manual

Installation and operating instructions

O2
Module

Weishaupt Combustion Managers W-FM 100 and W-FM 200 83054802 - 1/2009
Contents
1 1. General instructions 6

2 2 Safety instructions 7

3 3 Technical description
3.1 Function
8
8
3.2 Display and operating unit ABE 10

4 4. Installation
4.1 Safety instructions for installation
11
11
4.2 Installation of components 12
4.3 Basic wiring diagram (does not replace burner wiring
diagram) 14

5 5 Preparation for commissioning

5.1 Safety instructions
20
20
5.2 Steps to be taken on burner and frequency converter 21
5.3 Preparations on combustion manager 22

6 6 Commissioning - modulating
6.1 Set fuel and load points on W-FM
24
24
6.2 Commission burner 25
6.2.1 Set mixing pressure for ignition 25
6.2.2 Burner ignition 26
6.2.3 Set load point 1 27
6.2.4 Start full load 28
6.2.5 Optimise full load 29
6.2.6 Redefine intermediate load points 30
6.3 O2 functions - modulating 32
6.3.1 Set O2 guard 32
6.3.2 Set O2 trim 33
6.3.3 Set O2 regulating functions 34
6.3.4 Check and optimise O2 trim 35
6.3.5 Optimise O2 trim 36
6.4 Concluding work following commissioning 37
6.4.1 Set ratings range and flue gas temperature
limit values 37
6.4.2 Concluding work on the burner 37

7 7 Commissioning multi-stage
7.1 Set fuel and load required
38
38
7.2 Commission burner 39
7.2.1 Pre-set curve parameters 39
7.2.2 Burner ignition 40
7.2.3 Start full load 41
7.2.4 Set switch off point(s) 42
7.2.5 Check operating, switch on and off points 42
7.2.6 Check start behaviour 43
7.2.7 Define full load as required load 43

3
 8 8 Load controller
8.1 Set operating mode
44
44
8.2 Configure sensors 45
8.3 Setpoint (external) 46
8.4 Setpoint (internal) 47
8.5 Modulating load control 48
8.5.1 Parameter internal load control 48
8.5.2 Optimise internal load control 49
8.6 Multi-stage load control 50
8.7 Cold start function 51

9 9 Parameters and functions

9.1 Menu structure (ABE)
52
52
9.2 Operating display 62
9.3 Operation 63
9.4 Manual operation 64
9.5 Burner control 65
9.5.1 Times 65
9.5.2 Configuration 66
9.5.3 Serial number and Software version 67
9.6 Ratio control 68
9.6.1 Setting Gas/Oil 68
9.6.2 Times 74
9.6.3 Switch off behaviour 74
9.6.4 Programme stop 74
9.7 O2 trim and guarding 75
9.7.1 Setting Gas/Oil 75
9.7.2 Process data 79
9.8 Load controller 80
9.8.1 Control parameter 80
9.8.2 Temperature sensor 81
9.8.3 Cold start 82
9.8.4 Configuration load controller 84
9.8.5 Analogue output 88
9.8.6 Adaption 89
9.8.7 SW Version 89
9.9 AZL (ABE) 90
9.9.1 Times 90
9.9.2 Language 90
9.9.3 Date format 90
9.9.4 Physical units 90
9.9.5 eBus 90
9.9.6 Modbus 90
9.9.7 Display contrasat 91
9.9.8 Serial number and SW Version 91
9.10 Stepping motors 92
9.10.1 Addressing 92
9.10.2 Rotation direction 92
9.10.3 Serial number and SW Version 92
9.11 FC module 93
9.11.1 Configuration 93
9.11.2 Process data 94
9.11.3 Serial number and SW Version 94
9.12 O2 module 95
9.12.1 Configuration 95
9.12.2 Display values 95
9.12.3 Serial number and SW Version 95
9.13 Flue gas recirculation 96
9.14 System configuration 97
9.15 Operating hours 97
9.16 Start counter 98
9.17 Fuel meter 98
9.18 Updating 99
9.18.1 Parameter back-up 99
9.18.2 Load SW from PC 99
9.19 Password 99
9.20 TÜV Test 99

4
10 10 O2 sensor 106

11 11 Frequency converter
11.2 Parametering VLT 2800
108
108
11.3 Parametering FC 300 110

12 12 Cause and rectification of faults (fault list) 114

13 13 Service
13.1 Safety information for servicing
126
126
13.2 Service plan 126

14 14 Technical data
14.1 Combustion manager W-FM
127
127
14.2 Stepping motors SQM45.../48... 128
14.3 Flame monitoring 129
14.4 Display and operating unit (ABE) 130

A Appendix
Notes
131
131

5
 1 General information
These installation and operating instructions Hand-over and operating instructions
• are an integral part of the equipment and must be The contractor is responsible for passing the operating
kept permanently on site. instructions to the plant operator prior to hand-over. He
should also inform the plant operator that these
• are to be used by qualified personnel only. instructions should be kept with the heating appliance. The
address and telephone number of the nearest service
• contain the relevant information for the safe assembly, centre should be entered on the reverse of the operating
commissioning and servicing of the equipment. instructions. The plant operator must note that an agent of
the contractor or other suitably qualified person must
• are for the attention of all personnel working with the inspect the plant at least once a year. To ensure regular
equipment. inspections, -weishaupt- recommends a service contract.

• in addition to this installation and operating manual, The contractor should instruct the plant operator in the use
the documentation for the relevant burner and the of the equipment prior to hand-over and inform him as and
type of frequency converter must be observed. when necessary of any further inspections that are required
before the plant can be used.

Guarantee and liability

Weishaupt will not accept liability or meet any guarantee
Explanation of notes and symbols claims for personal injury or damage to property arising as
This symbol is used to mark instructions, a result of one or more of the causes below:
which, if not followed, could result in death or
serious injury. • Failure to use the equipment as intended
• Improper assembly, commissioning, operating or
DANGER servicing of the equipment.
• Operating the appliance with defective safety
equipment, or with non-recommended or non-
This symbol is used to mark instructions, functioning safety and protection devices
which, if not followed, could result in life • Failure to follow the information in the Installation and
threatening electric shock. Operating Instructions
• Alterations made to the construction of the equipment
DANGER by the plant operator
• Fitting additional components not tested or approved
for use with the equipment.
This symbol is used to mark instructions, • Alterations made to the equipment by the plant
which, if not followed, could result in damage operator (e.g. motor ratio - rating and speed)
to, or the destruction of the equipment and • Alterations made to the combustion chamber, which
environmental damage. hinders constructive, predetermined flame formation
ATTENTION
• Inadequate guarding of parts liable to wear and tear
• Improperly executed repairs
• Acts of God
• Damage caused by continued use despite the
☞ This symbol is used to mark procedures, occurrence of a fault
which you should follow. • Use of incorrect fuel
• Obstruction or damage of the supply lines
1. Procedures with more than one step are • Use of non-original -weishaupt- spare parts
2. numbered.
3.

❑ This symbol is used when you are required to

carry out a test.

• This symbol is used to list points.

➩ This symbol indicates detailed information

Abbreviations
Tab. Table
Ch. Chapter

6
2 Safety information 2
Dangers when using the equipment Electrical safety
Weishaupt products are manufactured in accordance with • Before starting work - isolate plant and protect against
the relevant existing standards and guidelines and the reactivation, check voltage is isolated, the unit is
recognised safety laws. However, improper use of the earthed, and protected from adjacent equipment that
equipment could endanger life of the user or a third party, might still be under voltage!
or result in damage to the plant. • Work on the electrical supply should be carried out by
a qualified electrician
To avoid unnecessary danger, the equipment is only to be • Electrical components should be checked during
used: servicing. Loose connections and heat damaged
• for its intended purpose cables should be dealt with immediately.
• under ideal safety conditions • The control panel should be locked at all times. Access
• with reference to all the information in the installation should be restricted to authorised button holder
and operating instructions personnel.
• in accordance with inspection and service work. • Should it be necessary to carry out work on live parts,
country specific safety regulations must be observed
Faults, which could affect the safe operation of the burner, and tools to EN 60900 must be used. A second
should be rectified immediately. person should be present to switch off the mains
supply in an emergency.

Personnel training
Only competent personnel may work on the appliance. Maintenance and fault rectification
Competent personnel according to this operating manual • Necessary installation, service and inspection work
are persons who are familiar with the installation, should be carried out at the specified time.
mounting, setting and commissioning of the product and • Inform the operator before beginning any service
have the necessary qualifications such as:- work.
• Training, instruction or authorisation to switch electrical • For all service, inspection and repair work, electrically
circuits and electrical devices on and off, to earth them isolate the equipment and ensure the mains switch
and to mark them in accordance with the safety cannot be accidentally switched back on. Cut off the
standards. fuel supply.
• Training, instruction or authorisation to carry out • Flame guarding devices, limit controls, correcting
installation, alteration and maintenance work on gas elements and all other safety devices must be
installations in buildings and on site. commissioned by, and may only be replaced by, the
manufacturer or an authorised agent.
• Following service work, all safety devices should be
Organisational measures tested to ensure they are functioning correctly.
• Everyone working on the plant should wear the
necessary protective clothing.
• All safety devices should be checked regularly. Alterations to the construction of the equipment
• No alterations to the equipment are to be made without
the approval of the manufacturer.
Informal safety measures All conversions require written confirmation from Max
• In addition to the installation and operating instructions, Weishaupt GmbH.
local codes of practice should also be adhered to. • Any parts not in perfect working order should be
Special attention should be paid to the relevant replaced immediately.
installation and safety guidelines given. • No additional components may be fitted, which have
• All safety and danger notices should be kept in a not been tested for use with the equipment.
legible condition. • Use only -weishaupt- replacement and connection
• Furthermore, all safety documentation and danger parts. Parts from other manufacturers are not
notes covering the frequency converter and burner guaranteed to be suitable to meet the necessary
must be observed. operational and safety requirements.

Safety measures in normal operation

• Only use the equipment when all the safety devices are
fully functional.
• The moving parts of the burner should not be touched
during operation.
• At least once a year the equipment, including the safety
devices, should be checked for signs of visible damage
and to ensure that the safety devices are operating
correctly.
• More frequent safety check may be required
depending on plant conditions.

7
 3 Technical description
The combustion manager W-FM contains all functions Functions
required for safe and efficient operation of multi-stage or • Burner control
modulating single fuel and dual fuel burners. • Electronic compound regulation for max. four or
The display and operating unit shows the conditions and six 1 stepping motors
allows programming via dial knob and function buttons. • Speed control 1
• O2 trim 1
• Valve proving
• True dual fuel operation
• Integral load controller 2
• Flame monitoring
• Separate ABE programmer

3.1 Function
Combustion manager Load controller 2
The combustion manager: The optional, integrated PID load controller can be used as
• controls the sequence of operation a temperature or pressure controller for multi-stage or
• monitors the flame modulating burners, depending on the connection and
• communicates with the stepping motors parametering. Furthermore the load controller contains a
• controls and monitors the frequency converter control reaction damper which protects the stepping
• carries out valve proving of the gas valves motors from unnecessary drive impulses, thus increasing
• has: – an integrated load controller 2 their life span.
– speed control 1 The load controller can be operated with one external
– O2 trim 1 setting value or setpoint input, or with two internal
setpoints.
The internal setpoints can be selected using an external,
Operating elements potential free contact.
The system can be controlled by several operating units: Switchover from external operation to the internal load
• A plug-in programmer ABE controller is via contact.
• PC module for onscreen control A separate start up programme is incorporated for boiler
• Remote main control system (Building Management cold start if required.
System)

Speed control 1
Flame sensor The frequency converter of the fan motor is started by a
Monitors the flame during all phases of operation. If the setpoint output (0/4 - 20 mA) and the speed is matched to
flame signal does not correspond to the sequence of the current burner rating required. The speed and the
operations, a safety lockout will occur. rotation are determined and monitored using an inductive
Flame sensors used: proximity switch in conjunction with an asymmetrical
• QRI and QRA 73 for continuous or intermittent transmitter disc. In compound with the stepping motors
operation for oil, gas and dual fuel burners. the required combustion air is automatically adjusted and
• Ionisation electrode only for gas, for continuous or the electrical consumption is reduced to a minimum.
intermittent operation. If the air supply fails or becomes insufficient, an air
• QRB photo resistor for intermittent operation for oil pressure switch initiates lockout.
burners.

O2 trim 1
Stepping motors The residual O2 content in the flue gas is determined by a
Stepping motors on: sensor, which compares it to the setpoints calculated
• Air damper during commissioning. Depending on the control
• Oil controller deviations the combustion manager controls the air
• Gas butterfly valve regulating devices and corrects the O2 content.
• Mixing head
Providing precise (0.1 degree acuracy) and direct control
of the correcting elements in compound. Low gas programme
The setting values are transmitted via CAN BUS from the If the control gas pressure falls below the setting of the low
combustion manager to the stepping motors, the stepping gas pressure switch during operation, the combustion
motors are electronically adjusted and the combustion manager starts a low gas programme.
manager constantly monitors their position return signals. If the gas pressure is below the setpoint prior to start, the
burner start is inhibited.

1
W-FM 200 only
2
optional on W-FM 100

8
 3
Valve proving (only on gas operation) Sequence diagram valve proving
Following each controlled shutdown, the combustion
1st. Test phase 2nd. Test phase
manager carries out a valve proving test of the gas
solenoid valves.
Following lockout or power failure, the valve proving test is Valve 1
carried out prior to the next burner start. 33 secs.
sek. 10 sek.
10 secs. 33 secs.
sek. 10 sek.
10 secs.

Valve 2
Function
1st. Test phase:
During a controlled shutdown valve V1 closes P between
V1 and V2
immediately, and valve V2 has a slight delay in closing
which permits the volume between the valve seats to Gas press.
depressurise. The section between V1 and V2 must switch VP
remain depressurised once the second valve has
closed.
Setting pressure gas pressure switch
2nd. Test phase:
Valve V1 opens and immediately closes again, PR + PV
allowing gas pressure build-up between V1 and V2 = setting pressure
valve seats. During the test phase, the pressure 2
between the valve seats must not fall below the
pressure setting of the gas pressure switch. PR = Control pressure into V1 (reduce impact pressure)
PV = Maximum pressure during pre-purge downstream of V2

9
 3
3.2 Display and operating unit ABE
Setting without tools Display and operating unit ABE
The advantage of electronic ratio control provided by the
W-FM lies in the simple setting via display menus. The
positioning for fuel, air, and auxiliary actuators is selected
digitally. With only a few input ratings-positions being
entered, the intermediate firing positions are automatically
interpolated.

Display
4 lines with scroll function

ESC button
Cancel or return
Info button
Return to operating display
Enter button
Execution
Scroll knob
Cursor control and value change

RS 232 interface (COM1)

For PC or Laptop connection
CAN Bus
Connection to W-FM
RJ45 interface for eBus/Mod Bus (COM2)
Connection to BMS via external eBus Interface

Emergency - Off function

Simultaneous pressing of the ESC and Enter buttons
immediately initiates lockout. The Emergency - Off function
is saved in the lockout history.

Contrast adjustment
To change the contrast of the display, press Enter button
and hold down whilst changing the contrast using the
scroll knob (+/–). (Only possible in menu Normal
operation, contrast adjustment with saving see Ch. 9.9.7).

10
4. Installation 4
4.1 Safety instructions for installation
Electrically isolate the plant
Prior to installation switch off the mains switch
and the safety switch.
Failure to comply could cause death or
serious injury by electric shock.
DANGER

Note Due to the frequency converters used it is

possible for some of the electrical
components to continue to be energised
following mains isolation. The waiting time
given must therefore be observed prior to
starting work.

11
 4
4.2 Installation of components
The electrical connections should be carried out to the
wiring diagram supplied with the burner. All country and
local codes of practice (i.e. EN, DIN, VDE, BS, etc.) must
be observed.

Line length External connections

The line length of the individual components to the W-FM Mains voltage carrying lines (230V; 50 Hz) should be
can be a maximum of 100 m. flexible and have a minimum cross section of 0.75 mm.
When installing the stepping motors and the ABE it is The PE terminals on the fixing plate of the W-FM should be
particularly important that the total line length of all Bus used for earth wire connection.
connections (CAN-Bus) does not exceed 100 m.

O2 sensor / O2 module (only W-FM 200)

Display and programmer unit ABE The electrical connection of the O2 sensor or O2 module
The installation of the ABE to the W-FM is carried out with should be carried out to the wiring diagram supplied with
a special CAN-Bus cable. This cable supplies voltage to the burner. Please note that the screened sensor line of
the ABE and transmits the BUS signals. the O2 sensor must be connected separately and line
length must not exceed 10 m.
Installation O2 sensor see Ch. 10.
Stepping motors
The installation is carried out as a serial Bus system.
• Air damper Bus connection
• Gas butterfly valve A Bus connection should be made on last component of
• Oil regulator the Bus line using the jumper supplied. On all other
• Mixing head components within the Bus, the Bus termination jumper
The voltage supply of the stepping motors and the must not be connected.
communication with the W-FM is carried out via CAN-Bus On the ABE the Bus connection is inbuilt.
cable.

Frequency converter (only W-FM 200)

The electrical connection of the frequency converter has to
be carried out to the wiring diagram supplied with the
burner. Please note that the screens of the cables must be
earthed at both ends. The FE terminals on the W-FM must
also be earthed.

Flame sensor
The 1.8 m senor line to the flame sensor can be extended
by up to 100m if installed separately (i.e. for W-FM in a
separate control panel).

Ignition line
The ignition cables should be installed as close as
possible to the ignition electrodes. Ignition cables must
have an adequate spacing away from any other wiring.

Gas valve train

The pre-wired gas valve train should be connected as per
the wiring diagram supplied with the burner. Cable entry is
via the cable entry access on the right of the burner.

12
 4
Installation example: W-FM in burner housing Installation example: W-FM in a control panel

O2-Modul Jumper with Bus (W-FM 200 only) O2 Module Jumper with Bus (W-FM 200 only)
connection connection

5 5

Burner Burner SQM 4… SQM 4… SQM 4…

SQM 4… SQM 4… SQM 4… Supply transf. 2 no Bus no Bus no Bus
no Bus no Bus no Bus con- con- con-

2 AT
con- con- con- nection nection nection
nection nection nection
ABE

5 5 5
5 5

AC1 12V 4 AT

AC2 12V 4 AT

AC2 12V
AC1 12V
CANH
CANL
GND
GND
5
AC2 12V 5
AC1 12V

AC2 12V
AC1 12V
CANH

CANH
CANL

CANL
GND

GND

4 AT

4 AT

ABE

3
6,3 AT
5

W-FM

AC2 12V
AC1 12V
CANH

CANH
CANL

CANL
GND

GND
Mains 4 AT

4 AT
5

(W-FM 200 only)

6,3 AT

Frequency W-FM
converter Supply transf. 1

Mains

(W-FM 200 only)

Frequency
converter

W-FM fitted into a control panel

A second supply transformer is required for the Bus supply
if distance between W-FM and burner is an extended
distance. The supply transformer 2 is fitted to the burner
and connected to the burner terminal rail. The voltage
supply of all following Bus components is exclusively via
supply transformer 2.
The voltage supply (AC1 and AC2) must not be connected
to the bus line from W-FM to burner terminal rail.
Bus line W-FM to control panel order number: 743 192.

13
 14
Motor start
contactor
Burner lockout
Safety circuit
230V 1/N/PE 50-60Hz
External connections
Additional connections

Pre-sel. Gas
Pre-sel. Oil
Return signal motor
protection contact
Burner reset
Burner on
ext. control
contact
Start release oil
Residual oil immediate
start
Start release Gas
Gas operation
Oil operation
Legend:

T1 Ignition unit

FE Earth connection
Y7 Magnetic coupling
F10 Air pressure switch

T2 Control transformer

Y10 Anti siphon fuel valve

A1 Combustion manager

S7 Burner flange limit switch

F35 Max. oil return pressure sensor
F36 Min. oil supply pressure sensor

Y9 Solenoid valve on air pressure switch

B3 Appliance’s temperature/ pressure sensor
Power Sensor
Setpoint switchover or type of
operation§ switchover load controller
Function X60 - X63 only
with internal load controller
X60/X61 = actual value
X62 = setpoint
X63 = plotter output
4.3 Basic wiring diagram (does not replace burner wiring diagram)
4
 On multi-stage
heavy oil burners
size 30 - 40
On modulating
heavy oil burners
sizes 30 - 70

On multi-stage
light oil burners
size 30 - 50
On modulating
light oil burners
sizes 30 - 70
Legend: Legend:

Y11 Partial load solenoid valve Y11 Solenoid valve/nozzle solenoid

Y12 Intermediate load solenoid valve Y12 Solenoid valve (normally open)
Y13 Full load solenoid valve Y14 Additional solenoid valve
Y14 Additional solenoid valve Y15 Additional solenoid valve
Y15 Additional solenoid valve
4

15
16
4

+24V
Start frequency converter
Lockout frequency converter
Setpoint
Earth
Screen
Connection
frequency converter

1 Optional screen connection if ambient conditions are Legend:

electrically unfavourable. B12 Proximity switch burner motor
B20 Fuel meter Gas (optional)
B21 Fuel meter Oil (optional)
 Bus interface

brown
blue
black
Connection control panel
External signalling pressure switch (optional)

Terminal box gas valve train Connection O2 module

Only with O2 trim (optional)

Legend:

A2 Display and operating unit

B1 Flame sensor
F11 Low gas pressure switch
F12 Valve proving pressure switch
F33 High gas pressure switch
Y1 Ignition gas solenoid valve
Y2 Main gas solenoid valves
Y3 Remote solenoid valve
Y17 Oil controller stepping motor
Y18 Gas butterfly stepping motor
Y19 Mixing head stepping motor
Y20 Air damper stepping motor
4

17
18
O2 sensor
Mains voltage
4

O2 Module

Legend:

B10 Combustion air temperature sensor

B11 Flue gas temperature sensor
Stepping motor connection
 Usensor FE
2 Wire
Pulse-IN 0

LOAD
3 Wire-PNP

X63
OUTPUT
0 4-20mA
PE X6-03 X6-02 X6-01 X7-03 X7-02 X7-01 PE
Reserve

P
FE

L
L
L

L
L
L
L
N
N

N
N
min

X70
N

PE
PE
PE

PE
PE
FE 0

X5-01
Start

Start

MOTOR SPEED INPUT

L V1

X8-03
Usensor 4-20mA

H0-Start
INPUT
2 Wire PE L
Pulse-IN 0-10V SET POINT

V2

V3

P
SV
M
3 Wire-PNP min
X62
PE
0

X5-02
OIL GAS OIL

X71
L N
FE FE
ON/OFF V1

X8-02
Usensor 0
2 Wire 3 L
Pulse-IN 4-20mA

X5-03
INPUT

3 Wire-PNP 2 OIL L
0 0-10V
TEMP./PRES.

X72
X8-01
L GAS L
X61

FUEL COUNTER INPUT

FE Power Supply
Sensor

FE
Start-OUT
min.

P
INT L
12-24VDC Alarm in
TEMP.

max.

P
GAS
0/4-20mA Setpoint OUT
Pt100

LT

X9-03

P
OIL
Pt/Ni1000

(CPI)
X60

X4-01
L

X73
FE PE
RESET

FREQUENCY CONVERTER
X9-02

PE IGNITION N
N V1 L

X4-02
L V2 L
FE
X9-01

P
PE PV L
12VAC2
N SV L
M

X4-03
TRAFO

L (START)
X52

12VAC1
X10-03

ION
FSV/QRI
PE
BUS

Anschlüsse
FLAME

L MOTOR
W-FM
L GND
X10-02

L ALARM
Power QRI CANL

Elektroanschluss
QRB CANH
L
L 12VAC2
FLANGE LINE
N 12VAC1

X3-01 X3-02 X3-03

L
X51

G0 Shield
X10-01

SAFETY 12VAC
G GND
L LOOP
CANL
PE
CANH

X3-04
L LINE
VOLTAGE 12VAC2
N
12VAC1
X50

Shield
BUS

F1/T6,3 F2/T4 F3/T4

IEC 127-2/V IEC 127-2/V IEC 127-2/V
4

19
 5 Preparation for commissioning
5.1 Safety note
Check installation
All installation work must be completed and
checked prior to commissioning. The burner
must be mounted on the appliance, ready for
operation and all control and safety devices
DANGER must be connected correctly.

❏ Burner mounted, including refractory as required

❏ Fuel supply complete
❏ Electrical connections and controls complete

Safety notes on initial commissioning

The initial commissioning must only be carried out by the
supplier, manufacturer or their appointed agent. At this
time, all the control and safety equipment must be
checked to ensure correct operation and, if it can be
adjusted, it should be checked that it has been set
correctly.

Furthermore the correct fusing of the circuits and the

measures for contact protection of electrical equipment
and of all wiring must be checked

20
 5
5.2 Preparation on the burner and the frequency converter
Burner
Check setting on burner, vent fuel lines and connect
measuring instruments.
If the burner is fitted with a moving mixing head, this should
be checked for freedom of movement.

Frequency converter 1 (only for Danfoss VLT… and

FC300)
Check parameter settings on frequency converter (see
parameter list Ch. 11).

Carry out automatic motor adaption on frequency

converter (not possible on all frequency converters).
• VLT 2800 via parameter 107.
• FC300 via parameter 1-29.

Note Due to the automatic motor adaption, the motor-slip

adjustment and the load compensation are set
back. These parameters must be re-set to the
weishaupt- data (parameter 134, 136 on VLT 2800
or 1-60, 1-61 and 1-62 on FC 300).

Further detailed information relating to the burner and

frequency converter can be found in the relevant
installation and operating manual.

