Weishaupt W-FM 25 User guide

Installation and operating instruction
Combustion manager W-FM 25 83293902 • 2/2014-09

60040000
Conformity certification
Manufacturer:
Address:
Product: Combustion Manager
The product described above conforms with
the regulations of directives:
This product is labelled as follows:
Schwendi, 02.09.2014
ppa. ppa.
Dr. Schloen Denkinger
Manager Research Manager Production and
and Development Quality Management
Max Weishaupt GmbH
Max-Weishaupt-Straße
D-88475 Schwendi
W-FM 25
GAD 2009 / 142 / EC
PED 97 / 23 / EC
LVD 2006 / 95 / EC
EMC 2004 / 108 / EC
Sprachschlüssel 02
CE-0085

1 User instructions ..................................................................................................................... 5
1.1 User guide ............................................................................................................. 5
1.1.1 Symbols ................................................................................................................. 5
1.1.2 Target group ......................................................................................................... 6
1.2 Guarantee and Liability ....................................................................................... 6
2 Safety ............................................................................................................................................ 7
2.1 Designated application ....................................................................................... 7
2.2 When gas can be smelled ................................................................................. 7
2.3 Safety measures .................................................................................................. 7
2.3.1 Normal operation ................................................................................................. 7
2.3.2 Electrical connection ........................................................................................... 7
2.3.3 Gas supply ............................................................................................................ 8
2.4 Alterations to the construction of the equipment ......................................... 8
2.5 Noise emission ..................................................................................................... 8
2.6 Disposal ................................................................................................................. 8
3 Product description ............................................................................................................... 9
3.1 Inputs and outputs ............................................................................................... 9
3.1.1 Gas burner ............................................................................................................ 9
3.1.2 Oil burner ............................................................................................................ 10
3.1.3 Dual fuel burner ................................................................................................. 11
3.2 Technical data ................................................................................................... 12
3.2.1 Electrical data ................................................................................................... 12
3.2.2 Ambient conditions ........................................................................................... 12
3.2.3 Dimensions ......................................................................................................... 13
4 Operation .................................................................................................................................. 14
4.1 Operating panel ................................................................................................ 14
4.2 Display ................................................................................................................. 16
4.2.1 Info level .............................................................................................................. 17
4.2.2 Service level ....................................................................................................... 20
4.2.3 Parameter level .................................................................................................. 22
4.2.4 Access level ....................................................................................................... 26
4.3 Linearisation ....................................................................................................... 27
5 Electrical connection ........................................................................................................... 28
6 Commissioning ...................................................................................................................... 29
6.1 Gas burner ......................................................................................................... 29
6.2 Gas burner with speed control ...................................................................... 34
6.3 Oil burner ............................................................................................................ 40
6.4 Dual fuel burner ................................................................................................. 45
6.4.1 Adjusting gas side ............................................................................................ 45
6.4.2 Adjusting oil side ............................................................................................... 50
7 Troubleshooting .................................................................................................................... 55
7.1 Procedures for fault conditions ..................................................................... 55
7.1.1 Display off ........................................................................................................... 55
7.1.2 Display flashes ................................................................................................... 55
7.1.3 Detailed fault code ........................................................................................... 56
Installation and operating instruction
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7.2 Rectifying faults ................................................................................................. 57
8 Spares ......................................................................................................................................... 62
9 Technical documentation ................................................................................................. 64
9.1 Program sequence ........................................................................................... 64
10 Key word index ...................................................................................................................... 66
Installation and operating instruction
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1 User instructions
This installation and operating manual forms part of the appliance and must be kept
on site.
Observe installation and operating manual of the burner.
This installation and operating manual supplements the following chapters in the in-
stallation and operating manual of the burner:
▪Technical description and/or Product description
▪Electrical connection,
▪Commissioning and operation and/or Commissioning
▪Cause and rectification of faults and/or Troubleshooting
▪Technical data.
The chapter Display and operating modes and operation is replaced completely.
1.1 User guide
1.1.1 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 equipment
and injury to personnel.
Important information
Requires direct action
Result after an action
Itemisation
Range of values
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Combustion manager W-FM 25
1 User instructions
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1.1.2 Target group
These installation and operating instructions are intended for the operator and quali-
fied personnel. They should be observed by all personnel working on the unit.
Work on the unit must only be carried out by personnel who have the relevant training
and instruction.
Persons with limited physical, sensory or mental capabilities may only work on the unit
if they are supervised or have been trained by an authorised person.
