83250302 1/2018-08

X5-02 X5-01 X9-04 X7-02 X4-02 X6-03 X3-05 X3-03

X56
BC
CO

X5-02 X5-01 X9-04 X7-02 X4-02 X6-03 X3-0 X3-03

max
L

L
L
L
L
N

N
P max/POC PE

PE

PE

PE

PE

PE
min

LT
X92

IGNITION
V3/PV

SV
P min

MOTOR
P P P

P LT

FLANGE
Installation and operating instruction

ALARM
MOTO
FUEL X54

SIEMENS
230 VAC
LMV27.210A2WH 50 or 60 Hz
FM
W-FM5
-20C to + 60C Best.-Nr.: 600402
1P -  4 F to +140 F
P

SAFETY
Siemens Building Technologies CE-xxxxxxxxxxxxx Geräte-Nr.: 0503020021

LOOP

L VOLTAGE
DIN VDE
HVAC Products GmbH Rg.xxxxxxxxxxxxxx
Made in Germany Refer to data sheet 7543 S
AIR

N LINE
OPERATION
FLAME

P air

V1

PE
RESET
X53

L
V2
+

COUNTER U
X3-0

FUEL

ON/OFF
QRB/C-
QRB/

QRA
QRA

3
2
ION
info

PE
PE
PE

N
L
•

L
L

L
L
FUSE 1
X75 X10-05 X10-06 X3-02 X5-03 X8-0 X8-02 X7-01 T6.3 IEC 60127-2/V

VSD X74
X64

+
h min s %
esc
1 1 1 1 1 1 1 1 1
X75 X10-05 X10-06 X3-02 X5-03 X8-04 X8-02 X7-01 X3-04 PE N L

–
V

A
VSD
S

F
P
i

Combustion Manager W-FM 50

 Installation and operating instruction
Combustion Manager W-FM 50

1 User instructions ..............................................................................................................  5
1.1   Target group ..................................................................................................................  5
1.2   Symbols ..........................................................................................................................  5
1.3   Guarantee and Liability ...............................................................................................  6

2 Safety  .....................................................................................................................................  7
2.1   Designated application ...............................................................................................  7
2.2   When gas can be smelled  .........................................................................................  7
2.3   Safety measures ...........................................................................................................  7
2.3.1   Normal operation ...................................................................................................  7
2.3.2   Electrical connection  ............................................................................................  7
2.3.3   Gas supply ..............................................................................................................  8
2.4   Alterations to the construction of the equipment  .................................................  8
2.5   Noise emission  .............................................................................................................  8
2.6   Disposal  .........................................................................................................................  8

3 Product description  ........................................................................................................  9

3.1   Function ..........................................................................................................................  9
3.1.1   Burner Control  .......................................................................................................  9
3.1.2   Low gas programme .............................................................................................  9
3.1.3   Valve proving .......................................................................................................  10
3.1.4   Variable speed drive  ..........................................................................................  10
3.1.5   Calculation ...........................................................................................................  11
3.1.6   Data backup  ........................................................................................................  11
3.1.7   Referencing the actuator ..................................................................................  12
3.1.8   Program sequence .............................................................................................  13
3.1.8.1   Operating phase ..........................................................................................  13
3.1.8.2   Gas direct ignition .......................................................................................  14
3.1.8.3   Gas with ignition pilot valve  ......................................................................  15
3.1.8.4   Fuel oil EL modulating and multi-stage, heavy oil multi-stage  ..........  16
3.1.8.5   Medium and heavy oil modulating  ...........................................................  17
3.2   Inputs  ............................................................................................................................ 18
3.2.1   Voltage supply  ....................................................................................................  18
3.2.2   Safety circuit ........................................................................................................  18
3.2.3   Reset .....................................................................................................................  18
3.2.4   Air pressure switch  ............................................................................................  18
3.2.5   Minimum pressure switch .................................................................................  19
3.2.6   Max. pressure switch .........................................................................................  19
3.2.7   Valve proving gas pressure switch  ................................................................  20
3.2.8   Heavy oil immediate start  .................................................................................  20
3.2.9   Flame sensor  .......................................................................................................  21
3.2.10   Load controller analogue input .....................................................................  22
3.2.11   Load controller building management  ........................................................  22
3.2.12   Load controller via contacts  ..........................................................................  23
3.2.13   Fuel Meter  .........................................................................................................  23
3.3   Outputs  ........................................................................................................................ 24
3.3.1   Alarm  .....................................................................................................................  24
3.3.2   Motor .....................................................................................................................  24
3.3.3   Ignition  ..................................................................................................................  24
3.3.4   Frequency converter ..........................................................................................  24

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 Installation and operating instruction
Combustion Manager W-FM 50

3.3.5   Analogue output  .................................................................................................  25

3.4   Technical data ............................................................................................................. 26
3.4.1   Electrical data  .....................................................................................................  26
3.4.2   Ambient conditions  ............................................................................................  26
3.4.3   Dimensions  ..........................................................................................................  27

4 Installation  ........................................................................................................................  28

4.1   Electrical connection ................................................................................................. 28

5 Operation  ..........................................................................................................................  30

5.1   Operating interface .................................................................................................... 30
5.1.1   Operating panel ..................................................................................................  30
5.1.2   Display  ..................................................................................................................  31
5.2   Displaying and adjusting parameters  .................................................................... 33
5.2.1   Password  .............................................................................................................  34
5.2.2   Manual load  .........................................................................................................  35
5.3   Parameters  .................................................................................................................. 36
5.3.1   Password level ....................................................................................................  36
5.3.2   Info level  ...............................................................................................................  44
5.3.3   Service level  ........................................................................................................  45

6 Commissioning ..............................................................................................................  46
6.1   Prerequisite  ................................................................................................................. 46
6.2   Adjusting the burner .................................................................................................. 46
6.2.1   Adjusting gas side  .............................................................................................  47
6.2.2   Adjust modulation oil side  ................................................................................  61
6.2.3   Adjust multi-stage oil side ................................................................................  75
6.3   Check combustion ..................................................................................................... 86
6.4   Calculate gas throughput ......................................................................................... 87

7 Servicing ............................................................................................................................  88
7.1   Notes on servicing  ..................................................................................................... 88
7.2   Service plan ................................................................................................................. 89

8 Troubleshooting  ............................................................................................................  90

8.1   Procedures for fault conditions ............................................................................... 90
8.1.1   Display OFF .........................................................................................................  90
8.1.2   Display OFF S .....................................................................................................  90
8.1.3   Fault .......................................................................................................................  91
8.1.4   Lockout .................................................................................................................  91
8.2   Fault history  ................................................................................................................. 92
8.3   Rectifying faults  .......................................................................................................... 94

9 Technical documentation ....................................................................................... 102
9.1   Frequency converter ...............................................................................................  102
9.1.1   Frequency converter Nord size I … III  ......................................................... 102
9.1.2   Frequency converter Nord size IV  ................................................................ 104

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 Installation and operating instruction
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10 Spares ............................................................................................................................... 106

11 Notes  ................................................................................................................................. 108

12 Key word index  ............................................................................................................ 109

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 Installation and operating instruction
Combustion Manager W-FM 50
1 User instructions

1 User instructions
This manual forms part of the equipment and must be kept on site.
Translation of original Carefully read the manual prior to working on the unit.
operating instructions

1.1 Target group

The manual is intended for the operator and qualified personnel. They should be
observed by all personnel working with the unit.
Work on the unit must only be carried out by personnel who have the relevant train-
ing and instruction.
Persons with limited physical, sensory or mental capabilities may only work on the
unit if they are supervised or have been trained by an authorised person.
Children must not play with the unit.

1.2 Symbols
Immediate danger with high risk.
Non observance can lead to serious injury or death.
DANGER
Danger with medium risk.
Non observance can lead to environmental damage,
serious injury or death.
WARNING
Danger with low risk.
Non observance can cause damage to the equip-
ment and injury to personnel.
CAUTION
Important information

Requires direct action

Result after an action
Itemisation
… Range of values

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 Installation and operating instruction
Combustion Manager W-FM 50
1 User instructions

1.3 Guarantee and Liability

Guarantee and liability claims for personal and equipment damage are excluded, if
they can be attributed to one or more of the following causes:
non approved application,
non-observance of the manual,
operation with faulty safety equipment,
continual operation despite a fault,
improper installation, commissioning, operation and service,
repairs, which have been carried out incorrectly,
the use of non original Weishaupt parts,
force majeure,
unauthorised modifications made to the unit,
the installation of additional components, which have not been tested with the
unit,
the installation of combustion chamber inserts, which impede full flame forma-
tion,
unsuitable fuels,
defects in the inlet lines.

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 Installation and operating instruction
Combustion Manager W-FM 50
2 Safety

2 Safety

2.1 Designated application

The combustion manager W-FM 50 is suitable for use with single fuel burners.
Improper use could:
endanger the health and safety of the user or third parties,
cause damage to the unit or other material assets.

2.2 When gas can be smelled

Avoid open flames and spark generation, for example:
do not operate light switches,
do not operate electronic equipment,
do not use mobile telephones.
Open doors and windows.
Close gas isolating valve.
Warn the inhabitants, do not ring door bells.
Leave the building.
Inform the heating contractor or gas supplier from outside of the building.

2.3 Safety measures

Safety relevant fault conditions must be eliminated immediately.
Components, which show increased wear and tear or whose design lifespan is or
will be exceeded prior to the next service should be replaced as a precaution.
The design lifespan of the components is listed in the service plan [ch. 7.2].

2.3.1 Normal operation

All labels on the unit must be kept in a legible condition.
Stipulated settings, service and inspection work should be carried out at regular
intervals.
Only operate the unit with its cover closed.
Do not touch moving parts during operation.
Do not touch the oil carrying parts of medium and heavy oil burners during oper-
ation.

2.3.2 Electrical connection

For work carried out on live components:
Observe the accident prevention instructions DGUV Regulation 3 and adhere to
local directives,
tools in accordance with EN 60900 should be used.

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 Installation and operating instruction
Combustion Manager W-FM 50
2 Safety

2.3.3 Gas supply

Only the gas supply company or an approved agent may carry out installation, al-
teration and maintenance work on gas appliances in buildings and properties.
Pipework must be subject to a combined load and valve proving test and/or us-
ability testing relative to the pressure range intended, e. g. DVGW-TRGI, work-
sheet G 600.
Inform the gas supply company about the type and size of plant prior to installa-
tion.
Local regulations and guidelines must be observed during installation, e. g.
DVGW-TRGI, worksheet G 600; TRF Band 1 and Band 2.
The gas supply pipework should be suitable for the type and quality of gas and
should be designed in such a way that it is not possible for liquids to form, e. g.
condensate. Observe vaporisation pressure and vaporisation temperature of li-
quid petroleum gas.
Use only tested and approved sealing materials, whilst observing all process in-
formation.
Re-commission the appliance when changing to a different type of gas.
Carry out soundness test after each service and fault rectification.

2.4 Alterations to the construction of the equipment

All conversions require written approval from Max Weishaupt GmbH.
No additional components may be fitted, which have not been tested for use
with the equipment.
Do not use combustion chamber inserts, which hinder flame burnout.
Use only original Weishaupt replacement parts.

2.5 Noise emission

The noise emissions are determined by the acoustic behaviour of all components
fitted to the combustion system.
Prolonged exposure to high noise levels can lead to loss of hearing. Provide oper-
ating personnel with protective equipment.
Noise emissions can further be reduced with a sound attenuator.

2.6 Disposal
Dispose of all materials and components in a safe and environmentally friendly way
at an authorised location. Observe local regulations.

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3 Product description

3.1 Function

3.1.1 Burner Control

A burner control for oil and gas burners is integrated in the combustion manager.
It controls the sequence of operation, monitors the flame and communicates with all
components.

3.1.2 Low gas programme

The low gas pressure switch monitors the gas connection pressure from operating
phase Ph22. If the gas pressure set at the low gas pressure switch is not
achieved, the combustion manager initiates a safety shutdown and starts the low
gas programme.
In the low gas programme the combustion manager carries out a safety shutdown
and initiates a restart after the low gas waiting time (10 seconds). This low gas
waiting time doubles after every unsuccessful start attempt. If the start attempts ex-
ceed the repetition limit value (parameter 223) the combustion manager goes to
lockout. The repetition counter and the low gas waiting time are automatically reset
when the burner starts.

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.1.3 Valve proving

The valve proving gas pressure switch checks if the valves are tight. It signals the
combustion manager if the pressure increases or decreases to an impermissible
level during valve proving.
Valve proving is carried out automatically by the combustion manager:
after every controlled shutdown,
prior to burner start following lockout or power outage.
1. Test phase (function sequence for valve proving valve 1):
Valve 1 remains closed, valve 2 opens,
the gas escapes and the pressure between valve 1 and valve 2 reduces,
valve 2 closes again,
both valves remain closed for 10 seconds.
If the pressure increases to above the value set during these 10 seconds, valve 1 is
leaking. The combustion manager initiates a controlled shutdown.
2. Test phase (function sequence for valve proving valve 2):
Valve 1 opens, valve 2 remains closed,
pressure between valve 1 and valve 2 increases,
valve 1 closes again,
both valves remain closed for 10 seconds.
If the pressure decreases to below the value set during these 10 seconds, valve 2
is leaking. The combustion manager initiates a controlled shutdown.

3s 10 s 3s 10 s 1 2
1 V1 V2
2
3
4
5 80 81 82 83 P P 4

1 Valve 1
2 Valve 2
3 Pressure between valve 1 and valve 2
4 Valve proving gas pressure switch
5 Operating phases

3.1.4 Variable speed drive

Via an analogue output, the W-FM controls the frequency converter of the fan mo-
tor and matches the speed to the burner capacity. This reduces electrical con-
sumption.
The speed and the rotation direction are monitored by an inductive proximity switch
and an asymmetrical transmitter disc.

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.1.5 Calculation
A calculation can be triggered in modulating commissioning, if P1 and P9 are pro-
grammed. During a calculation, a straight line is generated from the operating point
displayed to P1 or P9. The values on the straight are adopted as the new operating
points.
Initiate a calculation after P9: Press and hold [+] key for 3 … 5 seconds.
Initiate a calculation after P1: Press and hold [–] key for 3 … 5 seconds.
If during commissioning only P1 and P9 are programmed, the combustion manager
initiates an automatic calculation when exiting P1 and calculates P2 to P8.

1 2

P1 P2 P3 P4 P5 P6 P7 P8 P9 P1 P2 P3 P4 P5 P6 P7 P8 P9

1 Automatic calculation
2 Calculation from P5 to P9

3.1.6 Data backup

In the ABE, the settings of the combustion manager can be saved via para-
meter 050 (Backup). If the unit needs to be replaced, or if the parameters have
unintentionally been altered, the data can be transferred back to the combustion
manager.
Data transfer (Restore) from ABE to the combustion manager is only possible if the
burner data is identical [ch. 5.3].

Soot and CO formation because no combustion analysis has been carried

out.
At heat demand, the burner starts automatically approx. 30 seconds after the data
WARNING transfer (Restore).
Directly following the data transfer (Restore):
Check sequence of operation.
Carry out a combustion analysis at all load point.

Only in conjunction with frequency converter

Following data transfer (Restore) a speed standardisation with subsequent adjust-
ment must be carried out.

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.1.7 Referencing the actuator

In operating phase Ph10 (Home Run) the combustion manager references the
actuators, whereby the actuator drives over a reference marker. The actuator then
drives back and determines the inner edge of the reference marker. All settings are
referenced to this position.
The combustion manager references the fuel actuators to the reference
marker OPEN and the air actuator to the reference marker CLOSED. The setting
range of the air damper shaft is limited mechanically, therefore the air actuator can-
not drive to reference marker OPEN.
If the actuators have been mixed up, a reference fault is identified (fault code 85).

