy oil immediate start............................................................................... 26
3.3.11  Start release Gas............................................................................................. 26
3.3.12  Valve proving gas pressure switch.............................................................. 26
3.3.13  High gas pressure switch.............................................................................. 27
3.3.14  Low gas pressure switch............................................................................... 27
3.3.15  Flame sensor .................................................................................................... 28
3.3.16  External load controller (X5-03)................................................................... 30
3.3.17  External load controller (X62)....................................................................... 31
3.3.18  External load controller (Bus)........................................................................ 31
3.3.19  Setpoint switch-over....................................................................................... 32

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
83054802 1/2018-07 La 3-228
3.3.20  Temperature sensor........................................................................................ 33
3.3.21  Speed measurement....................................................................................... 33
3.3.22  Fuel Meter ......................................................................................................... 34
3.3.23  Flue gas temperature sensor ........................................................................ 34
3.3.24  Combustion air sensor / CO resistance circuit board............................ 34
3.3.25  O2 sensor ......................................................................................................... 35
3.4  Outputs ........................................................................................................................36
3.4.1  Alarm..................................................................................................................... 36
3.4.2  Motor..................................................................................................................... 36
3.4.3  Oil pump / magnetic coupling......................................................................... 36
3.4.4  Start signal, pressure switch relief................................................................. 37
3.4.5  Ignition .................................................................................................................. 37
3.4.6  Anti syphon valve................................................................................................ 38
3.4.7  Oil fuel valves...................................................................................................... 39
3.4.8  Fuel valves Gas .................................................................................................. 40
3.4.9  Operational display............................................................................................ 40
3.4.10  Analogue output............................................................................................... 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  Operation and system information.........................................................................66
6.4.1  Normal operation................................................................................................ 66
6.4.2  Fuel selection...................................................................................................... 66
6.4.3  Operating hours ................................................................................................. 67
6.4.4  Start-up counter................................................................................................. 67
6.4.5  Fuel Meter............................................................................................................ 68
6.4.6  Number of lockouts ........................................................................................... 69
6.4.7  Flame Signal........................................................................................................ 69
6.4.8  Product identification ........................................................................................ 69
6.4.9  Software version................................................................................................. 69
6.4.10  Burner identification........................................................................................ 70
6.5  Setting the display.....................................................................................................71
6.5.1  Setting the language ......................................................................................... 71
6.5.2  Set contrast......................................................................................................... 71

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
83054802 1/2018-07 La 4-228
6.5.3  Date/Time............................................................................................................. 72
6.5.4  Units ...................................................................................................................... 72
6.6  Interfaces .....................................................................................................................73
6.6.1  Select interfaces................................................................................................. 73
6.6.2  eBus...................................................................................................................... 74
6.6.3  Modbus................................................................................................................. 74
6.6.4  Trending data...................................................................................................... 75
6.7  Manual / Automatic / Off..........................................................................................76
6.8  Burner Control............................................................................................................77
6.8.1  Times..................................................................................................................... 77
6.8.2  Signalling start prevention................................................................................ 79
6.8.3  Normal or direct start ........................................................................................ 79
6.8.4  Oil pump............................................................................................................... 80
6.8.5  Forced intermittent............................................................................................. 80
6.8.6  Pre-purge Gas.................................................................................................... 80
6.8.7  Continuous running fan .................................................................................... 81
6.8.8  Additional air pressure switch......................................................................... 81
6.8.9  Configuring input X5-03 .................................................................................. 82
6.8.10  Configuring output X4-03 ............................................................................. 83
6.8.11  Extraneous light................................................................................................ 83
6.8.12  Repetition counter........................................................................................... 83
6.9  Electronic 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
6.10.3  O2 trim.............................................................................................................102
6.10.4  O2 control parameters.................................................................................104
6.10.5  O2 start mode................................................................................................108
6.10.6  Type of Fuel ....................................................................................................109
6.10.7  O2 sensor .......................................................................................................110
6.10.8  Service interval for O2 sensor....................................................................110
6.10.9  Define temperature sensor..........................................................................111
6.10.10  Flue gas temperature warning threshold...............................................111
6.10.11  Combustion efficiency ...............................................................................112
6.10.12  O2 controller control variable...................................................................112
6.10.13  Status O2 controller...................................................................................112
6.10.14  Air rating........................................................................................................112
6.10.15  Diagnostic code ..........................................................................................113
6.10.16  O2 content ...................................................................................................113
6.10.17  O2 setpoint ..................................................................................................114