Children must not play near or on the unit.
1.2 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 installation and operating instruction,
▪operation with faulty safety equipment,
▪continual operation despite a fault,
▪improper installation, commissioning, operation and service,
▪unauthorised modifications made to the unit,
▪the installation of additional components, which have not been tested with the unit,
▪the installation of combustion chamber inserts, which impede full flame formation,
▪repairs, which have been carried out incorrectly,
▪the use of non original Weishaupt parts,
▪unsuitable fuels,
▪defects in the inlet lines,
▪acts of God.
Installation and operating instruction
Combustion manager W-FM 25
1 User instructions
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2 Safety
2.1 Designated application
The combustion manager W-FM 25 is suitable for use with:
▪oil burners
▪gas burners
▪dual fuel burners.
Improper use could:
▪endanger the health and safety of the user or third parties,
▪cause damage to the appliance or other material assets.
2.2 When gas can be smelled
Avoid open flames and spark generation, for example:
▪do not operate light switches,
▪do not operate electronic equipment,
▪do not use mobile telephones.
▶Open doors and windows.
▶Close gas isolating valve.
▶Warn the inhabitants (do not ring door bells).
▶Leave the building.
▶Inform the heating company or gas supplier from outside of the building.
2.3 Safety measures
Safety relevant fault conditions must be eliminated immediately.
2.3.1 Normal operation
▪All labels on the unit must be kept in a legible condition,
▪the unit should only be operated with its cover in the closed position,
▪do not touch moving parts during operation,
▪stipulated settings, service and inspection work should be carried out at regular
intervals.
2.3.2 Electrical connection
For work carried out on live parts:
▪Observe the accident prevention instructions BGV A3 and adhere to local direc-
tives,
▪tools in accordance with EN 60900 should be used.
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2 Safety
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2.3.3 Gas supply
▪Only the gas supplier or an approved agent may carry out installation, alteration
and maintenance work on gas appliances in buildings and properties.
▪Pipe work must be subject to a combined load and valve proving test and usability
testing relative to the pressure range intended (e.g.
DVGW-TRGI, work sheet G 600).
▪Inform the gas supplier about the type and size of plant prior to installation.
▪Local regulations and guidelines must be observed during installation (e. g.
DVGW-TRGI, work sheet G 600; TRF Band 1 and Band 2).
▪The gas supply pipe work should be suitable for the type and quality of gas and
should be designed in such a way that it is not possible for liquids to form (e. g. con-
densate). Observe vaporisation pressure and vaporisation temperature of liquid
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.
▪Carry out soundness test after each service and fault rectification.
2.4 Alterations to the construction of the equipment
All conversions require written approval from Max Weishaupt GmbH.
▪No additional components may be fitted, which have not been tested for use with
the equipment,
▪use only original Weishaupt replacement parts.
2.5 Noise emission
The noise emissions are determined by the acoustic behaviour of all components fitted
to the combustion system.
Prolonged exposure to high noise levels can lead to loss of hearing. Provide operating
personnel with protective equipment.
Noise emissions can further be reduced with a sound attenuator.
2.6 Disposal
Dispose of all materials used in a safe and environmentally friendly way. Observe local
regulations.