0° 1
-8°
2
-6°

90°
108°
112°
4
3

1 Reference range CLOSED

2 Reference marker CLOSED (air actuator)
3 Reference range OPEN
4 Reference marker OPEN (fuel actuator)

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.1.8 Program sequence

3.1.8.1 Operating phase

Ph00 Lockout phase
Ph02 Safety phase
Ph10 Home run
Ph12 Standby
Ph22 Fan / safety valve ON
Ph24 Pre-purge position
Ph30 Pre-purge
Ph36 Ignition position
Ph38 Pre-ignition
Ph39 Test low gas pressure switch (fuel valve 1 opens, only with Gas)
Ph40 Fuel release
Ph42 Ignition OFF
Ph44 Flame Signal
Ph50 Flame stabilisation (only with Gas with pilot ignition)
Ph52 Ignition pilot valve OFF (only with Gas with pilot ignition)
Ph60 Operating setting 1
Ph62 Operating setting 2
Ph70 Post burn time
Ph72 Post-purge position
Ph74 Post-purge
Ph78 Post-purge
Ph80 Venting valve train (only during valve proving)
Ph81 Test without pressure (only during valve proving)
Ph82 Fill valve train (only during valve proving)
Ph83 Test with operating pressure (only during valve proving)
Ph90 Low gas waiting time

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.1.8.2 Gas direct ignition

1 00 02 10 12 22 24 30 36 38 39 40 42 44 60 62 70 72 74 78 80 81 82 83 90

2 X3-03:1, X3-04:1
3 X5-03:1
4 X10-05:2
5 X3-02:1
6 X5-01:2
7 X5-02:2
8 X9-04:2

9 X3-05:1
0 X4-02:3
q X6-03:3
w X8-02:1
e X7-01:3

Signal at input / output actuated

No signal on input
Input without influence
1 Operating phases
2 Safety circuit
3 Heat demand controller
4 Flame Signal
5 Air pressure switch
6 Minimum pressure switch
7 Max. pressure switch
8 Valve proving pressure switch
9 Fan motor
0 Ignition unit
q Safety valve
w Fuel valve 1
e Fuel valve 2

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.1.8.3 Gas with ignition pilot valve

1 00 02 10 12 22 24 30 36 38 40 42 44 50 52 60 62 70 72 74 78 80 81 82 83 90

2 X3-03:1, X3-04:1
3 X5-03:1
4 X10-05:2
5 X3-02:1
6 X5-01:2
7 X5-02:2
8 X9-04:2

9 X3-05:1
0 X4-02:3
q X6-03:3
w X8-02:1
e X7-01:3
r X7-02:3

Signal at input / output actuated

No signal on input
Input without influence
1 Operating phases
2 Safety circuit
3 Heat demand controller
4 Flame Signal
5 Air pressure switch
6 Minimum pressure switch
7 Max. pressure switch
8 Valve proving pressure switch
9 Fan motor
0 Ignition unit
q Safety valve
w Fuel valve 1
e Fuel valve 2
r Ignition pilot valve

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.1.8.4 Fuel oil EL modulating and multi-stage, heavy oil multi-

stage
1 00 02 10 12 22 24 30 36 38 40 42 44 60 62 70 72 74 78

2 X3-03:1, X3-04:1
3 X5-03:1
4 X10-05
5 X3-02:1
6 X5-01:2
7 X5-02:2

8 X3-05:1
9 X4-02:3 (1

0 X6-03:3
q X8-02:1
w X7-01:3 (2

e X7-02:3

(1
Only with heavy oil and long pre-ignition phase (parameter 281).
(2
Only with operating mode 12 (oil modulating).
Signal on input / output activated
No signal on input
Input without influence
1 Operating phases
2 Safety circuit
3 Heat demand controller
4 Flame Signal
5 Air pressure switch
6 Minimum pressure switch
7 Max. pressure switch
8 Fan motor
9 Ignition unit
0 Safety valve
q Fuel valve 1
w Fuel valve 2
e Fuel valve 3

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.1.8.5 Medium and heavy oil modulating

1 00 02 10 12 22 24 30 36 38 40 42 44 60 62 70 72 74 78

2 X3-04:1
3 X5-03:1
4 X10-05
5 X3-02:1
6 X5-01:2
7 X5-02:2
8 X9-04:2 (1

9 X3-05:1
0 X4-02:2
q X6-03:2
w X8-02:1
e X7-01:2
r X7-02:2

(1
Only for evaluation in operating phase PH38 … PH62 (para-
meter 286).
Signal on input / output activated
No signal on input
Input without influence
1 Operating phases
2 Safety circuit
3 Heat demand controller
4 Flame Signal
5 Air pressure switch
6 Minimum pressure switch
7 Max. pressure switch
8 Heavy oil immediate start
9 Fan motor
0 Ignition unit
q Safety valve
w Fuel valve 1
e Fuel valve 2
r Fuel valve 3

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.2 Inputs

3.2.1 Voltage supply

1 The voltage supply is connected to inputs X3-04:3-5.
L 2 The mains frequency is set in parameter 125.
X3-04

PE 3 PE
N 4 N
L 5 L

3.2.2 Safety circuit

1 In the diagnostic code, the inputs X3-03:1/2 and X3-04:1/2 are combined as
L 2 safety circuit. If one of the inputs is open the W-FM carries out at least one safety
X3-04

PE 3 shutdown. If the repetition value is exceeded an open input leads to lockout.

N 4 The repetition value can be set in parameter 215.
L 5
At input X3-04:1/2 all external components of the safety circuit are switched in se-
1 quence, these include:
X3-03

L 2 Emergency-Off switch
Safety time limiter (STL)
Low water safety interlock, etc.
The burner flange limit switch is connected to input X3-03:1/2.

3.2.3 Reset
(1 (2
1 A reset button can be connected to input X8-04:1. Pressing this button in lockout
X8-04

RESET

OPERATION 2 for 1 … 6 seconds will reset the combustion manager. Pressing the button for a
1 longer or shorter period will be ignored by the combustion manager and therefore
L 2 has no effect.
X3-04

PE 3 PE
N 4 N With lockout function(1
L 5 L
If the push button is also required for manual lockout, it must be connected to
MOTOR 1 mains input X3-04:5 (L). If the combustion manager is in an operating phase,
X3-05

ALARM 2 pressing the push button for 1 to 6 seconds will initiate a manual lockout.
MOTOR CONT 3
Without lockout function(2
If the push button is not required to carry out manual lockout it must be connected
to alarm output X3-05:2.

3.2.4 Air pressure switch

P The closing contact of the air pressure switch is connected input X3-02. If the sig-
1
X3-02

nal is missing once the fan has started, the combustion manager initiates a lockout.
L 2
The air pressure switch must have been deactivated, contact open, prior to the fan
starting.

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.2.5 Minimum pressure switch

PE 1 P
The closing contact of the min. pressure switch is connected to input X5-01.
X5-01

min 2 For burners without min. oil pressure switch, a bridge has to be connected to ter-
L 3 minal 2 and terminal 3.

Low gas pressure switch

In gas operation, the combustion manager expects a signal at input X5-01:2 from
operating phase Ph22 . If the pressure drops below the value set, the pressure
switch contact opens and the combustion manager starts the low gas programme
[ch. 3.1.2].

Minimum oil pressure switch

In oil operation, the combustion manager expects a signal at input X5-01:2 from
operating phase Ph38 or operating phase Ph40 (depending on para-
meter 276). If the pressure drops below the value set, the pressure switch contact
opens and the combustion manager initiates a lockout. Lockout occurs in operating
phase Ph38 (pre-ignition) after a delay of 30 seconds. In all subsequent phases,
lockout occurs immediately.

3.2.6 Max. pressure switch

PE 1 The opening contact of the max. pressure switch is connected to input X5-02.
X5-02

P
min 2 For burners without max. oil pressure switch, a bridge has to be connected to ter-
L 3 minal 2 and terminal 3.

High gas pressure switch

The combustion manager expects a signal at input X5-02:2 from operating
phase Ph40. If the value set at the pressure switch is exceeded, the pressure
switch contact opens and the combustion manager initiates a lockout.

Maximum oil pressure switch

The combustion manager expects a signal at input X5-02:2 from operating
phase Ph22 . If the value set at the pressure switch is exceeded, the pressure
switch contact opens and the combustion manager initiates a lockout. Lockout oc-
curs in operating phase Ph22 (fan ON) after a delay of 30 seconds. In all sub-
sequent phases, lockout occurs immediately.

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 Installation and operating instruction
Combustion Manager W-FM 50
3 Product description

3.2.7 Valve proving gas pressure switch

PE 1 The opening contact of the valve proving gas pressure switch is connected to in-
X9-04

P
min 2 put X9-04. Input X9-04 is only activated during valve proving [ch. 3.1.3]. The time
L 3 of valve proving can be set in parameter 241 .
If the pressure set is not achieved in operating phase Ph81 (test without pres-
sure), the contact closes.
If the pressure set is exceeded in operating phase Ph83 (test with operating
pressure), the contact opens.

3.2.8 Heavy oil immediate start

PE 1 The input is only activates for the return flow temperature sensor on heavy oil burn-
X9-04

min 2 ers. The release contact of the return flow temperature sensor is connected to in-
L 3 put X9-04.
In modulating heavy oil operation, the combustion manager carries out a nozzle cir-
culation for maximum 45 seconds. If the signal is present at X9-04 before this time
has elapsed, the nozzle circulation is shortened accordingly. If the signal is missing
after this time has elapsed, the combustion manager initiates a home run with sub-
sequent repetition.
During operation, the signal is monitored according to the setting of para-
meter 286.

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3 Product description

3.2.9 Flame sensor

If the flame signal in operating phase Ph44 does not correspond to the value re-
quired, the combustion manager initiates safety shutdown with restart.
If the flame signal during operation does not maintain the required value, the com-
bustion manager initiates a controlled shutdown with restart. Two controlled shut-
downs in sequence lead to lockout.
A flame signal at heat demand (operating phase Ph12) leads to start prevention.
A flame signal during pre-purge (operating phase Ph30 … Ph36) or post-purge
(operating phase Ph78) leads to lockout after one repetition and repeated occur-
rence.
Parameter 954 shows the current flame signal as a percentage value.

QRA…
BR
The flame sensor QRA… (UV cell) is connected to input X10-06.
X10-06

QRA 1 +
BU
QRA 2 Flame signal
Parameter 954
Response limit extraneous light greater than 18 %
Operation min 24 %

Ionisation electrode
PE 1 The ionisation electrode is connected to input X10-05:2.
ION 2
X10-05

Flame signal
QRB/C 3 Parameter 954
QRB/C-N 4
L 5 Sensor current min.: 4 μA approx. 30 %
Sensor current max.: 16 … 40 μA 100 %

QRB…
PE 1 The flame sensor QRB… (photo resistor) is connected to input X10-05:3/4.
ION 2
X10-05

Flame signal
QRB/C 3 Parameter 954
QRB/C-N 4
L 5 Response limit extraneous light (resistance less than approx. 10 %
400 kΩ)
Operation (resistance less than 230 kΩ) approx. 16 %
Short circuit identification (resistance less than –
0.5 kΩ)

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3 Product description

3.2.10 Load controller analogue input

ON/OFF 1 The contact for heat demand is connected to input X5-03:1 (burner ON/OFF).
X5-03

2 °C
The analogue load signal is connected to terminals X64:1 (4 … 20 mA) and
3

+
X64:2 (GND). A signal of less than 3 mA deactivates the analogue input and the
L 4 load pre-setting at input X5-03:2/3 has priority (parameter 942). If no load con-
-
troller is connected to input X5-03:2/3, the combustion manager remains at the
4...20 1 current rating until heat demand is interrupted.
GND 2
X64

3
4
5

Modulating operation with load controller

In modulating operation, parameter 123 determines the minimum correcting ele-
ment step.
Signal on X64:1/2 Load W-FM
3 … 4 mA 20 %
20 mA 100 %

Multi-stage operation (fuel oil only)

In multi-stage operation a hysteresis of 1 mA exists between the operating points,
which eliminates unnecessary load changes.

Two stage:
Signal on X64:1/2 Load W-FM
3 … 5 … 12 mA Stage 1
13 … 15 … 20 mA Stage 2

Three stage:
Signal on X64:1/2 Load W-FM
3 … 5 … 7 mA Stage 1
8 … 10 … 12 mA Stage 2
13 … 15 … 20 mA Stage 3

3.2.11 Load controller building management

ON/OFF 1 A BUS interface for building management can be connected to input COM X92:
Modbus: Bus-Interface Modbus OCI412.10 (Order No.: 660 285),
X5-03

2
3 eBUS: Adapter MPA eBUS (Order No.: 743 090).
L 4 To ensure that load pre-setting is carried out by the building management system,
input X5-03:1 (burner ON/OFF) must be connected to voltage output X5-03:4 for
COM
X92

Interface
burner start.
The settings required for Bus communication are set in parameters 141 to 148.

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3 Product description

3.2.12 Load controller via contacts

The contact for heat demand is connected to input X5-03:1 (burner ON/OFF).
The load control distinguishes between multi-stage and modulating operation. The
operating mode is set in parameter 201 .

Modulating operation with load controller

ON/OFF 1 If input X5-03:2 (CLOSED) is activated, the burner capacity reduces.
If input X5-03:3 (OPEN) is activated, the burner capacity increases.
X5-03

2 °C

3 If none of the two inputs is activated, the burner capacity remains unchanged.
L 4

Operating mode sliding two stage with thermostat

ON/OFF 1 If thermostats or pressure regulators are connected to inputs X5-03, the modulat-
P

ing fuel can only be operated in sliding two stage operation.

X5-03

2
3 At heat demand input X5-03:2 (CLOSED) is activated and the burner drives to par-
P

L 4 tial load. If the temperature drops below the value set, input X5-03:3 (OPEN) is ac-
tivated and the burner drives to full load. If a signal is applied to input X5-03:3, in-
ON/OFF 1 P P
put X5-03:2 is ignored.
X5-03

2 P

3 P P

L 4

Multi-stage operation (fuel oil only)

ON/OFF 1 Two and three stage:
X5-03

2 °C Input Operating mode

3
L 4
two stage three stage
X5-03:1 Stage 1 Stage 1
X5-03:2 Stage 1 Stage 2
X5-03:3 Stage 2 Stage 3
If input X5-03:3 is activated during three stage operation, the burner drives to
stage 3, the signal from stage 2 is no longer relevant.
ON/OFF 1 Low impact start:
P
X5-03

2 At heat demand and with the bridge between terminal 1 and 2 the burner ignites in
3 P stage 1 and then automatically drives to stage 2. If input X5-03:3 is also activated
L 4 the burner drives to stage 3.
Change-over release:
ON/OFF 1 P
A bridge connects terminals 2 and 3. At heat demand the burner drives to stage 1.
X5-03

2
3 If inputs X5-03:2/3 are then activated simultaneously the burner drives via stage 2
L 4
P
to stage 3.

3.2.13 Fuel Meter

1 It is possible to connect a fuel meter with Reed contact to input X75. A prerequisite
X75

2 for this is that no frequency inverter is connected and activated. The meter pulses
per unit volume must be set in parameter 128 . The impulse frequency must not
exceed 300 Hz.

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3 Product description

3.3 Outputs

3.3.1 Alarm
MOTOR 1 A mains voltage signal is given at alarm output X3-05:2 in lockout (operating phase
X3-05

ALARM 2 Ph00).
MOTOR CONT 3 In addition, start prevention can also be signaled. To do this, parameter 210
should be set to 1.