21
 5
5.3 Preparation on the combustion manager
1. Burner OFF Burner Off
To be able to carry out the following steps it is necessary
to set the burner to OFF in menu Manual Operation. Manual Operation ➩ Ch 9.4
Auto/Manual/Off
Auto/Manual/ Off
Curr: Automatic
New: Burner Off

2. Enter password Enter password

By asking for a password it is ensured that only authorised
personnel have access to the configuration and setting Enter PW ➩ Ch 9.19
parameter. Access SERV
Enter digit or number using the dial knob at the flashing Enter
cursor point and confirm with <ENTER>. password
Corrections can be made using <ESC>, empty data :........
spaces should be filled using <ENTER>. -

3. Carry out speed control standardisation 1 Speed standardisation

During speed control standardisation a setpoint signal of ➩ Ch 9.11.1
95% is given. The speed is determined and saved in Param + Display
parameter Standardised Speed. If, during FC module
standardisation more than the nominal frequency Configuration
(50Hz / 55Hz / 60Hz) is displayed, the motor-slip Speed
compensation (=0) on the frequency converter has to be Standardisation
checked. Standardisation
Curr:deactivated
The rotational direction of the motor should be checked New: activated
during speed standardisation.

Note After each speed standardisation, or changes to the

saved values, the combustion quality needs to be
checked.

4. Check configuration of O2 module 1 O2 module configuration

The following parameter should be check and set for ➩ Ch. 9.12.1
operation with O2 trim control. Param + Display
O2 module
• O2-Sensor: QGO20 Configuration
• Supply air sensor:PT1000 (if fitted) O2 sensor
• Flue gas sensor: PT1000 (if fitted) SupAirTempSens
• MaxTempFlueGas: Presetting 400° C FlueGasTempSens
MaxTempFlGas

1
W-FM 200 only when used with frequency converter
or O2 Module
22
 5
5. Check O2 sensor temperature 1 Check O2 sensor temperature
The O2 sensor requires an internal operating temperature ➩ Kap 9.12.2
of 700° C ±(15°C). If the sensor has been connected Param + Display
incorrectly, this can lead to overheating and thus damage O2 module
of the sensor. If the sensor temperature exceeds 750° C, Displayed values
the sensor should be isolated and the electrical QGO SensorTemp
connection should be checked. If the operating QGO HeatingLoad
temperature is not achieved, the combustion manager
initiates a start prevention (Ch 9.7.1)

Note The QGO SensorTemp und QGO

HeatingLoad should be monitored regularly
during the heat up process.

HeatingLoad: Start heating load to 100° C ___approx. 13%

Heat up process ____________approx. 60%
Operating temperature: __approx. 15… 25%

6. Deactivate O2 trim control 1 Automatic O2 trim control deactivate

For commissioning the O2 trim control for the individual ➩ Ch. 9.7.1
fuels, the O2Ctrl should initially be deactivated. Param + Display
The O2 controller and the O2 guard have no influence on O2Ctrl/GuardDeac
the burner operation at this setting. t Setting ...
OperatingMode
Note On dual fuel burners the O2 trim control should be OperatingMode
deactivated on both fuels. Curr: man deact
New: man deact

7. Enter fuel type Enter fuel type

To be able to calculate the combustion efficiency it is
necessary to define the type of fuel used. Param + Display ➩ Ch. 9.7.1
If a fuel is used which is not available for selection, its fuel O2Ctrl/Guard
specific values can be entered under Fuel typedef. Settings ...
Fuel type
Note On dual fuel burners both the oil and gas type must Fuel type def.
be entered.

1
W-FM 200 only when used with frequency converter
or O2 Module
23
 6 Commissioning - modulating
6.1 Set fuel and load limits on W-FM
Select fuel (only on dual fuel burners) Select fuel
Select the required fuel using the external fuel selection
switch. If an external fuel selection switch is not available, Operation ➩ Ch. 9.3
fuel selection is made using the ABE or BMS. Fuel
Fuel selection or:
Note The external fuel selection switch takes priority. That Fuel selection Fuel selection
means the commissioning can only be carried out Curr: Oil switch on Oil
with the fuel set at this switch. New: Gas

Check load limits Load limits

To ensure that the whole ratings range is available for
commissioning, check load points and adjust if necessary. Param + Display ➩ Ch. 9.6.1
MinRating: _______________________________ 0.0 % RatioControl
MaxRating: _______________________________ 100 % GasSetting
LoadLimits
Note On dual fuel burners the load points for oil and gas MinLoadGas
should be checked. On single fuel oil and gas MaxLoadGas
burners only one fuel appears in the display.

24
 6
6.2 Commissioning the burner
6.2.1 Set mixing pressure for ignition
Set Program stop 36 Program stop 36: Ignition position without ignition
Prior to the first ignition trial, the program stop must be set
to 36 IntionPos. After burner start the burner runs to the RatioControl ➩ Ch. 9.6.1
ignition position without actual ignition occurring. ProgramStop
ProgramStop
Note In its delivered condition the program stop has Curr: 36 IgnitionPos
already been factory pre-set to 36. New: 36 IgnitionPos

Open manual fuel shut off devices and the burner is Burner On
ready to start
After the fuel shut off devices have been opened the RatioControl ➩ Ch. 9.4
burner should be started in manual operation. Auto/Manual/Off
Auto/Manual/Off
Note For burner start all safety devices, pressure and Curr: Burner Off
temperature controllers should be in operating New: Burner ON
position. Ensure sufficient heat requirement for the
duration of the commissioning procedures.

Set ignition positions Ignition positions (example gas operation 3LN multiflam®)
Set the ignition positions whilst observing the mixing
pressure. RatioControl ➩ Ch. 9.6.1
The speed during ignition should not be less than 80% for GasSettings
oil and 70% for gas (only when using a frequency SpecialPositions
converter / W-FM200). IgnitionPos
If the measured mixing pressure is too high, this can be IgnitionPosGas IgnitionPosGas
adjusted by reducing the air damper position. IgnitionPosAir Curr: 10.5°
IgnitionPosAux New: 15°
The relevant ignition pre-settings should be taken from the IgnitionPosFC
installation and operating instructions of the burner or its
test data sheet. IgnitionPosAir
Curr: 13°
Note The auxiliary motor position on 3LN burners New: 10°
(multiflam®) in ignition position and during burner
operation must be a minimum of 18°.
IgnitionPosAux
Curr: 18°
New: 19°

IgnitionPosFC
Curr: 100%
New: 70%

25
 6
6.2.2 Burner ignition
Set program stop 52 Program stop 52: ignition after safety time
To ignite the burner the program stop should be set from
36 to 52. Fuel is released following pre-ignition. The SpecialPositions ➩ Ch. 9.6.1
motors remain in the ignition positions setting. ProgramStop
ProgramStop
Curr: 36 IgnitionPos
New: 52 Interv 2

Pre-set fuel pressure

On oil and dual fuel burners the oil throughput for full load
has been measured, that means the pump pressure has
been factory pre-set (19 to 29 bar) and should only be
adjusted if starting problems occur.

The gas setting pressure can be found in the installation

and operating instructions of the burner.

Carry out combustion analysis

Determine CO, O2 values and carry out smoke
measurement. If necessary, optimise combustion by
adjusting the ignition positions.

26
 6
6.2.3 Set load point 1
Deactivate program stop Deactivate program stop
To continue with commissioning the program stop has to
be deactivated. If the program stop is not deactivated, the RatioControl ➩ Ch. 9.6.1
burner remains in the position set and setting of additional ProgramStop
load points is not possible. ProgramStop
Curr: 52 Interv 2
New: deactivated

Set load point 1 Take over Ignition load point as load point 1
In Setting Oil, the first load point has been factory
pre-programme. Setting Gas ➩ Ch. 9.6.1
If the first load point has been deleted, the ignition load CurveParam
values will be taken over automatically as the first load Point Load :15.0
P Point Load :15.0
point just as with Setting Gas. Burn:15.0 : 1 Burn :15.0
In both cases the values should be matched and a ManualAir :10.0 O2 Air :10.0
combustion analysis should be carried out. Aux1 :19.0 4.9 Aux1 :19.0
FC :70.0 FC :70.0

At the first load point the fuel dependent minimum speed1 Change load point 1
should be aimed for whilst observing the combustion ➩ Ch. 9.6.1
quality and flame stability. Point Load: 10.5
Point I Point
Procedure: : 1 c
Change?
1. Drive up the air damper stepping motor until a residual Point Load:15.0 Point Load :15.0
O2 content in the flue gas of max. 8% has been 1 Burn:15.0 1 Burn:15.0
achieved (on 3LN burners multiflam® max. 7% residual O2 A
Air :10.0 O2 Air :223.6
O2 content in the flue gas). 4.9 Aux1 :19.0 4.9 Aux1 :19.0
FC :70.0 FC 50.2
:5
2. Reduce speed1 (not below minimum speed). To
achieve minimum speed it may be necessary to repeat
steps 1 and 2. esc
Point
save- >ENTER
3. Carry out combustion analysis and if necessary delete- >ESC
optimise combustion by adjusting the air damper
position.

4. Leave point 1 by pressing <ESC> and save by Point Load :15.0

pressing <ENTER>. : 1 Burn :15.0
O2 Air :23.6
5. Leave programming of point 1 by pressing <ESC>. 6.4 FC :50.2
Note If the burner is fitted with an auxiliary motor and
speed control the value selected by the turn knob is
displayed in the last line. Minimum speed

Fuel Setting Frequency

FC at transformer

Oil (pump separate) 60 % approx. 30 Hz

Oil (pump fitted) 70 % approx 35 Hz

Gas 50 % approx 25 Hz

1
W-FM 200 only when used with frequency converter
27
 6
6.2.4 Start full load
Drive to full load via intermediate load points Increase load manually
Starting from the first load point, drive to full load via the
intermediate load points. Point Load:15.0 ➩ Ch. 9.6.1
Burn :15.0
Procedure: aanual Air :23.6
m
1. Set cursor to Manual and press <ENTER>. Aux1 :19.0

2. Increase burner rating using the dial knob, whilst

guarding the combustion quality (excess air, flame O2 Load :15.0 O2 Load:25.0
stability). 6.4 Burn :15.0 6.1 Burn :23.8
Manual Air :23.6 Manual Air :31.4
3. Set intermediate point before reaching the combustion . Aux1 :19.0
:15.0 :19.8 Aux1 :27.3
limit by pressing <ENTER> (on 3LN multiflam max. 7%
residual O2 content in the flue gas).
Setting intermediate load points, correcting and saving
4. Carry out combustion analysis and correct intermediate
load point values. O2 Load :25.0 O2 Load :25.0
L
6.1 Burn :23.8 roint18.7
Punkt Load:25.0
5. Leave load point by pressing <ESC> and save with Manual Air :31.4 : 2uft :28.4
2 Burn :21.9
<ENTER>. :19.8 Aux1 :27.3 8O2 Hilfs:60.1
Air :228.8
26.0
5.9 Aux1 :2
Repeat procedure until full load (Load: 100) has been
reached. FC :56.0

esc
Point
Save- >ENTER
enter->ESC

Point Load :100

:5 Burn :73.6
O2 Air :67.8
3.8 Aux1 :78.5

28
 6
6.2.5 Optimising full load
Optimising full load
In the last load point (load = 100%) the exact fuel quantity
throughput for the required full load should be set.

Note Observe load data supplied by the appliance

manufacturer and the capacity graph of the burner.

Procedure:
1. Set fuel throughput
Optimising full load
Gas: At 65° to 70° gas butterfly setting, determine ➩ Ch. 9.6.1
gas throughput and adjust using the setting Point Load :100
screw on the pressure controller. 5 Burn 68.7
:6
O2 Air :67.8
Oil: Set pump pressure required, determine oil 4.5 Aux1 :78.5
throughput and adjust using stepping motor
setting of the oil controller (see burner test data
sheet: Indicator setting oil controller).

2. Determine combustion limit at full load and set excess

air. Point Load :100
The fan speed should be selected as low as possible 5 Burn:68.7
whilst observing NOx and flame stability, however it O2 Air :776.2
should not be below 40 Hz / 80% (only when using 3.8 78.0
Aux1 :7
frequency converter / W-FM 200).
FC 88.8
:8
3. Re-determine fuel quantity throughput and if necessary
adjust.
Once this step has been completed, the pump and gas
setting pressure must not be altered.

4. Save full load point.

29
 6
6.2.6 Re-define intermediate load points
Re-define load point 1 Drive to load point 1 and optimise combustion
To later allow O2 trim across the whole ratings range, point
1 must be a minimum 30% below the required partial load Point Load :100
(only when using an O2 module / W-FM 200). :5 Burn:68.7
O2 Air:76.2
Procedure: 3.8 Aux1 :78.2
1. Select point 1 with dial knob, press <ENTER>, confirm
Change point with <ENTER>, point 1 is started.

2. Check combustion quality, and optimise if necessary. Point Load :15.0 Point Point
Drive to combustion limit, note down and set excess air :1 Burn:15.0 : 1 c
vhange?
required for combustion limit. O2 Air :23.6 löschen?
Point Load:15.0
Excess air: • without O2 trim approx. 15% to 20% 6.4 Aux1 :19.0 11.9
: 1 Burn:1
• with O2 trim approx. 20% to 25% O2 Air :2 22.2
6.3 Aux: 18.6
Please observe the minimum speed and the mixing FC 50.0
:5
pressure required.

3. Determine fuel quantity throughput and carry out

ratings distribution.

4. Save load point 1.

Delete intermediate points Delete intermediate load points

Delete intermediate load points and re-define.
To achieve an even speed reference line, the fan speed at Point Load:15.0
the newly set intermediate load points should not be : 1 Burn:11.9
altered (only when using a frequency converter / O2 Air :22.2
W-FM 200). 6.3 Aux :18.6

Procedure;
Select point 2 with dial knob, press <ENTER>, confirm
“Delete point” with <ENTER>, point 2 is deleted and Point Load:19.8 Point Point
the setting values for the next intermediate load point : 2 Burn :19.3 : 2 change?
below point 2 appear automatically. O2 Air :25.5 Manual d
lelete?
Repeat procedure, until full load settings appear under 5.9 Aux1 :23.2 Point Load :449.6
point 2. : 2 Burn: 35.9
Do not delete the full load point (Load: 100) and Manual Air: 47.3
point 1. 47.1 Aux1 :444.2

Check:
Select point 3 with dial knob. If all intermediate load
points have been deleted, no values are defined in
point 3 and the following display is shown.
Point Load: 100
:2 Burn: 68.7
Point Load :XXXX O2 Air :76.2
: 3 Burn: XXXX 3.8 Aux1 :78.2
Manual Air :XXXX
Aux1 :XXXX

30
 6
Set new intermediate load points and carry out ratings Reduce rating and optimise combustion
distribution in percentages
For burner operation 5 load points are required, this means Point Load: 100 ➩ Ch. 9.6.1
at least 3 intermediate load points must be set. Burn :68.7
Depending on the installation, more intermediate load Hanual Air :76.2
M
points may be required (maximum 15 load points). Aux1 :78.2

Note When using O2 trim control, partial load cannot be

set below point 2, this means point 2 should be set O2 Load :100 O2 Load :90.0
smaller or equal to the eventual partial load. 3.8 Burn :68.7 3.9 Burn :62.0
Manual Air :76.2 Hand Air :69.7
Procedure 0 Aux1 :78.2
100 .
:90.0 Aux1 :71.2
1. Leave load point by pressing <ESC>, select manual Point Load :89.7
function using the dial knob and confirm with : 3 Burn: 62.0
<ENTER>. O2 Air: 68..8
70.7
4.0 Aux1 :7
2. Whilst observing the combustion quality, reduce the
FC :84.2
burner rating using the dial knob.
Recommendation: 10% steps
Point esc
3. Optimise combustion quality and set excess air
Save- >ENTER
required for the combustion limit
Delete->ESC
Excess air: approx. 15% to 20%

To maintain an even speed reference line, the speed

should not be adjusted after this process if at all Point Load :100
possible (only when using a frequency converter / W- : 3 Burn :68.7
FM 200). O2 air :76.2
4.0 Aux1 :78.2
4. Determine fuel quantity throughput, calculate rating
and carry out ratings distribution. esc

P
Point Load :89.7
5. Leave point using <ESC> and save with <ENTER>.
Burn :62.0
ManualAir :68.8
6. Repeat procedure for all curve points.
Aux1 :70.7
FC :84.2

Example ratings distribution

➩ Ch. 9.6.1
Throughput intermediate load point
Rating [%] = • 100
Throughput full load

Gas:

305 m3/h
Rating [%] = • 100 = 89.7 %
340 m3/h

Oil:

260 kg/h
Rating [%] = • 100 = 89.7 %
290 kg/h

Point .
Load:90.0 Punkt Load 89.7
:8
: 3 Burn:62.0 : 3 Burn :62.0
O2 Air :68.8 O2 Air :68.8
4.0 Aux1 :70.7 4.0 Aux1 :70.7

31
 6
6.3 O2 functions modulating
The settings for the O2 trim control must only be carried
out if a W-FM 200 with O2 trim control is to be used.

6.3.1 Set O2 guard

The combustion limit has to be determined for each point O2 guard
and saved in the guard function as the O2 minimum value.
The Operating type for O2-control/-guard must be Param + Display ➩ Ch. 9.7.1
deactivated during setting. O2Ctlr/Guard
If the O2 limit values are already known, these can be Setting ...
entered directly as O2 minimum values. O2 Guard
It is also possible to drive to the combustion limit of each
load point and to copy over the determined O2 setpoints
as O2 min. values.

Direct entry of known O2 limit values: Direct entry O2 min value

1. Select point to be set using the dial knob and confirm
with <ENTER>. Point:1
: 13.9% ➩ Kap 9.7.1
:9
Point:9 100%
2. Select 02 min value using dial knob and confirm Point:9 100% Point:9 100%
with <ENTER>. 02-Minval: 0.0. 02-Minval: 0..7
P-Airman : 0.0 P-Airman: 0.0
3. Enter the O2 min value using the dial knob and save
with <ENTER>.

4. Enter O2 min value in the O2 graph on the right.

Determine O2 value of combustion limit and note it: Determine combustion limit
1. Select the point to be set using the dial knob and
confirm with <ENTER>. Point:1
: 13.9% ➩ Ch. 9.7.1
:9
Point:9 100%
2. Select P-Air manual using dial knob and confirm Point:9 100% Point:9 100%
with <ENTER>. 02-Setpoint: 3.8 02-Setpoint: 0.7
P-AirHand: 0.0. 10.4 .
P-AirMan:1
3. Turn dial knob to the right. The air rating is reduced on
the curve flow line in relation to the ratings setting of
P-Air manual. The fuel quantity throughput remains
unchanged.
Reduce air rating until the combustion limit (CO or O2 graph
soot) has been reached. 8

4. Leave setting level with <ESC> and save the O2 value 7

as min value for the guard function using <ENTER>. 6
O2 content [%]

5
5. Enter O2 min value in the graph on the right.
4
3
2
1
0
0 10 20 30 40 50 60 70 80 90 100

Burner rating [%]

32
 6
6.3.2 Set O2 trim
For subsequent O2 trim settings, a standardisation has to O2 trim
be carried out at each point.
Param + Display ➩ Ch. 9.7.1
Procedure: O2Ctlr/Guard
1. Select point to be set using the dial knob and confirm Setting ...
with <ENTER>. O2 trim

2. As soon as the O2 value is stabilised confirm with

<ENTER>.

3. Turn dial knob to the right. The air rating is reduced on

the curve flow line in relation to the ratings setting of
Standardisation value. The fuel quantity Standardisation
throughput remains unchanged. ➩ Ch. 9.7.1
The standardised O2 value should be 1 to 1.5% points Point:2
: 21.1%
above the combustion limit (O2 min value of guard 02-Verbund
: :xxxx
Point:2 21.1% Point :221.1%
function) and minimum of 1 % point below the O2 02-Sollwert:xxxx
O2 RatioCon: 6.0 O2 RatioCon: 6.0
ratio. Normierert :xxxx
If the value is stable O2 SetPoint:3.9
continue with ENTER StandardVal:11.3
.
4. Leave setting level with <ESC> and save the O2 value
using <ENTER>. esc
Point
Note At point 2 and with 100% the time (Dew) between save- >ENTER
the air quantity change and its recognition at the O2 delete->ESC
sensor is determined. This results in the controller
parameters for subsequent O2 control.

Following completion of the O2 standardisation the Ratio Delay time is

curve points should not be altered, otherwise the measured O2 Actual
standardisation for the point altered will be deleted and O2 value: 4.2
trim will not be possible. If a curve point is altered, the Measurem success
standardisation for this point will have to be repeated. ControlParam has
been determined
continiue with ESC
Control limit
At burner ratings in the lower load range, the flue gas
velocity at the O2 sensor may not be sufficient for correct Example: O2 setpoints
and problem free control. In this case the O2 control limit
must be increased accordingly (see Ch. 9.7.1). 8
7
Flue gas velocity [v]: min. = 1 m/s
6 O2
max. = 10 m/s or sensor temperature ratio
O2 Content [%]

min. 680°C 5
O2 S
4 etpo
int
3 O2 G
uard
2
1
T+273
QB · L · λ 0
0 10 20 30 40 50 60 70 80 90 100
273
v= Burner load [%]
d2 · 0.785 · 3600

QB = Fuel throughput (kg/h) (m3/h)

L = Stoichiometric air requirement (m3/kg) (m3/m3) O2 control limit
λ = Air number ➩ Ch. 9.7.1
T = Flue gas temperature °C Param + Display
d = Flue gas pipe diameter (m2) O2Ctrl/Guard
Setting ...
O2CtrlThreshold
QB · 0.0046 T+273
General formula: v = ·
d2 273

33
 6
6.3.3 Set O2 regulating functions
The O2 trim control function is set using OptgMode. O2 operating mode

man deact Param + Display ➩ Ch. 9.7.1

The O2 trim and O2 guard are deactivated. The burner O2Ctrl/Guard
starts with cold sensor (only for commissioning, not Setting ...
recommended for normal operation). OptgMode
OptgMode
O2 guard Curr: man deact
Only the O2 guard is active. New: conAutoDeac
Start-up only when the operating temperature of the
sensor has been reached.
If the O2 guard reacts, or if an error is detected during
measuring, lockout occurs, if there is no possibility of
repetition.

O2 controller
The O2 controller and O2 guard are active.
Start-up only when the operating temperature of the
sensor has been reached.
If the O2 guard reacts, or if an error is detected during
measuring, lockout occurs, if there is no possibility of
repetition.

conAutoDeact
The O2 controller and O2 guard are active.
Start-up before operating temperature of the sensor has
been reached.
If the O2 guard reacts, or if an error is detected during
measuring the function auto deact is initiated.

auto deact (not recommended)

The O2 controller and the O2 guard have been deactivated
automatically by the function

34
 6
6.3.4 Check and optimise O2 trim
Check O2 trim
Procedure:
1. Re-start burner in automatic operation. The start
behaviour can be checked again.

2. Change rating with external signal, so that the O2 value

can be checked on the display of the ABE
• i.e. connect a 3 pole switch to X5-03 and change over
the LC operating type to ExtLC X5-03.

3. In menu “OperationalStat” select “NormalOperation”

and change over to the second display using
<ENTER>.

4. Carry out various load changes across the whole

ratings range whilst observing the O2 controller’s
behaviour.

If the O2 sensor has reached its operating temperature,

and the controller’s damping time (10 x Dew in partial
load) has elapsed, pre-control starts and the O2 value
goes close to the setpoint. If within the delay time (approx.
2 x Dew in full load) no load changes occur, control
goes to the O2 setpoint. The actual O2 value should then
be equal to the O2 setpoint.

When a load change occurs the O2 controller is locked at

the existing value, and the air motors are re-adjusted with
the pre-control starting from the previous differential value
setting. This means that the O2 setpoint is almost
maintained even during pre-control.

Note The O2 trim can also be guarded using recording

software.

35
 6
6.3.5 Optimise O2 trim
Depending on site specific requirements it may be O2 trim parameters
necessary to adjust the O2 trim parameters in the HE level.
Param + Display ➩ Ch. 9.7.1
O2Ctlr/Guard
Settings ...
ControlParams

O2 actual value fluctuates

If the control fluctuates parameter I and P should be
optimised.

In the lower ratings range: i

increase I-Partial reduce
or
reduce PP-Partial load

In the upper ratings range”:

increase I-Full load load
or
reduce P-Full load

O2 control remains locked

If a ratings change occurs prior to the end of the locking
times the controller remains stationary.

Increase LoadCtrlSuspend
Reduce FilterTmeLoad

O2 guard reacts at ratings change

A rapid ratings change will result in lockout by the O2
guard.

O2Offset increase

36
 6
6.4 Concluding work following commissioning
6.4.1 Set ratings range and flue gas temperature limit values

Lower load limit (partial load) Set lower load limit

Observing the instructions given in the installation and
operating instructions of the burner and the instructions GasSettings ➩ Ch. 9.6.1
given by the appliance manufacturer, partial load and the LoadLimits
control range should be set in menu Load limits. Here, MinLoadGas
partial load is defined with parameter MinLoad. MinLoadGas
Curr: 0.0%
New: 22.8%

Flue gas temperature limit value Set flue gas temperature limit values
If the limit value is exceeded the warning “Flue gas
temperature too high” is given. A prerequisite for this is a Param + Display ➩ Ch. 9.12.1
configured flue gas temperature sensor on the O2 module O2 Module
(only W-FM 200). Configuration
The limit value should be set approx. 20% above the flue MaxTempFlueGas
gas temperature at nominal load.

Overheating due to flue gas temperatures

above 300°C can damage the O2 sensor.

DANGER

Select second fuel (only on dual fuel burners) Fuel Selection

Select required fuel using the external fuel selection
switch. If an external selection switch is not available fuel Operation ➩ Ch. 9.3
selection is made with the ABE or BMS. Fuel
Curr fuel or:
Note The external fuel selection switch has priority, this Fuel selection Fuel selection
means commissioning can only be carried out with Curr: Oil switch set
the fuel selected with this switch. New: Gas to oil

6.4.2 Concluding work on the burner

Following commissioning the following, concluding work
has to be carried out on the burner.
• Set air pressure switch.
• Set gas and oil pressure switches.
• Remove measuring devices,
• etc ...

More detailed information can be obtained from the

installation and operating instruction of the burner.

37
 7 Commissioning multi-stage
Prior to commissioning the preparations necessary for
commissioning (Ch. 5) must be completed.