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2 Safety
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3 Product description
3.1 Inputs and outputs
3.1.1 Gas burner
-weishaupt-
13
3
N
7
3
C
4
1
6
5
14
L
N
T1
T2
S3
B4
B5
T6
T7
T8
G L/A AM FU NA P TWI
8
11
15
12
X6
X7
F7
TWI TWI interface (Vision Box)
P free
NA Speed signal (Namur)
FC Frequency converter
AM Operating panel
L/A Air damper actuator
G Gas butterfly valve actuator
1Slot analogue module EM3/3 or Fieldbus module EM3/2
1 External liquid petroleum gas valve
3C Burner motor for continuous running fan
3N Burner motor or frequency converter or valve continuous running fan
4 Ignition unit
5 Multifunction assembly or double gas valve
6 free
7 Bridging plug No. 7
8 Gas meter (impulse generator)
11 Air pressure switch
12 Low / valve proving gas pressure switch
13 Ionisation
14 Remote reset or low gas pressure switch (optional)
15 Bridging plug No. 15 or high gas pressure switch or
LDW2 (ducted air intake)
X6 7 pole connection plug
X7 4 pole connection plug
F7 Internal unit fuse (6.3 AT)
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3.1.2 Oil burner
-weishaupt-
13
3
N
7
3
C
4
1
6
5
14
L
N
T1
T2
S3
B4
B5
T6
T7
T8
G L/A AM FU NA P TWI
8
11
15
12
X6
X7
F7
TWI TWI interface (Vision Box)
P free
NA Speed signal (Namur)
FC Frequency converter
AM Operating panel
L/A Air damper actuator
G Coded plug (black)
1Slot analogue module EM3/3 or Fieldbus module EM3/2
1 Safety solenoid valve (Y14)(1 or stage 1 solenoid valve (Y11)(2
3C Burner motor for continuous running fan
3N Burner motor or frequency converter
4 Ignition unit
5 Stage 1 solenoid valve (Y11)(1
6 Stage 2 solenoid valve (Y12)
7 Bridging plug No. 7
8 Oil meter (impulse generator)
11 Air pressure switch (optional)
12 Bridging plug No. 12 or oil pressure switch
13 Flame sensor
14 Remote reset
15 LDW2 (ducted air intake)
X6 7 pole connection plug
X7 4 pole connection plug
F7 Internal unit fuse (6.3 AT)
(1 Burner with safety solenoid valve
(2 Burner without safety solenoid valve
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3.1.3 Dual fuel burner
-weishaupt-
13
3
N
7
3
C
4
1
6
5
14
L
N
T1
T2
S3
B4
B5
T6
T7
T8
G L/A AM FU NA P TWI
8
11
15
12
X6
X7
F7
TWI TWI interface (Vision Box)
P free
NA free
FC free
AM Operating panel
L/A Air damper actuator
G Gas butterfly valve actuator
1Slot analogue module EM3/3 or Fieldbus module EM3/2
1 Stage 1 solenoid valve (Y11)
3C Pump motor and safety solenoid valve Oil (Y14)
3N Burner motor and external LPG valve
4 Ignition unit
5 Multifunction assembly or double gas valve
6 Stage 2 solenoid valve (Y12)
7 Bridging plug No. 7
8 Fuel change-over
11 Air pressure switch
12 Low / valve proving gas pressure switch and oil pressure switch
13 Flame sensor
14 Remote reset or low gas pressure switch (optional)
15 Bridging plug No. 15 or high gas pressure switch or
LDW2 (ducted air intake)
X6 7 pole connection plug
X7 4 pole connection plug
F7 Internal unit fuse (6.3 AT)
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3.2 Technical data
3.2.1 Electrical data
Mains voltage/frequency 230 V / 50 … 60 Hz
Consumption max 12 W
Internal unit fuse 6.3 A slow
Type of protection IP 40
3.2.2 Ambient conditions
Temperature in operation -20 … +60 °C
Temperature during transport / storage -20 … +70 °C
Relative humidity DIN 60730-1,
no dew point
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3.2.3 Dimensions
80 mm 46 mm
92 mm 60 mm
275 mm
-weishaupt-
Installation and operating instruction
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4 Operation
4.1 Operating panel
No. Key Function
1[G] Gas Select gas butterfly actuator
2[–] Change values
[+]
4[L/A] Air Select air damper actuator
5[ENTER] Reset burner; call up information
press approx. 0.5 seconds = Info level
press approx. 2 seconds = Service level
3and 5[+] and [ENTER] press approx. 2 seconds = Parameter level
(only possible with display OFF)
4and 5[L/A] and [ENTER] Select fan speed
Various actions (e. g. changing the display, reset) are only triggered when the key is
released.
Operating level
The current actuator position or the fan speed can be displayed by pressing keys in
operating level (10).
Displaying air damper setting:
▶Press key [L/A].
Displaying gas butterfly valve setting:
▶Press key [G].
Displaying fan speed:
▶Press keys [Enter] and [L/A] simultaneously.
Off function
▶Press keys [ENTER], [L/A] and [G] simultaneously.
✓Immediate lockout with error 18h.
Installation and operating instruction
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Operating phase
The exact operating phase of the combustion manager can also be displayed. This
simplifies determining the cause of the fault during troubleshooting (see Ch. 9.1).
The display can be called up in Standby (OFF).
▶Press and hold keys [+] and [–] simultaneously for approx. 3 seconds.
✓The combustion manager changes to operating display. In the display, the current
operating phase is shown with a number.
Switching back to standard display:
▶Press and hold keys [+] and [–] simultaneously for approx. 3 seconds.