3.3.2 Motor
MOTOR 1 Normal operation
X3-05

ALARM 2 M
The fan motor is connected to output X3-05:1 via contactor or star delta switching.
MOTOR CONT 3 L N
Continuous operation
The fan motor is connected to output X3-05:3 via contactor or star delta switching.
MOTOR 1 If an air pressure switch is fitted, continuous running fan is only possible via pres-
X3-05

ALARM 2 sure switch relief. To do this, a vent valve has to be fitted to the air pressure switch
MOTOR CONT 3 and connected to output X3-05:1.
M

L N

3.3.3 Ignition
PE 1 The ignition unit is connected to output X4-02.
X4-02

N 2
L 3 Ignition behaviour Gas
Pre-ignition in operating phase Ph38 can be adjusted in parameter 226 .

Ignition behaviour Oil

In parameter 281 ,the switch-on point of ignition (operating phase Ph22 or
Ph38) is determined.
Pre-ignition in operating phase Ph38 can be adjusted in parameter 266 .

3.3.4 Frequency converter

24 V 1 The frequency converter and the speed sensor are connected at output X74.
2
X74

0...10 V 3
4
Frequency converter
10 V 5 Terminal Function
X74:1 24 V input; supply from frequency converter
X74:2 Signal acquisition
X74:3 Speed setpoint signal (parameter 645)

Speed measurement
Terminal Function
X74:4 Speed return signal (input actual speed)
X74:5 10 V; supplied by combustion manager

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3.3.5 Analogue output

24 V 1 Instead of the frequency converter, a load dependent analogue signal can be emit-
2 ted at output X74:3. Prerequisite is an external 24 V DC voltage source at in-
X74

0...10 V 3 put X74:1/2.
4 The values given relate to an analogue signal of 0 … 10 V, if a signal of 2 … 10 V
10 V 5 or 0/2 … 10 V is set in parameter 645 the voltages listed will change.
Conversion: (original value x 0.8) + 2 =new value

Modulating operation
Rating Curve point Analogue signal
Off – 0V
Ignition load P0 1V
Partial load (20 %) P1 2V
Full load (100 %) P9 10 V

Two stage operation

Rating Curve point Analogue signal
Off – 0V
Stage 1 P1 5V
Stage 2 P2 10 V

Three stage operation

Rating Curve point Analogue signal
Off – 0V
Stage 1 P1 3V
Stage 2 P2 5V
Stage 3 P3 10 V

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3 Product description

3.4 Technical data

3.4.1 Electrical data

Combustion Manager
Mains voltage / Mains frequency 230 V / 50 … 60 Hz
Consumption max 30 W
Internal unit fuse T6.3H, IEC 127-2/5
External fuse max 16 AB
Type of protection IP 00

Display and operating unit (ABE)

Mains voltage DC 5 V
Consumption max 50 mW
Type of protection (front) IP54 to IEC 529
Type of protection (rear) IP00 to IEC 529
Protection class II to DIN EN 60 730-1

Actuator
STE 50 1.2 Nm STE 50 3 Nm
Mains voltage DC/AC 24 V / DC/AC 24 V /
50 … 60 HZ 50 … 60 HZ
Consumption max 7.5 W max 10 W
Torque 1.2 Nm 3 Nm
Setting time 5 s / 90° 4 s / 90°
Type of protection IP 54 IP 54
Protection class II II

3.4.2 Ambient conditions

Temperature in operation –20 … +60 °C
Temperature during transport / storage –20 … +60 °C
relative humidity max 95 %, no dew point

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3 Product description

3.4.3 Dimensions

Combustion manager

230 mm

60 mm 217 mm

135 mm

122 mm
Display and operating unit (ABE)
Recess dimension: 127 x 91 mm ± 0.5 mm

17 mm 96 mm

18 mm 90,6 mm

S
126,4 mm

P
132 mm

info
V h min s %
VSD esc

F A - +

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4 Installation

4 Installation

4.1 Electrical connection

Risk of electric shock
Working on the device when voltage is applied can lead to electric shock.
Isolate the device from the power supply prior to starting any work.
DANGER Safeguard against accidental restart.

Electric shock despite disconnection from the voltage supply

It is possible that electrical components on burners with frequency converters con-
tinue to carry voltage and cause electric shock even after the voltage supply has
WARNING been disconnected.
Wait approx. 5 minutes before commencing work.
Electric voltage has dissipated.

The electrical connection must only be carried out by qualified electricians. Ob-
serve local regulations.

Connect combustion manager

Use cable entry grommets on the housing.
Connect wiring to wiring diagram enclosed.
Control circuits, which are taken directly via a 16 AB fuse from a 3 phase or
single phase alternating current supply, must only be connected between a phase
conductor and earth potential neutral conductor.
On mains supply, which does not have a neutral, the control voltage must be sup-
plied via an isolating transformer. The pole of the transformer, which is to be used
as the neutral conductor, must be earthed.
Phase L must not be mixed up with the neutral conductor N. Contact protection will
otherwise no longer be given. Malfunctions, which endanger operational safety
could occur.
The cable cross section of the voltage supply must be suitable for the nominal cur-
rent of the external fuse (maximum 16 AB). All other cable connections must be
suitable for the relevant internal unit fuse (T6.3H).
Earthing and neutral conductor must conform to local regulations.
The following applies for cable length:
Display and operating unit, load controller, safety interlock circuit, burner flange,
reset key - maximum 20 m (100 pF/m).
BCI interface maximum 20 m (100 pF/m).

Connecting the burner motor

The motor must be protected against thermal overload and short circuit. Weishaupt
recommend the use of a motor protection switch.
Open terminal box on motor.
Connect voltage supply to wiring diagram enclosed, observe motor rotation.

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4 Installation

Variable speed drive (optional)

If the frequency converter is located on the motor, the cable to the frequency con-
verter is not screened.
If the frequency converter is separate the control line and the motor connection
must be screened.
Apply screen to the screen clamp on frequency converter.
Use screen cable glands (metal) on the burner.

Connect gas valve train

Observe wiring diagram supplied.
Connect double gas valve (plug K32).
Solenoid coil on W-MF or DMV
Actuator on VGD.
Connect limit switch for valve lift monitoring (plug S33 / S35), only with VGD.
Connect ignition gas valve (plug K31).
Connect low gas pressure switch (plug B31).
Connect valve proving gas pressure switch (plug B32).
If required, connect high gas pressure switch (plug B33).

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5 Operation

5 Operation

5.1 Operating interface

5.1.1 Operating panel

Display and operating unit (ABE)

S 1
P
i

V h min s % info

VSD esc

F A - +
5 2

4 3

1 [Enter] back-up of value changes;

entry to parameter and values
[info] call up information
press for approx. 3 seconds: Info level
press for approx. 5 seconds: Service level
2 [+] navigation through parameter structure;
3 [–] changing values
2 and 3 [+] and [–] press simultaneously: return/cancel
4 [A] Air selects the damper position
5 [F] Fuel selects the fuel supply
4 and 5 [F] and [A] press simultaneously: selects the frequency
converter (optional)

OFF function
Press [ENTER] and any other key simultaneously.
Immediate lockout.

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5 Operation

5.1.2 Display
The black cursor in the display shows the status of the inputs and outputs, the unit
of values and the active level.

1 2 3 4 5 6

S
u P
z i
t
V h min s %

r e w q 0 9 8 7

1 Heat demand by the boiler control (start)

2 Burner motor
3 Ignition
4 Fuel valves
5 Flame signal on
6 Flame failure or lockout
7 Degree of angle setting
8 Percentage value
9 Second
0 Minute
q Hour (together with volume = V/h)
w Volume (m3, l, ft3, gal)
e Actuator OPEN
r Actuator CLOSED
t Service level
z Info level
u Parameter level (engineer level)

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5 Operation

Display OFF
The parameter setting is missing, incomplete or has been de-
leted.
No heat demand from controller (input X5-03:1).

Safety circuit not closed at heat demand (input X3-03:1/2 and

X3-04:1/2).

Display Ph
The combustion manager is in an operating phase and waits for
signals or activates outputs depending on the program se-
quence.
The combustion manager is in an operating phase and shows
the remaining run time programmed (example: pre-purge).

Display Op
The combustion manager is in modulating operation and shows
the current load in percent.
The combustion manager is in multi-stage operation and shows
the current fuel stage.
When the fuel stage is changed, the additional display on or
of indicates the switching of the relevant fuel valve.

Display flashes
Manual load is activated. The combustion manager is in manual
load default.
Deactivate manual load:
Press and hold [esc] key for 5 seconds.

Fault display
During a fault condition, the display alternately shows the error code C and dia-
gnostic code D [ch. 8.3].
The combustion manager is in lockout.
Once the fault has been rectified, the combustion manager has
to be reset [ch. 8.1.4].

The combustion manager initiates a safety shutdown.

The burner restarts automatically once the fault condition has
been rectified.

The combustion manager shows an occurrence, which does not

lead to a shutdown.

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5 Operation

5.2 Displaying and adjusting parameters

Password level (engineer level) Info-/Service level
call up level
Press [F] and [A] keys simul- The Info or Service level can only
taneously and then enter the be called up from the standard
password [ch. 5.2.1]. display.
Press [Enter].
For Info level 1 … 3 s
For Service level 3 … 5 s

Next parameter
Press [+] key. Press [+] key.
– or –
Briefly press [Enter].

Previous parameter
Press [–] key. Press [–] key.

One level lower

Press [Enter]. Press [Enter] 1 … 3 s.

One level higher

Press [esc]. Press [Enter] 3 … 5 s.
– or –
Briefly press [esc] key.

Change value
Press [+] or [–] key. not possible

Save value
Press [Enter]. not possible

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5.2.1 Password

Enter password
Press [F] and [A] simultaneously for approx. 2 seconds.
The display shows CodE.
Enter the first digit using [+] or [–] and confirm with [ENTER].
Repeat procedure until the password has been entered.
Exit password entry using [ENTER].
The display shows PArA (parameter level) for a short time and then changes
over to 400: SEt (setup).

S
P
i

S S
V h min s %P P
i i
S
V h min s % V h min s %P
i

V h min s %

Deactivating password
If no key is activated for 30 minutes, the combustion manager automatically deac-
tivates the password and blocks the level.
In the password level, the password can be aborted early:
Press [esc] key until the display shows CLr CodE.
Let go of the [esc] key.
The combustion manager blocks the password level and changes to the operat-
ing display.

S
P
i

V h min s %

S S
P P 3s
i i

V h min s % V h min s %

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5 Operation

5.2.2 Manual load

If a signal is applied to input X5-03:1 (burner ON), each load setting within the load
limit can be selected manually. If manual load is activated, the current load flashing
in the operating display. Manual load can be activated using a key combination or
parameter 121 . If manual load is set via parameter 121 additional functions are
available.
Load default Function
Parameter 121 Key combination
---- Manual load deactivated not possible
0.0 … 19.9 Manual OFF, remains active even after not possible
fuel changeover.
P0 Initiate ignition position (multi stage op- not possible
eration only)
20.0 … 100.0 Initiate load setting within the load limits. Initiate load setting within the load limits.
P1 … P3 Values outside of the load limits can be Only values within the load limits can be
adjusted, but not initiated. If the load lim- adjusted.
its are extended during active manual
load, the burner reacts accordingly.
For the duration of commissioning (400 Set), manual load is ignored.
With the exception of Manual OFF, manual load is deactivated during fuel change-
over.

Manual load via key combination

Activate manual load:
Press and hold [F] key.
The display shows LoAd.
Set manual load using [+] or [-] key.
The manual load set flashes.
Manual load burner OFF:
Drive to minimum load position and release [F] and [-] keys.
Press [F] and [-] keys again.
Deactivate manual load:
Press and hold [esc] key for approx. 5 seconds.

S S
P P
i i

V h min s % V h min s %

S S
P P
i i

V h min s %
5s V h min s %

Manual load via parameter 121

Enter password [ch. 5.2.1].
Select parameter 121 .
Press [Enter].
Set manual load using [+] or [-] key.
Press [Enter].
Manual load is initiated.

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5 Operation

5.3 Parameters

5.3.1 Password level

Internal parameter (000: Int)

Parameter Function
050 Data backup [ch. 3.1.6]
Transfer of data sets between W-FM and ABE with identical burner identification (parameter 113). If
the backup or restore is incorrect, a negative value is displayed. The cause of the error is described in
error code 137 see.
Save from W-FM to ABE (Backup):
Press [Enter].
The display shows bAC_up.
Press [Enter].
Set 1 using [+] key and confirm with [Enter].
Following successful execution the display is reset to 0.
Save from ABE to W-FM (Restore):
Press [Enter].
The display shows bAC_up.
Press [+] key.
The display shows rEStorE.
Set 1 using [+] key and confirm with [Enter].
Following successful execution the display is reset to 0.
055 Burner identification of data backup (read only).
056 ASN excerpts of data backup (read only).
057 Software version when creating backup (read only).

General parameters (100: PArA)

Parameter Function
102 Date of manufacture DD.MM.YY
103 Production number
104 Parameter default setting: Customer code
105 Parameter default setting: Version
107 Software version
108 Software variation
111 ASN excerpt for comparison with data backup (parameter 056)
113 Burner identification: Identical to the burner serial number (name plate). The burner identification has to
be reset if the combustion manager has been replaced.
121 Manual load
123 Minimum setting step in percent
Only load changes, which exceed the value set are initiated, this avoids unnecessary setting move-
ments in modulating operation.
123.00: Load default from building management
123.01: Analogue load controller on X64
123.02: Load controller contact on X5-03

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Parameter Function
124 Flame failure test (TÜV test)
The flame failure test can only be carried out in operating setting 1 (operating phase Ph60). The flame
failure test closes the fuel valves and calculates the time up to flame failure. The calculated time is dis-
played in the diagnostic code in multiples of 0.2 seconds (example Loc.D: 8 = 1.6 seconds).
For the flame failure test the burner drives to the load defined under parameter 133 . If no load is
defined in parameter 133 , the flame failure test is carried out at the current load.
Press [Enter].
Set value 1 using [+] key and confirm with [Enter].
Following successful execution, the display alternately shows the error code Loc.c: 7 and dia-
gnostic code Loc.d: x.
125 Mains frequency
0: 50 Hz
1: 60 Hz
126 Display illumination
128 Fuel meter
The value must correspond to the number of impulses per unit of volume (l, m³) of the fuel meter. If the
value is set to 0 , the fuel meter stops.
130 Delete error history [ch. 8.1]
133 Load for flame failure test
141 Operating mode building management
0: OFF
1: Modbus, the combustion manager operates as Slave, the RTU transfer mode is used (Remote Ter-
minal Unit)
2: eBUS
142 Recurrence time if communication is interrupted (setting range: 0 … 7200 s)
If communication to the building management system fails, the next load controller according to priority
will be activated once this time has elapsed. If no other load controller is connected, the burner re-
mains at the current load or it drives to the load defined in parameter 148.
Priority 1: Load controller building management
Priority 2: Load controller on analogue input  X64
Priority 3: Load controller on input X5-03
143 Unit address of combustion manager as eBUS participant
1: Address 03
2: Address 13
3: Address 33
4: Address 73
5: Address F3
6: Address 1F
7: Address 3F
8: Address 7F
144 Send cycle in seconds for the eBUS 05 and 09
145 Unit address of combustion manager as Modbus participant
146 Baud rate Modbus
The Baud rate of the combustion manager and the building management system must be identical.
0: 9600
1: 19200
147 Parity Modbus
The parity of the combustion manager and the building management system must be identical.
0: no Parity bit
1: odd Parity bit
2: even Parity bit

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Parameter Function
148 Replacement load (setting range: 0 … 100 %)
Load default for communication failure with building management system.
–––: no replacement load
0 … 19.9: burner OFF
161 Number of lockouts
162 Operating hours since last reset
Reset:
Press [Enter].
Press [–] key.
The display shows 0, operating hours have been reset.
163 Total operating hours (voltage applied to combustion manager)
164 Start-ups since last reset
Reset:
Press [Enter].
Press [–] key.
The display shows 0, start-ups have been reset.
166 Total start-ups
167 Fuel volume since last reset
Reset:
Press [Enter].
Press [–] key.
The display shows 0, the fuel volume has been reset.
190 Position of actuators at lockout
0: Standby position
1: Post-purge position
191 … 193 not used
195 Repetition counter for heavy oil immediate start
Number of heavy oil start attempts with missing signal at input X9-04 until lockout.