7.1 Set fuel and load required

Burner OFF Burner OFF
To be able to carry out the following steps the burner has
to be set to OFF in menu Manual Operation. Manual operation ➩ Ch. 9.4
Auto/Manual/Off
Auto/manual/Off
Curr: Automatic
New:: Burner Off

Select fuel Oil (only on dual fuel burners) Select fuel

Select fuel Oil using the external fuel selection switch. If an
external fuel selection switch is not available, fuel is Operation ➩ Ch. 9.3
selected using the ABE or BMS. Fuel
Curr fuel or:
Note The external fuel selection switch has priority, this Fuel selection Fuel selection
means commissioning can only be carried out with Curr: Gas switch is set
the fuel selected with this switch. New: Oil to Oil

Select load required S1 Select fuel

In menu Manual opertion call up the function Load
required and set to S1. Manual operation ➩ Ch. 9.4
Load required
Load required
Curr: S3
New: S1

38
 7
7.2 Adjust burner
7.2.1 Preset curve parameter

For commissioning the fan speed1 and air damper setting Call up stepping motor positions
of each operating point as well as the On/Off switch points ➩ Ch. 9.6.1
must be checked and if necessary adjusted. Param + Display
Ratio
Procedure; Oil setting
1. Call up stepping motor positions. Curve parameter
Curve setting
2. Select option Without start Stepping motor
positions
3. Call up operating, the on and off stage switch points With start
one by one using the dial knob and compare air damper Without start
setting (air stepping motor) and fan speed1 (FC) with
table values. If they deviate, overwrite the parameter
by Activate option ‘without start’
• calling up operating, on and off switch points with
<ENTER>, ➩ Ch. 9.6.1
• selecting parameter using dial knob and confirming Stepping motor Point Air :40.0
with <ENTER>, positions ::BS1 FC :80.0
• inputting parameter value (dial knob +/-) and saving With start O2
with <ENTER>. W
Without start xxxx
• continue procedure until all parameters are the same
as the table values.
Call up operating, on and off switch points
1
Two Air damper [°<] Speed [%] ➩ Kap 9.6.1
operating stages Air PC Point Air :40.0 Point Air :40.0
::BS1 FC :80.0 ES2 FC
::E :90.0
Operating point BS1 40 80* O2 O2
Switch on point ES2 xxxx xxxx
Switch off point AS2 70 100
Operating point BS2
Overwrite parameters

Three Air damper [°<] Speed [%]1 Point Air :40.0

operating stages Air motor Auxiliary motor ES2 Point
::E FU LLir
ir0 :40.0
:ES2 FC :90.0
Operating point BS1 30 80* O2
Switch on point ES2 xxxx

Switch off point AS2 change values with dial knob

Operating point BS2 50 90*
Switch on point ES2 Point Air :40.0 Point Air :40.0
:ES2 FFC :90.0 :ES2 FC 80.0
:8
Switch off point AS3 70 100 O2 O2
Operating point BS3 xxxx xxxx

* Valid only if the installation and operating manual of the Point Air :40.0
burner does not indicate a different value. :ES2 FFC :80.0 save values
O2
xxxx
4. Exit level with <ESC>.
Exit level

Without start SSpecialPositions

Operating point S3
esc
CurveParams
Air motor: 70.0 LoadLimits
AAux motor: 100

1
only W-FM 200 in connection with frequency
converter 39
 7
7.2.2 Burner ignition
Set programme stop 36 Programme stop 36: Ignition position without ignition
Prior to first ignition the programme stop has to be set to
36 IgnitionPos. After burner start, the burner then SpecialPositions ➩ Ch. 9.6.1
drives to ignition position without igniting (with long pre- ProgramStop
ignition, ignition is carried out without fuel release). ProgramStop
Curr: 36 IgnPos
Note In its delivered condition the programme stop has New: 36 IgnPos
already been factory pre-set to 36.

Open manual fuel isolating devices and start burner Burner On

Once the fuel shut off devices have been opened the
burner should be started in manual operation. Ration ➩ Ch. 9.4
Auto/Manual/Off
Note For the burner start all safety devices, pressure and Auto/Manual/Off
temperature controllers must be in operating Curr: Burner Off
position. New: Burner On
Sufficient heat demand must be ensured for the
duration of commissioning.

Setting ignition position Set air damper fan speed and ignition position
The fan speed and the ignition position of the air damper
should be set whilst observing the mixing pressure. The Ratio ➩ Ch. 9.6.1
ignition speed1 should not be below 80%. Depending on Oil setting
the burner, the mixing pressure for ignition should be SpecialPositions
between 3 and 5 mbar. The mixing pressure can be IgnitionPos * The IgnitionPosOil does
adjusted with the air damper and diffuser positions. not need to be set for
IgnPosOil* multi-stage operation, as
It is recommended to note down the IgnPos values set. IgnPosAir no oil throughput
IgnPosAux regulator valve and thus
IgnPosFC no stepping motor is
fitted.

Set programme stop 44 Program stop 44: ignition position after safety time
To be able to ignite the burner the programme stop has to
be set from 36 to 44. Once the pre-ignition time has SpecialPositions ➩ Ch. 9.6.1
elapsed fuel is released. The stepping motors remain in the Curvenpater
ProgramStop
ignition position setting. Lostgrenzen
Igndpos rcksetz
ProgramStop
Curr: 36 IgnPos
New: 44 Interv 1

Check fuel pressure

The atomising pump pressure is factory pre-set and can be
determined from the burner test data sheet.

Deactivate programme stop Deactivate program stop

The programme stop has to be deactivated to continue
commissioning. If the programme stop is not deactivated, ProgramStop ➩ Ch. 9.6.1
the burner remains in the existing position, the setting of Curr: 44 Interv 1
new load points is therefore not possible. New: deactivated

1
only W-FM200 in connection with frequency
40 converter
 7
7.2.3 Start full load
Activate option “With start” Activate option “With start”
In stepping motor positions activate the option “With
start” by pressing <ENTER>. CurveParams ➩ Ch. 9.6.1
Lastgrenzen
Curve Settings
Stepping motor Point Air :40.0
Note Operation of the switch off points should be positions ::BS1 FC :80.0
avoided during commissioning, as this can lead to WMith start O2
excessive air deficiency. Without start xxxx

Pre-set operating point S1 Pre-set operating point and set switch on point
1. Select operating point BS1using the dial knob and
confirm with <ENTER>. Point Air :40.0 ➩ Ch. 9.6.1
2. Call up parameter values using the dial knob and ::BS1 FC :80.0
<ENTER> and adjust operating point BS1 whilst O2
observing the combustion quality. xxxx

Note The speed1 should not be selected below

70% (35 Hz).
Lir
Point A :36.0 Point Air 36.0
:3
3. Exit parametering with <ESC>. :BS1 F C :80.0 :BS1 FC 74.0
:7
O2 O2
xxxx xxxx
Set switch on point S2
1. Select switch on point ES2 using the dial knob and esc
confirm with <ENTER>.
Start next operating or
2. Call up parameter values using the dial knob and Point Air :33.0 switch on point and set
<ENTER> and increase excess air whilst observing the ::BS1 FC :63.0 parameter.
flame stability. O2
3. Note down values. Do not operate switch off
xxxx point
4. Exit parametering with <ESC>.

Note When using a three stage burner the procedure has

to be repeated for operating point BS2 and switch
on point ES3.

Set Full Load

1. Select full load point using the dial knob and confirm
with <ENTER> .
Two stage burner: operating point BS2
Three stage burner: operating point BS3

2. Determine fuel throuhput and adjust if necessary.

3. Call up the parameter values using the dial knob and

<ENTER> , and optimise combustion (carry out a
combustion test)

4. After saving with <ENTER> exit parametering with

<ESC> .

1
only W-FM200 in connection with frequency converter
41
 7
7.2.4 Set switch off point(s)
Change over to option “Without start” Activate option “Without start”
Exit option With start in stepping motor positions with
<ESC> and re-enter Curve setting to select option Curve Settings ➩ Ch. 9.6.1
Without start and activate with <ENTER>. Stepping motor Point Air :33.0
positions ::BS1 FC :63.0
With start O2
W
Without start xxxx

Set switch off point S2 Set switch off point(s)

1. Using the dial knob select switch off point AS2 and
confirm with <ENTER>. Point Air :50.0 ➩ Ch. 9.6.1
2. The air damper and motor speed of switch on point of AS2 FC
::A :90.0
ES2 should also be set for the switch off point of AS2. O2
and save with <ENTER>. xxxx
3. Exit parametering with <ESC>.

Note When using three stage burners repeat procedure

and transfer values from switch on point ES3 to iir
Point A :50.0 Point Air 42.0
:4
switch off point AS3. :AS2 F C :90.0 :AS2 FC 69.0
:6
O2 O2
xxxx xxxx

esc

On three stage burners:

Point Air :42.0 Call up switch off point AS3
::AS2 FC :69.0 and transfer the values
O2 from switch on point ES3.
xxxx

7.2.5 Check operation of on and off switch points

As the pump pressure has been changed during full load
adjustment the operating and switchover points has to be
checked.

Carry out combustion check

• Activate option With start.

• Drive to operating point BS1 and check combustion

quality.

• If necessary, optimise combustion quality by changing

the air damper setting and burner motor speed.
During this procedure, the pump pressure must not be
altered.

Note With three stage operation an additional

combustion quality check for stage 2 (operating
point BS2) is required.

Check on and off switch points

Drive to operating points several times, whilst checking the
on and off switching behaviour of the second or third
stages and optimise if necessary.

42
 7
7.2.6 Check start behaviour
Procedure: ProgramStop
1. Set ProgramStop to phase 44.
SpecialPositions ➩ Ch. 9.6.1
2. Re-start burner in manual operation. ProgramStop
ProgramStop
3. Check start behaviour and if necessary correct ignition Curr: deactivated
load setting. New: 44 Interv 1

Note If the ignition load setting has been altered, the start
behaviour has to be rechecked.
Restart burner
4. Deactivate programme stop.
Auto/Maual/Off ➩ Ch. 9.4
Auto/Manual/Off
Curr: Burner Off
New: Burner Off
Auto/Manual/Off
Curr: Burner On
New: Burner On

7.2.7 Define full load as load required

Call up function required load in menu ‘Manual operation’ Set load required
and set to full load.
Manual operation ➩ Ch. 9.4
Two stage operation: BS2 Load requird
Three stage operation: BS3 Load required
Curr: BS1
New: BS3

43
 8 Load controller
The controller has to be configured relevant to the
installation to ensure safe and reliable load control. On the
W-FM100 the load controller is optional.

8.1 Set operating mode

The operating mode determines if and how the internal Set operating mode
load controller is used and if an external load controller is
connected. Param + Display ➩ Ch. 9.8.4
If the internal load controller is deactivated in menu LoadController
SystemConfig, it can only be reactivated in this menu. Configuration
LC-OptgMode
Note As an emergency function switchover from the LC-OptgMode
external load controller to the Int LC can be Curr: Int LC
carried out with a switch contact on input X62. The New: Int LC
Int LC must be configured for this and must be
equipped with a process condition
(temperature/pressure) sensor.

ExtLC X5-033 Three point step input signal of external

load controller to X5-03
.
Int LC Internal load controller with 2 setpoints.

Int LC Bus Digital setpoint signal from building

management system via eBus or Modbus.
The ABE acts as interface.

Int LC X62 Analogue setpoint signal from the

building management system on input
X62
(4 to 20 mA or 0 to 10V).
switchover to the internal setpoint W1 is
possible with an external switch contact
on terminal X62:1/2.

Ext LC X62 Analogue setting signal from the building

management system on input X62 (4 to
20 mA or 0 to 10V).
Switchover to the internal setpoint W1 is
possible with an external switch contact
on terminal X62:1/2.

Ext LC Bus Load control is carried out by the building

management system.
Signal transfer is carried out with eBus or
Modbus, the ABE acts as interface.

44
 8
8.2 Configuring sensors
Sensors used Configuring sensors
Sensor selection has to be configured depending on
whether the actual value is determined by a temperature Param + Display ➩ Ch. 9.8.4
sensor (input X60) or a temperature or pressure sensor Load Controller
(input X61). Configuration
Sensor selection
PT 100 PT 100 sensor on terminal X60:1/2/4, Sensor selection
temperature limit function is active. Curr: PT 100
New: PT 100
PT 1000 PT 1000 sensor on terminal X60:3/4,
temperature limit function is active.

Ni 1000 Ni 1000 sensor on terminal X60:3/4,

temperature limit function is active.

PT100 PT1000 PT 100 sensor on terminal X60:1/2/4

for temperature controller function.
PT 1000 sensor on terminal X60:3/4
for temperature limit function.

PT 100 Ni 1000 PT 100 sensor on terminal X60:1/2/4

for temperature controller function.
Ni 1000 sensor on terminal X60:3/4 for
temperature limit function.

TempSensor Temperature sensor on input X61, no

temperature limit function.

PressureSens Pressure sensor on input X61, no

temperature limit function.

None No sensor fitted to W-FM.

Sensor measuring range Set measuring range
To allow correct actual value determination the measuring
range of the sensor has to be defined. Param + Display ➩ Ch. 9.8.4
LoadController
MeasR PtNi : 150°C/302°F, Configuration
400°C/752°F or MeasureRange PtNi MeasureRange
850°C / 1562°F MRange TempSens Curr: 150°C/302°F
MRange PressSens New: 400°C/752°C
With setting 850°C / 1562°F, the end of the measuring
range can be defined via parameter Var.Meas.R. PtNi.

MeasR TempSensor : 0…2000°C

MeasR PressSens : 0…99.9 bar

The measuring range is also the setting range for the

external setpoint.

Sensor signal Set analogue signal at input X61

If the actual value is determined by a sensor’s connection ➩ Ch. 9.8.4
to input X61, the relevant analogue signal has to be set. Param + Display
LoadController
4 to 20 mA : Current signal on terminal X61:3 Configuration
with load limit (TL) ExtInp X61 U/I
Ext Inp X61 U/I
2 to 10 V : Voltage signal on terminal X61:2 Curr: 0 ... 10 V
with load limit (TL) New: 4 ... 20 mA
0 to 10 V : Voltage signal on terminal X61:2
without load limit.

45
 8
8.3 Setpoints (external)
External load / setpoint signal Define analogue signal at input X62
If a load controller is connected to input X62
(Ext LC X62), or if the setpoint signal for the internal load Param + Display ➩ Ch. 9.8.4
controller (Int LC X62) is given by this input, the type of LoadController
analogue signal must be defined. Configuration
Ext Inp X62 U/I
Ext LC X62 (load signal) : 4 to 20 mA or 2 to 10 V Ext Inp X62 U/I
Curr: 4 ... 20 mA
Int LC X62 (setpoint signal) : 4 to 20 mA or 0 to 10 V New: 0 ... 10V

Set limit values for external setpoint Set limit values

The setpoint signal for the internal load controller
(Int LC X62) can be limited in parameter Param + Display ➩ Ch. 9.8.4
Ext MinSetpoint and Ext MaxSetpoint. LoadController
The percentages given for the limit relate to the value set Configuration
under MeasureRange PtNi. Ext MinSetpoint Ext MaxSetpoint
Ext MinSetpoint Ext MaxSetpoint
Example: Curr: 0% Curr: 100%
New: 33% New 5 3%
Upper setpoint limit required = 80°C

MeasureRange PtNi = 150°C

Calculation:

80°C
• 100 ≈ 53.3%
150°C

46
 8
8.4 Setpoints (internal)
Internal setpoints (W1 / W2) Internal setpoints (W1 / W2)
Two internal setpoints can be stipulated.
Switchover is with potential free contact on the terminals Param + Display ➩ Ch. 9.8.1
X62:1/2. LoadController
The setpoints cannot be set above the temperature limit ControlParam
value already entered. ContParamSelect
Setpoint W1
Setpoint W2
Setpoint W1
Curr: 80°C
New: 70°C

Switching differential Switch differential

The on and off switch point is given in percent relating to
the setpoint. Param + Display ➩ Ch. 9.8.1
LoadController
ControlParam
Setpoint 70°C Sd_ModOn Sd_ModOn
Sd_ModOff 10% (from 70°C = + 7.0K) Sd_ModOff Curr: 3%
Sd_ModOn- 5% (from 70°C = - 3.5K) New: - 5%

Installation Off 70°C + 7.0K = 77.0°C

Installation On 70°C - 3.5K = 66.5°C

Note If a positive Sd_ModOn is defined, the switch

on point will be above the setpoint.

Temperature limit (TL) Temperature limit

If the temperature limit is exceeded, the installation
switches off and the message Internal temperature Param + Display ➩ Ch. 9.8.2
limit has reacted is displayed. LoaadController
The switch on threshold is given in percent relative to the TempLimiter
setpoint temperature. TL_ThreshOff TL_ThreshOff
If a thermocouple or pressure sensor has been configured, TL_SDiffOn Curr: 95
the limit function is inactive. New: 90

TL Threshold Off 90°C

TL SDiff On - 10% (from 80°C = 9.0K)

Installation Off 90°C

Switch on threshold 90°C - 9.0K = 81°C

47
 8
8.5 Modulating load control
8.5.1 Parametering internal load control
Adaption Filter time
During adaption, the internal load controller recognises the
control section and calculates the PID parameter. Param + Display ➩ Ch. 9.8.1
Adaption can be started in manual or automatic operation LoadController
independent of the operating phase (standby or ControlParam
operation). SW-FilterTmeCon
During adaption, the parameter SW-FilterTmeCon should SW-FilterTmeCon
be between 2 and 4 seconds. If the value selected is too Curr: 3 s
high, this can stop the adaption or lead to insufficient New: 3 s
control parameters.

Adaption load Adaption Load

If during adaption insufficient heat demand is available, full
load can be limited to up to 40% in parameter Param + Display ➩ Ch. 9.8.6
AdaptionLoad. LoadController
However, if the AdaptionLoad selected is too low, this Adaption
can stop the adaption. AdaptionLoad
AdaptionLoad
Curr: 100%
New: 80%

Start adaption Start adaption

Select parameter StartAdaption and confirm with
<ENTER>. The respective phases of adaption are Param + Display ➩ Ch. 9.8.6
displayed alternately with the actual value and load signal. LoadController
Adaption
Phases of adaption: Start adaption Start adaption
• Decreasing of temperature (Temp decrease) with ENTER 12
Before the adaption can be started, the actual setpoint 80°C
temperature (or pressure) must be 5% below the Actual value 79°C
setpoint temperature (or steam pressure).

• Determine actual value (Stabilising phase)

The direction of the actual value is determined for 5 min.
During this time the actual value should be constant.
If strong fluctuations occur the time is increased to
maximum 10 min, and anything greater leads to
termination.

• Start-up (Heating)
The direction of the actual value during the heat up
phase is determined.
Adaption complete
• Calculation of control parameter (Adaption ok)
Using the measured values of the stabilising phase, Adaption ok Adaption ok
the heat input and reaction times and the PID P-content (Xp) P-content (Tu)
parameter are calculated. 11.2% 53s
The values calculated can be called up using the dial continue with <> continue with <>
knob.

Standard control parameters Standard control parameters

If an adaption is not possible or not necessary, standard
parameters can be used as PID values. Various settings ➩ Ch. 9.8.1
Param + Display
are available depending on the behaviour of the control LoadController
section. ControlParam
ContParamSelect
P (Xp) I (Tn) D (Tv) StandardParam
very slow 30 % 400 s 10 s SW-FilterTmeCon
slow 15 % 320 s 40 s Curr: XXX
normal 7% 90 s 50 s New: Normal
fast 4% 35 s 17 s
very fast 40 % 55 s 15 s
48
 8
8.5.2 Optimising internal load control
Control behaviour Adapt PID parameters
Observe load control for some time during operation and if
necessary optimise the PID parameter. Param + Display ➩ Ch. 9.8.1
LoadController
ControlParam
ContParamSelect
P-Part (Xp)
I-Part (Tn)
D-Part (Tv)

Setting adjustment stability Setting adjustment stability

With the MinActuatorStep unnecessary drive impulses
of the stepping motors can be reduced and thus Param + Display ➩ Ch. 9.8.1
increasing their life span. LoadController
However, the MinActuatorStep adjustment affects the ControlParam
precision control and stability of the load control. MinActuatorStep
MinActuatorStep
Curr: 1.0%
New: 2.0%

Erroneous signal filter Fault signal filter

Using a filter with time constants (SW FilterTmeCon),
signals which affect the D-Part can be weakened. Param + Display ➩ Ch. 9.8.1
However, a time filter that is too long will have a negative LoadController
effect on the control. ControlParam
SW_FilterTmeCon
Recommendation: 2 to 4 seconds (Pt 100) SW_FilterTmeCon
6 to 8 seconds (steam pressure Curr: 3 s
sensor) New: 4 s

49
 8
8.6 Multi-stage load control
Switching differentials Switching differentials
The switching differentials are formed in percentages
depending on the current setpoint. Param + Display ➩ Ch. 9.8.1
LoadController
SD_SStage1On: ControlParam
At this switching differential the control circuit is closed SD_Stage1On SD_Stage1On
and the burner is switched on. SD_Stage1Off Curr: 1.0%
SD_Stage2Off New: 1.0%
SD_SStage1Off: SD_Stage3Off
As this switching differential is exceeded the control circuit
is opened and the burner is switched off.

SD_SStage2Off:
As this switching differential is exceeded the system is
switched from stage 2 to stage 1.

SD_SStage3Off:
As this switching differential is exceeded the system is
switched from stage 3 to stage 2.

Switch thresholds Switch thresholds

This is the integral (I) from the control devitation multiplied
by the time. Param + Display ➩ Ch. 9.8.1
This function monitors the behaviour of the installation. LoadController
depending upon demand the next higher load stage is ControlParam
selected. ThresholdStage2On ThresholdStage2On
The control devitation refers to the setpoint (W1 or W2). ThresholdStage3On Curr: 300
New: 300
ThresholdStage2On:
Switch criteria for the release of second stage.

ThresholdStage3On:
Switch criteria for the release of third stage.

Notes for 2 stage operation

If a burner with 3 nozzles is only to be operated in two
stage mode, ThresholdStage2On should be set to “0”.
This means that with the release of the load control the
second nozzle is immediately switched on. The burner is
then in partial load. To ensure correct switch off behaviour,
SD Stage2Off and SD Stage1Off should be set to the
same value.

With external analogue load signal (ext LC analog) only

possible if the lowest analogue signal is higher the 10 mA
or 5 V.

With load control via Bus (ext LC Bus) stage 1 and

stage 2 must be couppled simultaneously via Bus.

50
 8
8.7 Cold start function
Activate cold start function Activate cold start function
In order to avoid the appliance operating at its maximum
loading before the required minimum appliance Param + Display ➩ Ch. 9.8.3
temperature has been reached, the cold start function has LoadControl
to be activated. Cold start On Cold start On
Curr: deactivated
New: activate

Additional sensor Configure additional sensor

A separate temperature sensor (terminal X60) for the cold
start function must only be activated if either a temperature Param + Display ➩ Ch. 9.8.3
or pressure sensor on terminal X61 is used for the load LoadController
control. Cold start
The switch thresholds then relate to the setpoint for the Additionalsensor Setpoint add sens
additional sensor. Additional sensor Setpoint add sens
Curr: deactivated Curr: 60°C
New: Pt 1000 New: 70°C

Switch thresholds Set switch thresholds

The thresholds relate to the current setpoint (W1/W2) or if
an additional sensor is fitted to the setpoint add sens. Param + Display ➩ Ch. 9.8.3
LoadController
ThresholdOn: Cold start
If the actual temperature falls below the switch on threshold ThresholdOn ThresholdOn
the burner starts in the cold start function. ThresholdOff Curr: 20%
New: 25%
ThresholdOff:
If the actual temperature exceeds the switch off threshold
the cold start function is deactivated.