Installation and operating instruction
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4.2 Display
Operating panel
The display shows the current operating status and operating data.
1Setting level activated 5Actuator runs OPEN
2Start phase activated 6Burner in operation
3Info level activated 7Lockout
4Actuator runs CLOSED 8Service level activated
No heat demand
No heat demand
(fuel selected: Gas)
No heat demand
(fuel selected: Oil)
Safety circuit interrupted
(Bridging plug No. 7 unplugged)
Programming not completed
Programming of gas part not completed
Programming of oil part not completed
Switch off via Fieldbus
Insufficient gas low gas pressure switch
Low voltage (display flashes)
Connection to Fieldbus faulty (display flashes)
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4.2.1 Info level
Gas burner
Burner data can be interrogated in the Info level.
▶Press [Enter] key approx. 0.5 seconds.
✓The Info level is activated.
▶Press [Enter] to reach the next information.
l,m³
No. Information
0Total gas consumption in m³ (via X3:8)
Reset value:
▶Press [L/A] and [+] keys simultaneously for approx. 2 seconds.
1Operating hours
2- no function -
3Burner starts
4Device item number
5Index of device item number
6Unit number
7Production date (DDMMYY)
8Fieldbus address
9Valve proving behaviour
11 Current fan speed (only in conjunction with speed control)
Display of standardised speed:
▶Press key [L/A].
12 Current gas consumption (0.1 m³/h)
13 Analogue module EM3/3 or Fieldbus module EM3/2 available
0= No
1= Yes
After information 13 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
Installation and operating instruction
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Oil burner
Burner data can be interrogated in the Info level.
▶Press [Enter] key approx. 0.5 seconds.
✓The Info level is activated.
▶Press [Enter] to reach the next information.
l,m³
No. Information
0Total oil consumption in litres (via X3:8)
Reset value:
▶Press [L/A] and [+] keys simultaneously for approx. 2 seconds.
1Operating hours stage 1
2Operating hours stage 2
3Burner starts
4Device item number
5Index of device item number
6Unit number
7Production date (DDMMYY)
8Fieldbus address
10 Oil pressure switch function
11 Current fan speed (only in conjunction with speed control)
Display of standardised speed:
▶Press key [L/A].
12 Current oil consumption (0.1 l/h)
13 Analogue module EM3/3 or Fieldbus module EM3/2 available
0= No
1= Yes
After information 13 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
Installation and operating instruction
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4 Operation
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Dual fuel burner
Burner data can be interrogated in the Info level.
▶Press [Enter] key approx. 0.5 seconds.
✓The Info level is activated.
▶Press [Enter] to reach the next information.
l,m³
No. Information
0- no function -
1Operating hours in gas operation or oil operation stage 1
2Operating hours in oil operation stage 2
3Total burner starts
4Device item number
5Index of device item number
6Unit number
7Production date (DDMMYY)
8Fieldbus address
9Valve proving behaviour
10 Oil pressure switch function
11 - no function -
12 - no function -
13 Analogue module EM3/3 or Fieldbus module EM3/2 available
0= No
1= Yes
After information 13 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
Installation and operating instruction
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4.2.2 Service level
Gas burner / dual fuel burner (Gas operation)
The service level gives information about:
▪Actuator position of individual operating points
▪The most recent fault
▪Flame signal during operation.
▶Press [ENTER] key for approx. 2 seconds.
✓The service level is activated.
▶Press [Enter] to reach the next information.
Only in conjunction with speed control
The speed set can be displayed at information 0… 9.
Displaying fan speed:
▶Press key [L/A].
No. Information
0Actuator position in operating point P0
1Actuator position in operating point P1
2Actuator position in operating point P2
3Actuator position in operating point P3
4Actuator position in operating point P4
5Actuator position in operating point P5
6Actuator position in operating point P6
7Actuator position in operating point P7
8Actuator position in operating point P8
9Actuator position in operating point P9
10 … 18 most recent fault … ninth last occurred fault
Display additional information:
1. Detailed fault code / operating phase
▶Press [+] key.
2. Detailed fault code
▶Press keys [+] and [-] simultaneously.
3. Detailed fault code
▶Press key [L/A].
Repetition counter
▶Press key [G].
19 Flame signal:
00 = no flame ... 58 = high intensity
After information 19 or a waiting time of approx. 20 seconds the combustion manager
changes over to the operating level.
Installation and operating instruction
Combustion manager W-FM 25
4 Operation
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