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Burner control (200: PAr0)

Parameter Function
201 Operating mode
––: not defined (delete curves)
1: Gas direct ignition
2: Gas pilot ignition
5: fuel oil EL, MS and S two stage Z
6: fuel oil EL, MS and S three stage T
12: fuel oil EL modulating
23: fuel oil MS and S modulating
Other settings without function (3, 4, 7 … 11, 13 … 22 und 24 … 27).
204 not used
208 Program stop
0: deactivated
1: Pre-purge position (operating phase Ph24)
2: ignition position (operating phase Ph36)
3: interval time 1 (operating phase Ph44)
4: interval time 2 (operating phase Ph52)
210 Alarm at start prevention
Determines whether a signal is given at output X3-05:2 during start prevention.
0: no alarm (no signal at output X3-05:2)
1: Alarm (signal at output X3-05:2)
211 Fan run-up time (setting range: 2.0 … 60 s)
Time from fan start to start of actuators.
212 Switch off behaviour / max. time to partial load (setting range: 0.2 … 45 s.)
If heat demand is no longer present, the burner drives as far as possible to partial load in a predeter-
mined time and then switches off.
The burner takes approx. 32 seconds to drive from 100% load to 20% (partial load).
215 Repetition counter safety circuit (setting range: 1 … 16)
Number of safety shutdowns by the safety circuit before lockout occurs [ch. 3.2.2].
221 Flame sensor Gas
0: QRC
1: ionisation electrode/QRA
222 Pre-purge Gas
When using a valve proving system and two Class A fuel valves pre-purge following a controlled shut-
down can be omitted (to EN 676).
0: OFF
1: ON (pre-purge phase parameter 225)
223 Repetition counter low gas pressure switch (setting range: 1 … 16)
Number of safety shutdowns by the low gas pressure switch before lockout occurs [ch. 3.1.2].
225 Pre-purge time Gas in operating phase Ph30 (setting range: 20 … 3600 s)
Once the pre-purge positions have been reached, the combustion manager remains in Ph30 for the
duration of the time set.
226 Pre-ignition Gas (setting range: 0.2 … 3600 s)
Duration of pre-ignition time in operating phase Ph38.
230 Interval time 1 Gas
The interval time 1 in operating phase Ph44 acts as stabilisation time following flame formation.
232 Interval time 2 Gas
The interval time 2 in operating phase Ph52 acts as stabilisation time following flame formation.

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5 Operation

Parameter Function
233 Post burn time Gas (setting range: 0.2 … 60 s)
The combustion manager remains in operating phase Ph70 for the duration of the time set, the flame
sensor is ignored during this time.
234 Post-purge time Gas (setting range: 0.2 … 6480 s)
Once the post-purge position has been reached, the combustion manager remains in operating
phase Ph74 for the duration of the time set, the flame sensor is ignored during this time.
236 Low gas pressure switch input / installation position
0: OFF
1: Low gas pressure switch fitted upstream of valve 1 (factory setting)
2: Low gas pressure switch fitted between valve 1 and valve 2, valve proving via low gas pressure
switch
237 High gas pressure switch
If a high gas pressure switch is fitted, set parameter to 1.
0: OFF
1: high gas pressure switch
2: valve closing contact
239 With forced intermittent activated, a controlled shutdown with subsequent restart is initiated after 23
hours and 45 minutes uninterrupted burner operation.
0: OFF
1: forced intermittent activated
241 Valve proving
In accordance with DIN EN 676 valve proving is not necessary if pre-purge is activated and the burner
rating is less than 1200 kW.
0: valve proving OFF (only with capacity < 1200 kW, parameter 222 must be set to 1: ON)
1: valve proving at stat-up
2: valve proving at shutdown (factory setting)
3: valve proving at stat-up and shutdown
248 Post-purge time 3 Gas (setting range: 0.2 … 6480 s)
The combustion manager remains in operating phase Ph78 for the duration of the time set except if a
new heat demand interrupts the post-purge time 3 in operating phase Ph78.
261 Flame sensor Oil
0: QRB
1: QRA
265 Pre-purge time Oil in operating phase Ph30 (setting range: 15 … 3600 s)
Once the pre-purge positions have been reached, the combustion manager remains in operating
phase Ph30 for the duration of the time set.
266 Pre-ignition time Oil (setting range: 0.6 … 3600 s)
Once the ignition positions have been reached, the combustion manager remains in operating phase
Ph38 for the duration of the time set.
270 Interval time 1 Oil
The interval time 1 in operating phase Ph44 acts as stabilisation time following flame formation.
272 not used
273 Post-burn time Oil (setting range: 0.2 … 60 s)
The combustion manager remains in operating phase Ph70 for the duration of the time set, the flame
sensor is ignored during this time.
274 Post-purge time Oil (setting range: 0.2 … 6480 s)
Once the post-purge position has been reached, the combustion manager remains in operating
phasePh74 for the duration of the time set, the flame sensor is ignored during this time.

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5 Operation

Parameter Function
276 Minimum oil pressure switch
0: OFF
1: active from operating phase Ph38
2: active from operating phase Ph40 with solenoid valve upstream of pressure switch (e.g. pump
with valve)
277 Max. oil pressure switch
If a max. oil pressure switch is fitted set parameter to 1.
0: OFF
1: oil pressure switch
2: valve closing contact
279 With forced intermittent activated, a controlled shutdown with subsequent restart is initiated after 23
hours and 45 minutes uninterrupted burner operation.
0: OFF
1: forced intermittent activated
281 Point of ignition Oil
0: ignition on in operating phase Ph38 (short pre-ignition)
1: ignition on in operating phase Ph22 (long pre-ignition at fan start)
284 Post-purge time 3 Oil (setting range: 0.2 … 6480 s)
The combustion manager remains in operating phase Ph78 for the duration of the time set except if a
new heat demand interrupts the post-purge time 3 in operating phase Ph78.
286 Evaluation of heavy oil immediate start
If the signal is missing during the operating phase set, the W-FM initiates a shutdown with a sub-
sequent restart (repetition). The number of repetitions can be set in parameter 195 .
0: signal only required in operating phase Ph38
1: signal required in operating phases PH38 … PH62
287 Maximum waiting time for signal for heavy oil immediate start in operating phase PH38 (setting
range: 1 … 45 s)

Commissioning parameter (400: SEt)

Parameter set 400 is used to adjust the fuel air compound regulation (see Ch. 6).

Compound (500: PArA)

Parameter Function
501 Special positions fuel actuator
501.00: standby position (is activated in operating phases Ph10, Ph12 and Ph00 )
501.01: Pre-purge position (is only activated in operating phase Ph24 )
501.02: Post-purge position (is activated in operating phase Ph72 )
502 Special position air actuator
502.00: standby position (is activated in operating phases Ph10, Ph12 and Ph00 )
502.01: Pre-purge position (is activated in operating phase Ph24 )
502.02: Post-purge position (is activated in operating phase Ph72 )
503 Special positions frequency converter
503.00: standby position (is activated in operating phases Ph10, Ph12 and Ph00 )
503.01: pre-purge position (is activated in operating phase Ph24 )
503.02: Post-purge position (is activated in operating phase Ph72 )
522 Drive up ramp (setting range: 5 … 20 s)
The ramp should be at least 20% slower than that of the frequency converter.
523 Drive up ramp (setting range: 5 … 20 s)
The ramp should be at least 20% slower than that of the frequency converter.

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 Installation and operating instruction
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5 Operation

Parameter Function
542 Activation of frequency converter
0: not activated
1: activated
544 Operating ramp modulating
Time for the actuators to drive from low load to high load.
Recommended factory setting: 32 s
545 Lower load limit (setting range: 20 … 100 %)
Defines the lower modulating limit (partial load). If no limit has been defined, the lower load limit in op-
eration is automatically set to 20 %.
– – – –: no load limit defined (20 %)
546 Upper load limit (setting limit: 20 … 100 %)
Defines the upper modulating limit (full load). If no limit has been defined, the upper load limit in opera-
tion is automatically set to 100 %.
– – – –: no load limit defined (100 %)

Actuators (600: ACtr)

Parameter Function
601 … 613 Configuration of actuators
606.00: fuel actuator
606.01: air actuator
641 Speed standardisation
During speed standardisation, a setpoint signal of 95 % (9.5 V) is sent to the frequency converter. The
speed achieved is saved as 100% value, which means that a reserve of 5% is available during opera-
tion. The maximum frequency at the frequency converter must therefore be 52.6 Hz. If the frequency
converter is fitted to the burner, the maximum frequency has been factory preset. If the frequency con-
verter is external, the maximum frequency has to be set to this value.
Starting standardisation:
Press [Enter].
Set value 1 using [+] key and confirm with [Enter].
The fan motor starts with the air damper open.
Following successful execution the display is reset to 0.
If a negative value appears (-X), the normalisation has failed.
The combustion values must be checked after every speed standardisation.
642 Standardised speed
During speed standardisation a 95% signal is signalled to the frequency converter and the speed
achieved is saved as the standard speed.
642.00: Standard speed saved from micro controller 1.
642.01: Standard speed saved from micro controller 2.
The speeds of the two micro controllers may vary by up to 1.5 %.
645 Analogue output X74
This output can be used to signal a load dependent analogue signal [ch. 3.3.5] or to activate a fre-
quency converter [ch. 3.3.4]. In conjunction with a frequency converter the voltage at output X74 and
and at setpoint input of the frequency converter must be set identically.
0: DC 0 … 10 V
1: DC 2 … 10 V
2: DC 0/2 … 10 V

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5 Operation

Parameter Function
652 Activation of the frequency converter with safety circuit open
0: no activation
1: frequency converter is activated with 0
653 Speed monitoring in standby, standby speed 0 %
0: no speed monitoring
1: speed monitoring activated

Fault history (700: HISt)

Parameter set 700 is used to localise and correct faults [ch. 8.2].

Process data (900: dAtA)

Parameter Function
903 Current capacity
903.00: Fuel
903.01: Air
922 Actuator step position
922.00: fuel actuator
922.01: air actuator
935 Absolute speed
Current actual speed (recorded by transmitter disc on motor)
936 Standardised speed
Current speed signal in percent.
942 Active load source (load controller)
The parameter shows the load source currently active. If more than one load source is available, the
combustion manager prioritises to the sequence listed below. The priority cannot be altered.
1: load by curve setting
2: manual load
3: load controller via building management
4: external load controller via analogue input X64 terminal 1 / terminal 2
5: external load controller via contacts X5-03 terminal 2 / terminal 3
947 Contact interrogation W-FM (bit coded output)
947.00: inputs
1: min. pressure switch
2: max. pressure switch
4: internal fuel selection
8: air pressure switch
16: load controller OPEN
32: load controller ON
64: load controller CLOSED
128: safety circuit
947.01: outputs
1: safety valve
2: ignition
4: fuel valve 1
8: fuel valve 2
16: fuel valve 3 / pilot valve
32: internal fuel selection 1
948 Contact return signal network meter

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 Installation and operating instruction
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5 Operation

Parameter Function
950 Relay nominal condition (Bit coded output)
1: alarm
2: safety valve
4: ignition
8: fuel valve 1
16: fuel valve 2
32: fuel valve 3 / pilot valve
951 Mains voltage (standardised)
Value displayed x factor = current voltage
Factor 230 V: 1.683
Factor 120 V: 0.843
954 Current flame signal in percent [ch. 3.2.9]
960 Current fuel throughput
961 Current operating phase [ch. 3.1.8]
981 Fault history: fault codes
982 Fault history: diagnostic codes
992 Fault flags

5.3.2 Info level

In the Info level, parameter values can be displayed but not altered.
Select parameter using [+] or [-] key.
Press [Enter] 1 … 3 s.
Parameter value appears.
Parameters Function
167 Fuel volume since last reset
162 Operating hours since last reset
164 Start-ups since last reset
163 Total operating hours (voltage applied to combustion manager)
166 Total start-ups
113 Burner identification: identical to the burner serial number (name plate)
107 Software version
108 Software variation
102 Date of manufacture DD.MM.YY
103 Production number
104 Parameter default setting: Customer code
105 Parameter default setting: Version
143 Unit address of combustion manager as eBUS participant

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5 Operation

5.3.3 Service level

In the service level, parameter values can be displayed but not altered.
Select parameter using [+] or [-] key.
Press [Enter] 1 … 3 s.
Parameter value appears.
Parameters Function
954 Current flame signal in percent [ch. 3.2.9]
960 Current fuel throughput
121 Manual load
922 Actuator step position
922.00: fuel actuator
922.01: air actuator
936 Standardised speed
Current speed signal in percent
161 Number of lockouts
701 FaultHistory [ch. 8.1.3]
…
725

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6 Commissioning

6 Commissioning

6.1 Prerequisite
Commissioning must only be carried out by qualified personnel.
Only correctly carried out commissioning ensures the operational safety.
Observe the prerequisites for commissioning in the installation and operating
manual of the burner. This manual contains detailed information about:
general installation regulations,
nozzle selection,
connecting measuring devices,
replacing filter inserts,
checking the gas connection pressure,
carrying out soundness test,
venting the gas valve train,
setting the gas pressure regulator,
pre-setting the pressure switch.

6.2 Adjusting the burner

In addition to this chapter, the information about adjustment in installation and oper-
ating manual of the burner should be observed. This manual contains detailed in-
formation about:
speeds (in in conjunction with frequency converter),
pump pressure,
flow and return pressure,
default settings,
mixing pressure.

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6 Commissioning

6.2.1 Adjusting gas side

Prerequisite
Open gas isolating valve.
Pressure in gas valve train increases.
Close isolating valve.
Switch on voltage supply.
The display shows either OFF UPr or OFF.

S S
P P
i i

V h min s % V h min s %

OFF UPr burner off and not programmed

OFF burner off

1. Enter password
Press [F] and [A] simultaneously for approx. 2 seconds.
The display shows CodE.
Enter the first digit using [+] or [–] and confirm with [ENTER].
Repeat procedure until the password has been entered.
Exit password entry using [ENTER].
The display shows PArA (parameter level) for a short time and then changes
over to 400: SEt (setup).

S
P
i

S S
V h min s %P P
i i
S
V h min s % V h min s %P
i

V h min s %

2. Switch on burner
Ensure there is a demand for heat.
A black dash appears below the S symbol (start).
A heat demand from the boiler controller is required for the duration of commission-
ing, that means signal on input X5-03:1.

S
P
i

V h min s %

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6 Commissioning

3. Start setup
Press [ENTER].
If the combustion manager has been pre-programmed, the display shows run 1.
Select type of setting (from step 9).
If the combustion manager has not been programmed, the display shows parameter
201 2.
Define parameters 201, 542 and 641 and set P0 (from step 4).
201: Operating mode
542: Activation of frequency converter
641: Speed standardisation

S
P

1 i

S V h min s %
P
i

V h min s % S
P
2 i

V h min s %

4. Set operating mode

The following steps must only be carried out if the combustion manager is not pro-
grammed. If the combustion manager has been pre-programmed, proceed with
step 9.

Press [ENTER].
The display shows only the parameter value.
Set operating mode using [+] or [–] keys and confirm with [Enter].
1: direct ignition
2: pilot ignition
Exit entry using [esc].
The display shows parameter 201 with the current operating mode.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

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6 Commissioning

5. Activate/deactivate frequency converter

Press [+] key.
The display shows parameter 542.
Press [Enter].
The display shows only the parameter value.
Activate or deactivate the frequency converter using [+] or [–] and confirm with
[ENTER].
0: without frequency converter
1: with frequency converter
Exit entry using [esc].
The display shows parameter 542 with the current setting.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

6. Carry out speed standardisation

Speed standardisation must only be carried out in conjunction with a frequency

converter.
If no frequency converter is fitted, skip speed standardisation 641 using the [+]
key.