Load steps (only with modulating operation) Set StageLoad

At parameter, StageLoad the load increase can be set up
to that of the ThresholdOff value. Param + Display ➩ Ch. 9.8.3
LoadController
Cold start
StageLoad StageLoad
Curr: 15%
New: 15%

StageSetp_Mod Set StageSetp_Stage

StageSetp Mod (stage setpoint modulating):
If the actual temperature exceeds the next stage setpoint , Param + Display ➩ Ch. 9.8.3
the cold start load increases by the value set under LoadController
StageLoad. Cold start
StageSetpMod StageSetpMod
StageSetp Stage: (stage setpoint multi-stage): StageSetpStage Curr: 5%
If the actual temperature exceeds the next stage setpoint , New: 5%
the next stage is released

Time controlled load increase Time controlled load increase

If the actual temperature does not reach the
StageSetPoint ..., the cold start load (StageLoad) is Param + Display ➩ Ch. 9.8.3
increased following the MaxTmeStage... LoadController
Cold start
MaxTmeMod MaxTmeMod
MaxTmeStage Curr: 3 min
New: 3 min

51
 9 Parameters and functions
9.1 Menu structure (ABE)
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
OperationalStat NornalOperation
esc
Status/Reset
FaultHistory
LockoutHistory
Alarm Act/deact

Operation Boiler setpoint Setpoint W1

esc esc
Setpoint W2

LoadLimitAB ABmaxLoadMod
esc
ABmaxLoad St

Fuel CurrentFuel
esc
FuelSelect

Date/TimeOfDay DisplayClock Date

esc esc
TimeOfDay
Weekday

SetClock Date
esc
TimeOfDay
Weekday

HoursRun GasFiring
esc
OilStage1/Mod
OiStage2
OilStage3
TotalHoursreset
TotalHours
SystemOnPower

StartCounter GasStartCount
esc
OilStartCount
TotalStartCountR
TotalstartCount

Fuel meter Curr Flow Rate

esc
Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset Date Gas
Reset Date Oil

LockoutCounter

O2 Module Current O2 value

esc
only W-FM 200 O2 Setpoint
SupplyAirTemp
FlueGasTemp
CombEfficiency

BurnerID

OptgModeSelect InterfacePC
esc
GatewayBASon
GatewayBASoff
Type of Gateway

O2 trim activate
only W-FM 200
End user: Access without password
Engineer: Access with HE password
52
 9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
ManualOperation SetLoad
esc
Auto/Manual/Off

Param & Display BurnerControl Times Times Startup1 FanRunup Tme

esc esc esc esc Prepurge TmeGas
Prepurge TmeOil
PrepTmeTI1Gas
PrepTmeTI3Gas
PrepTmeTI1Oil
PrepTmeTI3Oil
PreIgnTme_Gas
PreIgnTme_Oil
MinOnTmeOilpump

TimesStartup2 Interval1Gas
esc
Interval1Oil
Interval2Gas
Interval2Oil

TimesShutdown MaxTmeLowFire
esc
Postpurge
Postpurge1Gas
Postpurge1Oil
Postpurge3Gas
Postpurge3Oil

TimesGeneral AlarmDelay
esc
DelayStartPrev
Postpurge_lockout

Configuration ConfigGeneral AlarmStartprev

esc esc Norml/DirectStart
Oil pump coupling
ForcedIntermit
Prep.Gas skipped
Cont.RunFan

Config Inp/Outp Start/PS valve

esc

Config FlamSensor Flamesig QRI_B

esc Flamesig ION

Repetition counter Heavy oil

esc
Start release
Safety circuit

ProductID ASN
esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

SW Version

End user: Access without password

Engineer: Access with HE password
53
 9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
RatioControl GasSettings SpecialPositions HomePosition
esc esc esc esc
Param & Display PrepurgePosition
IgnitionPosition
PostpurgePosition
ProgramStop
IgnitionPos reset

CurveParams

LoadLimits MinLLoad_Gas
esc
MaxLLoad_Gas

Blank out load range B/out LR bottom

esc
B/out LR top

OilSetting SpecialPositions HomePos

esc esc
PrepurgePos
IgnitionPos
PostpurgePos
ProgramStop
ResetignitPos

CurveParams Curve Settings

esc

LoadLimits MinLoadOil
esc
MaxLoadOil

Blank out load range B/out LR bottom

esc
B/out LR top

Auto/Manual/Off

Times OperatRampMod
esc
OperatRampStage
DriveRamp

ShutdownBehav

ProgramStop

End user: Access without password

Engineer: Access with SERV password
54
 9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5

O2Contr/Guard GasSettings OptgMode

esc esc esc
Param & Display (only W-FM 200) O2 Control
O2 guard

Control parameter P Low-Fire

esc
I Low-Fire
Dew Low-Fire
P High-Fire
I High-Fire
Dew High-Fire

O2CtrlThreshold
PLoadAdaptPtNo
Type of fuel

Fuel user-def V_LNmin

esc esc
V_afNmin
V_atrNmin
A2
B / 1000

Type air change asTheory

esc
as P-Air

O2-Offset Gas
LoadContLock
FilterTimeLoad

OilSettings OptgMode
esc esc
O2 Control
O2 Guard

Control parameter P Low-Fire

esc
I Low-Fire
Dew Low-Fire
P High-Fire
I High-Fire
Dew High-Fire

O2CtrlThreshold
PLoadAdaptPtNo
Type of fuel

Fuel user-def V_LNmin

esc esc
V_afNmin
V_atrNmin
A2
B / 1000

Type air change as Theory

esc
as Air

O2-Offset Oil
LoadContLock
FilterTimeLoad

Process Data CombEfficiency

esc esc
ManVar O2 Ctrl
State O2 Ctrl
Air-related Load
Diag Reg State

End user: Access without password

Engineer: Access with HE password
55
 9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5

LoadController ControlParameter ControlParamList StandardParam

esc esc esc esc
Param & Display (optional on W-FM P-Part (Xp)
100) I- Part (Tn)
D-Part (Tv)

MinActuatorStep
SW_FilterTmeCon
SetpointW1
SetpointW2
SD_ModOn
SD_ModOff
SD_Stage1On
SD_Stage1Off
SD_Stage2Off
SD_Stage3Off
ThreshStage2On
ThreshStage3On

TempLimiter TL_ThreshOff
esc
TL_SD_On

ColdStart ColdStartOn
esc
ThresholdOn
StageLoad
StageSetp_Mod
StageSetp_Stage
MaxTmeMod
MaxTmeStage
ThresholdOff
AdditionalSens
TempAddSensor
Setp AddSensor
Release Stages

Configuration LC_OptgMode
esc
Sensor Select
MeasureRangePtNi
var.Meas.Ran.PtNI
Ext Inp X61 U/I
MRange TempSens
MRange PressSens
Ext Inp X62 U/I
Ext MinSetpoint
Ext MaxSetpoint

esc
AnalogueOutput Select output value
Current Mod 0/4ma
Scal 20mA Proc
Scal 20mA Temp
Scal 20mA Press
Scal 20mA Angle
Scaling 0/4mA

Adaption StartAdaption
esc
AdaptionLoad

SW Version

End user: Access without password

Engineer: Access with HE password
56
 9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
Times Sum/WinterTime
esc AZL esc esc
Time EU/US
Param & Display

Language
DateFormat

PhysicalUnits UnitTemperature
esc
UnitPressure

eBus Address
esc
SendCycleBU

ModBus Address
esc
Baudrate
Parity
Timeout
Local/Remote
Remote Mode
W3

Display Contrast

ProductID ASN
esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

SW Version

End user: Access without password

Engineer: Access with HE password
57
 9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
Actuators Addressing 1 AirActuator
esc esc esc
Param & Display 2 GasActuat(Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2
6 AuxActuator3

Rotation Direction Delete curves

esc

Product ID 1 Air Actuator ASN

esc esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

2 Gas Act.. (Oil) ASN

esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

3 Oil Actuator ASN

esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

4 Auxiliary Actuator ASN

esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

5 Auxiliary ASN
esc
Actuator 2 ProductionDate
(only on W-FM 200) SerialNumber
ParamSet Code
ParamSet Vers

6 Auxiliary ASN
esc
Actuator 3 ProductionDate
(only on W-FM 200) SerialNumber
ParamSet Code
ParamSet Vers

SW Version 1 AirActuator
esc
2 GasActuat(Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2
6 AuxActuator3

End user: Access without password

Engineer: Access with HE password
58
 9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
Configuration ReleaseCont. FC
esc FC Module esc esc
Param & Display
(optional on
W-FM 100)
Speed Num Puls per R
esc
Standardisation
StandardisedSp
AbsoluteSpeed
Setpoint Output

Fuel meter PulseValueGas

esc
PulseValueOil

Process Data Max Stat Dev

esc
Max Dyn Dev
Num Dev >0.3%
Num Dev >0.5%
Absolute Speed

ProductID ASN
esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

SW Version

O2 module SW Version
Konfiguration O2 Sensor
esc esc esc
(only W-FM 200) SupAirTempSens
FlueGasTempSens
MaxTempFlGasGas
MaxTempFlGasOil

Displayed Values Current O2 Value

esc
O2 Setpoint
SupplyAirTemp
FlueGasTemp
CombEfficiency
QGO SensorTemp
QGO HeatingLoad
QGO Resistance

ProductID ASN
esc
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

SW Version

Flue gas Type Oper. FGR

esc esc
recirculation FGR sensor
actTmpFGRsensor
FGR On Temp Gas
FGR On Time Gas
FGR On Temp Oil
FGR On Time Oil

End user: Access without password

Engineer: Access with HE password
59
 9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
SystemConfig LC_OptgMode
esc esc
Param & Display Inp3Config..I/U

TempLimiter TL_Thresh_Off
esc
TL_SD_On
Sensor Select
MeasureRangePtNi

O2Ctrl/LimitrGas
O2Ctrl/LimitrOil
LR AnalogueOutput
Max.perm.Potidiff

HoursRun GasFiring
esc esc
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
TotalHours
SystemOnPower

Reset GasFiring
esc
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset

StartCounter GasStartCount
esc
OilStartCount
TotalStartCountR
TotalStartCount

Reset GasStartCount
esc
OilStartCount
TotalStartCountR

Fuel Meter Curr Flow Rate

esc
Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset DateGas
Reset DateOil

Updating ParamBackup Backup Info Date

esc esc esc
TimeOfDay
BU included?
AZL included?
LC included?
ACT1 included?
ACT2 included?
ACT3 included?
ACT4 included?
ACT5 included?
ACT6 included?
FC included?
O2 included?

LMV5… -> AZL

AZL -> LMV5…

Load_SW_from_PC

End user: Access without password

Engineer: Access with HE password
60
 9
Menu level 1 Menu level 2 Menu level 3 Menu level 4 Menu level 5
PW Login
PW Logout

TÜV Test LossFlameTest

esc
SLT Test
SLT TestLoadMod
SLT TestLoadSt

End user: Access without password

Engineer: Access with HE password
61
 9
9.2 Operating display
The operating display is accessible by pressing the Info
button, by pressing ESC you return to the previous menu.

NormalOperation

Display of:
• Phases during start up
• Setpoints and actual values
• Current burner rating
• Flame signal
• By pressing ENTER the stepping motor positions,
speed and the O2 value can be displayed.

Status/Reset

If a lockout is present at display “NormalOperation”, this

can be reset using parameter “Status/Reset” or a button
on input X4-01:4.

The display alternates between displaying fault information

and clear text description of the fault. The display is exited
using ESC and the plant can be reset by pressing ENTER.

FaultHistory

Fault memory with the last 21 faults.

Display of:
• Fuel at onset of fault
• Fault group
• Fault and diagnostic codes (C/D) ☞ see Ch. 12
• Phase, in which the fault occurred
• Load position and start No.

LockoutHistroy

Memory of the last 9 faults, which caused lockout.

Display of:
• Date and time when lockout occurred
• Fault and diagnostic codes (C/D) ☞ see Ch. 12
• Phase, in which lockout occurred (P)
• Load position and fuel

Alarm act/deact

With this function the lockout signal output on terminal

X3-1:2 can be reactivated or deactivated. Deactivation
of the output remains active until reset, the next start or a
system reset.

62
 9
9.3 Operation
Boiler Setpoint

Two setpoints (W1/W2) can be entered for the internal Setpoint switchover W1/W2
load controller. The setpoints cannot be set using the
current guarding temperature (optional on W-FM 100).

Switchover from setpoint W1 to W2 is carried out with

X62
potential free contact at input X62:1/2 Activation 2
2nd setpoint W2
1

LoadLimitAB

It is possible to further limit the common full load within the

load limits (Ch. 9.6.1) in the user level.

ABmaxLoadMod: Load limit for modulating operation

ABmaxLoad ST: Load limit for multi-stage operation

(stage 1, 2, 3).

The minimum load set under load limits is maintained at all

times.

Fuel

Fuel determination with “CurrentFuel” (read only) External fuel selection switch

If an external fuel selection switch has been fitted, this has

priority.
X4-01

If an external fuel selection switch is not fitted, or if this Preselection Oil

2
switch has been set to W-FM internal the current fuel can Preselection Gas
1
be changed with the ABE using “FuelSelect”. W-FM internal
Fuel selection with ABE or eBus (BMS) have equal 012
preference, this means the option selected last is valid.

Date/TimeOfDay LockoutCounter

In this menu the date, time and weekday are shown and Total number of lockouts since commissioning (cannot be
can be adjusted if required. reset).

HoursRun Combustion Efficiency

HoursRun is read only. Reset of the individual counters is Display of the current efficiency during burner operation
only possible in level Param & Display in menu (see Ch. 9.7.1).
HoursRun (see Ch. 9.15).
BurnerID
StartCounter Here, the burner specific serial number is saved at the
factory.
The burner starts are read only. Reset of the individual start Using the serial number it is possible to replace a failed
counters is only possible in level Param & Display in unit with one that has the same factory pre-settings.
menu StartCounter (see Ch. 9.16). BurnerID also acts as copy protection; this means burner
specific data in the memory of the ABE cannot be
transferred to another W-FM.
Fuel meter

see Ch. 9.17 Param & Display - fuel meter

63
 9
OptgModeSelect

Here, the operating mode of ABE for serial interface is set.

Interface PC
The ABE acts as PC interface. The W-FM is set using a
PC and software.

Gateway BMS on
Access by building management (BMS) to the W-FM
using the ABE. The ABE remains functioning.

GatewayBMS off
Operation without building management. Access to the
W-FM only with ABE.

Type of Gateway
Stipulated by the relevant bus protocol (eBus or Modbus).

9.4 Manual operation

Target rating

0-100%
Load started in manual operation (burner On). If not
specified, partial load is started.

S1-S3
Highest stage which can be started in manual operation
(burner On).

Auto / Manual / Off

Burner operation is set using this parameter.

This menu is also accessible from level RatioControl.

Automatic
The burner is regulated by an external or the internal load
controller to setpoint. Regulation can be two stage, three
stage or modulating.

Manual On
The burner starts and is switched of by the external or
internal temperature guard. Prerequisite is a closed control
circuit or bridge at input X5-03 terminals 1 and 4.

Manual Off
Burner switches off. Even if the switch on hysteresis is not
reached, the burner remains off.

64
 9
9.5 Burner control
Depending on the password entry the relevant parameter
for the operator or the engineer is displayed.

9.5.1 Times

Time start up 1 Time general

Fan run up time Alarm delay time

Duration of fan start up to start of stepping motors. This time stipulates how soon the combustion manager
signals lockout. The self-test of the system can take up to
Pre-purge time gas/oil 35 seconds. If the fault has been rectified during this test
Duration after reaching the pre-purge positions up to drive phase, the installation re-starts.
to ignition positions.
Delay Start Prevention
Pre-purge time part 1 gas/oil This stipulates after how many seconds the display
Duration for phase 30, in which the auxiliary actuator 3 message is shown if start prevention is active during heat
(FGR) is in standby position. demand.

Pre-purge time part 3 gas/oil Postpurge time in lockout

Duration for phase 30, in which the stepping motors are in Duration for postpurge following lockout in gas operation
pre-purge position. (Phase 00).

Pre-ignition time gas/oil

Duration for phase 38. Once this time has elapsed, fuel is
released for ignition.
Gas: 2 seconds
Oil: 2 seconds
Medium and heavy oil: 10 to 20 seconds

Min. switch on time of oil pump

Duration for phase 36. This time can be extended for heavy
oil to ensure the fuel pressure is sufficient for ignition.

Time start up 2

The interval times act as stabilisation periods following

flame formation. The interval time 2 is only active with pilot
ignition.

Time shutdown

MaxTime_LowFire
If the burner is shut down, or if fuel change over is initiated,
the shutdown program starts at the latest after completion
of this time. If low fire is reached prior to this time elapsing,
the shutdown program starts when low fire is reached.

Postpurge time 1
Duration of postpurge in phase 74. Once this time has
elapsed, the auxiliary actuator 3 (FGR) drives to postpurge
position and the air pressure switch of the flue gas
recirculation on termonal X4-01:3 is interrogated.

Postpurge time 3
Duration of postpurge.

65
 9
9.5.2 Configuration

General configuration Config Input/Output

Alarm start prevention Start/PS valve

Stipulates if start preventions are signalled by the alarm Start signal:
output (terminal X3-01:2) Output X4-03:3 is actuated from phase 21 to 78.

Normal or direct start PS-Relief:

Start behaviour at heat demand during shutdown in Output X4-03:3 is actuated in phase 79 (function is not
phase 78. needed).

During normal start the fan is switched off and start-up PS-Relief_Inv
begins in phase 10. In phase 21 and Phase 79, the pressure switch relief
valve on output X4-03:2/3 is de-energised to test the air
During direct start the fan continues to run and start-up pressure switch.
jumps from phase 79 to phase 24.
This shortened start-up procedure is only possible with an
air pressure switch in conjunction with a pressure switch ConfigFlame Sensor
relief valve at output X4-03:2/3. Parameter Start/PS-
Valve in menu Config In-/Outp must be set to PS- Flame signal
RelVal Inv. Display of the current signal at the flame sensor.

Oil pump coupling Repetition counter

Type of oil pump control.
Determines the number of start attempts before the
Magnetic coupling: combustion manager goes to lockout.
On dual fuel burners with magnetic coupling or oil burners
with separate oil pump. Heavy oil
If a signal is applied to input X6-01:3 within circulation
Direct coupling: phase 38 in heavy oil operation, the circulation phase is
Oil pump is driven directly by the fan motor. The safety shortened and the combustion manager changes into
valve is therefore connected to output (magnetic coupling/ phase 40.
pump X6-02:3). With direct coupling, the output switches If no signal is given for 45 seconds, a home run
off with a delay and thus prevents an impermissibly high (Phase 10) is initiated with subsequent repetition.
vacuum at the pump.
Start prevention
ForcedIntermit If not all start criteria are fulfilled in phase 2, the unit
With ForcedIntermit active, a controlled shutdown with changes over to phase 10 or phase 01 with subsequent
immediate restart is carried out after 23 h 50 mins. This repetition.
should be selected if no continuous operation flame
sensor is used. Safety circuit
If the safety circuit (X3-04:1) is interrupted, at least one
Skip Prepurge Gas shutdown is initiated with subsequent repetition.
If this parameter is activated, prepurge in gas operation is
skipped. In accordance with EN 676 this only permitted
with Class A valves in conjunction with a valve proving
system (soundness test).
Prepurge is not skipped following:
• a lockout,
• 24 h standby,
• power failure,
• safety shut down if gas supply is insufficient.

Continous run fan

If this parameter is activated, the fan runs in all operating
phases. If an air pressure switch is connected, continous
run fan is only possible with a pressure switch relief valve
on output X4-03:2/3. Parameter Start/PS-Valve in
menu Config In-/Outp shoud be set to PS-RelV Inv.

66
 9
9.5.3 Product ID and software version

Product ID

The “ProductID” gives information about:

• Type description (LMV...)
• Production date
• Serial number
• Parameter set codes
• Parameter set version

SW version

The “SW Version” gives information about the software

version of the burner control.

67
 9
9.6 Ratio control
The setting parameters in menu “RatioControl” can only be
accessed with the password for the engineer.

9.6.1 Settings gas/oil

Special positions

The special positions are fuel specific and can be entered Ignition positions
individually for oil and gas. This parameter is used to set the stepping motor positions
and speed for ignition. Ignition (phase 38) is only carried
Home positions out when all motors have reached their ignition positions.
This parameter is used to set the stepping motor positions
or speed control in Standby.
HomePosFC = 0 Frequency converter deactivated IIgnPosGas : Ignition must be carried out with excess
(frequency = 0Hz). air. The gas pressure has to be set to the
HomePosFC > 0 Start release frequency converter instructions given in the installation and
Fan motor starts with relevant operating instructions of the burner.
speed set (in %). Gas butterfly opening during ignition:
– with ignition pilot 10 to 20°<)
Pre-purge positions – without ignition pilot approx. 10°<)
This parameter is used to set the air determining stepping
motor positions or the motor speed for pre-purge. IgnPosOil : Position of the oil controller. The ignition
Pre-purge only starts once all motors have reached their position for oil can be found on the burner
pre-purge positions. test data sheet. The indicator position
given is the same as the data given for the
Post-purge positions degree of angle. If an oil controller is not
The parameter PostpurgePos allows separate setting of fitted (multi-stage) the ignition position of
the individual stepping motors. oil has no influence.
Pre-set values have been entered at the factory. Generally,
setting values are required, which ensure sufficient cooling IgnPosAir : When the fuel is ignited a pressure
of the mixing head whilst still maintaining adequate heat in increase occurs in the combustion
the heat exchanger. chamber. The burner must create a
resistance against this to avoid a back
Program stop flow of flue gases. Therefore ignition with
In menu, ProgramStop the start of the burner can be open air damper and matching of the
stopped at 7 defined positions and adjustments to the mixing pressure by speed only is not
burner settings can be made. possible. A setting of approx. 20°<) for the
air damper is recommended. The actual
24 PrePurgPos : Nominal load pre-purge position air damper opening will be determined
32 PreP FGR : Nominal load pre-purge for FGR later by the mixing pressure measurement.
36 IgnitPos : Ignition position without ignition
44 Interv 1 : End of first safety time IgnPosAux : The position of the adjustable mixing head
52 Interv 2 : End of second safety time can be found in the installation and
72 PostPPos : Air damper in post-purge position operating instructions of the burner. If an
(shutdown) adjustable mixing head is not fitted, the
76 PostPFGR : Air damper in post-purge position fixed sleeve or the adjustable flame head
for FGR must be pre-set to the operating points in
the capacity graph.
Reset ignition position
The values of ignition position for oil, air and auxiliary motor IgnPosAux2 : Auxiliary motors for special applications.
are deleted, existing programming points remain. IgnPosAux3 : For example: Second fuel Kerosene or
The burner without ignition position data can no longer Liquid Petroleum Gas, flue gas damper
start. etc. (only W-FM 200)

Note: In its delivered condition a provisional ignition IgnPosFC : The ignition speed depends on the fuel
position has been set, for fuel oil also the program and should not be below 70% for gas and
point P1 (these values are needed for burner 80% for oil. If the mixing pressure for
testing). ignition is outside of the limit, correction
To ensure that the burner does not start at the must be made using the air damper or
installation, a program has been set in phase 36. mixing head position (only in connection
with a frequency converter / W-FM 200).

68
 9
Curve parameters (modulating)

Increase load manually Manual load increase starting from point P1

Due to burner testing load point 1 (P1) has been factory
90 100
pre-programmed for fuel oil. If P1 has been deleted the

Motor positions °<)

Speed %
W-FM suggests the ignition position as load point 1. 80 90

Starting at the first load point reference lines for the 70

80
maximum stepping motor position are created up to full
4 70
load (100%), if no other load point is defined. 60
60
If the load is now increased in menu curve 50
parameter/manual, the stepping motors and the frequency 50
converter are driven by the predetermined reference lines. 40
40

Set intermediate load points 30

3 30
When nearing the combustion limit, a further load point has 2
20 P2
to be set and combustion optimisation has to be carried out. 1 20

10 10
Once the new load point has been saved, a new reference P1
line is created. The reference lines are drawn between the 0 0
previous and the new load point and are further extra- 0 10 20 30 40 50 60 70 80 90 100
polated. in manual load increase, the stepping motors are Rating %
now driven on the basis of the new reference lines.

This procedure is repeated until full load has been Curve lines after saving P2
reached.
90 100
Motor positions °<)

Speed %
80 90

80
70

4 70
60
60
50
50
40
40
30 3
30

20 2
20
1 P2
10 10
P1
0 0
0 10 20 30 40 50 60 70 80 90 100
Rating %

69
 9
Optimising full load Drive to full load and optimise
The required nominal load in full load has to be set with the
90 100
fuel throughput.

Motor positions °<)

Speed %
80 90
Gas: Due to the control characteristic of the gas butterfly
this should be set to 65° to 70°. The gas throughput 70
80
has to be determined and adjusted using the setting
4 70
screw on the pressure controller. 60
P5
60
Oil: Set required pump pressure in accordance with the 50
information given in the installation and operating P4 50
instructions or the burner test data sheet. Determine 40
oil throughput and adjust using the setting of the oil 40
controller’s stepping motor. 30 3
30
P3
2
Determine combustion limit at full load and set excess air. 20
20
1 P2
Excess air: approx. 15 to 20% 10 10
P1
0 0
For the air quantity setting this means, that the speed is set 0 10 20 30 40 50 60 70 80 90 100
to a minimum, depending on the load and the emissions, Rating %
however not below 40Hz (80%). If at all possible, the
position of the mixing head should be set for maximum
mixing energy and the air damper should be set to the
effective point. With additional O2 control, this will ensure
an effective involvement of the air damper.

Due to the changes made to the mixing pressure and the

speed the fuel quantity throughput should be checked and
adjusted if required.
The pump or gas setting pressure must not be alter once
this process has been completed.

Deleting points Delete intermediate load points

If a curve point is deleted, the numbering is automatically
90 100
changed to the next point. The reference line will then run
Motor positions °<)

Speed %
linear with the neighbouring points. 80 90

80
70

4 70
60
P4
P5 60
50
P3 50
40 P4
40
30
3 30
P2
2 P3
20
20
1 P2
10 10
P1
0 0
0 10 20 30 40 50 60 70 80 90 100
Rating %

70
 9
Insert load points Enter intermediate load points
If a new load point is inserted, its number is always the
90 100
number of existing load points plus one. In setting

Motor positions °<)

Speed %
“Manual” the load is set with the burner in operation to the 80 90
value at which the load point is required (recommendation:
all 10%). 70
80
Carry out combustion optimisation and once the fuel
70
throughput has been determined, carry out load 60
4
P7
apportionment. To achieve an even speed curve line, the P8 60
speed should not be adjusted during combustion 50
optimisation. 50
40
P8 40
When saving the intermediate load point, an automatic P7
“re-sorting” of the load points is carried out according to 30 P6
3 30
the load. P5
20
This means: The new point 8 now becomes point 7, 2
P4 20
P3
point 7 becomes point 8. 1
10 P2 10
P1
It is possible to optimise ratio control with up to 15 points. 0 0
0 10 20 30 40 50 60 70 80 90 100
Note: If O2 control is used, point P2 forms the minimum Rating %
O2 control load.
For loads below P2, the O2 control is deactivated 1 – Air damper
and the burner runs on the normal ratio control 2 – Fuel
curve. 3 – Mixing head
Point P1 is important for the air ratings reduction of 4 – Speed
the O2 control. This must have sufficient distance
to P2. – Manually started load points
– Saved load points
– Deleted load points

Load assignment
Once the curve points have been saved, they automatically
sort themselves according to the load assigned to them.

The percentage load assignment depends on the current

and full load fuel throughput.

Current throughput
Load [%] = x 100 %
Full load throughput

If the calculated load deviates too much from the load

point, the fuel throughput can be matched by adjusting the
stepping motor position.

Example;
Current throughput at point 7 (70%): 250m3/h
Throughput full load: 340 m3/h

250 m3/h
Load [%] = x 100 = 73.5 %
340 m3/h

In this case the fuel throughput (P7) can be reduced with

the fuel motor, the combustion optimisation now has to be
repeated.