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
83054802 1/2018-07 La 5-228
6.10.18  Combustion air temperature / CO switching threshold.....................114
6.10.19  Flue gas temperature .................................................................................114
6.10.20  O2 sensor temperature .............................................................................114
6.10.21  O2 sensor heating capacity .....................................................................115
6.10.22  O2 sensor wear and tear ..........................................................................115
6.10.23  Activate / deactivate O2 controller.........................................................115
6.11  CO monitor and CO controller ......................................................................... 116
6.11.1  Operating mode CO function.....................................................................118
6.11.2  Time delay limit value exceeded.................................................................118
6.12  Load controller ...................................................................................................... 119
6.12.1  Setpoint ...........................................................................................................119
6.12.2  Load controller operating mode.................................................................120
6.12.3  Sensor selection (actual value) ..................................................................122
6.12.4  Analogue inputs .............................................................................................123
6.12.5  Measuring range............................................................................................124
6.12.6  External setpoint ............................................................................................125
6.12.7  Analogue output.............................................................................................126
6.12.8  Control parameters of internal load controller ........................................128
6.12.9  Control 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................................................................................................................ 138
6.13.1  Addressing......................................................................................................138
6.13.2  Delete curves..................................................................................................139
6.13.3  Position control ..............................................................................................139
6.14  VSD / Frequency converter................................................................................ 140
6.14.1  Frequency converter release contact .......................................................140
6.14.2  Speed measurement.....................................................................................140
6.14.3  Speed standardisation .................................................................................140
6.14.4  Actual speed...................................................................................................141
6.14.5  Setpoint output ..............................................................................................141
6.14.6  Speed deviation.............................................................................................141
6.15  Flue Gas Recirculation........................................................................................ 142
6.15.1  FGR function ..................................................................................................142
6.15.1.1  Fan on burner.......................................................................................... 142
6.15.1.2  Separate fan............................................................................................ 144
6.15.2  FGR Mode.......................................................................................................146
6.15.3  Define temperature sensor..........................................................................147
6.15.4  FGR sensor temperature .............................................................................147
6.15.5  FGR release....................................................................................................147
6.15.6  Temperature compensation ........................................................................148
6.15.7  Operating temperature.................................................................................150

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
83054802 1/2018-07 La 6-228
6.15.8  Position limit FGR damper ..........................................................................150
6.16  Data backup .......................................................................................................... 151
6.16.1  Backup copy...................................................................................................151
6.16.2  Updating software.........................................................................................152
6.17  TÜV Test................................................................................................................. 153
6.17.1  Loss of flame...................................................................................................153
6.17.2  Safety temperature limiter............................................................................153
7 Commissioning............................................................................................................154
7.1  Prerequisite .............................................................................................................. 154
7.1.1  Adapting the motor to the frequency converter........................................154
7.2  Adjusting the burner............................................................................................... 155
7.2.1  Preparatory measures .....................................................................................155
7.2.1.1  Carry out speed standardisation .......................................................... 157
7.2.1.2  O2 module presetting ............................................................................. 158
7.2.1.3  Deactivate flue gas recirculation........................................................... 159
7.2.2  Adjusting gas side ...........................................................................................160
7.2.3  Adjust modulation oil side..............................................................................166
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 amplifierLT3....................................................................186
7.5.2  Set CO control .................................................................................................187
7.6  Flue gas recirculation (temperature compensated) ........................................ 188
7.7  Set pressure switches ........................................................................................... 190
7.8  Concluding work..................................................................................................... 190
7.9  Check combustion.................................................................................................. 191
7.10  Calculate gas throughput................................................................................... 192
7.11  Ratings apportionment........................................................................................ 193
8 Servicing..........................................................................................................................194
8.1  Notes on servicing.................................................................................................. 194
8.2  Service plan.............................................................................................................. 195
9 Troubleshooting ..........................................................................................................196
9.1  Procedures for fault conditions............................................................................ 196
9.1.1  Deactivating an alarm......................................................................................197
9.2  Fault............................................................................................................................ 198
9.3  Lockout...................................................................................................................... 199
9.4  Rectifying faults....................................................................................................... 200

Installation and operating instruction
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

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
1 User instructions
83054802 1/2018-07 La 8-228
1 User instructions
Translation of original
operating instructions
This manual forms part of the equipment and must be kept on site.
Carefully read the manual prior to working on the unit.
1.1 Target group
The manual is intended for the operator and qualified personnel. They should be
observed by all personnel working with the unit.
Work on the unit must only be carried out by personnel who have the relevant 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 medium risk.
Non observance can lead to environmental damage,
serious injury or death.
CAUTION
Danger with low risk.
Non observance can cause damage to the equip-
ment and injury to personnel.
Important information
Requires direct action
Result after an action
Itemisation
… Range of values

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
1 User instructions
83054802 1/2018-07 La 9-228
1.3 Guarantee and Liability
Guarantee and liability claims for personal and equipment damage are excluded, if
they can be attributed to one or more of the following causes:
non approved application,
non-observance of the manual,
operation with faulty safety equipment,
continual operation despite a fault,
improper installation, commissioning, operation and service,
repairs, which have been carried out incorrectly,
the use of non original Weishaupt parts,
force majeure,
unauthorised modifications made to the unit,
the installation of additional components, which have not been tested with the
unit,
the installation of combustion chamber inserts, which impede full flame forma-
tion,
unsuitable fuels,
defects in the inlet lines.

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200
2 Safety
83054802 1/2018-07 La 10-228
2 Safety
The combustion manager W-FM 100/200 is suitable for use with:
oil burners
gas burner
dual fuel and triple fuel burners,
dual gas burners.
Improper use could:
endanger the health and safety of the user or third parties,
cause damage to the unit or other material assets.
2.1 When gas can be smelled
Avoid open flames and spark generation, for example:
do not operate light switches,
do not operate electronic equipment,
do not use mobile telephones.
Open doors and windows.
Close gas isolating valve.
Warn the inhabitants, do not ring door bells.
Leave the building.
Inform the heating contractor or gas supplier from outside of the building.
2.2 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 unit must be kept in a legible condition.
Stipulated settings, service and inspection work should be carried out at regular
intervals.
Only operate the unit with its cover closed.
Do not touch moving parts during operation.
Do not touch the oil carrying parts of medium and heavy oil burners during oper-
ation.
2.2.2 Electrical connection
For work carried out on live components:
Observe the accident prevention instructions DGUVRegulation3 and adhere to
local directives,
tools in accordance with EN 60900 should be used.