Press [+] key.

The display shows parameter 641.
Press [ENTER].
Set value to 1 using the [+] and start speed standardisation by pressing
[ENTER].
Check rotation direction of burner motor
The fan motor starts with open air damper setting. Once standardisation is com-
plete, the display changes form 1 to 0.
Exit speed standardisation using [esc].
The standardised speed can be read in parameter 642.

S S S
P P P
i i i

S S
V h min s % P % P % m 3 m 3/h l l/h
i i

V h min s % V h min s %

S
P
i

V h min s %

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6 Commissioning

7. Preset ignition load point

Press [+] key.
The display shows the ignition load point P0.
press and hold [A] and using [+]/[–] set air damper setting 4.0 … 9.0.
Press and hold [F] and set gas butterfly valve setting 8.0 … 13.0° using [+]/[–].

Only in conjunction with frequency converter

The ignition speed must not be less than 70 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed using [+]/[–].

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

h min s %
S
P
i

V h min s %

8. Preset full load point

Press [+] key.
The display shows the full load point P9.
Press and hold [A] and using [+]/[–] set air damper setting from setting diagram.
Press and hold [F] and set gas butterfly valve setting 45.0 … 50.0° using [+]/[–].

Only in conjunction with frequency converter

Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % using
[+]/[–].

Press [+] key.
Exit pre-setting.
The display changes to run.

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S
P
i

V h min s %

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6 Commissioning

9. Select type of setting

The following can be selected as type of setting:
Adjustment with flame
Pre-setting without flame
Pre-setting without flame is only used, if the operating points are known, for ex-
ample if the combustion manager is exchanged.

Adjustment with flame 1

Press [Enter].
Check rotation direction of burner motor
The burner starts pre-purge Ph12 and stops in ignition position Ph36 without
flame formation.
The display shows the ignition load point P0.
Set mixing pressure in ignition position (from step 11).

Pre-setting without flame 2

Briefly press [esc] key.
The display shows the ignition load point P0.
The black dash below the S symbol disappears.
Pre-set operating points without flame (from step 10).

S S
P P
1 i i

S V h min s % S %
P P
i i

V h min s % S V h min s %
P
2 i

V h min s %

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6 Commissioning

10. Pre-set points without flame

This step must only be carried out, if the type of setting without flame has been se-
lected previously. The adjustment with flame (from step 11) is not replaced by this
process.
Press [+] key.
The display shows the operating point P1.
Press and hold [A] and pre-set air damper setting using [+]/[–].
Press and hold [F] and pre-set gas butterfly valve setting using [+]/[–].

Only in conjunction with frequency converter

Press and hold [A] and [F] (VSD) simultaneously and pre-set speed using [+]/
[–].

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

Press [+] key.

The display shows CALC. The combustion manager starts the calculation.
The display then shows the operating point P2.
Set position air damper setting [A] and gas butterfly valve [F], with optional fre-
quency converter also set speed [A] and [F] (VSD).
Using the [+] key select and pre-set points P3 to P9 in sequence.

S
P
i

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S S
P P
i i

V h min s % V h min s %

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6 Commissioning

Exit pre-setting using [esc].

The display shows 400 SEt.
Press [ENTER].
The display shows run.
Press [ENTER].
Check rotation direction of burner motor
The burner starts pre-purge and stops in ignition position without flame forma-
tion.
The display shows the ignition load point P0.

S
P
i

V h min s %

S
P
i

V h min s %

S
P
i

V h min s %

11. Check mixing pressure in ignition position

The mixing pressure in ignition position must be 0.5 … 2 mbar above the combus-
tion chamber pressure.
If necessary, adjust mixing pressure via air damper setting:

Only in conjunction with frequency converter

The ignition speed must not be less than 70 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed using [+]/[–].

S
P
i S
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

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6 Commissioning

12. Check gas valves

Press [+] key and ensure that the valves open and close correctly.
The burner attempts to ignite.
The low gas pressure switch reacts.
After the interruption, the display shows OFF UPr.
Open gas isolating valve.
Press [ENTER], until the burner starts again.
The display shows P0 again with the values set for mixing pressure in ignition
position.

13. Igniting the burner

Press [+] key.
The burner starts and stops in ignition position.
The display shows the following operating phases:
PH 38: Ignition ON
PH 40: Fuel valve
Ph 42: Ignition OFF
PH 44: Flame in ignition position

S
P S
i P S
i
P
V h % S
i
P
V h % S
i l
P
V h %
i
V h min %

V h min s %

14. Adjust setting pressure on pressure regulator

Check the setting pressure at the pressure regulator and if necessary adjust.

15. Check combustion

Determine combustion values at ignition position.
Set O2 content approx. 4 … 5 % above gas butterfly valve setting.

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6 Commissioning

16. Pre-set operating point P1

Press [+] key.
The display shows the operating point P1.
Pre-set gas throughput [F] and air quantity [A] whilst observing combustion val-
ues.
Operating point P1 must lie below the partial load required and within the capa-
city graph.

Only in conjunction with frequency converter

Select speed in operating point P1 as low as possible, but not less than 50 %.
Observe flame stability.
Slowly reduce speed using [F] and [A] (VSD), whilst opening air damper setting
alternately using the [A] key.

Press [+] key.

The display shows operating point P2.
If no other points have been defined, the combustion manager carries out a cal-
culation and calculates all missing points up to P9, the display briefly shows
CALC.

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P m
i

V h min s %

S
P
i S
P m l l/h
i
V h min s %

V h min s %

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6 Commissioning

17. Drive to full load

Using the [+] key, drive to the points in sequence up to P9.
Check combustion values at each point and if necessary correct via the gas but-
terfly valve setting [F].

S
P
i S
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S S
P P
i i

V h min s % V h min s %

18. Adjust full load

When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.

Only in conjunction with frequency converter

Select speed at full load as low as possible, but not less than 80 %. Observe flame
stability.

Calculate gas throughput (operating volume VB) required [ch. 6.4].

Set gas butterfly setting [F] in full load point to approx. 60 … 70°.
Adjust setting pressure at the pressure regulator until gas throughput (VB) is
achieved.
Check combustion values
Determine combustion limit and set excess air [ch. 6.3].
Determine gas throughput again.
If necessary adjust setting pressure at pressure regulator and reset excess air.

The setting pressure must not be altered once this work has been completed.

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

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6 Commissioning

19. Re-define point 1 (only for ZMI)

This step should only be carried out on burners in version ZMI. On burners of differ-
ent version, skip this step and proceed with step 20.

Drive to P1 using the [–] key.

Reduce gas butterfly valve setting [F] until minimum burner rating has been
achieved.
Check combustion values and if necessary adjust whilst observing the minimum
air damper setting [A].
Minimum air damper setting [A]
Combustion head Combustion head
CLOSED OPEN
Natural Gas
Without variable speed drive 0° 3°
with VSD 5° 8°
Liquid Petroleum Gas
Without variable speed drive 0° 8°
with VSD 5° 13°

S
P
i S
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

To achieve a constant operating behaviour, it is necessary to initiate a calculation

from P9 to P1.
Drive to P9 using the [+] key.
Press [–] for approx. 4 seconds.
The display shows CALC.
Release [–] key.
The combustion manager starts the calculation.
The display then shows the operating point P8.

S S
P P
i i

S
V h min s % V h min s %
P
i

V h min s %

Continue with Adjusting operating points (step 21).

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Combustion Manager W-FM 50
6 Commissioning

20. Initiate a calculation

To achieve a constant operating behaviour, it is necessary to initiate a calculation
from P9 to P1.
Press [–] for approx. 4 seconds.
The display shows CALC.
Release [–] key.
The combustion manager starts the calculation.
The display then shows the operating point P8.

S S
P P
i i

S
V h min s % V h min s %
P
i

V h min s %

21. Adjusting the operating points

If the [–] key is pressed again for more than 4 seconds, a calculation is started from
the point shown to P1.
Briefly press [–] key, to ensure points calculated or set are not overwritten.

The operating points should only be adjusted via the fuel supply [F]. Changes to the
air quantity influence the linearity, which has a negative effect on the load control
and VSD.
Check combustion values
Press and hold [F] key and using [+]/[–] optimise combustion values.
Optimise combustion values at each operating point, until P1 has been
reached.

S
P
i S
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S S
P P
i i

V h min s % V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

22. Define upper load limit (full load)

Full load can be limited via parameter 546 .
Exit setting mode using [esc].
The display shows 546 – – – –. Full load has not been defined, that means
full load ≙ P9 (100 % load assignment).
If full load is to be limited:
Press [Enter].
The display shows only the parameter value.
Set load limit using [+] or [–] and confirm with [ENTER].
Burner drives to value set.
Exit entry using [esc].
The display shows 546 with the current upper load limit.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

23. Define lower load limit (partial load)

Partial load can be limited via parameter 545.
When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
Press [+] key.
The display shows 545 – – – –.
Partial load has not been defined, that means partial load ≙ P1.
Press [Enter].
The display shows only the parameter value.
Set load limit using [+] or [–] and confirm with [ENTER].
Burner drives to value set.
Determine fuel throughput and if necessary adjust load limit.
Exit entry using [esc].
The display shows 545 with the current lower load limit.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

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Combustion Manager W-FM 50
6 Commissioning

24. Save points

Exit level using [esc].
The display shows 400 SEt.
Exit entry using [esc].
The display shows oP (Operate) with the current rating.

S S S
P P P
i i i

V h min s % V h min s % V h min s %

25. Check start behaviour

Switch off and restart burner.
Check start behaviour and if necessary correct ignition position.
If the ignition position has been altered:
Re-check start behaviour.

26. Carry out data backup

Press keys [F] and [A] simultaneously.
Select 000: Int using [-] key and confirm with [ENTER].
The display shows parameter 050.00: 0
Press [Enter].
The display shows bAC_up.
Press [Enter].
Set 1 using [+] key and confirm with [ENTER].
Following successful data backup the display is reset to 0 .
The values have been backed up from the combustion manager to the ABE.
Exit levels using [esc].

27. Set pressure switch and carry out concluding work

For further details see burner installation and operating manual.

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

6.2.2 Adjust modulation oil side

Prerequisite
Open oil shut off devices.
Switch on voltage supply.
The display shows either OFF UPr or OFF.

S S
P P
i i

V h min s % V h min s %

OFF UPr burner off and not programmed

OFF burner off

1. Enter password
Press [F] and [A] simultaneously for approx. 2 seconds.
The display shows CodE.
Enter the first digit using [+] or [–] and confirm with [ENTER].
Repeat procedure until the password has been entered.
Exit password entry using [ENTER].
The display shows PArA (parameter level) for a short time and then changes
over to 400: SEt (setup).

S
P
i

S S
V h min s %P P
i i
S
V h min s % V h min s %P
i

V h min s %

2. Switch on burner
Ensure there is a demand for heat.
A black dash appears below the S symbol (start).
A heat demand from the boiler controller is required for the duration of commission-
ing, that means signal on input X5-03:1.

S
P
i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

3. Start setup
Press [ENTER].
If the combustion manager has been pre-programmed, the display shows run 1.
Select type of setting (from step 9).
If the combustion manager has not been programmed, the display shows parameter
201 2.
Define parameters 201, 542 and 641 and set P0 (from step 4).
201: Operating mode
542: Activation of frequency converter
641: Speed standardisation

S
P

1 i

S V h min s %
P
i

V h min s % S
P
2 i

V h min s %

4. Set operating mode

The following steps must only be carried out if the combustion manager is not pro-
grammed. If the combustion manager has been pre-programmed, proceed with
step 9.

Press [ENTER].
The display shows only the parameter value.
Set operating mode using [+] or [–] keys and confirm with [Enter].
12: fuel oil EL modulating
23: medium and heavy oil modulating
Exit entry using [esc].
The display shows parameter 201 with the current operating mode.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

5. Activate/deactivate frequency converter

Press [+] key.
The display shows parameter 542.
Press [Enter].
The display shows only the parameter value.
Activate or deactivate the frequency converter using [+] or [–] and confirm with
[ENTER].
0: without frequency converter
1: with frequency converter
Exit entry using [esc].
The display shows parameter 542 with the current setting.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

6. Carry out speed standardisation

Speed standardisation must only be carried out in conjunction with a frequency

converter.
If no frequency converter is fitted, skip speed standardisation 641 using the [+]
key.

Press [+] key.

The display shows parameter 641.
Press [ENTER].
Set value to 1 using the [+] and start speed standardisation by pressing
[ENTER].
Check rotation direction of burner motor
The fan motor starts with open air damper setting. Once standardisation is com-
plete, the display changes form 1 to 0.
Exit speed standardisation using [esc].
The standardised speed can be read in parameter 642.

S S S
P P P
i i i

S S
V h min s % P % P % m 3 m 3/h l l/h
i i

V h min s % V h min s %

S
P
i

V h min s %

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Combustion Manager W-FM 50
6 Commissioning

7. Preset ignition load point

Press [+] key.
The display shows the ignition load point P0.
The ignition load point P0 is factory preset, see burner data sheet. If values are
available proceed with step 8. If the combustion manager is not programmed (e. g..
if it has been replaced) the air damper position and the position of the oil quantity
regulator must be enter
Press and hold [A] and using [+]/[–] set air damper setting.
Press and hold [F] and using [+]/[–] set position of oil quantity regulator.

Only in conjunction with frequency converter

The ignition speed should be 100 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % us-
ing [+]/[–] key.

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

h min s %
S
P
i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

8. Preset full load point

Press [+] key.
The display shows the full load point P9.
Press and hold [A] and using [+]/[–] set air damper setting from setting diagram,
see burner installation and operating manual.
Determine the position of the oil quantity regulator from the burner data sheet.
Press and hold [F] and set value using [+]/[–] key.

Only in conjunction with frequency converter

Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % using
[+]/[–].

Press [+] key.
Exit pre-setting.
The display changes to run.

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S
P
i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

9. Select type of setting

The following can be selected as type of setting:
Adjustment with flame
Pre-setting without flame
Pre-setting without flame is only used, if the operating points are known, for ex-
ample if the combustion manager is exchanged.

Adjustment with flame 1

Press [Enter].
Check rotation direction of burner motor
The burner starts pre-purge Ph12 and stops in ignition position Ph36 without
flame formation.
The display shows the ignition load point P0.
Set mixing pressure in ignition position (from step 11).

Pre-setting without flame 2

Briefly press [esc] key.
The display shows the ignition load point P0.
The black dash below the S symbol disappears.
Pre-set operating points without flame (from step 10).

S S
P P
1 i i

S V h min s % S %
P P
i i

V h min s % S V h min s %
P
2 i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

10. Pre-set points without flame

This step must only be carried out, if the type of setting without flame has been se-
lected previously. The adjustment with flame (from step 11) is not replaced by this
process.
Press [+] key.
The display shows the operating point P1.
Press and hold [A] and pre-set air damper setting using [+]/[–].
Press and hold [F] key and using [+]/[–] key preset position of oil quantity regu-
lator.

Only in conjunction with frequency converter

Press and hold [A] and [F] (VSD) simultaneously and pre-set speed using [+]/
[–].

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

Press [+] key.

The display shows CALC. The combustion manager starts the calculation.
The display then shows the operating point P2.
Set position air damper setting [A] and oil quantity regulator [F], with optional fre-
quency converter also set speed [A] and [F] (VSD).
Using the [+] key select and pre-set points P3 to P9 in sequence.

S
P
i

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S S
P P
i i

V h min s % V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

Exit pre-setting using [esc].

The display shows 400 SEt.
Press [ENTER].
The display shows run.
Press [ENTER].
Check rotation direction of burner motor
The burner starts pre-purge and stops in ignition position without flame forma-
tion.
The display shows the ignition load point P0.