71
 9
Curve parameter (multi-stage)

The operating mode “multi-stage” is only possible in oil On and off switch point - 2 stage operation
operation. Depending on burner version two or three stage
operation is available. A three stage burner can also BS2
operate in two stage mode with low impact start.

Set operating and switch points

The setting of the operating and switch points can be
carried out with or without starting up. By turning the dial
knob the positions of all operating and switch points
entered can be viewed. This does not have any effect on Solenoid valve
the system. Even if “with start up” is selected the stepping AS2 stage 2 opens
motors do not follow! ES2 Solenoid valve
stage 2 closes
Without start-up
The stepping motor positions can be set without the
motors following; they remain in the required load set
under manual operation. BS1

With start-up
By pressing the ENTER button the point called up is
started and the motors follow the current settings made
with the dial knob.
The on and off switch points are also started, however the
valve does not yet switched at the on and off switch point.
This procedure is required to optimise the air quantity to
the fuel quantity.

If the burner is set to “Off” in manual operation, only the

stepping motors follow, the solenoid valves of the
individual stages, however, are not operated.

Operating points
BS1: Stipulates the air quantity for fuel quantity for
stage 1 (excess air approx. 20 to 25%).

BS2: Stipulates the air quantity for fuel quantity for

stage 2 (excess air approx. 15 to 20%).

BS3: Stipulates the air quantity for fuel quantity for

stage 3 (excess air approx. 15 to 20%).

Switch on point
Only once the switch on point has been exceeded will the
solenoid valve for the next stage open. This means the
solenoid valve of the next stage remains closed at the
direct start of the point. This allows the flame stability can
be checked prior to switching to the next stage.

Switch off point

If the burner is reset by one stage, the relevant solenoid
valve will close when the switch off point has been
exceeded (stage 3 or stage 2).
A direct start of the switch off point is not recommended,
as the solenoid valve of the higher stage will remain open,
which leads to soot due to insufficient air.

72
 9
Load limits Load limits

Using the parameter min and max load, the burner can be
1 P15
limited fuel specific in its load range within the
programmed curve lines.

MinLoad_Gas/Oil P1
Limits the load range downwards (low fire).
The min load cannot be set below point 1 and if used with 0 100

MinLoad Gas

MaxLoad Gas
O2 control not below point 2.

MaxLoad_Gas/Oil
Limits the load range upwards (full load).

Blank out load range

1 2 1 P15
This parameter can be used to blank out a load range,
which could lead to operating problems. The range
defined can only be passed through, but not directly
started.
P1
The system drives from the bottom to the defined limit
(B/out LoadR bottom) and only drives through the 0 100

B/out Load bot.

range when the load default has reached the upper limit

B/out Load top

(B/out LoadR top).
If the load default decreases the system remains at the
upper limit and only drives through the range when the
load default has reached the bottom limit.

1 Operating range within the load limits

2 Blanked out load range

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9.6.2 Times
The duration of the slowest motor across a setting section
of 90° is important for parametering the drive times.

OptgRampMod

Gives the run time of the motors in modulating operation.

OptgRampStage

Gives the run time of the motors in multi-stage operation.

DriveRamp

Gives the run time of the motors during the operating

phase without flame.

9.6.3 Switch off behaviour

Using the parameter Switch off behaviour it is

stipulated, how the ratio control behaves during lockout.

SM stopped

The stepping motors remain in the position at the time of

lockout.

Post purge

If lockout occurs the combustion manager carries out a

post purge.

HomePos

At lockout the motors drive to the given home positions.

9.6.4 Programme stops

In menu programme stop the commissioning of the burner

can be interrupted at 7 pre-defined positions and the
burner setting adjustments can be made.

24 PrePurgP : Nominal load pre-pre purge position

32 PreP FGR : Nominal load pre-purge for FGR
36 IgnitPos : Ignition position without ignition
44 Interv 1 : End first safety time
52 Interv 2 : End second safety time
72 PostPPos : Air damper in post purge position
(shutdown)
76 PostPFGR : Air damper in post purge position for
FGR

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9.7 O2 control and guarding
Here, the relevant parameters for the operator or the
engineer are displayed depending on the password
entered (only W-FM 200).

9.7.1 Setting Gas/Oil

The following parameters are fuel specific and can be
entered separately for oil and gas.

Operating mode
auto deact
Is activated automatically, if the O2 control is switched off
in operating mode “RegAuto deact”.
O2 controller and guard are deactivated and ratio control
drives on the curve lines programmed. At the same time a
warning message appears in the display. Manual activation
of operating mode is not recommended.

man deact
O2 controller and guard are deactivated. The systems
drives on the parametered ration control curve lines. The
burner starts with cold sensor (only for commissioning, not
recommended for normal operation).

O2 guard
Only the O2 guard is active.
If the O2 sensor has not reached operating temperature,
start is prevented.
If the O2 guard reacts, or if a fault occurs in connection
with the O2 measurement, the O2 module or the O2 sensor,
a safety shutdown is initiated. If repetition is not possible
lockout occurs.

O2 controller
The O2 controller and guard are active. The same data
applies as for O2 guard.

ConAutodeact
The O2 controller and guard are active. Start-up is carried
out prior to the operating temperature of the O2 sensor
being reached (700°C ±15°C). Activation of the O2
control in operation is only carried out once the operating
temperature has been reached and the sensor test has
been successful.

If the O2 guard reacts, or if a fault occurs in connection

with the O2 measurement, the O2 module, the O2 sensor
or the sensor test, the O2 controller and O2 guard are
deactivated automatically.

The system drives to the O2 ratio control setting. The

operating mode is set to “auto deact”. The ABE displays
the note about the automatic deactivation. The fault code
remains until the operating mode is changed.

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O2 trim
Using this parameter an O2 setpoint standardisation has to
be carried out at each point.
The air determining stepping motors are driven down on
the programmed ration control curve lines in line with the
standard values given. The air load this reduced, but the
fuel quantity remains unchanged.

During standardisation of point 2 and the last load point

(full load) the PI control parameters are determined. In
these two points the O2 ratio control value is started after
the standardised value has been saved and the
reactivation time (Dew) is determined. This means the
delay time between changes to the air stepping motor
positions and the actual value at the O2 sensor are
determined.

O2 guard
Using this parameter, an O2 limit value has to be set for O2 min limit
each point (CO/soot).
If during operation, the O2 min limit is not reached for 3,0
3 secs. this leads to either a safety shutdown or an
automatic deactivation of the O2 control / guarding 2,5
function, depending on the operating mode selected.
2,0
O2 content [%]

The O2 min limit can be entered directly if the combustion

limit has already be determined, or it can be determined by 1,5
reducing the air load.
1,0
Direct input:
If the O2 values on the combustion limit are already known
these can be assigned as O2 min value for the Guard 0,5
function.
0
Determination: 0 10 20 30 40 50 60 70 80 90 100
Burner rating [%]
Using P-Air manual reduce air load until the combustion
limit (CO/soot) has been reached and save the O2 actual O2 min limit for guard function
value displayed as limit value. Increased O2 min value with steep CO increase at the
combustion limit (+0.2 to 0.3 % points)
Note If the CO increases sharply at the combustion limit,
the O2 min value for the guard function can be
selected 0.2 to 0.3% points higher.

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Control parameter
The O2 control is supported by the pre-control function. O2 control behaviour
If equal ambient conditions are present, the pre-control
calculates the air load reduction for the total load range. If O2 Currual value

O2 content [%]
the load signal changes, a setting size alteration (air) of the O2 setpoint
ratio control is carried out by the pre-control. This means,
the O2 control only has to adjust deviations in ambient
conditions (temperature, air pressure, ...).

Pre-control becomes active at entry into the load control

after 10 x Dew low fire. If during the delay time full load no
load changes occur, the O2 control becomes active. 4
1
5
At each load change the actual load is calculated. If the
difference of the reference line exceeds the
LoadContLock value the O2 control is stopped.
If the load signal remains constant and the difference is not 1

Load [%]
exceeded, the O2 control becomes active again once the 2 3
delay time full load has elapsed.
1 Parameter LoadContLock
Using the control parameter the behaviour of the O2 2 Locked range
control can be influenced. 3 Delay time full load ( 2 x Dew full load)
4 Burner load
5 Following actual load
P Low/high fire
Proportional part of O2 control.

I Low/high fire
Integral part of O2 control.

Dew low fire

Flue gas reaction time determined during standardisation.
set in LFAdaptPtNR point (factory setting: Point 2).

Dew high fire

Reaction time at 100% determined during standardisation.

LoadContLock
Limit value of the load difference from which the O2 control
is locked. The smaller the value, the more often the 02
control will be locked and driven to the value 02 Offset
set.

FilterTimeLoad
Lock time after which a load change in the size of the
LoadContLock can be made.

O2 Offset Gas / Oil

Increase of O2 content in percent points, if the O2 control
is locked during load increase via parameter
LoadContLock.
The O2 Offset ensures that the O2-MinValue is
maintained during LoadContLock .

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O2 control limit
For burner ratings below the set value, the O2 control is
deactivated and the system drives on the programmed
curve lines of the ratio control. If the burner rating
increases to 5% points above the control limit, the O2
control is reactivated.

PartLoadAdaptPtNo
The parameter Partial Load Adaption Point Number
determines the intermediate load point at which the Dew
Partial Load (flue gas reaction time) is calculated.

If the O2 Control Limit (O2ContLimit) is above the

intermediate load point 3, PartLoadAdaptPtNo should be
set to the point directly below the O2 Control Limit.

Example.:
If the O2ContLimit is between point 4 and point 5,
PartLoadAdaptPtNo should be set to 4.

Note If the flue gas velocity is insufficient when

determining Dew Partial Load, this
parameter can be used to set an intermediate
load point with a higher rating.

Type of Fuel
To calculate the combustion efficiency the fuel currently The values
used must be set. V_Lnmin = Air volume under normal conditions at λ 1
V_afNmin = Flue gas volume wet under normal cond. λ 1
If the fuel is not available, its fuel values can be entered V_atrNmin = Flue gas volume dry under normal cond. λ 1
under FuelUseDef. are required for converting O2 wet to O2 dry
In parameter FuelUseDef the calculation values for the
combustion efficiency will be displayed. A2 = Adjustable constancies for ηF
B/1000 = Adjustable constancies for ηF
are constancies depending on the fuel.

Type air change

Influences the calculation procedure for pre-control.

As P Air:
A change in air density (temperature pressure) will affect
the fuel throughput.
Recommended setting for fuel Gas.

In theory:
A change in air density (temperature pressure) will not
affect the fuel throughput.
Recommended setting for fuel Oil.

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 9
LoadContLock
Limit value of the load difference from which the O2 control
is locked.

FilterTimeLoad
Lock time after which a load change in the size of the
LoadContLock can be made.

O2 Offset Gas/Oil
O2 Offset Gas / Oil
Increase of O2 content in percent points, if the O2 control
is locked during load increase via parameter
LoadContLock.
The O2 Offset ensures that the O2-MinValue is
maintained during LoadContLock .
9.7.2 Prozessdaten
The menu process data is read only:
– about the current combustion efficiency
– about the setting size of the O2 controller
– release of O2 controller (activated/deactivated)
– current load of the air determining motors
– diagnostic codes if the controller is locked

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9.8 LoadController
Here, the relevant parameters for the operator or the
engineer are displayed depending on the password
entered.
On W-FM 100 the load controller is optional.

Note: To set the internal load controller this must be

activated in SystemConfig (Ch. 9.14).

9.8.1 ControlParam

ControlParamSelect
Under (StandardParam) 5 standard parameter sets and Adapt control parameters
the adaption PID values can be accessed. Each one of
these parameter sets can be copied direct into the PID Xp too small Xp too large
memory, the existing values will be overwritten.

StandardParam P (Xp) I (Tn) D (Tv)

very slow 30 % 400 s 10 s
slow 15 % 320 s 40 s
normal 7% 90 s 50 s
fast 4% 35 s 17 s
very fast 40 % 55 s 15 s Tn, Tv too small Tn, Tv too large
Adaption values determined during adaption

The control parameters can also be entered manually:

P-Part (Xp): Proportional band

I-Part (Tn): Integral action
D-Part (Xv): Derivative action

MinActuatorStep
The smallest possible correcting element step is used for
setting value damping.
If the difference between the new calculated setting size
and the current setting size is smaller than
MinActuatorStep, the current setting size is maintained.

SW FilterTmeCon
Using the filter time actual value fault signals, which
predominantly affect the D content, can be weakened.
However, if the filter time is too long this influences the
actual value determination and has a negative effect on the
control accuracy.

A filter time of 2 to 4 seconds should be set for automatic

adaption.
On steam plant the filter time after the adaption should be
increased to 6 to 8 seconds.
If the time selected is too long this can lead to automatic
adaption being stopped.

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Setpoints W1/W2
Two setpoints (W1/W2) can be set for the internal load Setpoint switchover W1/W2
controller. The setpoints can not be set above the current
limit temperature.

Switchover from setpoint W1 to W2 is by potential free

X62
contact at input X62:1/2 Activation 2
2. setpoint 1

SD ModOn/Off
Switch difference in percent for modulating operation.
With positive SD ModOn the switch difference is above the
setpoint, with negative below.

SD Stage On/Off
Switch difference in percent for multi-stage stage
operation.
With positive SD Stage1On the switch difference is above
the setpoint, with negative below.
ThresholdStage... On
If control deviations occur an integral is created over the Switch ThresholdStage... On
time.
If the integral drops below the ThresholdStage...On Actual
the next stage is switched. This can influence the value
Setpoint
switching frequency of the individual stages.
SD_Stage
1 On

Stage 2
Q2 Q2
Stage 3
Q3

O2 = switch threshold stage 2 (ThresholdStage2On)

O2 = switch threshold stage 3 (ThresholdStage3On)

9.8.2 Temperature switch

The temperature switch is only active in connection with
the relevant sensors (see Ch. 9.8.4).

The TL ThresholdOff stipulates the temperature at

which the installation is switched off. Once the switch on
hysteresis TL SD On is reached, the installation is released
again.

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9.8.3 Cold start

ColdStartOn Cold start function

Activates/deactivates the cold start function. The cold start

function ensures that the boiler is not operated at its
maximum loading if the preset minimum boiler temperature
Setpoint
has not been reached. This operating mode protects the
material of the boiler.

Threshold On Threshold
Off
Switch on threshold in percent relating to the setpoint StepSetpoint
(W1/W2) or Setpoint AddSens. Threshold
The cold start function is started if the boiler temperature is On
below this switch on threshold at heat demand.
Actual
value
Step Load (modulating) appliance

The cold start load increases by this value, when the boiler
Cold start load modulating
temperature has reached the next setpoint step. If the
setpoint step is not reached, the cold start load is
increased after completion of the parametered
MaxTmeMod.

Step Setpoint m/s

Stipulates the cold start set point increase. Step load

If the boiler temperature reaches the current cold start set
Partial
point, this is increased by the given value. load

MaxTime MaxTmeMod

MaxTimeMod: Cold start load multi-stage

Time after which a load increase is carried out (modulating
operation).
Stage 3
MaxTimeStage:
Time after which the next stage is released. Pre-requisite is Stage 2
that Release Stages is activated.

ThresholdOff Stage 1

Switch off threshold in percent relating to the setpoint

(W1/W2) or Setpoint AddSens. Once the switch off
threshold has been reached the installation switches to MaxTmeStage
control operation.

Additional sensor

Activates the temperature sensor on terminal X60.

The additional sensor is required if a pressure sensor has
been fitted to terminal X61 and if start-up is to be carried
out with media temperatures below 100° C.

TempAddSensor

Current temperature at additional sensor on terminal X60.

Setpoint AddSens

If the Additional sensor has been activated this

setpoint is the reference size for the on and off switch
threshold of the cold function.

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Release Stages

Not released:
Cold start only in the first burner stage. Stage 2 and stage
3 are locked during the cold start.

Released:
Cold start is carried out in the first burner stage. Once the
boiler temperature reaches the current cold start setpoint,
the next stage is released.

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9.8.4 Configuration load controller

LC operating mode
The load controller setting (internal/external) in
SystemConfig has priority. This means that if an external
load controller has been activated in SystemConfig,
operating mode selection is not possible.

extLC X5-3 External LC on input X5-03

Load control is via three-point step signal of an external
controller at input X5-03. The input must not be switched 1 Stage 1 LC
ϑ
P
On
with radio interference suppressors.
2 Stage 3 Closed

X5-03
°C

3 Stage 2 Open
4
L

int LC Ext. analogue signals and switchover to int. LC

Activates the internal load controller. Setpoints (W1/W2)
are set using the ABE.
If a different operating mode is selected, the int LC GLT
operating mode can be activated using one of the switch
contacts on terminal X62:1/2. In this case, control is to
setpoint W1. ext. switch contact Int LR
The internal load controller must be configured and
optimised to carry out this function.

int LC Bus External setpoint / load input via Bus

The building management system stipulates the setpoint
for the internal load controller. Signal switchover is carried
out by the ABE and an additional eBus interface. For this
the Gateway has to be activated in menu Operation, GLT
parameter Select operating mode (Ch. 9.3) and the Bus
protocol (Gateway type) has to be entered. If the Gateway
type ModBus has been selected, the ModBus must be set
to local in menu AZL (Ch. 9.9.6).

int LC X62
The building management system stipulates an analogue eBus
signal as setpoint for the internal load controller. The setting Interface
range automatically matches itself to the parametered W-FM 200
measuring range of the sensor (MeasureRange PtNI).
Additionally, it is possible to limit the setpoint range both up
and down (Ext SetPoint ...).

Load signal output - only with internal load controller -

X63

0
2
4…20 mA
1

For the operating modes with internal load controller a load

signal of 4 to 20 mA is given to output X63:1/2.

4 mA ➙ 0% load
20 mA ➙ 100% load

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ext LC X62 External load input
The building management system stipulates an analogue Modulating Multi-stage
load signal (tab. External load input). The W-FM Analog.
converts the signal and starts the relevant motors or the signal Low fire High fire Stage 1 Stage 2 Stage 3
frequency converter.
I (mA) 4 20 5 10 15

U (V) 2 10 2.5 5 7.5

Ext LC Bus External load control via Bus

Load control is carried out by the building management
system. Start-up is carried out by the ABE and an
additional eBus interface. For this the gateway has to be
activated in menu Operation, parameter Select operating
mode (Ch. 9.3) and the Bus protocol (Gateway type) has
to be entered. If the Gateway type ModBus has been
selected, ModBus must be set to remote in menu AZL
(Ch. 9.9.6).

eBus
Interface
W-FM 200

Senor selection
PT100 Sensor connection
PT 100 sensor on terminal X60:1/2/4 (three core switching)
➔ temperature limiting function is active.
Pt 100 Pt/Ni 1000
4
PT1000
X60

3
PT 1000 sensor on terminal X60:3/4
2
➔ temperature limiting function is active.
1

Ni 1000
Ni 1000 sensor on terminal X60:3/4
➔ temperature switch function is active.

PT100 PT1000
PT 100 sensor on terminal X60:1/2/4 (three core switching)
for temperature switch function.
PT1000 sensor on terminal X60:3/4 for temperature
limitng function.

PT100 Ni 1000
PT 100 sensor on terminal X60:1/2/4 (three core switching)
for temperature switch function.
Ni 1000 sensor on terminal X60:3/4 for temperature
limiting function.

TempSensor Sensor connection

Temperature sensor at input X61
➔ no temperature limiting function. P/ϑ
0
4
PressSens
X61

4…20 mA
3
Pressure sensor at input X61 0…10 V
2
➔ no limiting function. 20V DC
1

none
No sensor connected to W-FM (i.e. external ratings input
without temperature guarding function).

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Measuring range PtNi
The start of the measuring range is fixed at 0° C or 32° F
and cannot be altered.

The end of the measuring range can be configured.

Three possibilities are available:
• 150°C / 302°F
• 400°C / 752°F
• 850°C / 1562°F

Note If the measuring range end has been set to

850°C / 1562°F, the range end can be further
limited via parameter var.Meas.R.PtNi.

Valid for Pt100:

Load balancing of the three core switching is not required,
if the resistance of the connecting lines are equal.

var.Meas.R. PtNi
The start of the measuring range is fixed at 0° C or 32° F
and cannot be altered.
The end of the measuring range can be configured via this
parameter (max. 850°C / 1562°F).

The function is only active if parameter Measuring range

PtNi has been set to 850°C / 1562°F.

Ext Input X61 U/I

Input X61 has to be configured depending on the sensor
used.

4...20 mA : Current signal to terminal X61:3

with line monitoring

0...20 mA : Current signal to terminal X61:3

without line monitoring

2...10 V : Voltage signal to terminal X61:2

with line guarding

0...10 V : Voltage signal to terminal X61:2

without line monitoring

The supply voltage (20V DC) on terminal X61:1 cannot be

altered.

MeasureRange TempSens / PressSens

The measuring range of the temperature or pressure sensor
can be parametered freely within the preset limits.

MeasureRange TempSens: 0 to 2000° C or 32 to 3632° F

MeasureRange PressSens: 0 to 99.9 bar or 0 to 1450 psi

Values 10% outside of the measuring range are interpreted

as sensor short circuit or as line break.

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Ext Input X62 U/I
If an external load or setpoint signal is switched at terminal
X62, the analogue signal has to be defined.

4...20 mA : Current signal on X62:3/4

Load or setpoint signal with line monitoring

0...20 mA : Current signal on X62:3/4

Load or setpoint signal without line
monitoring

2...10 V : Voltage signal on X62:2/4

Load input with line monitoring

0...10 V : Voltage signal on X62:2/4

Setpoint input without line monitoring

Ext Setpoint min/max

The external analogue setpoint signal is applied as a Measure Range Setpoint input
percentage in the internal load controller to the
temperature range set under MeasureRange PtNi or PtNi Current signal Voltage signal
var.MeasR. PtNi.
Temperature inputs outside of this limit will not be included 0/4 mA 20 mA 0V 10 V
into the control by the load controller, even if the external
input does not reach or exceeds these values. 0…150°C 0°C 150°C 0°C 150°C

0…400°C 0°C 400°C 0°C 400°C

0…850°C 0°C 850°C(1 0°C 850°C(1

(1
or measuring range set under var.Meas.R. PtNi

Example 1 (setpoint signal in mA): Example 2 (setpoint signal in Volt):

Upper setpoint limit required = 80° C Lower setpoint limit required = 50° C

MeasureRange PtNi MeasureRange PtNi

150° C 400° C

ExtInput X62 U/I ExtInput X62 U/I

40 to 20 mA; corresponds to analogue range of 16 mA 0 to 10 V; corresponds to analogue range of 10 volt

Calculation: Calculation:

80°C 50°C
• 100 ≈ 53.3% • 100 = 12.5%
150°C 400°C

Corresponds to a setpoint signal of Corresponds to a setpoint signal of

16 mA 10 V
• 80°C + 4mAOffset ≈ 12.53 mA • 50°C = 1.25 V
150°C 400°C

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 9
9.8.5 Analogue output

Select output value

Stipulates which value is given as current signal at
output X63:1/2.

Load Flame
Load signal of internal load controller Flame signal

O2 Temp Pt... / Temp Ni1000

Residual oxygen content in the flue gas Temperature sensor input X60

Pos ... Temp X61 / Pressure X61

Setting of the relevant stepping motor Temperature/ pressure sensor input X61

Speed FC
Setpoint speed

Current Mod 0/4mA

Stipulates the current range at output X63:1/2.
• 0...20 mA
• 4...20 mA

Current Mod 0/4mA

Defines the internal value (%, °C, bar or efficiency) at
which 20 mA is given at output X63:1/2.

Scal 20mA Proc Scal 20mA Pressure

Percent value (0...999.9%) at 20 mA, valid for: Pressure (0...99.9 bar) at 20 mA, valid for:
• Load • Pressure X61
• O2
• Speed FC Scal 20mA angle
• Flame Degree of angle of stepping motor (0...90°) at 20 mA,
valid for:
Scal 20mA Temp • Pos Air
Temperature (0...2000°C) at 20 mA, valid for: • Pos BurnSt
• Temp Pt1000 / Ni1000 / Temp Pt100 • Pos Aux...
• Temp X61

Scaling 0/4mA
Defines the internal value at which 0/4 mA is given at
output X63:1/2. The relative designation relates to the
values set under Current Mod 0/4mA.

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9.8.6 Adaption

Start adaption
The adaption allows the load controller to automatically
identify the control section and to create the PID
parameter from the data determined. Adaption is available
for both temperature and pressure control. The adaption
can be started in manual or automatic operation. The
installation can be in operation or standby.
Adaption is not possible in multi-stage operation.

Adaption Load
With this parameter, the adaption load can be reduced by
up to 40%. This could be necessary, if the heat demand
during adaption for full load (100%) is insufficient and the
installation switches off during the adaption process.
If the adaption load is selected so low that the set
temperature is not reached this leads to interruption of the
adaption.

9.8.7 SW Version
The “SW Version” supplies details about the software
version of the load controller.

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9.9 AZL (ABE)
9.9.1 Times

Sum/Winter time Time EU/US

Manual or automatic changeover from Summer to Winter European or American Summer / Winter times can be
time can be selected. selected.

9.9.2 Language
Six languages are available for selection. Note An exception is the ABE in version Eastern
If the required language is not available the language Europe 2, whre the language group function is
group can be overwritten with PC software. A total of 4 not supported.
language groups, each with 6 languages, are available in
the software.

9.9.3 Date format

Available for selection are the European format: DD, MM,
YY or the international format: MM, DD, YY.

9.9.4 Physical units

Temperature can be selected as degrees Celsius or
degrees Fahrenheit, pressure in bar or psi.