S
P
i

V h min s %

S
P
i

V h min s %

S
P
i

V h min s %

11. Check mixing pressure in ignition position

The mixing pressure in ignition position must be 2 … 5 mbar above the combustion
chamber pressure.
If necessary, adjust mixing pressure via air damper setting:

Only in conjunction with frequency converter

The ignition speed should be 100 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % us-
ing [+]/[–] key.

S
P
i S
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

12. Check pump pressure

The pump pressure in ignition position must be approx. 1 … 2 bar less than that of
the full load pressure, see burner data sheet.
Check pump pressure at pressure gauge.
Remove closing cap 1 (types T and TA only).
Undo locknut 2 (types T and TA only).
Set pump pressure using pressure regulating screw 3.
increase pressure: clockwise rotation,
decrease pressure: anticlockwise rotation.

3 3
1
+

3 2 2 3

13. Igniting the burner

Press [+] key.
The burner starts and stops in ignition position.
The display shows the following operating phases:
PH 38: Ignition ON
PH 40: Fuel valve
Ph 42: Ignition OFF
PH 44: Flame in ignition position

S
P S
i P S
i
P
V h % S
i
P
V h % S
i l
P
V h %
i
V h min %

V h min s %

14. Check combustion

Determine combustion values at ignition position.
Set O2 content of approx. 4 … 5 % by positioning the oil quantity regulator [F]
whilst observing the return pressure.
Fuel oil EL: min 6 … 8 bar
Heavy oil: min 12 bar

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 Installation and operating instruction
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6 Commissioning

15. Pre-set operating point P1

Only in conjunction with frequency converter

In oil operation, the speed should only be reduced so far, that the pump pressure
set at full load does not fall by more than 15 %.

Press [+] key.
The display shows the operating point P1.
Check combustion values and correct if necessary.
Press [+] key.
The display shows operating point P2.
If no other points have been defined, the combustion manager carries out a cal-
culation and calculates all missing points up to P9, the display briefly shows
CALC.

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P m
i

V h min s %

S
P
i S
P m l l/h
i
V h min s %

V h min s %

16. Drive to full load

Using the [+] key, drive to the points in sequence up to P9.
Check combustion values at each point and correct via the position of the oil
quantity regulator [F].

S
P
i S
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S S
P P
i i

V h min s % V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

17. Adjust full load

When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.

Only in conjunction with frequency converter

Select speed at full load as low as possible, but not less than 80 %. Observe flame
stability.

The burner has been factory pre-sized for a specific oil throughput, see burner data
sheet.
Set pump pressure and oil quantity regulator position to the data given on the
burner data sheet.
Determine oil throughput, if necessary adjust position of oil quantity regulator [F]
until the oil throughput required is achieved.
Check combustion values
Determine combustion limit and set excess air [ch. 6.3].

S
P
i S
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

The pump pressure must not be altered once this work has been completed.

18. Initiate a calculation

To achieve a constant operating behaviour, it is necessary to initiate a calculation
from P9 to P1.
Press [–] for approx. 4 seconds.
The display shows CALC.
Release [–] key.
The combustion manager starts the calculation.
The display then shows the operating point P8.

S S
P P
i i

S
V h min s % V h min s %
P
i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

19. Adjusting the operating points

If the [–] key is pressed again for more than 4 seconds, a calculation is started from
the point shown to P1.
Briefly press [–] key, to ensure points calculated or set are not overwritten.

The operating points should only be adjusted via the fuel supply [F]. Changes to the
air quantity influence the linearity, which has a negative effect on the load control
and VSD.
Check combustion values
Press and hold [F] key and using [+]/[–] optimise combustion values.
Optimise combustion values at each operating point, until P1 has been
reached.

S
P
i S
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S S
P P
i i

V h min s % V h min s %

20. Define upper load limit (full load)

Full load can be limited via parameter 546 .
Exit setting mode using [esc].
The display shows 546 – – – –. Full load has not been defined, that means
full load ≙ P9 (100 % load assignment).
If full load is to be limited:
Press [Enter].
The display shows only the parameter value.
Set load limit using [+] or [–] and confirm with [ENTER].
Burner drives to value set.
Exit entry using [esc].
The display shows 546 with the current upper load limit.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

21. Define lower load limit (partial load)

Partial load can be limited via parameter 545.
When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
Press [+] key.
The display shows 545 – – – –.
Partial load has not been defined, that means partial load ≙ P1.
Press [Enter].
The display shows only the parameter value.
Set load limit using [+] or [–] and confirm with [ENTER].
Burner drives to value set.
Determine fuel throughput and if necessary adjust load limit.
Exit entry using [esc].
The display shows 545 with the current lower load limit.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

22. Save points

Exit level using [esc].
The display shows 400 SEt.
Exit entry using [esc].
The display shows oP (Operate) with the current rating.

S S S
P P P
i i i

V h min s % V h min s % V h min s %

23. Check start behaviour

Switch off and restart burner.
Check start behaviour and if necessary:
correct ignition position,
increase oil temperature at oil preheater.
If the ignition position has been altered:
Re-check start behaviour.
If the oil temperature has been altered:
Re-check start behaviour.
Restart each point and check combustion values.

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6 Commissioning

24. Carry out data backup

Press keys [F] and [A] simultaneously.
Select 000: Int using [-] key and confirm with [ENTER].
The display shows parameter 050.00: 0
Press [Enter].
The display shows bAC_up.
Press [Enter].
Set 1 using [+] key and confirm with [ENTER].
Following successful data backup the display is reset to 0 .
The values have been backed up from the combustion manager to the ABE.
Exit levels using [esc].

25. Set pressure switch and carry out concluding work

For further details see burner installation and operating manual.

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

6.2.3 Adjust multi-stage oil side

Only in conjunction with frequency converter

When using a frequency converter please note:
Ignition speed and speed in full load should be 100 %.
It is recommended that the speed at the on and off switch points is 100 %.
Speed at the operating points below full load must only be reduced so far as to
ensure safe operating behaviour whilst:
maintaining speed at 60 %,
maintaining minimum pump pressure, see installation and operating manual of
burner.

Prerequisite
Open oil shut off devices.
Switch on voltage supply.
The display shows either OFF UPr or OFF.

S S
P P
i i

V h min s % V h min s %

OFF UPr burner off and not programmed

OFF burner off

1. Enter password
Press [F] and [A] simultaneously for approx. 2 seconds.
The display shows CodE.
Enter the first digit using [+] or [–] and confirm with [ENTER].
Repeat procedure until the password has been entered.
Exit password entry using [ENTER].
The display shows PArA (parameter level) for a short time and then changes
over to 400: SEt (setup).

S
P
i

S S
V h min s %P P
i i
S
V h min s % V h min s %P
i

V h min s %

2. Switch on burner
Ensure there is a demand for heat.
A black dash appears below the S symbol (start).
A heat demand from the boiler controller is required for the duration of commission-
ing, that means signal on input X5-03:1.

S
P
i

V h min s %

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6 Commissioning

3. Start setup
Press [ENTER].
If the combustion manager has been pre-programmed, the display shows run 1.
Select type of setting (from step 9).
If the combustion manager has not been programmed, the display shows parameter
201 2.
Define parameters 201, 542 and 641 and set P0 (from step 4).
201: Operating mode
542: Activation of frequency converter
641: Speed standardisation

S
P

1 i

S V h min s %
P
i

V h min s % S
P
2 i

V h min s %

4. Set operating mode

The following steps must only be carried out if the combustion manager is not pro-
grammed. If the combustion manager has been pre-programmed, proceed with
step 9.

Press [ENTER].
The display shows only the parameter value.
Set operating mode using [+] or [–] keys and confirm with [Enter].
5: two stage
6: three stage
Exit entry using [esc].
The display shows parameter 201 with the current operating mode.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

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6 Commissioning

5. Activate/deactivate frequency converter

Press [+] key.
The display shows parameter 542.
Press [Enter].
The display shows only the parameter value.
Activate or deactivate the frequency converter using [+] or [–] and confirm with
[ENTER].
0: without frequency converter
1: with frequency converter
Exit entry using [esc].
The display shows parameter 542 with the current setting.

S S
P P
i i

S
V h min s % P %
i

V h min s %

S
P
i

V h min s %

6. Carry out speed standardisation

Speed standardisation must only be carried out in conjunction with a frequency

converter.
If no frequency converter is fitted, skip speed standardisation 641 using the [+]
key.

Press [+] key.

The display shows parameter 641.
Press [ENTER].
Set value to 1 using the [+] and start speed standardisation by pressing
[ENTER].
Check rotation direction of burner motor
The fan motor starts with open air damper setting. Once standardisation is com-
plete, the display changes form 1 to 0.
Exit speed standardisation using [esc].
The standardised speed can be read in parameter 642.

S S S
P P P
i i i

S S
V h min s % P % P % m 3 m 3/h l l/h
i i

V h min s % V h min s %

S
P
i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

7. Preset ignition load point

Only in conjunction with frequency converter

The ignition speed should be 100 %.
Press and hold [A] and [F] (VSD) simultaneously and set speed to 100 % us-
ing [+]/[–] key.

Press [+] key.

The display shows the ignition load point P0.
Press and hold [A] and using [+]/[–] set air damper setting, see burner installa-
tion and operating manual.
Press [+] key.
Exit ignition load point pre-setting.
The display changes to run.

S
P
i S
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S
P
i

V h min s %

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6 Commissioning

8. Select type of setting

The following can be selected as type of setting:
Adjustment with flame
Pre-setting without flame
Pre-setting without flame is only used, if the operating points are known, for ex-
ample if the combustion manager is exchanged.

Adjustment with flame 1

Press [Enter].
Check rotation direction of burner motor
The burner starts pre-purge Ph12 and stops in ignition position Ph36 without
flame formation.
The display shows the ignition load point P0.
Set mixing pressure in ignition position (from step 10).

Pre-setting without flame 2

Briefly press [esc] key.
The display shows the ignition load point P0.
The black dash below the S symbol disappears.
Pre-set operating points without flame (from step 9).

S S
P P
1 i i

S V h min s % S %
P P
i i

V h min s % S V h min s %
P
2 i

V h min s %

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Combustion Manager W-FM 50
6 Commissioning

9. Pre-set points without flame

This step must only be carried out, if the type of setting without flame has been se-
lected previously. The adjustment with flame (from step 10) is not replaced by this
process.
Using [+] key select and pre-set the following points in sequence:
P1 Point 1 (ignition stage)
P2on Switch point from P1 to P2
P2 Operating point 2
P3on Switch point from P2 to P3 (only with three stage operation)
P3 Operating point 3 (only with three stage operation)
Press and hold [A] and pre-set air damper setting using [+]/[–].

S
P
i S
P
i
V h min s %

V h min s %
S
P
i

V h min s %

S
P
i

V h min s %

Using [–] key select and pre-set the following points:

P3oF Switch point from P3 to P2
P2oF Switch point from P2 to P1
Press and hold [A] and pre-set air damper setting using [+]/[–].
Exit pre-setting using [esc].
The display shows 400 SEt.
Press [Enter].
The display shows run.
Press [Enter].
The burner starts pre-purge and stops in ignition position without flame forma-
tion.
The display shows the ignition load point P0.

S
P
i

V h min s %
S
P
i

V h min s %
S
P
i

V h min s %
S
P
i

V h min s %

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

10. Check mixing pressure in ignition position

The mixing pressure in ignition position must be 2 … 5 mbar above the combustion
chamber pressure.
If necessary, adjust mixing pressure via air damper setting:

S
P
i S
P
i S
V h min s %
P
i
V h min s %

V h min s %
S
P
i

V h min s %

11. Check pump pressure

The pump pressure must be set according to the nozzle selected.
Check pump pressure at pressure gauge.
Remove closing cap 1 (types T and TA only).
Undo locknut 2 (types T and TA only).
Set pump pressure using pressure regulating screw 3.
increase pressure: clockwise rotation,
decrease pressure: anticlockwise rotation.

3 3
1
+

3 2 2 3

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Combustion Manager W-FM 50
6 Commissioning

12. Igniting the burner

Press [+] key.
The burner starts and stops in ignition position.
The display shows the following operating phases:
PH 38: Ignition ON
PH 40: Fuel valve
Ph 42: Ignition OFF
PH 44: Flame in ignition position
Check pump pressure.
Check combustion values
Standard: approx. 5 % O2 content
3LN (multiflam): approx. 4 … 4.5 % O2 content
If necessary adjust air damper setting whilst observing the mixing pressure.

S
P S
i P S
i
P
V h % S
i
P
V h % S
i l
P
V h %
i
V h min %

V h min s %

13. Adjusting operating point P1

Press [+] key.
The display shows point P1.
If P1 has not been pre-set, the values from P0 are adopted for P1 .
Pre-set air damper setting [A] whilst observing the combustion values.

S
P
i

S
V h Pl l/h %
i

S
P m 3 m h min s %
i

V h min s %

14. Determine switch point P2on

Press [+] key.
The display shows P2on.
Valve operating point 2 remains closed.
If P2on has not been pre-set, the values from P1 are adopted for P2on .
Set excess air (O2 content approx. 7 %) via air damper setting [A] whilst ob-
serving flame stability.

S
P
i

S
V h Pl l/h %
i

S
P m 3 m h min s %
i

V h min s %

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Combustion Manager W-FM 50
6 Commissioning

15. Set pre-set point P2_d

Press [+] key.
The display shows the pre-set point P2_d.
Valve operating point 2 remains closed.
Pre-set air damper setting [A] expected for the operating point P2 .
The value is not activated yet.
The pre-set point reduces insufficient air during the activation of operating
point P2.

S
P
i

S
V h Pl l/h %
i

S
P m 3 m h min s %
i

V h min s %

16. Activate operating point P2

Press [+] key.
The display shows P2.
Valve operating point 2 opens.
The preset air damper setting from P2_d is activated.
Pre-set air damper setting [A] whilst observing the combustion values.

S
P
i

S
V h Pl l/h %
i

S
P m 3 m h min s %
i

V h min s %

17. Adjust full load

When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
Repeat procedure for three stage operation:
switch point P3on (step 14),
pre-set point P3_d (step 15),
operating point P3 (step 16).

S S S
P P P
i i i

V h min s % V h min s % V h min s %

Determine fuel throughput and if necessary adjust pump pressure.

Check combustion values
Determine combustion limit and set excess air [ch. 6.3].

The pump pressure must not be altered once this work has been completed.

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

18. Initiate partial load

Press [–] key.
The display shows switch point P3oF.

The switch point determines, at which air damper setting the valve of the stage
above closes. The point itself can not be activated.

Adapt air damper setting [A].

The switch point must lie minimum 5° above the switch point of the respective
stage.
Press [–] key and observe switch off behaviour.
Check combustion values in operating point P2 .
Set excess air via air damper setting [A], do not alter fuel pressure in the pro-
cess.
Repeat procedure for operating point P1.

S
P
i

S
V h Pl l/h %
i

S
P m 3 m h min s %
i

V h min s %

S S
P P
i i

V h min s % V h min s %

19. Check operating behaviour

Activate operating points several times using the [+] and [–] keys and observe
the switch-over behaviour.
If the flame is unstable or a pressure surge occurs:
Decrease air damper setting [A] in the change-over point.
If soot or CO is formed:
Increase air damper setting [A] in the change-over point.

20. Save points

The operating point P1 must be activated once, otherwise the display shows
OFF UPr when exiting commissioning and the combustion manager remains un-
programmed.

Activate operating point P1 .

Press [esc] twice.
The display shows oP (Operate) and an operating point.

S S S
P P P
i i i

V h min s % V h min s % V h min s %

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Combustion Manager W-FM 50
6 Commissioning

21. Check start behaviour

Switch off and restart burner.
Check start behaviour and if necessary:
correct ignition position,
increase oil temperature at oil preheater.
If the ignition position has been altered:
Re-check start behaviour.
If the oil temperature has been altered:
Re-check start behaviour.
Restart each point and check combustion values.

22. Carry out data backup

Press keys [F] and [A] simultaneously.
Select 000: Int using [-] key and confirm with [ENTER].
The display shows parameter 050.00: 0
Press [Enter].
The display shows bAC_up.
Press [Enter].
Set 1 using [+] key and confirm with [ENTER].
Following successful data backup the display is reset to 0 .
The values have been backed up from the combustion manager to the ABE.
Exit levels using [esc].

23. Set pressure switch and carry out concluding work

For further details see burner installation and operating manual.

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

6.3 Check combustion

Determine excess air

Slowly close air damper(s) in the relevant operating point, until the combustion
limit is reached (CO content approx. 100 ppm or smoke number approx. 1).
Measure and document O2 content.
Read air number (λ).
Increase air number to ensure sufficient excess air:
by 0.15 … 0.2 (equates to 15 … 20 % excess air),
by more than 0.2 for more difficult conditions, such as:
dirty combustion air,
fluctuating intake temperature,
fluctuating chimney draught.
Example
λ + 0.15 = λ*

Set air number (λ*), do not exceed CO content of 50 ppm.

Measure and document O2 content.

Check flue gas temperature

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

Determine flue gas losses

Drive to full load.
Measure combustion air temperature (tL) near the air damper(s).
Measure oxygen content (O2) and flue gas temperature (tA) at the same time at
one point.
Determine flue gas losses using the following formula:

A2
qA = (tA - tL ) ( )+B
21- O2

qA Flue gas losses [%]

tA Flue gas temperature [°C]
tL Combustion air temperature [°C]
O2 Volumetric content of oxygen in dry flue gas [%]
Fuel factors Natural Gas Liquid Petroleum Fuel oil
Gas
A2 0.66 0.63 0.68
B 0.009 0.008 0.007

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 Installation and operating instruction
Combustion Manager W-FM 50
6 Commissioning

6.4 Calculate gas throughput

Formula symbol Explanation Example values
VB Operating volume [m3/h] –
Volume measured at gas meter at current pressure and
temperature (gas throughput).
VN Standard volume [m3/h] –
Volume gained by gas at 1013 mbar and 0 °C.
f Conversion factor –
QN Heat rating [kW] 6000 kW
η Boiler efficiency (e. g. 92 % ≙ 0.92) 0.92
Hi Calorific value [kWh/m3] at 0 °C and 1013 mbar 10.35 kW/m3 (Natural Gas
E)
tGas Gas temperature at gas meter [°C] 10 °C
PGas Pressure at gas meter [mbar] 250 mbar
PBaro Barometric air pressure [mbar], see table 500 m ≙ 955 mbar
VG Gas throughput determined at gas meter 18.2 m³
TM Measuring time [seconds] 120 seconds

Calculate normal volume

Calculate the normal volume (VN) using the following formula.

QN 6000 kW
VN = VN = = 630.1 m³/h
η Hi 0.92 10.35 kW/m³

Calculate conversion factor

Determine gas temperature (tGas) and pressure (PGas) at gas meter.
Determine barometric air pressure (PBaro) from table.
Height 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
above
sea level [m]
PBaro 1013 1001 990 978 966 955 943 932 921 910 899 888 877 866
[mbar]
Calculate conversion factor (f) using the following formula.

PBaro + PGas 273 955 + 250 273

f= f= = 1.148
1013 273 + tGas 1013 273 + 10

Calculate operating volume (gas throughput) required

VN 630.1 m³/h
VB = VB = = 548.9 m³/h
f 1.148

Determine current operating volume (gas throughput)

Measure gas throughput (VG) at gas meter, measuring time (TM) should be a min-
imum of 60 seconds.
Calculate operating volume (VB) using the following formula.

3600 VG 3600 18.2 m³

VB = VB = = 546.0 m³/h
TM 120 s

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 Installation and operating instruction
Combustion Manager W-FM 50
7 Servicing

7 Servicing

7.1 Notes on servicing

Risk of explosion due to leaking gas
Improper service work can lead to escaping gas and explosion.
Close fuel shut off devices prior to starting work.
DANGER Care should be taken when dismantling and assembling gas carrying compon-
ents.
Close the screws on the test points ensuring the tests points are sealed.

Risk of electric shock

Working on the device when voltage is applied can lead to electric shock.
Isolate the device from the power supply prior to starting any work.
DANGER Safeguard against accidental restart.

Danger of getting burned on hot components

Hot components can lead to burns.
Allow components to cool.
WARNING

Servicing must only be carried out by qualified personnel. The combustion plant
should be serviced annually. Depending on site conditions more frequent checks
may be required.
Components, which show increased wear and tear or whose design lifespan is or
will be exceeded prior to the next service should be replaced as a precaution.
The design lifespan of the components is listed in the service plan [ch. 7.2].

Weishaupt recommends a service contract is entered into to ensure regular in-

spections.

The following components must only be replaced and must not be repaired:
combustion manager
flame sensor
actuator
gas valve
oil solenoid valve
nozzle head (shut off needle),
pressure regulator
pressure switch

Prior to every servicing

Inform the operator about the extent of service work to be carried out.
Switch off mains switch of installation and safeguard against accidental reactiva-
tion.
Close fuel shut off devices.

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 Installation and operating instruction
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7 Servicing

Following servicing
Check tightness of oil and gas carrying components.
Check function of:
adjustable mixing head,
ignition,
flame monitoring,
gas carrying components (gas connection pressure and setting pressure),
oil pump (pump pressure and suction resistance),
pressure switch
Check control and safety devices.
Check combustion values, if necessary re-adjust the burner.
Enter combustion values and settings in the commissioning record and/or test
sheet.

7.2 Service plan

For detailed information see installation and operating manual of burner.

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 Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting

8 Troubleshooting

8.1 Procedures for fault conditions

Check prerequisites for operation:
Voltage supply available.
Heating switch is set to On.
The combustion manager recognises irregularities of the burner and displays these
on the display and operating unit (ABE).
The following conditions can occur:
Display OFF [ch. 8.1.1]
Display OFF S [ch. 8.1.2]
Fault [ch. 8.1.3]
Lockout [ch. 8.1.4]

8.1.1 Display OFF

The following faults may be corrected by the operator:

Fault Cause Rectification
Burner not operating Temperature regulator or pressure regu- Adjust temperature regulator or pres-
lator on heat exchanger has been set in- sure regulator on heat exchanger.
correctly
Boiler or heating circuit control is not Check function and setting of boiler
functioning or has not been set correctly or heating circuit control.

8.1.2 Display OFF S

The following faults may be corrected by the operator:

Fault Cause Rectification
Safety circuit open Temperature limiter or pressure limiter Reset temperature limiter or pressure
on heat exchanger has triggered(1 limiter on heat exchanger.
Low water safety interlock on heat ex- Top up water.
changer has triggered(1 Reset low water safety interlock on
heat exchanger.
(1
Notify your heating contractor or Weishaupt Customer Service if the problem occurs repeatedly.

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8 Troubleshooting

8.1.3 Fault
If a fault occurs, the combustion manager initiates a controlled shutdown.
The display and operating unit alternates between Err.c: (error code) and
Err.d: (diagnostic code).
The burner restarts automatically as soon as the fault condition has been rectified.
Example

Faults must only be rectified by qualified personnel.

Read the fault code and proceed according to the fault message [ch. 8.3].

8.1.4 Lockout
If a lockout condition occurs, the combustion manager initiates a fault shutdown
and burner lockout.
The display and operating unit alternates between Loc.c: (error code) and
Loc.d: (diagnostic code).
Once the fault has been rectified, the combustion manager has to be reset for re-
start.
Example

Lockouts must only be rectified by qualified personnel.

Read the fault code and proceed according to the fault message [ch. 8.3].

Resetting

Damage resulting from incorrect fault repair

Incorrect fault repair can cause damage to the equipment and injure personnel.
Do not carry out more than 2 lockout resets successively.
WARNING Faults must be rectified by qualified personnel.

If the ABE displays a fault:

Press [Enter] for approx. 2 seconds.
rESEt is displayed.
Release key.
The burner has been reset.

Exchanging the unit

If the combustion manager or the ABE are replaced:
Select and check fault history and lockout history and include a copy when re-
turning the unit for exchange.

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 Installation and operating instruction
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8 Troubleshooting

8.2 Fault history

The combustion manager stores the last 25 faults and lockouts in the fault history
(parameter 700), 701 is the fault, which occurred last. The fault history can be
called up in the service level or password level.

Display faults
Select service level or password level [ch. 5.2]
Select parameter 700 using the [+] key and confirm with [Enter] (password level
only).
Select faults in sequence using [+] or [–] key.
press [Enter] (press service level 1 … 3 s).
Fault level flashes.
Select fault level in sequence using [+] or [–] key.
If fault levels 05 and 06 show ·-·- in the display:
press [Enter] (press service level 1 … 3 s).
Value is displayed.

S
P
i

V h min s %

S S
P P
i i

V h min s % V h min s %

S S
P P
i i

V h min s % V h min s %

Parameters Level Definition

701 01 Fault codes
… 02 Diagnostic code
725 03 Fault class (arranges faults by 0: Lockout, highest priority
priority) 1: Safety shut down with software reset
2: Low voltage
3: Safety shut down in safety phase
4: Safety shutdown start prevention
5: Safety shutdown shutdown
6: Signal without switch off reaction
04 Operating phase Operating phase at time of fault [ch. 3.1.8].
05 Start-up counter Number of start-ups at time of fault.
Press [Enter] to display.
06 Rating Load at time of fault. Press [Enter] to display.

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8 Troubleshooting

Delete faults
Only the fault history in the service level can be deleted. The fault history in the
password level is not affected by the deleting process.
Enter password [ch. 5.2.1].
Select parameter 130.
Press [Enter].
The display shows value 0.
Set value to 1 within 3 seconds using [+] key, confirm with [Enter] key, then set
value to 2 and confirm again with [Enter] key.
When the display changes to 0 the delete process has been completed. If the
display shows -1 the duration of 3 seconds was exceeded and the delete pro-
cess was aborted.

S S
P P
i i

S
V h min s % P V h min s %
i

V h min s %

S
P
i 3s
S
P V h min s %
i

V h min s %

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Combustion Manager W-FM 50
8 Troubleshooting

8.3 Rectifying faults

Fault code Diagnostic Cause Rectification
codes
2 1 No flame signal in operating phase Ph44 Check flame sensor (soiled, defective,
2 No flame signal in operating phase Ph52 signal strength…)
Correct ignition load point
3 0 No air pressure switch signal from operat- Check air pressure switch (setting,
ing phase PH24 connection)
Clean fan wheel and air guide
Check pressure and negative pressure
hoses
1 Air pressure switch signal prior to operat- Check air pressure switch
ing phase Ph22
4 Air pressure switch signal prior to start-up
4 0 Flame signal during pre-purge Check flame sensor
1 Flame signal during shutdown
2 Flame signal during start-up
7 0 Loss of flame Check flame sensor (soiled, defective,
signal strength…)
Check fuel supply
Check combustion
3 … 255 Flame failure due to TÜV test Duration of fuel values closed to flame fail-
ure.
Solution: 0.2 s (value 5 = 1 s)
12 81 Valve proving V1 leaking Check valve proving pressure switch
83 Valve proving V2 leaking [ch. 3.1.3]
Check solenoid valve
14 0 POC open Check valve closing contact (function,
1 POC closed connection)
64 POC open prior to start-up
20 0 Low pressure switch has reacted Check low pressure switch
Check fuel supply
1 Low gas programme [ch. 3.1.2] Check gas supply
21 0 High pressure switch has reacted Check high pressure switch
Check fuel supply
22 0 Safety circuit / burner flange open Check safety devices
1 Safety circuit / burner flange open during
start-up
50 … 67 # Internal fault Replace combustion manager if fault
reoccurs
70 23 Load invalid –
26 Modulating curve point undefined Set curve points for all actuators
71 0 Standby position undefined Set special positions for all actuators
1 Pre-purge position undefined
2 Post-purge position undefined
3 Ignition position undefined
72 # Internal fault Replace combustion manager if fault
reoccurs
73 23 Load invalid –
26 Multi-stage curve points undefined Set curve points for all actuators

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8 Troubleshooting

Fault code Diagnostic Cause Rectification

codes
75 1 Current load incorrect –
2 Target load incorrect –
4 Target position incorrect –
16 Different positions reached Repeat standardisation
76 # Internal fault Replace combustion manager if fault
reoccurs
80 1 Combustion manager was unable to cor- Combustion manager has not been stand-
rect speed deviations and has reached the ardised for this motor
lower regulating limit. Frequency converter Repeat standardisation
speed to high. The ramp times of the frequency converter
2 Combustion manager was unable to cor- are longer than those of the combustion
rect speed deviations and has reached the manager.
upper regulating limit. Frequency con- Check ramp times (parameter 522,
verter speed too low. 523).
The reference line of the frequency con-
verter is not linear:
Adjust combustion manager/frequency
converter control signal (parameter
645).
Frequency converter reacts too slowly:
Check frequency converter settings (in-
let filter, slip compensation, fade-out of
different speeds).
81 1 Interference impulses on sensor line Optimise EMC measures.
speed input

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8 Troubleshooting

Fault code Diagnostic Cause Rectification

codes
82 1 Ramp time during run down during stand- Increase ramp time (parameter 523).
ardisation too short
2 Standardised speed not saved Repeat standardisation
3 No speed signal Check the connection
Check distance speed sensor / trans-
mitter disc.
4 Motor did not reach stable speed during The ramp times of the frequency converter
start. are longer than those of the combustion
Frequency converter run-up time too long. manager.
Check ramp times (parameter 522,
Speed below minimum limit for standard- 523).
isation.
The reference line of the frequency con-
verter is not linear:
Adjust combustion manager/frequency
converter control signal (parameter
645).
Frequency converter reacts too slowly:
Check frequency converter settings (in-
let filter, slip compensation, fade-out of
different speeds).
Speed of frequency converter is below the
minimum standardised speed (650 rpm)
Increase speed of frequency converter.
5 Incorrect rotation direction Check rotation direction.
Check installation of transmitter disc.
6 Impulse pattern (60°, 120°, 180°) incor- Check the connection
rect, interference impulses on the sensor Check distance speed sensor / trans-
line mitter disc.
Optimise EMC measures.
7 Standardised speed is not within the per- –
mitted range
15 Speed deviation between micro control- Repeat standardisation
ler 1 und micro controller 2
20 Standardisation in incorrect operating Switch off heat demand and repeat
phase standardisation.
21 Safety circuit / burner flange open during Repeat standardisation
standardisation.
22 Air actuator not referenced Check actuator.
23 Frequency converter deactivated Activate frequency converter and repeat
standardisation.
24 Standardisation started without valid oper- Check operating mode (parameter
ating mode 201, 301) and repeat standardisation.
128 Frequency converter is activated, but is Carry out standardisation.
not standardised.
255 Motor is rotating, but is not standardised Carry out standardisation.