9.9.5 eBus

Addresse Send cycleGG

Here the eBus address of the W-FM is set, which the Here the cycle time for sending operating data of the
building management uses to communicate with the combustion manager to the BMS is set.
combustion manager.
9.9.6 Modbus

Addresse Local / Remote

Here the Modbus address of the W-FM is set, which the In Local setting the internal load controller of the
building management uses to communicate with the combustion manager becomes active.
combustion manager. In remote setting, the building management system is
active.
Baud rate
Remote Modus
The baud rate stipulates the transfer speed.
The baud rate of the combustion manager and the BMS The parameter is read only, input is by BMS.
must be identical.
Remote Auto : Setpoint input W3 by BMS
Parity Remote on : Set degree input by BSM
Remote off : The internal load controller is active
Parity is a safety feature for data words during transfer.
The parity of the combustion manager and the BMS must W3
be identical.
Setpoint input press or temperature by BMS.
Timeout

This time stipulates, after what time the ABE automatically

switches from remote to local if Modbus communication
fails.
This means the building management system is
deactivated and the internal load controller of the W-FM
takes over control.

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9.9.7 Display contact
With this selection the dial knob is active and the required
contrast can be set and saved.

The display contrast can also be altered without saving it.

To do this turn the dial knob left or right whilst holding
down the ENTER button (only possible in the operating
display normal operation).

9.9.8 Product ID and SW Version

Product ID SW Version
The “Product ID” gives information about: The “SW Version” gives information about the software
• Type description (ABE) version of the display and operating unit (ABE).
• Production date
• Serial number
• Parameter set code
• Parameter set version

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9.10 Stepping motors (Actuators)
9.10.1 Addressing
If only one stepping motor is changed the addressing and Addressing stepping motor
the rotational direction will remain the same. If more than
one stepping motor is changed, a new address has to be
entered for each new motor.

Bus connection
If the stepping motor is the last unit in the bus line,
a bus connection has to be made using a jumper. The bus
connection on all other units must be deactivated (the ABE
has a fixed bus connection).

Addressing stepping motors Address button

Select relevant motor in the menu and confirm with Enter.
Then start the address assignment by pressing Enter and
press the address button on the stepping motor to be LED
addressed.
Following addressing the LED shows the flashing code
and the display shows a confirmation message. Jumper

Delete address
If a wrong address has been entered, this can be deleted
by pressing the push button on the stepping motor for 10
seconds, if necessary disconnect the mains voltage whilst
holding down the button. The LED will return to continuous without bus with bus
illumination. connection connection

Flashing codes LED continuous illumination = no address

Air stepping motor 1 impulse
Gas stepping motor (Oil) 2 impulses
Oil stepping motor 3 impulses LED continuous flashing = addressing in progress
Auxiliary motor 4 impulses
Auxiliary motor 2 5 impulses
Auxiliary motor 3 6 impulses LED flashing codes = addressed

9.10.2 Rotation direction

Delete Curves
Deletes curve lines of all stepping motors, only required to
change the rotation direction in menu level OEM.

9.10.3 Product ID and SW Version

Product ID SW Version
The “Product ID” gives information about: The “SW Version” gives information about the software
• Type description (stepping motor) version of the stepping motor.
• Production date
• Serial number
• Parameter set code
• Parameter set version

92
 9
9.11 FC-Modul
Depending on the password entered this displays the
parameters for the operator or the engineer
(only W-FM200).

9.11.1 Configuration

Release cont. FC
The release contact for the frequency converter (X73:1/2)
closes automatically, if the setpoint speed is higher than 0%.

In standby position (0%), the switch condition of the release

contact can be preset for the Home Run phase (10) via this
parameter.

Recommended setting: closed

Speed
Number of impulses per rotation Speed determination
Speed determination is carried out with an asymmetrical
transmitter (3 impulses per rotation) at input X70. The 180°
asymmetrical transmitter construction (60°, 120°, 180°) is 10 V DC 60°
1
2 wire
used for recognising the rotation direction, motor start with 2 Pulse
3 wirePNP
X70
the wrong direction is therefore not possible. 3 GND
120°
4 Reserve
Standardisation Screen Pulse sequence: 60°, 120°, 180°
5
During standardisation a setpoint signal of 95% is given
at open air or auxiliary stepping motor. This means that
there is a shortfall of 5% of the max. frequency set at the
transformer (52.5 Hz x 0.95 = 50 Hz). The speed reached Connection frequency converter
at the standardised 50 Hz is saved in parameter
Standardised Speed as 100% value for the speed control. 1 24 V FU
If more than 50 Hz is shown during standardisation, the 2 Start FU
motor slip adjustment (=0) on the frequency converter has 12…24 V DC in (Alarm)
X73

3
to be checked. 4 0/4…20 mA out (setpoint)
If the standardised speed is not reached during operation 5 GND
at 100%, a reserve of 5% is available to the system. 6 Screen

Note Following speed standardisation or changes to the

speed saved, the combustion values should be
checked.

Standardised speed
The speed determined during standardisation is saved in
this parameter and can be altered if necessary (not
recommended).

Absolute speed
Displays the current speed determined.

Setpoint output
The output signal (0/4…20 mA) on terminal X73 of the
W-FM and the input signal of the frequency converter
must be matched to one another.
The setting 4…20 mA should be selected on the W-FM
and frequency converter to monitor the signal line.

93
 9
Fuel meter
Fuel meters with Namur or Reed output and Open Fuel meter
Collector (pnp) can be used.
The system continually calculates the current fuel Gas 10 V DC Fuel meter
1
throughput for the fuel selected. Calculation time 2 wire Gas
Pulse

X71
2
is dynamic and is between 1 and 10 seconds. GND
3 wire PNP
3
If the meter does not supply an impulse for 10 seconds, Screen
4
throughput “Zero” is displayed. This means that the
transmitter should have a minimum impulse frequency of
0.1 Hz at minimum throughput.
At maximum throughput the maximum frequency is 300 Hz. Oil 1 10 V DC Fuel meter
2 wire Oil
Pulse

X72
2
3 wire PNP
3 GND
Example: Screen
4
Data on gas meter: 250 impulses per m3
Throughput full load: 20 m3/h ^
= 5000 Imp./h ^
= 1.388Hz
Throughput partial load: 4 m3/h ^
= 1000 Imp./h ^
= 0.277Hz

Impulse value Gas

Depending on the type of gas meter, m3 or ft3 can be
selected.

Impulse value Oil

Depending on the type of oil meter, l or gal can be
selected.

9.11.2 Process data

The process data is located in the volatile memory and is
reset automatically following lockout.

MaxStatDeviation NoDeviation>...
The “maximum static deviation” shows the largest speed Shows the frequency of static deviations at the end of a
deviation at the end of value input alteration. value input alteration, which were > 0.3% or > 0.5%.

MaxDynDeviation Absolute Speed

The “maximum dynamic deviation” shows the largest Shows the actual speed.
speed deviation between actual speed and set speed in
multi-stage operation.

9.11.3 Product ID and SW Version

Werkskennung SW Version
The “Product ID” gives information about: The “SW Version” gives information about the software
• Type description (FC module) version of the FC module.
• Production data
• Serial number
• Parameter set code
• Parameter set version

94
 9
9.12 O2 Module
Depending on the password entered this displays
the parameters for the operator or the engineer (only
W-FM200).

9.12.1 Configuration

O2 sensor MaxTempFlueGas ...

To determine O2 the O2 sensor QGO20 has to be If the flue gas temperature set is exceeded a warning
activated. message is given. The set limit can be set individual for oil
and gas and indicates increased appliance losses. The set
value should be approx. 20% above the nominal flue gas
Supply air sensor / flue gas sensor temperature of the appliance manufacturer.
To be able to determine the combustion efficiency the
supply air sensor and the flue gas sensor must be
connected and configured.

9.12.2 Display values

Current O2 value QGO Heating Load

Current O2 value measured by the sensor QGO20. Display of the actual heat rating in %.
The heat rating is in the range of 0 to 60%. The percentage
displayed corresponds to an impulse/pause ratio relating
Supply air temperature to 2 seconds and 230 V.
60% heat rating corresponds to 1.2 seconds impulse and
Air intake temperature measured by the Pt/Ni sensor. 0.8 seconds pause.
Used to determine combustion efficiency. After approx. 15 minutes the sensor has reached the set
point of 700° C (pre-requisite for release of the O2 control).

Heating Load:
Flue gas temperature Start heat load up to 100° C ______________approx. 13%
Flue gas temperature measured by the Pt/Ni sensor. Used Heat up process approx. 60%
to determine combustion efficiency. Operating temperature ______________approx. 15 to 25%

QGO Resistance
The internal resistance is a measure for the function ability
QGO SensorTemp of the sensor. It changes during the operating time.
Current operating temperature of the O2 sensor. If the internal resistance is < 5 Ω or > 150 Ω the sensor is
ageing.

9.12.3 Product ID and SW version

Product ID SW Version
The “Product ID” gives information about: The “SW Version” gives details about the software version
• Type description (O2 module) of the O2 module.
• Production date
• Serial number
• Parameter set code
• Parameter set version

95
 9
9.13 Flue gas recirculation
Depending on the password entered, the relevant
parameters for the operator or for the heating engineer are
displayed (W-FM 200 only).

Type of operation FGR

Deactivated
No flue gas recirculation.

Time
Flue gas recirculation without O2 module.

Temperature
Flue gas recirculation with O2 module.

FGR sensor

Configuration of flue gas temperature sensors connected

to the O2 module (X86:1/2 flue gas sensor B11) for FGR
function.

CurrTmpFGR sensor

Current temperature at flue gas temperature; only in con-

junction with O2 module.

FGR On Temp ...

Auxiliary motor 3 only starts once the temperature set has

been reached; only in conjunction with flue gas
temperature sensor.

FGR On Time ...

Auxiliary motor 3 starts once the time set has elapsed.

96
 9
9.14 SystemConfig
LC operating mode LC analogue output

The configuration of the load controller operating mode is Stipulates which value is given as current signal at
identical to that in menu LoadController (Ch. 9.8.4). output X63:1/2.
However, the setting in SystemConfig has priority.
This means that if an external load controller is selected in Load
menu SystemConfig you cannot change over to internal Load signal of internal load controller
operating mode in menu LoadController.
O2
Ext Input X62 U / I Residual oxygen content in the flue gas

The configuration of the external input X62 is identical to Pos ...

that in menu LoadController (Ch. 9.8.4). Setting of the relevant stepping motor

TempLimit Speed FC
Setpoint speed
The configuration of the TL ThresholdOff and
TL SD Off is identical to that in menu LoadController Flame
(Ch. 9.8.2). Flame signal

The configuration for SensSelect and for MeasureRange Temp Pt... / Temp Ni1000
is identical to that in menu LoadController (Ch. 9.8.4). Temperature sensor input X60

O2Ctrl/Guard..... Temp X61 / Pressure X61

Temperature/ pressure sensor input X61
The configuration is identical with that in menu
O2Ctrl/Guard (Ch. 9.7.1).

9.15 Operating hours

Gas operation TotalOperHoursR
Operating hours for fuel Gas since last reset. Total operating hours oil and gas since last reset.

Stage1 / Mod TotalOperHours

Operating hours of stage 1 or modulating (oil) since last Total operating hours oil and gas.
reset. This value cannot be reset.

Stage2 Unit under voltage

Operating hours of stage 2 (oil) since last reset. Total hours the W-FM has been connected to mains
voltage.
This value cannot be reset.
Stage3 Reset
Operating hours of stage 3 (oil) since last reset. Here all parameters, which can be reset, can be set to
“Zero”.

97
 9
9.16 Start counter
Start counter Gas TotalStartCounterR
Burner starts with fuel gas since last reset. Total burner starts with fuel oil and gas since last reset.

Start counter Oil TotalStartCounter

Burner starts with fuel oil since last reset. Total burner starts with fuel oil and gas.
This value cannot be reset.

Reset
Here all parameters, which can be reset, can be set to
“Zero”.

9.17 Fuel meters

If an oil or gas meter is installed and configured
(Ch. 9.11.1), the fuel quantities determined can be called
up and reset here.

Current throughput Volume Gas R

Displays the current throughput for gas in m3/h or oil in l/h. Fuel throughput for gas in m3 since last reset. Reset by
pressing the ENTER button.

Volume Gas
Reset date Gas
Total gas throughput in m3.
This value cannot be reset. Date of last reset for fuel gas.

Volume Oil Reset date Oil

Total oil throughput in litres. Date of last reset for fuel oil
This value cannot be reset.

Volume Gas R
Fuel throughput for oil in litres since last reset. Reset by
pressing ENTER button.

98
 9
9.18 Updating
9.18.1 Parameter backup

Backup-Info AZL -> LMV5...

Displays information about the date and time of the last Loads the data from the display and operating unit (ABE)
parameter backup as well as their system components. to the base unit (W-FM). Pre-requisite is that the burner
identification of the ABE and the W-FM are identical or
that burner identification of the W-FM is still in its delivery
condition.
LMV5... -> AZL The data in the W-FM are overwritten and can no longer
be reproduced.
Loads the data from the base unit (W-FM) to the display
and operating unit (ABE).
Any data in the ABE is overwritten and can no longer be
reproduced.

9.18.2 Load SW from PC

Updates the software of the display and operating unit
(ABE) with PC-Tool using a serial interface.

9.19 Password
PW login Deactivate PW (PW Logout)
After entering the engineer’s password additional access Using this parameter the password protected level can be
to the engineer’s level is available. The password is protected at an earlier stage.
deactivated 120 minutes after the last input.

9.20 TÜV Test

LossFlameTest
The flame failure test interrupts the flame sensor signal and STL TestLoad...
it can be checked if the W-FM will go to lockout.
Manual load setting for the safety temperature limiter test.

STL Test

During the SLT Test the control circuit as well as the

temperature guard are bridged and the burner is operated
at the rating set at STL-TestLoad.., allowing the
response of the safety temperature limiters to be checked.

99
 Start up Operation Shutdown Valve proving

100
tv TSA1 TSA2
9

ON

Safety

Standby
Fuel valve

Home run
Pre-purge

Fan = ON
Press test

Safety fuel
Post purge

relay = ON
Direct start

valve = ON
Pre-ignition
Ignition OFF

Safety phase
Fill valve train

Test no press

Interval time 2

Lockout phase
ignition position
Ignition position
Low fire position

Flame signal ON
After burner time
Empty valve train

Stepping motor in

pre-purge position
Flame stabilisation
Operating phase 1
Operating phase 2
post purge position

Air stepping motor in

Air stepping motor in
tn1
V1 = Closed, V2 = Open
Gas direct ignition V1 = Open, V2 = Closed

tn3 5
6
V1 = Closed, V2 = Closed
V1 = Closed, V2 = Closed

Operating phase 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79 80 81 82 83
Timer-Event- Link and and or and
Timer 1 t0 t10 t21 t22 t30 t34 t38 t42 t44 t52 t62 t70 t74 t78 t80 t81 t82 t83
Timer 2 9 tv TSA

Times
Timer 3 = Phase max. time t01 tmx1 tmx1 tmx2 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx2
Fuel switch GAS X4-01: 1 C B B B B B B B B B F F F F G B
Safety circuit X3-04: 1 C B B B B B B B B B D D D D D D D D E B w D D D D
Sequence diagram gas with direct ignition

Temperature guard internal C B B B B B B B B B F F F F F F F F E B

Controller ON C B B B B B B B B B F F F F G m 5 7
Flame signal X10-02: 6 q c k i i i i L L L L L L k k k k k i i i i
9.20 Sequence of operation diagrams

Air press. switch APS X3-02: 1 1 A/c A/c c C A A A A A A A A A A A A A A A A A A c A A A A

Gas + Oil
BrnFan motor aux-contact X4-01: 3 e A/c A/c 9 C A A A A A A A A A A A A A A A A A A A A A A

Inputs
FGR-LP alt. to GSK X4-01: 3 A/c A/c c C A A A A A A A A A A A A A A A c A A A A
CPI alt. to valve proving DK
X9-03: 2 C A A A A A A A A A a a A A A A A
Low gas press.switcg X9-03: 4 3t G B B B B B B B D D D D D D D D H w D D D D
Release Gas X7-03: 1 3w G B B B B B B B D D D D D D D D H w D D D D

Gas
Lockout HGPS. X9-03: 3 3 A A A A A A A A
Gas pressure switch GPSVP X9-03: 2 A a
Burner motor / Fan X3-01: 1 9/0 9 9 9 9 N N N N N N N N N N N N N N N N N N N N N N N N N
Ignition X4-02 N N
Start signal / DW valve X4-03 u 49 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 N 4 4 4 4
Alarm X3-01: 2 i N 8

Gas + Oil
Safety relay internal X3-04: 1/2 N N N N N N N N N N N N N N N N N N N N N N N N N N N
Safety relay Gas X9-01: 1 N N N N N N N N N N N N N N N N N N N N N

Outputs
Valve pilot ignition Gas X9-01: 2

Gas
Fuel valve 1 Gas X9-01: 4 N N N N N N N N N
Fuel valve 2 Gas X9-01: 3 N N N N N N N N N

90° (Full load)

Pre-purge position
Post-purge position

Fuel
Partial load
Ignition position
Standby position

Actuators
90° (Full load)
Pre-purge position
Post-purge position

Air
Partial load
Ignition position
Standby position
 Start up Operation Shutdown Valve proving

tv TSA1 TSA2

ON

Safety

Standby
Fuel valve

Home run
Pre-purge

Fan = ON
Press test

Safety fuel
Post purge

relay = ON
Direct start

valve = ON
Pre-ignition
Ignition OFF

Safety phase
Fill valve train

Test no press

Lockout phase
ignition position
Ignition position
Low fire position

Flame signal ON
After burner time
Empty valve train

pre-purge position
Flame stabilisation
Operating phase 1
Operating phase 2

Stepping motors in
post purge position
Air stepping motor in

Air stepping motors in

tn1

Pilot ignition valve OFF

V1 = Closed, V2 = Open
V1 = Open, V2 = Closed

Gas pilot ignition

tn3 5
6
V1 = Closed, V2 = Closed
V1 = Closed, V2 = Closed

Operating phase 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79 80 81 82 83
Timer-Event- Link and and or and
Timer 1 t0 t10 t21 t22 t30 t34 t38 t42 t44 t52 t62 t70 t74 t78 t80 t81 t82 t83
Timer 2 9 tv TSA

Times
Timer 3 = Phase max. time t01 tmx1 tmx1 tmx2 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx1 tmx2
Fuel switch GAS X4-01: 1 C B B B B B B B B B F F F F G B
Sequence diagram gas with pilot ignition

Safety circuit X3-04: 1 C B B B B B B B B B D D D D D D D D E B w D D D D

Temperature limit internal C B B B B B B B B B F F F F F F F F E B
Controller ON C B B B B B B B B B F F F F G m 5 7
Flame signal X10-02: 6 q c k i i i i L L L L L L k k k k k i i i i
Air press. switch APS X3-02: 1 1 A/c A/c c C A A A A A A A A A A A A A A A A A A c A A A A

Gas + Oil
BrnFan motor aux-contact X4-01: 3 e A/c A/c 9 C A A A A A A A A A A A A A A A A A A A A A A

Inputs
FGR-LP alt. to GSK X4-01: 3 A/c A/c c C A A A A A A A A A A A A A A A c A A A A
CPI alt. to valve proving DK X9-03: 2 C A A A A A A A A A a a A A A A A
Low gas press. sw. LGPS X9-03: 4 3t H B B B B B B B D D D D D D D D H w D D D D
Release Gas X7-03: 1 3w H B B B B B B B D D D D D D D D H w D D D D

Gas
Lockout HGPS. X9-03: 3 3 A A A A A A A A
Gas press. switch GPSVP X9-03: 2 A a
Burner fan / motor X3-01: 1 9/0 9 9 9 9 N N N N N N N N N N N N N N N N N N N N N N N N N
Ignition X4-02 N N
Start signal / DW valve X4-03 u 49 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 N 4 4 4 4
Alarm X3-01: 2 i N 8

Gas + Oil
Safety relay internal X3-04: 1/2 N N N N N N N N N N N N N N N N N N N N N N N N N N N
Safety relay Gas X9-01: 1 N N N N N N N N N N N N N N N N N N N N N

Outputs
Valve pilot ignition Gas X9-01: 2 N N N N

Gas
Fuel valve 1 Gas X9-01: 4 N N N N N N N N N
Fuel valve 2 Gas X9-01: 3 N N N N N N

90° (Full load)

Pre-purge position
Post-purge position

Fuel
Partial load
Ignition position
Standby position

Actuators
90° (Full load)
Pre-purge position
Post-purge position

Air
Partial load
Ignition position
Standby position
9

101
 Start up Operation Shutdown

102
tv TSA1 TSA2
9

ON

Safety

Standby
Fuel valve

Home run
Pre-purge

Fan = ON
Safety fuel
Post purge

relay = ON
Direct start

valve = ON
Pre-ignition
Ignition OFF

Safety phase
Interval time 2

Lockout phase
ignition position
Ignition position
Low fire position

Flame signal ON
After burner time

pre-purge position
Flame stabilisation
Operating phase 1
Operating phase 2

Stepping motors in
post purge position
Air stepping motor in

Air stepping motors in

tn1
tn3 5
6

Light oil direct ignition

Operating phase 00 01 10 12 20 21 22 24 36 38 40 30 32 34 42 44 50 52 54 60 62 70 72 74 76 78 79
Timer-Event-Link and and and and or and
Timer 1 t10 t21 t22 t30 t34 t36 t38 t42 t44 t52 t62 t70 t74 t78 tmx1
Timer 2 9 tv TSA1

Times
Timer 3 = Phase max time t01 tmx1 tmx1 tmx2 tmx1 tmx1 tmx1 tmx3 tmx1 tmx1 tmx1 tmx1 tmx1 tmx2
Fuel switch OIL X4-01: 2 C B B B B B B B B B D D D D G B
Safety circuit X3-04: 1 C B B B B B B B B B D D D D D D D D E B
Temperature limit internal C B B B B B B B B B D D D D D D D D E B
Controller ON C B B B B B B B B B D D D D G m 5
Sequence diagram light oil with direct ignition

Flame signal X10-02: 6 q c k i i i i L L L L L L k k k k k

Air press. switch APS X3-02: 1 1 A/c A/c c C A A A A A A A A A A A A A A A A A A c

Gas + Oil
BrnFan motor aux-contact X4-01: 3 e A/c A/c 9 C A A A A A A A A A A A A A A A A A A

Inputs
FGR-LP alt. to GSK X4-01: 3 A/c A/c c C A A A A A A A A A A A A A A A c
CPI alt. to valve proving DK X9-03: 2 C A A A A A A A A A A A A A A A A A A A A A A A
Low oil press. sw. LOPS X5-02: 1 3 r C A A A A A A A A
High oil press. sw. HOPS X5-02: 2 3

Oil
C A A A A A A A A A A A A A A A
Start release Oil X6-01: 1 3 H B B B B B B B D D D D D D D D H
Burner fan /motor X3-01: 1 9/0 9 9 9 9 N N N N N N N N N N N N N N N N N N N N N
Ignition X4-02 2 2 2 2 2 2 N N
Start signal / DW valve X4-03 49 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 N
Alarm X3-01.2 u N 8

Gas + Oil
Safety relay internal X3-01: 1/2 i N N N N N N N 2
N N N N N N N N N N N N N N N N
Safety relay Oil X6-03: 3 N N N N N N N N N N N N N N N N N N

Output
Fuel valve 1 Oil X8-02/-03 N N N N N N N N

Oil
Fuel valve 2 Oil X7-01 N
Fuel valve 3 Oil X7-02 N
Magnetic clutch/sep. pump X6-02: 3 z 2 2 2 2 2 2 N N N N N N N N N

90° (Full load)

Pre-purge position
Post-purge position

Fuel
Partial load
Ignition position
Standby position

Actuators
90° (Full load)
Pre-purge position
Post-purge position

Air
Partial load
Ignition position
Standby position
 Start up Operation Shutdown

tv TSA1 TSA2

ON

Safety

Standby
Fuel valve

Home run
Pre-purge

Fan = ON
Safety fuel
Post purge

relay = ON
Direct start

valve = ON
Pre-ignition
Ignition OFF

Safety phase
Interval time 2

Lockout phase
ignition position
Ignition position
Low fire position

Flame signal ON
After burner time

pre-purge position
Flame stabilisation
Operating phase 1

Stepping motors in
Operating phase 2
post purge position
Medium/heavy oil
Air stepping motor in

Air stepping motors in

tn1
direct ignition
tn3 5
6

Operating phase 00 01 10 12 20 21 22 24 36 38 40 42 44 30 32 34 50 52 54 60 62 70 72 74 76 78 79
Timer-event-connection and and and and or and
Timer 1 t10 t21 t22 t30 t34 t36 t38 t42 t44 t52 t62 t70 t74 t78 tmx1

Time
Timer 2 9 tv TSA1
Timer 3 = Phase max time t01 tmx1 tmx1 tmx2 tmx1 tmx1 tmx1 tmx3 tmx1 tmx1 tmx1 tmx1 tmx1 tmx2
Fuel switch OIL X4-01: 2 C B B B B B D D D D G B
Safety circuit X3-04: 1 C B B B B B B B B B D D D D D D D D E B
Temperature limit internal C B B B B B B B B B D D D D D D D D E B
Controller ON C B B B B B B B B B D D D D G m 5
Flame signal X10-02: 6 q c k i i i i L L L L L L k k k k k
Air press. switch APS X3-02: 1 1 A/c A/c c C A A A A A A A A A A A A A A A A A A c

Gas + Oil
BrnFan motor aux-contact X4-01: 3 e A/c A/c 9 C A A A A A A A A A A A A A A A A A A

Input
FGR-LP alt. to GSK X4-01: 3 A/c A/c c C A A A A A A A A A A A A A A A c
CPI alt. to valve proving DK X9-03: 2 C A A A A A A A A A A A A A A A A A A A A A A A
Sequence diagram medium/heavy oil with direct ignition

Low oil press. sw. LOPS X5-02: 1 3 r C A A A A A A A A

High oil press. sw. HOPS X5-02: 2 3

Oil
C A A A A A A A A A A A A A A A
Start release Oil X6-01: 1 3 H B B B B B B B D D D D D D D D H
H
Burner motor / fan X3-01: 1 9/0 9 9 9 9 N N N N N N N N N N N N N N N N N N N N N
Ignition X4-02 2 2 2 2 2 2 N N
Start signal / DW valve X4-03 u 49 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 N
Alarm X3-01.2 i N 8

Gas + Oil
Safety relay internal X3-01: 1/2 N N N N N N N N N N N N N N N N N N N N N N N
Safety relay Oil X6-03: 3 N N N N N N N N N N N N N N N N N N

Output
Fuel valve 1 Oil X8-03 N N N N N N N N N

Oil
Fuel valve 2 Oil X7-01 N N N N N N N N
Fuel valve 3 Oil X7-02 z N
Magnetic clutch/sep. Pump X6-02: 3 2 2 2 2 2 N N N N N N N N N N
90° (Full load)
Pre-purge position
Post-purge position

Fuel
Partial load
Ignition position
Standby position

Actuator
90° (Full load)
Pre-purge position
Post-purge position

Air
Partial load
Ignition position
Standby position
9

103
 9
Legend for sequence diagrams
Signal “ON” Signal “OFF” Reaction if relevant signal to sequence diagram is not given

A a Jump to operating phase 01, with repetition counter = 0 on to phase 00 otherwise in Ph 12

B Jump to operating phase 10
C c Stop until completion of Phase max. time (tmx...), then jump to phase 01
D d Jump to operating phase 70
E With heat demand from controller and parametered direct start jump to phase 79,
otherwise to phase 10
F Without valve proving jump to operating phase 70, otherwise to phase 80
G Jump to operating phase 62
H Stop until completion of Phase max. time (tmx...), then jump to phase 10
i 0…3 s Jump to operating phase 01, with repetition counter = 0 on to phase 00 otherwise in Ph 12
k 0…30 s Jump to operating phase 01, with repetition counter = 0 on to phase 00 otherwise in Ph 12
L 0…3 s Jump to operating phase 01, with repetition counter = 0 on to phase 00 otherwise in Ph 12
i With parametered direct start jump to phase 79, otherwise to phase 10
N Output: ON
Output: OFF
Input: no influence

1 Depending on parametering with or without LP

2 Depending on parametering short or long pre-ignition time and pump on time

3 Delayed shutdown in TSA1 + TSA2

4 Depending on parametering output as start signal or PS relief valve

5 Depending on parametering Normal/Direct start

6 Follow on phase 24

7 Only with valve proving during commissioning

8 Depending on parametering with or without alarm at start inhibition

9 With parametered continuous running fan

0 Fan remains driven as before

q Depending on parametering with or without extraneous light test in standby

w With deviation during start up follow on phase 10

e With normal venting: Check for ON in phase 10, stop until completion of phase max. time, then jump to phase 01
With continuous running fan: Check for ON in phase 10 and 12, stop until completion of phase max. time, then jump to
phase 01

r If the min. oil pressure switch input has been parametered to “Act from ts” no check is carried out prior to completion of
TSA 1 time

t If the low gas pressure switch input has been parametered to “deactOgp” no check is carried out with oil with gas pilot
ignition

z If the output is parametered to “DirectCoupl”, the safety valve Oil has to be connected. The output is driven together
with the fan and stops 15 s after the fan in time delay.
u If the output is parametered to “PS relief”, this (output PS relief valve) is inverted logically

i The alarm output can be temporarily deactivated for the current fault

104
 9
Assignment times:

Time Description

t0 Post-purge lockout setting

t01 MaxTime_SiPhase
t10 MinTimeHomerun
t21 MinTimeStartrelease
t22 FanRunupTime
t30 Prepurgetime part 1
t34 Prepurgetime part 3
t36 MinOnTimeOilPump
t38 PreIgnTime_Gas / Oil
t42 PreIgnTime_Off
t44 IntervalTime 1 Gas / Oil
t52 IntervalTime 2 Gas / Oil
t62 MaxTime low fire
t70 Afterburn time
t74 PostpurgeTime 1 Gas / Oil (tn1)
t78 PostpurgeTime 3 Gas / Oil (tn3)
t80 Valve proving empty time
t81 Leakage test test time atm. pressure
t82 Leakage test filling test
t83 Leakage test test time gas pressure
tmx1 Max. damper run time
tmx2 MaxTime start release
tmx3 MaxTime venting HO Oil
TSA1 Safety time 1 Gas / Oil
TSA2 Safety time 2 Gas / Oil
tv Prepurge time_Gas / Oil

Actuators
In Standby:
The SA can be moved within the permitted
position range, will however, always be driven
to the standby position, and must be in
standby for phase change.

Abbreviations
FGR Flue gas recirculation
CPI Closed position indicator
PS Pressure switch
VP Valve proving
BrnFan Auxiliary contact burner fan contactor
PL or LF Low fire position
AD Air damper
APS Air pressure switch
PP Post-purge position / post-purge
S Standby
SR Safety relay
STB Safety temperature limiter
TL Temperature guard
PV Pre-purge position / pre-purge
Z Ignition position

105
10 O2 sensor
Installing the O2 sensor

Electrically isolate the plant During operation, the sensor is heated to

Prior to installation, switch off the mains approx. 700°C.
switch and the safety switch.
Failure to comply could cause death or seri-
DANGER ous injury by electric shock. DANGER

• The O2 sensor must only be fitted with the relevant Sensor position
flanges and to the enclosed drawing.

• No infiltrated air must enter before, and at least 2 x

diameters of the flue gas ducting after the sensor.

• The sensor should be fitted as close as possible after

the flue gas outlet terminal of the appliance, but no min.
closer than 1 diameter of the flue gas pipe.

• The sensor must not be fitted vertically from below,

pointing upwards.

• The favourable fitting position is vertically from above

or up to 45 ° angle either side of vertical.

• The minimum distance between the inner wall of flue

gas duct and the flue gas sampling outlet hole on the
flange is 10 mm.

Flange dimensions Air

180 mm

115 mm

53,5 mm up to 45°

Installation instruction

Gas tight (sealed)

welding min. 10 mm
mm

mm
64

90

do not insulate

106
 10
Electrical connection

The 6 core connection line between the terminal rail X1 of

the O2 module and the sensor is fitted with a screened line
twisted in pairs (3 x 2 x 0.25 mm2).
One side of the screening should be attached to the
mounting plate of the O2 module. There must be no
connection between GND and earth.

The sensor heating L (Q4), N (Q5), PE should be fitted to

the O2 module terminal rail X10 Pin 1, 2, 3 with a minimum
3 x 0.75 mm2.
The line of the sensor heating must be a separate cables.
Outside diameter of the cable = max. 8 mm.

Connection to O2 module

O2 Module
L
X89-01

Mains

N
PE 1
L (Q4)
X89-02

N (Q5)
PE 1

Q5
Q4
GND

U3 U3
G2 G2
M
M B2
X81

B2 M
B1
M
B1 1

L, N, PE: Supply voltage sensor heating 230V pulsed Nernst voltage at 700° C sensor temperature
(N switching)
700°C
U3 : Temperature compensation 1 µA/K relating to 120
absolute zero, i.e. 273 µA corresponds to a
sensor temperature of 0° C 100
Nernst voltage [mV]

G2 : Feeder voltage temperature compensation 80

2 to 10V
60
B2 / M : Thermo element 0 to 33 mV
29.1 mV corresponds to approx. 700° C
40

B1 / M : Nernst voltage (0 to 700 mV)

20

0
0,05 0,1 0,2 0,5 1 2 5 10 20
O2 content [%]

107
11 Frequency converter
If the W-FM 200 is used in connection with a frequency
converter VLT 2800 or FC 300 (Danfoss), the
parametering of the frequency converter has to be
checked and if necessary adjusted.

If a frequency converter (Siemens) fitted directly to the

burner motor is used, parametering of the FC is not
required or indeed possible.

Further information and details relating to the frequency

converter can be found in the manufacturers
documentation.

11.2 Parametering the VLT 2800

In connection with the W-FM 200, certain parameters on
the frequency converter have to be checked and set if
necessary.

No. Description Value Unit Meaning

019 Mains-On-Mode 0 - automatic restart at mains activation

100 Configuration 0 - speed control with motor slip adjustment

101 Torque reference line 1 - constant torque

102 Motor rating xx.yy kW to name plate

103 Motor voltage xx V to name plate

104 Motor frequency xx Hz to name plate

105 Motor current xx.yy A to name plate

106 Motor speed xxxx kW to name plate

123 Frequency stop function 2 Hz activation motor free run if not reached

126 Direct current brake time 2 sec. duration for DC brake

127 Frequency DC brake 2 Hz activation of DC brake if exceeded

128 Thermal motor protection

132 Voltage DC brake 50 % brake voltage

133 Voltage increase 0 V no voltage increase

134 Load compensation 80 % load reference line

136 Slippage adjustment 0.0 % no motor slip adjustment

144 Increase AC brake 1.0 - alternating current brake deactivated

108
 11
No. Description Value Unit Meaning

202 Max. frequency 52.5 Hz upper limit value output frequency

204 Min setpoint 0.0 Hz minimum setpoint input

205 Max. setpoint 52.5 Hz maximum setpoint input

207 Ramp time Open 1 81/152/283 sec. acceleration time from 0 Hz to nominal frequency

208 Ramp time From 1 81/152/283 sec. delay time from nominal frequency to 0 Hz

211 Ramp time Jog 81/152/283 sec. acceleration/delay time fixed speed

212 Ramp time From Quick Stop 81/152/283 sec. delay time quick stop

213 Frequency Jog 0 Hz frequency for fixed speed

226 Warning fmax limit 52.5 Hz

302 Input 18 digital 7 - Start signal from W-FM200 contact X73:1/2

303 Input 19 digital 0 - No function, input deactivated

304 Input 27 digital 5 - Direct current brake

305 Input 29 digital 0 - No function, input deactivated

307 Input 33 digital 1 - Recording, reset with W-FM 200

308 Input 53 analogue 0- no function, input deactivated

314 Input 60 analogue 1 - setpoint signal from W-FM200 terminal X73:4

314 Input 60 min. scaling 4.0 mA lower setpoint signal min.

315 Input 60 max. scaling 20 mA upper setpoint signal max.

318 Function after setpoint fault 0 - off, function deactivated

319 Output 42 analogue 7 - recorder output 0-20 mA

323 Relay output 1 - 38-contacts are switched at alarm

341 Output 46 digital 8 - output reacts at alarm or warning

349 Delay speed comp. 0 ms system delay time

400 Brake function 4 - with alternating current brake

405 Type of recording 10 - 10 automatic restart trials after termination

445 Motor hold switching 1 - Holding the motor

1 up to size 50
2 for sizes 60 to 70
3 WK burners

109
11
11.3 Parameter setting FC 300
The burner delivery includes a parameter list with specific
setting values (MCT 10 Set-up Software). In connection
with the W-FM 200 certain parameters on the frequency
converter have to be checked and set if necessary.

Parameter Setting Meaning

0-01 Language [1] German Display language

0-02 Hz/UMP switch-over [1] Hz Display of motor parameter in Hz 1

0-03 Country settings [0] International Sets the unit for parameters 1-20 to kW

0-04 Mains-On-Mode (manual) [2] LCP Stop, setp.= 0 With Mains-On the frequency converter is at stop

0-10 Actual set [1] Set 1 Actual parameter set

0-11 Program set [1] Set 1 To edit available parameter set

0-40 [Manual-On]-LCP button [1] Activated Function of Manual-On button on operating panel

0-41 [Off]-LCP button [1] Activated Function of Off button on operating panel

0-42 [Auto-On]-LCP button [1] Activated Function of Auto-On button on operating panel

0-43 [Reset]-LCP button [1] Activated Function of Reset button on operating panel

0-60 Main menu Password [100] Password for the main menu (Main-Menu button)

0-61 Main menu Access w/o PW [1] No access Access via operating panel only with password

1-00 Control behaviour [1] Without return signal Speed control with automatic slip adjustment
(without actual value signal from motor)

1-01 Control principle [1] VVCplus Voltage Vector Control

1-03 Torque behaviour of load [1] Constant Matches the U/f ratio to a constant load 1
torque

1-04 Overload mode see list Overloading of torque for 1 minute 1

MCT 10 Set-up

1-05 Manual/Local operation [1] as par. 1-00 Defines the control behaviour in manual operation
configuration (Manual-On button) 1

1-10 Motor, type [0] Asynchronous Selection of motor type or MCT 10 Set-up list 1

1-20 Motor, nominal rating [0.09 - 1200 kW] see name plate of motor or MCT 10 Set-up list 1

1-22 Motor, voltage [10 - 1000 V] see name plate of motor or MCT 10 Set-up list 1

1-23 Motor, nominal frequency [20 - 1000 Hz] / [55 Hz2] see name plate of motor or MCT 10 Set-up list 1

1-24 Motor, nominal current [... A] see name plate of motor or MCT 10 Set-up list 1

1-25 Motor, nominal speed [10 - 60000 Hz] see name plate of motor or MCT 10 Set-up list 1

1-52 Min. speed norm. [0.5] Frequency limit for normal magnetisation current
magnetis. [Hz]

1 Parameter can not be changed with motor running.

2 Burner size 70/4only

110
 11
Parameter Setting Meaning

1-60 Load adjust. low [0] Load compensation in lower speed range

1-61 Load adjust. high [0] Load compensation in upper speed range

1-62 Slip. adjustment [0] No fine tuning of slip adjustment

1-76 Start current [0] Increased start-up current

1-80 Function at Stop [0] motor override Function after stop signal

1-82 Set speed [0] Frequency of stop function

stop funct. [Hz]

1-90 Thermal motor protection [4] ETR Alarm 1 Switches off motor if overloaded

2-00 DC hold current [10] Hold current in % relating to motor nominal current.
Only active if 1-80 is set to [1]

2-01 DC brake current [50] Brake current in % relating to motor nominal current

2-02 DC brake time [2] Duration of brake function in seconds

2-04 DC brake ON [Hz] [2] DC brake current is active from this frequency

2-10 Brake function [2] Brake resistance Configuration frequency converter with brake resistance

2-11 Brake resistance (Ohm) see list Brake resistance in Ohm

MCT 10 Set-up

2-12 Brake resistance rating see list Monitoring limit in kW for brake power
MCT 10 Set-up

2-13 Brake resistance [2] Alarm If the monitoring limit is exceeded, the frequency
load monitoring converter switches off and signals an alarm

2-15 Brake resistance test [2] Alarm Test with shutdown and alarm signal if fault occurs

3-00 Setpoint range [2] Min. to Max Only positive setpoint and actual values are permitted.

3-01 Setpoint/Act. value unit [2] Hz Unit for PID process control

3-02 Minimum setpoint value [0] Hz Minimum permissible setpoint default

3-03 Maximum setpoint value [52] / [572] Hz Maximum permissible setpoint default

3-04 Setpoint function [0] adding A total is created for several setpoints

3-15 Setpoint source 1 [1] Analogue input 53 Setpoint signal on terminal 53

3-16 Setpoint source 2 [0] deactivated No function

3-16 Sepoint source 3 [0] deactivated No function

3-18 Relativ. scal setpoint [0] deactivated No function

3-40 Ramp type 1 [0] linear Ramp type for acceleration and deceleration

3-41 Ramp time Up 1 [83] / [154] / [285] Acceleration time from 0 Hz to nominal speed

3-42 Ramp time Down 1 [83] / [154] / [285] Deceleration time from nominal speed to 0 Hz

3-81 Ramp time quick stop [83] / [154] / [285] Deceleration time quick stop

1 Parameter can not be changed with motor running.

2 Burner size 70/4only
3 up to burner size 50
4 Burner size 60...70
5 WK burners

111
11
Parameter Setting Meaning

4-10 Motor rotation direction [0] Clockwise only Rotation direction required1

4-12 Min. frequency [Hz] [0] Hz Defines 0 Hz as absolute minimum speed

4-14 Max. frequency [Hz] [52] / [57 Hz2] Maximum frequency incl. control correction

4-16 Torque limit motorised [160.0] Torque limit for motorised operation

4-18 Current limit [160.0] Limits the maximum current of the frequency converter,
If 160 is not possible set value in % relating to motor nominal current
maximum value

4-19 Maximum output frequency [52] / [572] Absolute limit of output frequency1

4-53 Warning speed high [3120] / [34202] Warning if speed set is exceeded.

5-00 Switch logic [0] PNP Configuration of digital inputs and outputs to positive
switch logic

5-01 Terminal 27 function [1] Output Configures terminal 27 as output1

5-10 Terminal 18 digital input [8] Start On frequency converter terminal 18 start signal from
W-FM 200

5-11 Terminal 19 digital input [0] no function Input 19 is deactivated

5-12 Terminal 27digital input [0] no function Input 27 is deactivated

Parameter only visible if 5-01 = [0] input

5-14 Terminal 32 digital input [0] no function Input 32 is deactivated

5-15 Terminal 33 digital input [1] Reset Resets the frequency converter following alarm shutdown
via terminal 33

5-19 Terminal 37 Safe Stop [0] SafeStopAlarm only on FC302

5-30 Terminal 27 digital output [0] Alarm Alarm signal is given via the output on terminal 27.
Only visible if 5-01 = [1] output

6-14 Terminal 53 scal. [0] Hz The min. value on analogue input 53 is assigned with
min. setpoint/actual value 0Hz.

6-15 Terminal 53 scal. [52] / [572] Hz The min. value on analogue input 53 is assigned with
max. setpoint/actual value the stipulated frequency.

6-50 Terminal 42 analogue output Motor current [A] Output signal 0...20 mA

6-51 Term. 42, output [0] At minimum value the minimum current (mA) set
min. scaling under 6-50 is applied

6-52 Term. 42, output [100] At maximum value (100%) 20mA is applied
max. scaling

1 Parameter can not be changed with motor running.

2 Burner size 70/4only

112
 11
Parameter Setting Meaning

14-03 Over modulation [1] On Output voltage can exceed mains voltage by 15%

14-04 PWM-Jitter [0] Off Function deactivated

14-10 Mains failure function [1] Ramp stop Frequency converter carries out a controlled Ramp down
at mains failure.

14-20 Recording [10] 10 x Autom. 10 automatic restarts following abort

recording

14-21 Autom. recording time [10] secs. Waiting time between automatic recording functions

1 Parameter can not be changed with motor running.

2 Burner size 70/4 only

113
12 Cause and rectification of faults (fault list)
Faults are displayed alternating as codes and clear text Display - Fault history / Lockout history
information. The following fault possibilities are listed in
order of fault code and diagnostic code. Operating mode
Fault history
Fault rectification: Lockout history Stepping motor
• Call up fault history - analyse last fault 1 18.06.99 10:35 fault from ECR
• Determine cause, determine reason C:15 D:1 P:81
• Rectify fault Start No: 123456
• If necessary, record fault Load:25.0 Gas
C: = Fault code
D: = Diagnostic code
P: = Phase

Fault list

Fault Fault Cause Recommended measures

list code

01 01 ROM Fault • 1)
02 01…07 RAM Fault • 1)
03 01…44 Fault at internal data comparison • 1)
04 – Synchronisation fault • 1)
05 01,02 Fault flame signal booster test • 1)
• Replace flame sensor
06 01…04 Fault internal hardware test • 1)
10 01…1B Fault inputs / outputs The number of the diagnostic codes shows
which input is faulty.
01 Load controller on/off • Neutral conductor may be missing, (or not zero V)
02 Fan contact
03 Oil operation selection • The fault could be caused by capacitance loads,
04 Gas operation selection causing longer than 10 ms to reduce the voltage
05 Reset to 0 Volts before the relay switches off.
06 Pressure switch Oil maximum
07 Pressure switch Oil minimum
08 Pressure switch valve proving • Check control wiring
09 Safety valve Oil return signal
0A Fuel valve 1 Oil return signal • 1)
0B Fuel valve 2 Oil return signal
0C Fuel valve 3 Oil return signal
0D Safety valve Gas return signal
0E Fuel valve 1 Gas return signal
0F Fuel valve 2 Gas return signal
10 Fuel valve 3 Gas return signal
11 Safety circuit burner flange
12 Safety relay return signal
13 Pressure switch Gas minimum
14 Pressure switch Gas maximum
15 Ignition transformer return signal
16 Fan pressure switch
17 Start release Oil
18 Residual oil immediate start
19 Load controller open
1A Load controller closed
1B Start release Gas

1) If it occurs sporadically improve EMC measures.

If it occurs permanently replace W-FM

114
 12
Fault Fault Cause Recommended measures
list code

11 01 Short circuit contact return signal network • 1)

15 01…3F Stepping motor position or The diagnostic value is made up of the
speed not reached faults listed or their combination.
The individual diagnostic codes are added
hexadecimal.
01 Positioning fault air stepping motor • With sporadic occurrences improve EMC measures.
02 Positioning fault fuel stepping motor
04 Positioning fault auxiliary stepping motor 1 With permanent occurrence, replace relevant
08 Positioning fault auxiliary stepping motor 2 stepping motors (see diagnostic code).
10 Speed not reached
20 Positioning fault auxiliary stepping motor 3 • Check if motor is overloaded
16 00…23 Plausibility fault in ECR The diagnostic code describes the cause
00 Fault ratio curve air stepping motor • Check ratio curve of relevant motor or FC module
01 Fault ratio curve fuel stepping motor and parameter if necessary.
02 Fault ratio curve auxiliary stepping motor 1
03 Fault ratio curve auxiliary stepping motor 2
04 Fault ratio curve auxiliary stepping motor 3
05 Fault ratio curve frequency converter
0A P-content outside of permissible range • Check O2 control parameter and adjust if necessary
0B I-content outside of permissible range
0C Dew outside of permissible range
0D Calculated O2 setpoint outside • Check if the values entered are valid.
of permissible range If necessary repeat setting for O2 control
0E Calculated O2 min value outside
of permissible range
0F Calculated O2 ratio value outside
of permissible range
13 Load /point number input of the
ABE outside of permissible range
14 Calculated standardisation
value outside of permissible range
20 With hysteresis compensation, exceeding 1)
the permissible adjustment range
21 Load /point number input of the ABE
outside of permissible range
22 At switch command none
of the def. cases was met
23 At switch command no defined
ECR phase was recognised
17 01–03, 3F Internal communication fault ECR
01 TimeOut at programme run 1)
synchronisation of data transfer
02 TimeOut at data transmission
03 CRC fault at data transfer
3F Different values detected at
data synchronisation

1) With sporadic occurrences improve EMC measures.

With permanent occurrence replace W-FM

115
12
Fault Diagnostic Cause Recommended measures
code code

18 – Invalid curve data Check curve data for invalid entries.

• For initial commissioning of the unit:
Correct to the valid value range
• If previously operating correctly:
Replace defective base unit
19 01…2F Fault at comparison pot channel A to B. The diagnostic value is made up of the faults listed
The diagnostic code shows which motor or their combination. The individual diagnostic codes
is faulty. are added hexadecimal.
01 Air stepping motor faulty at comparison • With sporadic occurrences, improve EMC
pot channel A to B measures.
02 Active fuel stepping motor faulty • With permanent occurrence, replace relevant
at comparison pot channel A to B steppingmotors (see diagnostic code).
04 Auxiliary stepping motor 1 faulty
at comparison pot channel A to B
08 Auxiliary stepping motor 2 faulty
at comparison pot channel A to B
20 Auxiliary stepping motor 3 faulty
at comparison pot channel A to B
1A 01 The curve gradient of a partial Max. gradient between two support points:
curve section is too high - 3.6° per 0.1 % (30s ramp)
- 1.8° per 0.1 % (60s ramp)
- 0.9° per 0.1 % (120s ramp)
Alter load matching of the support point until
the conditions are met.
1B – The programming mode remains active Curve parametering should be carried out in manual
in phase 62 and the set positions operation to avoid shutting down the load controller.
(normal operation) have not been However, if the TL reacts this can lead to shutdown.
reached The value (curve point) currently being changed
can however be saved in Standby or lockout.

1C 01…3F The relevant ignition positions The diagnostic value is made up of the faults listed
have not been parametered. or their combination. The individual diagnostic
codes are added hexadecimal.
01 Ignition pos. air stepping motor not param. Set ignition position
02 Ignition pos. of active fuel stepping motor
not parametered
04 Ign. pos. auxiliary stepping motor 1 not param.
08 Ign. pos. auxiliary stepping motor 2 not param.
10 Ignition pos. FC not parametered
20 Ign. pos. auxiliary stepping motor 3 not param.
1D 01…3F Run time fault stepping motors / The diagnostic value is made up of the faults listed
frequency converter or their combination. The individual diagnostic
codes are added hexadecimal.
01 Run time fault air stepping motor • Check motor for mechanical overload.
02 Run time fault current fuel stepping motor • Check supply voltage and fuses.
04 Run time fault auxiliary stepping motor 1 • Drive ramp of the stepping motor must be ≤
08 Run time fault auxiliary stepping motor 2 parametered ramp.
10 Run time fault frequency converter • Ramp of the frequency converter must be smaller than the
20 Run time fault auxiliary stepping motor 3 ramp parameter in the WM-F. Recommendation 20%.

116
 12
Fault Diagnostic Cause Recommended measures
code code

1E 01…3F The base unit has detected, that one The diagnostic value is made up of the faults listed
or more stepping motors (incl. FC) have or their combination. The individual diagnostic
not reached the special position codes are added hexadecimal.
required for the phase.
01 Special pos. air stepping motor not reached • Check motor for mechanical overload.
02 Special pos. current fuel stepping motor • Check supply voltage and fuses.
not reached
04 Spec. pos. auxiliary stepping motor 1 not reached
08 Spec. pos. auxiliary stepping motor 2 not reached
10 Spec. pos. FC (speed) not reached
20 Spec. pos. auxiliary stepping motor 3 not reached
1F 01…06 Fault detected with FC module With sporadic occurrences:
Check CAN Bus wiring or improve EMC measures.
With permanent occurrence, replace W-FM
01 Fault internal test in FC module
02 Wrong rotation direction of fan • Check rotational direction of motor and transmitter disc.
• Check rotational direction on FC, correct if necessary
03 Impulse sequence and length at speed • Check installation of transmitter disc and transmitter.
input different than expected • Check distance and connection inductive transmitter.
04 Nominal speed not reached stable • Check motor is running
• Check distance and connection inductive transmitter.
05 Air stepping motor(s) did not reach open • Check motor(s) for mechanical overload.
position for standardisation • Check voltage supply to stepping motors
06 Fault internal speed test FC module
21 – Safety circuit opened
22 – Temperature guard value exceeded
23 – Extraneous light during start up
24 – Extraneous light during shutdown
25 – No flame end of safety time ts1
26 – Flame failure during operation
27 – Impermissible air pressure signal “On”
28 – Impermissible air pressure signal “Off”
29 – Impermissible message “On”
from fan relay contact
2A – Impermissible message “Off”
from fan relay contact
2B – Impermissible air pressure signal “On”
flue gas recirculation
2C – Impermissible air pressure signal “Off”
flue gas recirculation
2D 00, 01 Impermissible message “On”
from valve closing contact
2E 00, 01 Impermissible message “Off”
from valve closing contact
2F – Low gas pressure switch has reacted Check gas supply pressure
30 – High gas pressure switch has reacted Check setting gas pressure switch
31 – Gas pressure switch VP has reacted V1 leaking
32 – Gas pressure switch VP not reacted V2 leaking
33 – Unexpected oil pressure present
34 – Low oil pressure switch has reacted Min. permissible oil pressure not reached
35 – High oil pressure switch has reacted Max. permissible oil pressure exceeded

117
12
Fault Diagnostic Cause Recommended measures
code code

36 No start release oil

37 – No release residual oil immediate start
38 – Low gas programme active Check gas supply pressure
39 01…03 Parameter of safety time faulty
01 Internal fault at timer1
02 Internal fault at timer2
03 Internal fault at timer3
3A – No burner ID defined Parameter burner ID
3B – No engineer’s password defined Enter engineer’s password
40 – Setting internal safety relay With sporadic occurrences, improve EMC
measures.
With permanent occurrence, replace W-FM
41 – Internal ignition contact setting Check wiring of output
42 01…FF Contact setting fault of internal The diagnostic value is made up of the faults listed
fuel valve relays or their combination. The individual diagnostic codes
are added hexadecimal.
01 Safety valve - Oil Check wiring of output.
02 Fuel valve V1 - Oil /
operating signal Oil
04 Fuel valve V2 - Oil
08 Fuel valve V3 - Oil
10 Safety valve - Gas
20 Fuel valve V1 - Gas
operating signal Oil
40 Fuel valve V2 - Gas
80 Fuel valve V3 - Gas
43 01…0D Fault during plausibility check
01 No fuel selected or both selected via
input X4-01
02 No def. fuel train parametered
03 Variable “train” not defined
04 Variable “fuel” not defined
05 Undefined mode of operation with LC
06 Pre-purge time gas too short
07 Pre-purge time oil too short
08 Gas Safety time 1 too long
09 Oil Safety time 1 too long
0A Ignition - Off - Time > ts1 Gas
0B Ignition - Off - Time > ts1 Oil
0C Gas Safety time 2 too long
0D Oil Safety time 2 too long
44 01…0A Deactivated inputs connected
01 Controller input to X62 Activate input or connect nothing
02 Air pressure switch input X3-02
03 Brn Fan / FGR air pressure switch X4-01:3
04 Low gas pressure switch terminal X9-03:4
05 High gas pressure switch terminal X9-03:3
06 Low oil pressure switch terminal X5-01
07 High oil pressure switch terminal X5-02
08 Start signal Oil input X6-01:1/2
09 Residual Oil immediate start input X6-01:3/4
0A Start signal Gas input X7-03

118
 12
Fault Diagnostic Cause Recommended measures
code code

45 – At STB test activated a controlled

shutdown was carried out
46 01…07 A programme stop has been activated
01 Phase 24: Pre-purge If the programme stop (see Ch. 9.6.1) is no longer
02 Phase 32: Pre-purge for FGR required, deactivate it.
03 Phase 36: Ignition positions
04 Phase 44: End first safety time
05 Phase 52: End second safety time
06 Phase 72: Post-purge position
07 Phase 76: Post-purge position FGR
47 – Start release Gas = Off
48 – 1 sensor operation parametered, but
2 flame signals present
50 00…07 Fault in key value check 1)
51 00…07 Time block overrun
52 01…03 Stack fault
53 01 Faulty reset condition
58 – Parameter setting is incorrect Reset unit
59 – Parameter setting is incorrect If this fault occurred during parametering:
5A – Parameter setting is incorrect check parameter last changed for plausibility.
5B – Parameter setting is incorrect If reset does not achieve faultless condition:
5C – Backup restore was carried out Restore parameters from ABE
5D – Internal fault Otherwise replace defective base unit.
5E – Internal fault
5F – Last Backup-Restore invalid (was
cancelled)
60 – Internal fault
61 01…23 Internal fault
70 01…04 Fault at rectification of 1)
lockout information
71 – Manual lockout with contact The lockout by the external contact
is cancelled by re-activating.
72 01…04 Plausibility fault at fault entry 1)
80 01…03 Impermissible cond. auxiliary stepping motor3 Check CAN wiring and Bus connection.
81 01…03 Impermissible condition air stepping motor
82 01…03 Impermissible con. gas stepping motor (Oil) With sporadic occurrences, improve EMC measures.
83 01…03 Impermissible condition oil stepping motor
84 01…03 Impermissible cond. auxiliary stepping motor1 With permanent occurrence, replace relevant motor.
85 01…03 Impermissible cond. auxiliary stepping motor2
86 01…03 Impermissible condition of internal LC 1)
87 01…03 Impermissible condition of ABE Check CAN wiring and Bus connection.
With sporadic occurrences, improve EMC measures.

With permanent occurrence, replace ABE

1) With sporadic occurrences, improve EMC measures.
With permanent occurrence, replace W-FM

119
12
Fault Diagnostic Cause Recommended measures
code code

88 01…05 Plausibility fault

01 Non defined fault stepping motors With sporadic occurrences,
02 Non defined fault load controller improve EMC measures.
03 Non defined fault ABE With permanent occurrence replace defective unit
04 Non defined fault FC module (see diagnostic code) or base unit.
01 Non defined fault O2 module
90 – ROM-CRC-fault auxiliary stepping motor3 Check CAN wiring and Busconnection.
91 – ROM-CRC-fault air stepping motor
92 – ROM-CRC-fault gas stepping motor (oil) With sporadic occurrences, improve EMC measures.
93 – ROM-CRC-fault oil stepping motor
94 – ROM-CRC- fault auxiliary stepping motor1 With permanent occurrence replace defective unit
95 – ROM-CRC- fault auxiliary stepping motor2 (see diagnostic code) or base unit.
96 – ROM-CRC-fault load controller
97 – ROM-CRC-fault ABE
98 – Multiple components with the same Check addressing of connected components
address on the CAN Bus and correct if necessary.
99 – CAN is in Busoff Check CAN wiring
9A – CAN- Warning- level With sporadic occurrences, improve EMC measures.
9B 01, 02 CAN Queue overrun
With permanent occurrence, replace W-FM

120
 12
Fault Diagnostic Cause Recommended measures
code code

A0 01…1F Auxiliary stepping motor3 has signalled fault With sporadic occurrences,
A1 01…1F Air stepping motor has signalled fault improve EMC measures.
A2 01…1F Gas stepping motor has signalled fault With permanent occurrence,
A3 01…1F Oil stepping motor has signalled fault replace the relevant motor.
A4 01…1F Auxiliary stepping motor1 has signalled fault
A5 01…1F Auxiliary stepping motor2 has signalled fault
01 CRC fault at ROM test
02 CRC fault at RAM test
04 Fault in button value test
05 Time block overrun
07 Sync fault or CRC fault
08 Revolution counter
09 Fault at stack test
0C Temperature warning and shutdown Check housing temperature (max. 60° C)
0D Wrong rotation direction
0E Ramp time for stretch too small • Match ramp time to slowest motor
• Reduce spanning between special positions
10 Timeout at AD change
11 Fault at ADC test
12 Fault at AD change
13 Stepping motor is outside of the valid Check setting range (0-90°), reset mechanically
degree of angle (0-90°)
15 CAN fault Check CAN wiring
16 CRC fault of one parameter section
17 Section was opened too long Reset unit
18 Section is damaged If this fault occurred during parametering:
19 Invalid access to parameter check parameter last changed for plausibility.
1B Fault at copying parameter section If reset does not achieve faultless condition:
Restore parameters from ABE
Otherwise, replace defective base unit.
1E Invalid setting in drive order Check special positions are within valid range
1F Plausibility fault internal Improve EMCmeasures

121
12
Fault Diagnostic Cause Recommended measures
code code

A6 10…FF Internal LC has signalled fault Type of fault: see diagnostic code
10 No actual value increase 1)
12 Invalid XP identified
13 Invalid TN identified
14 TV larger than identification time
15 Invalid TV identified
16 Timeout during observation time
17 Cold start thermal shock protection is active
18 Timeout during adaption load
22 Temp controller setpoint larger limit value
30…32 Internal fault load controller
33 Invalid CRC when reading a section Reset unit, poss. repeat Backup Restore
34…3B Internal fault load controller 1)
40 Section open too long Reset unit. If this fault occurred during parametering:
check parameter last changed for plausibility.
If reset does not achieve faultless condition:
Restore parameters from ABE.
Otherwise, replace defective base unit.
41…43 Internal fault load controller 1)
44 Section was set to ABORT Reset unit
45 Section was set to RESTO If this fault occurred during parametering: check para-
46 Section has invalid status meter last changed for plausibility. If reset does not
achieve faultless condition: Restore parameters from ABE
Otherwise, replace defective base unit.
4A…4E CAN fault 1)
50 PT 100 sensor short circuit Check wiring and sensor
on input X60:1/4
51 PT 100 sensor break
on input X60:1/4
52 Break in compensation line
on input X60:2/4
53 PT 1000 sensor short circuit
on input X60:3/4
54 PT 1000 sensor break
on input X60:3/4
55 Ni 1000 sensor short circuit
on input X60:3/4
56 Ni 1000 sensor break
on input X60:3/4
57 Over voltage on input X61
58 Break or short circuit
on input X61
59 Over voltage on input3, terminal X62
5A Break or short circuit at
input X62
5B Analogue output value (X63:1/2) not Check setting Analogue output and Sensor
available in current configuration. selection

5C FGR sensor not available in current Check setting FGR - Sensor

configuration.
1) With sporadic occurrences, improve EMC measures.
With permanent occurrence, replace W-FM

122
 12
Fault Diagnostic Cause Recommended measures
code code

60…6F Internal fault load controller 1)

70 Measurement value variation, PT 100 sensor Check wiring of input
71 Measurement value variation, PT 100 line
72 Measurement value variation, PT 1000
73 Measurement value variation, PWM 1)
74 Measurement value variation, U input X61 • Check wiring of input
75 Measurement value variation, I input X61 • Check signal for ripple voltage
76 Measurement value variation, U input X62
77 Measurement value variation, I input X62
78 Over voltage or wrong polarity Check wiring of input
PT 100 sensor, input X60
79 Over voltage or wrong polarity
PT 100 sensor, input X60
7A Over voltage or wrong polarity
PT 1000 sensor, input X60
7B Over voltage or wrong polarity PWM 1)
7C Over voltage or wrong polarity • Check wiring of input
U measurement input X61 • Check input voltage or current
7D Over voltage or wrong polarity
I measurement input X61
7E Over voltage or wrong polarity
U measurement input X62
7F Over voltage or wrong polarity
I measurement input X62
80…A6 Internal fault load controller 1)
A7 Impermissible selection for the additional A pressure or temperature sensor must
sensor be fitted to X61 (see Ch. 9.8.3 and 9.8.4)
B0…FF Internal fault load controller 1)
A7 01…8A The ABE signals faults. With sporadic occurrences, improve EMC measures.
Type of fault, see diagnostic code With sporadic occurrences, improve EMC measures.

With permanent occurrence, replace ABE

01 …08 Internal fault ABE
09 Fault signal Emergency-Off Function ABE
0A Internal fault ABE
0B Service message through burner starts Carry out service, reset start counter
0C Fault parameter backup
0D Fuel changeover from oil to gas Change to menu “Settings Gas”
0E Fuel change over from gas to oil Change to menu “Settings Oil”
15 …1A Internal fault ABE
1B Fault during copying parameter section Reset unit, if necessary repeat parameter backup
1C…28 Interner Fehler ABE
30 Fault during eBus communication
38 Interface mode could not be stopped
40 Parameter fault PC Tool
88…8A Internal fault ABE

1) With sporadic occurrences, improve EMC measures.

With permanent occurrence replace W-FM

123
12
Fault Diagnotic Cause Recommended measures
code code

A9 01…1F FC module has signalled a fault

01…09 Internal fault FC module 1)
0A Poss. fault on line to speed • Check cabling, use screened
transmitter • 1)
0C Frequency converter has initiated fault Read fault codes of frequency converter
0D FC module could not control speed • Check if current interfaces on frequency converter
difference within its control limit and FC module are set the same (0/4 to 20 mA).
• Carry out speed standardisation incl.
burner adjustment (fuel / air ratio)
0E Fault during speed calculation test 1)
15 Interrupted CAN Bus transmission • With sporadic occurrence check CAN Bus wiring,
improve EMC measures
• Check closed resistance, correct if necessary
16 CRC fault of a parameter section Reset unit
17 Section was open too long If this fault occurred during parametering:
18 Section has been destroyed check parameter last changed for plausibility.
19 Invalid access to parameter If reset does not achieve faultless condition:
1B Fault during copying parameter section Restore parameters from ABE
Otherwise, replace defective base unit.
1E Invalid entries in drive order Check special positions for valid range
1F Plausibility fault internal 1)
AB 01…3F O2 module has signalled a fault
01…0A Internal fault O2 module 2)
10 Nernst voltage QGO sensor (B1/M) Check connection (poling, short circuit, break)
12 Voltage thermo element (B2/M)
13 Voltage compensation element (G2/U3)
15 Supply air sensor out of range • Check connection (short circuit, break)
16 Flue gas sensor out of range • Check ambient temperature (-20° C to +400° C)
17…1B Internal fault O2 module during test phase 2)
20 Temperature of O2 sensor too low Check heating start up O2 sensor (Q4/Q5)
21 Temperature of O2 sensor too high Check QGO temperature
22 Fault during calculation test 2)
23 Internal resistance of sensor is smaller • Check connection (poling, short circuit)
5 Ohm or larger 150 Ohm • Replace O2 sensor
24 Reaction time O2 sensor more than 5 s • Check position of O2 sensor
• Check soiling of O2 sensor
• O2 sensor
25 Faulty O2 sensor test Check variation of O2 value
30 Internal fault O2 modul 2)
31 CRC fault of a parameter section Reset unit
32 Section was open too long If this fault occurred during parametering:
33 Section has been corrupted check parameter last changed for plausibility.
34 Invalid access to parameter If reset does not achieve faultless condition:
38 Fault during copying parameter section Restore parameters from ABE
3E Invalid external entry Otherwise, replace defective base unit.
3F Plausibility internal fault 2)
1) With sporadic occurrences, improve EMC measures. 2) With sporadic occurrences, improve EMC measures.
With permanent occurrence, replace W-FM With permanent occurrence, replace O2 module

124
 12
Fault Diagnotic Cause Recommended measures
code code

B0 01, 02 Fault during testing port outputs 1)

B1 01 Fault during short circuit testing 1)
from inputs to outputs
B5 01...07 Fault during O2 guarding 1)
01 O2 min value not reached • Check settings of ratio curve
• Increase O2 Offset
• Increase differential O2 set point to O2 min value
02 Invalid O2 min value Define all O2 min values
03 Invalid O2 set point Define all O2 set points
04 Adaption fault in partial load adaption Repeat standardisation at this point (Ch. 9.7.1)
point 2 or at 100%
05 No valid O2 actual value > = 3 s Check connection O2 module and O2 sensor
06 Air oxygen content at pre-purge • Increase pre-purge time
not achieved • Replace O2 sensor
07 O2 value during operation above 15% • Check installation and connection O2 sensor
BA 01 Test O2 sensor not successful 1)
BF – Fault in connection with O2 control In the fault history immediately prior to fault “BF”
or O2 guard the reason for switch off can be read
C5 01…2F ABE has detected old versions during the The diagnostic value is made up of the faults
version comparison of individual units listed or their combination. The individual diagnostic
codes are added hexadecimal.
01 Software version of LC not current Prior to replacing any units switch on the system
02 Software version of ABE not current and wait for approx. 1 min. (until the display “parameters
04 Software version of stepping motor(s) not current are being updated” disappears when entering the
08 Software version of FC module not current parameter level). Then reset. If the fault still persists,
10 Software version of O2 module not current replace the relevant unit.
20 Software version of O2 module not current
D1 01…03 Impermissible condition frequency converter 1)
D3 01…03 Impermissible condition O2 module 1)
E1 ROM - CRC fault in FC module 1)
E3 – ROM - CRC fault in O2 module 1)
F0 – Plausibility at interpolation calculation 1)
F1 01…07 Fault during pre-control calculation • Check curve setting
• Check setting of fuel parameter depending
on the fuel selected
F2 07…0A Wrong temperature values from
O2 module during calculation of
air load change
07 O2 module transmitted invalid
value
08 Flue gas temperature outside of Increase permitted flue gas temperature
permitted value range
0A QGO sensor not heated Wait until sensor reaches operating temperature
sufficiently
F3 01 The control algorithm is missing Check control parameters
the PID parameters
F4 – Fault return signal O2 modul Check CAN wiring
F5 – Fault return signal load controller Check CAN wiring

1) With sporadic occurrences, improve EMC measures.

With permanent occurrence, replace W-FM

125
13 1Service
3
13.1 Safety information for servicing
Failure to carry out maintenance and service Endangering operational safety
work properly can have severe conse- Maintenance work on the following parts may only be
quences, including the loss of life. Pay close carried out by the manufacturer or their appointed agent
attention to the following safety notes. on the individual components.
DANGER • Combustion manager
• Stepping motors
Detailed information and instructions for maintenance can • Flame sensor
be found in the installation and operating instructions of • Gas pressure switch
the burner. • Air pressure switch
• Oil pressure switch
Qualified personnel • Solenoid valves
Only qualified and experienced personnel must carry out
maintenance and service work.

Prior to all maintenance and service work:

1. Electrically isolate the equipment
2. Close all fuel shut off devices

After all maintenance and service work:

1. Function test.
2. Check flue gas analysis i.e. CO2 / O2 / CO values,
smoke No.
3. Complete a test sheet.

13.2 Service plan

The operator should ensure that combustion plant is
serviced at least once a year by an agent of the supplier or
other suitably qualified person.
During this service all system components with high wear
and tear, or components with a specific life span should be
replaced. Notes to be made of such exchanges.

126
14 Technical data 14
14.1 Combustion manager W-FM
Mains voltage AC 230 V –15 % / + 10 % Low-voltage transformer
When the W-FM is fitted into a control panel, the burner
Transformer AGG5,220 – primary AC 230 V must also be fitted with a low-volt transformer for the
– secondary 3 x AC 12 V control voltage to the stepping motors.

Mains frequency 50...60 Hz ±6 %

Ambient conditions for all components:
Consumption < 30 W
• Transport DIN EN 60 721-3-2
Type of protection housing IP00, IEC 529 - climatic conditions Class 2K2
- temperature ranges -20 to + 70° C
Protection Class I with parts according to II and III - humidity < 95 % r. h.
to DIN EN 60 730-1
• Operation DIN EN 60 721-3-3
Mains pre-fusing (external) max. 16 AT - climatic conditions Class 3K5
Unit fusing (internal) 6.3 AT (IEC 127 2 / 5) - temperature ranges -20 to + 60° C
2 x 4.0 AT (IEC 127 2 / 5) - humidity < 95 % r. h.

• Mechanical requirements Class 2M2

Mains supply input current depending on
unit condition Dew point, freezing, water ingress not permitted

Individual contact loading: CE Conformity To the guidelines of the EU

Nominal voltage AC 230V + 10% / - 15%, 50-60 Hz Electromagnetic compatibility
- Fan motor contactor max. 1 A EMC 89 / 336 EU incl. 92 / 31 EU
- Ignition transformer 2A
- Fuel valves Gas 2A Interference transmission To EN 55022
- Fuel valves oil 1A
- Oil pump / solenoid valve max. 2 A Interference fastness To IEC 1000-4-3
- LP test valve max. 0.5 A
- Alarm output 1A
- Ratings factor cosϕ > 0.4
Housing dimension
Signal inputs Input currents/input voltages

UeMaxUmains + 10%
UeMinUmains - 15%
leMax 1.5 mA peak
leMin 0.7 mA peak

Total contact loading (Safety circuit)

200
182

Nominal load AC 230 V +10% / –15%, 50-60 Hz

Unit input current max. 5 A

Cable lengths max. 100m (100pF/m)

CAN-Bus total length max. 100m

CAN-Bus special cable Weishaupt No. 743 192

Cable diameter min. 0.75 mm2 232

250 82,3
(multi-core to VDE 0100)

The cable diameters of the mains supply (L, N, PE) and the
safety circuit (STB, low water, etc.) must be selected for
the nominal currents relative to the selected external pre-
fusing.
The cable diameters of the remaining conductors should
be dimensioned in relative to the internal unit fusing (max.
6.3 AT).

Internal fusing: F1 6.3 AT (IEC 127 2 / 5)

F 24 AT(IEC 127 2 / 5)
F3 4 AT(IEC 127 2 / 5)

127
14
14.2 Stepping motors SQM45.../48...
Supply voltage AC 2 x 12 V Cable connection
The connection of the screened Bus cable is via plug
Protection class Install low voltage cables with safe screw terminal Rast 3.5. The two connection sockets
separation from mains voltages (x1, X2) on the stepping motor have the same value.

Consumption - SQM45... 9...15VA Cable and cable screening

- SQM48... 26...34 VA Only special cable (Weishaupt No. 743 192) may be used.
Cable screening must be connected to the circuit board
Angular adjustment max. 90 °< with the flat plug provided.

Installation optional Housing cover

The housing cover must only be removed for the short
Degree of protection to EN 60529 IP54 with relevant period during wiring and addressing. Ensure dirt particles
version of cable entry cannot enter the internals of the stepping motor.
The stepping motor contains a printed circuit board with
Torque: - SQM45... up to 3 Nm ‘static’ sensitive components. Its surface is protected
- SQM48... up to 20 Nm against direct contact by a protective cover. Contact with
the underside of the circuit board should be avoided.
Repeat accuracy ± 0.2 ° The protective cover must not be removed!

Rotation direction Can be set in W-FM

Run times: - SQM45... 10 to 120 s

- SQM48... 30 to 120 s

Weight: - SQM45... approx. 1.0 kg

- SQM48... approx. 1.6 kg

Dimensions

90
,4
15 116 76 ø5
2
12
ø1
0 +0
,0 6
0 5
41
+0,1

3N9
33

2,5 0
ø10 h8
ø16

SQM 45
Groove for
25

Woodruff key
3 x 3.7 DIN 6888
122
137

87

50
Prepared for
self tapping screws
+0,1
6 0 M5, 10mm deep,
to DIN 7500
7814m01

25,5
47 2 x M16x1,5
+0,1
0

P9
5
1,9

Groove for parallel

ø18

key 5 x 28

36
SQM 48 39
2 28
ø14 h8

128
 14
14.3 Flame monitoring
QRI QRI flame sensor
The infrared flame sensor QRI... has the following
characteristics:
• Infrared flame sensor with IR sensitive sensor for gas
and oil flames
• Integrated flame signal amplifier
• Self checking of flame signal for continuous run
• For front or side (90°) viewing
• Fitted to burner body with flange and clamp

Supply voltage: - Operation DC 14 V + 5%

- Test DC 21 V + 5% bl blue wire = reference
br brown wire = supply conductor
Signal voltage: sw black wire = signal conductor
Range DC 0...5V
minimum DC 3.5 V; Display flame approx. 50%

Consumption < 0.5 W

Type of protection IP54

Protection class II

Length of sensor connection cable max. 1.8 m

Length of additional sensor line max. 100 m
Installation optional
Vibration to IEC 68-2-6 max. 1g / 10...500 Hz
Weight with cable approx. 0.175 kg

Ionisation electrode
Flame supervision with ionisation electrode for gas
operation is suitable for continuous run.

Idle voltage approx. Umains

Short circuit voltage max. 0.5mA (AC)
Sensor current
minimum 6 µA (DC); display flame approx. 50%
maximum 85 µA (DC); display flame approx. 100%

Sensor line length max. 100m

(core-ground 100 pF (/m)

Note: With increased sensor line (length) the current at

the sensor electrode decreases. For longer line
lengths where very high Ohmic values are
probable, the use of a low capacity sensor line (i.e.
low-loss ignition cable) may be necessary.

129
14
14.4 Display and operating unit (ABE)
Supply voltage via Bus cable AC 12 V Dimensions

Installation optional

Type of protection to EN 60529 IP54

(Viewing side in installed condition)

Ambient conditions see basic unit (Ch. 14.1)

Door cut-out for panel mounting

Height 12.5 ± 1 mm
Width 90.5 ± 1 mm
Depth (within panel) 25 mm
Free space for connection cable (below the unit) 50 mm

Cable - line length max. 100 m

Only original -weishaupt- CAN-BUS cable
(order No. 743 192) must be used.

130
Appendix A
Notes

131
 Max Weishaupt GmbH
D-88475 Schwendi

Find Weishaupt adresses

and telephone numbers
on www.weishaupt.de

Print No.. 83054802, July 2009

Printed in Germany
All rights reserved

Product Description Performance

W-Burners The compact series, proven millions of times over: Up to 570 kW

Economical, reliable, fully automatic. Gas, oil and
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multiflam® burners Innovative Weishaupt technology for large burners: Up to

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For environmentally friendly heating.
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Heat pumps The heat pump programme offers solutions for utilisation Up to 130 kW
of heat from air, soil and ground water. The
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Solar systems Free energy from the sun:

Perfectly coordinated components, innovative, proven.
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Water heater / The attractive domestic water heating range

energy reservoir includes classic water heaters which are supplied
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building systems – at Weishaupt you can find the entire
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