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Combustion Manager W-FM 50
8 Troubleshooting

Fault code Diagnostic Cause Rectification

codes
83 1 Speed not achieved, lower control limit Rectification see error code 80.
was activated
2 … 3 Speed not achieved, upper control limit Rectification see error code 80.
was activated
4 … 7 Aborted due to interference impulses on Optimise EMC measures.
sensor line
8 … 15 Modulating operation: Curve gradient fre- Check ramp times (parameter 522,
quency converter too steep (speed not 523).
achieved)
Depending on the ramp time (parameter
522, 523), the speed alteration between
two operating points must not exceed a
specific percentage.
10 % at 20 s
20 % at 10 s
40 % at 5 s
16 … 31 No speed signal Check the connection
Check distance speed sensor / trans-
mitter disc.
32 … 63 Speed deviation too high Check ramp times (parameter 522,
523).
84 1 Modulating operation: Curve gradient fre- Check ramp times (parameter 522,
quency converter too steep 523).
Depending on the ramp time (parameter
522, 523), the speed alteration between
two operating points must not exceed a
specific percentage.
10 % at 20 s
20 % at 10 s
40 % at 5 s

2 … 3 Modulating operation: Curve gradient fuel The position change between two operat-
actuator too steep ing points must not exceed maximum 31°:
4 … 7 Modulating operation: Curve gradient air Adjust operating points.
actuator too steep
85 0 Fuel actuator referencing error Check, if actuators have been mixed up.
1 Air actuator referencing error Check, if actuator is blocked.
128 … 255 Parameter settings of one actuator have –
been changed.
86 0 Position error fuel actuator Check, if actuator is blocked.
1 Fuel actuator line break min 0.5 V between Pin 5 and 2 or 6 and
2:
Check wiring
8 Modulating operation: Curve gradient fuel The position change between two operat-
actuator too steep ing points must not exceed maximum 31°:
Adjust operating points.
16 … 255 Fuel actuator overloaded or mechanically Check, if actuator is blocked.
twisted

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8 Troubleshooting

Fault code Diagnostic Cause Rectification

codes
87 0 Position error air actuator Check, if actuator is blocked.
1 Air actuator line break min 0.5 V between Pin 5 and 2 or 6 and
2:
Check wiring
8 Modulating operation: Curve gradient air The position change between two operat-
actuator too steep ing points must not exceed maximum 31°:
Adjust operating points.
16 … 255 Air actuator overloaded or mechanically Check, if actuator is blocked.
twisted
90 … 91 # Internal fault Replace combustion manager if fault
reoccurs
93 3 Flame sensor short circuit Check flame sensor
Check wiring
95 # External voltage relay contact (internal) Check flame sensor
3 Ignition unit Check wiring
4 Fuel valve 1
5 Fuel valve 2
6 Fuel valve 3
96 # Relay contact fused (internal) Check relay contact:
3 Ignition unit Apply voltage.
Output X3-05:1 must be de-energised.
4 Fuel valve 1 Switch off voltage and unplug plug
5 Fuel valve 2 X3-05.
6 Fuel valve 3 No ohmic connection must exist
between output X3-05:1 and input
X3-04:4 (N).
If a criteria is not met:
Replace combustion manager
97 0 Safety relay fused (internal) or external Rectification see error code 96.
voltage applied to safety relay
98 # Relay does not activate (internal) Replace combustion manager if fault
2 Safety valve reoccurs
3 Ignition unit
4 Fuel valve 1
5 Fuel valve 2
6 Fuel valve 3
99 … 100 # Internal fault relay activation Replace combustion manager if fault
reoccurs

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8 Troubleshooting

Fault codeDiagnostic Cause Rectification

codes
105 # Internal fault contact interrogation Can be caused by capacitive loads or dir-
0 Minimum pressure switch ect current feed at the inputs. The input, at
which the fault occurred is displayed with
1 Max. pressure switch diagnostic code.
2 Valve proving pressure switch
3 Air pressure switch
4 Load controller OPEN
5 Load controller ON / OFF
6 Load controller CLOSED
7 Safety circuit / burner flange
8 Safety valve
9 Ignition unit
10 Fuel valve 1
11 Fuel valve 2
12 Fuel valve 3
13 Reset
106 … 110 # Internal fault Replace combustion manager if fault
reoccurs
111 # Mains frequency too low –
112 # Voltage return No fault
113 … 115 # Internal fault Replace combustion manager if fault
reoccurs
116 # Operating cycle lifespan exceeded Replace combustion manager
117 # Lifespan exceeded Replace combustion manager
120 0 Interference impulses on fuel meter input Optimise EMC measures.
121 … 124 # Internal fault Reset parameters or reset data using
Restore.
Replace combustion manager if fault
reoccurs
125 … 126 # Internal fault Reset parameters.
Replace combustion manager if fault
reoccurs
127 # Internal fault Reset parameters or reset data using
Restore.
Replace combustion manager if fault
reoccurs
128 0 Internal fault Replace combustion manager if fault
reoccurs
129 … 131 # Internal fault Reset parameters.
Replace combustion manager if fault
reoccurs
132 # Internal fault Replace combustion manager if fault
reoccurs
133 … 135 # Internal fault Reset parameters.
Replace combustion manager if fault
reoccurs
136 1 Restore started No fault

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 Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting

Fault code Diagnostic Cause Rectification

codes
137 255 (-1) Aborted due to Time-out during Backup / Check the connection
Restore or ABE does not have this func- Repeat Backup / Restore.
tion. Replace ABE.
254 (-2) Aborted due to transfers error Repeat Backup / Restore.
253 (-3) Restore cannot be carried out at present
252 (-4) Restore incomplete
251 (-5) No burner identification Define burner identification (parameter
113).
250 (-6) Backup data set invalid, Restore not pos- –
sible
249 (-7) Backup has unsuitable burner identifica- –
tion and must not be uploaded.
248 (-8) Restore cannot be carried out at present Repeat Backup / Restore.
247 (-9) Backup data set invalid, Restore not pos- –
sible
246 (-10) Aborted due to Time-out during Restore Repeat Backup / Restore.
245 (-11) Access error Restore
244 (-12) Software version and Backup data set not –
compatible, Restore not possible
243 (-13) Backup data comparison between the mi- Repeat Backup / Restore.
cro controllers incorrect
242 (-14) Backup is incorrect and cannot not re- –
loaded
241 (-15) Backup contains unsuitable ASN and –
must not be uploaded
240 (-16) No Backup in ABE –
239 (-17) Backup memory in ABE faulty Repeat Backup / Restore.
157 (-99) Restore successful, however Backup data –
less than in current system
146 1 Modbus Time-out –
2 eBUS Time-out –
150 1 (-1) TÜV test in invalid operating phase Start TÜV test in operating phase
Ph60
2 (-2) Load during TÜV test less than lower load Adjust load and repeat TÜV Test.
limit (parameter 545)
3 (-3) Load during TÜV test higher then upper
load limit (parameter 546)
4 (-4) Manual abort TÜV test No fault
5 (-5) No flame failure after fuel valves have shut Check for extraneous light.
down Check wiring
Check soundness of valves.
165 … 166 # Internal fault –

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 Installation and operating instruction
Combustion Manager W-FM 50
8 Troubleshooting

Fault code Diagnostic Cause Rectification

codes
167 1 Manual lockout by contact No fault
2 Manual lockout by ABE –
3 Manual lockout by PC-Tool
8 Communication between W-FM and ABE –
was interrupted during curve setting
9 Communication between W-FM and PC- –
Tool was interrupted during curve setting
33 Reset attempt by PC-Tool –
168 … 171 # Internal fault Replace combustion manager if fault
reoccurs
200 # System fault free –
201 1 No operating mode selected –
2 … 3 No fuel supply defined –
4 … 7 No curves defined –
8 … 15 Standardised speed undefined –
16 … 31 Backup / Restore was not possible –
202 # Internal fault operating mode setting Redefine operating mode (parameter
201).
203 # Internal fault operating mode setting Redefine operating mode (parameter
201).
Replace combustion manager if fault
reoccurs
204 24 … 52 Program stop is activated. Operating Deactivate program stop (parameter
phase is shown in diagnostic code. 208).
205 # Internal fault Replace combustion manager if fault
reoccurs
206 0 Impermissible unit combination (combus- –
tion manager - ABE)
207 0 Combustion manager version too old –
1 ABE version too old –
208 … 209 # Internal fault Replace combustion manager if fault
reoccurs
210 0 Impermissible operating mode Redefine operating mode (parameter
201).
240 … 250 # Internal fault Replace combustion manager if fault
reoccurs

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 Installation and operating instruction
Combustion Manager W-FM 50
9 Technical documentation

9 Technical documentation

9.1 Frequency converter

Detailed information see Frequency converter CD.

The construction and arrangement of diagnostic LEDs is dependent on the size of

the frequency converter.

9.1.1 Frequency converter Nord size I … III

1 2 3

1 2
1 2

ON
3

1 Interfaces
2 DIP switches
3 Diagnostic LED's

Interface
The interface is used to access the frequency converter via a PC.
The Software required can be found on the Frequency Converter CD.
A connection cable RJ12 to SUB-D9 is required for the connection (Order No. 743
361). A readily available USB interfaces converter USB to RS232 is also required
for the connection to the USB port.

DIP switches
The analogue inputs AIN1 and AIN2 are configured via setting of the DIP switches.
Factory setting (2 … 10 V):
Switch 1: OFF
Switch 2: OFF

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 Installation and operating instruction
Combustion Manager W-FM 50
9 Technical documentation

Diagnostic LED's
LED Signal Description
1 (BUS-S) – System bus status (not used)
2 (BUS-E) – System bus fault (not used)
3 (DS) OFF No mains voltage and no control voltage
Green Operation, FC operating
Flashing green 0.5 Hz(1 Ready for operation
4 Hz(1 Start blocked
Flashing red/green 4 Hz(1 Warning
1 … 25 Hz(1 Intensity overload
Flashing red Fault, flashing codes see Frequency
Number ≙ flashing codes converter CD
(1
1 Hz ≙ once per second

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 Installation and operating instruction
Combustion Manager W-FM 50
9 Technical documentation

9.1.2 Frequency converter Nord size IV

1 2 3

2 3
1 4
9 0 B A
8 5
7 6

1 Interfaces
2 Diagnostic LED's
3 Status LED's

Interface
The interface is used to access the frequency converter via a PC.
The Software required can be found on the Frequency Converter CD.
A connection cable RJ12 to SUB-D9 is required for the connection (Order No. 743
361). A readily available USB interfaces converter USB to RS232 is also required
for the connection to the USB port.

Diagnostic LED's
LED Signal Description
1 (DOUT1 ) yellow Alarm from frequency converter (digital
output 1)
2 (DOUT2) yellow Signal at digital output 2
3 (BRAKE) yellow Mechanical brake
4 (TEMP) yellow Excess temperature at motor
5 (DIN4) yellow Signal at digital input 4
6 (DIN3) yellow Signal at digital input 3
7 (DIN2) yellow Signal at digital input 3
8 (DIN1) yellow Frequency converter start release (digital
input 1)
9 (BUS-S) OFF No Bus communication (system bus)
Green Bus communication
Flashing green Bus warning
0 (BUS-E) OFF System bus is operating correctly
Flashing red Monitoring fault
red No system bus

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 Installation and operating instruction
Combustion Manager W-FM 50
9 Technical documentation

Status LED's
LED Signal Description
A (AS-i) – Status AS interface (not used)
B (DS) OFF No mains voltage and no control voltage
Green Operation, FC operating
Green ON + Frequency converter not ready for oper-
red flashing ation,
control voltage applied but no mains
voltage
Flashing green 0.5 Hz(1 Ready for operation
4 Hz(1 Start blocked
Flashing red/green 4 Hz(1 Warning
1 …  25 Hz(1 Intensity overload
Flashing red Fault, flashing codes see Frequency
Number ≙ flashing codes converter CD
(1
1 Hz ≙ once per second

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 Installation and operating instruction
Combustion Manager W-FM 50
10 Spares

10 Spares

1.01
1.03

1.04

1.02

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 Installation and operating instruction
Combustion Manager W-FM 50
10 Spares

Pos. Description Order No.

1.01 ABE for W-FM 50/54 600 408
1.02 Plug cable ABE-W-FM 50
–2m 400 406
– 10 m 600 407
1.03 Combustion manager W-FM50 230 V 50/60 Hz 600 402
1.04 W-FM plug
– X3-02 Air pressure switch 716 301
– X3-03 Limit switch burner flange 716 302
– X3-04 Mains and safety circuit 716 303
– X3-05 Fan, alarm 716 410
– X4-02 Ignition unit 716 305
– X5-01 Min. oil pressure switch 716 307
– X5-02 Max. oil pressure switch 716 308
– X5-03 Control circuit 716 309
– X6-03 Safety valve 716 312
– X7-01 Oil valve stage 2 716 313
– X7-02 Oil valve stage 3 716 314
– X8-02 Oil valve stage 1 716 317
– X8-04 Operation Reset 50 716 411
– X9-04 Valve proving pressure switch 716 418
– X10-05 Flame sensor QRB, QRD, ionisation 716 413
– X10-06 Flame sensor QRA 716 414
– X64 Reserve 4-20mA 716 416
– X74 Frequency converter connection 716 417
– X75 Fuel meter 716 415

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 Installation and operating instruction
Combustion Manager W-FM 50
11 Notes

11 Notes

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 Installation and operating instruction
Combustion Manager W-FM 50
12 Key word index

12 Key word index

A Extraneous light ................................................................... 21

ABE ........................................................................................ 26
Actuator................................................................................. 43 F
Air actuator ........................................................................... 41 Fan motor.............................................................................. 24
Air number ............................................................................ 86 Fan run-up time ................................................................... 39
Air pressure .......................................................................... 87 Fault ....................................................................................... 90
Air pressure switch............................................................. 18 Fault code..........................................................................  101
Alarm..............................................................................  24, 39 Fault history .......................................................................... 43
Ambient conditions............................................................. 26 Flame failure test ................................................................. 37
Analogue input..................................................................... 22 Flame sensor.........................................................  21, 39, 40
Analogue signal...........................................................  22, 25 Flame signal ......................................................................... 21
Atomising pressure.....................................................  69, 81 Flame stabilisation time ..................................................... 39
Flashing .........................................................................  32, 35
B Flue gas losses.................................................................... 86
Backup ....................................................  11, 36, 60, 74, 85 Flue gas measurement....................................................... 86
Baud rate .............................................................................. 37 Flue gas temperature ......................................................... 86
Building management ................................................  22, 37 Frequency ............................................................................. 37
Burner control (200: PAr0)............................................... 39 Frequency converter ...........  24, 41, 42, 49, 63, 77, 102
Burner flange limit switch.................................................. 18 Fuel meter.....................................................................  23, 37
Burner identification ........................................................... 36 Fuel stage ............................................................................. 32
Burner motor ........................................................................ 24 Fuel valve ........................................................ 14, 15, 16, 17
Burner ON ....................................................................  22, 23 Fuel volume .......................................................................... 38
Bus interface........................................................................ 22 Full load ............................................  42, 56, 59, 71, 72, 83
Fuse ....................................................................................... 26
C
G
Calculation............................................................................ 11
Change-over release.......................................................... 23 Gas connection pressure....................................................  9
CO content .......................................................................... 86 Gas temperature ................................................................. 87
Combustion control............................................................ 86 Gas throughput ................................................................... 87
Combustion limit ................................................................. 86 Guarantee...............................................................................  6
Combustion Manager ........................................................ 26
Commissioning.....................................................  46, 47, 61 H
Compound............................................................................ 41 Heat demand ...............................................................  22, 23
Condensate............................................................................  8 Heavy oil intermediate start .............................................. 20
Connection pressure ...........................................................  9 High gas pressure switch ................................................. 40
Consumption........................................................................ 26 Humidity ................................................................................ 26
Contact interrogation ......................................................... 43
Continuous ventilation ....................................................... 24 I
Conversion factor ............................................................... 87
Ignition load point ................................................  50, 64, 78
Ignition pilot valve................................................................ 15
D
Ignition position ................................................................... 50
Data backup ...........................................  11, 36, 60, 74, 85 Ignition speed ..............................................................  50, 53
Data set ................................................................................. 36 Ignition unit .............................................  14, 15, 16, 17, 24
Design lifespan ............................................................... 7, 88 Illumination............................................................................ 37
Diagnostic code ...............................................................  101 Impulse frequency............................................................... 23
Dimensions........................................................................... 27 Info level ................................................................................ 33
Direct ignition....................................................................... 39 Input COM X92................................................................... 22
Display ............................................................. 30, 31, 33, 37 Input X10-05..........................................  14, 15, 16, 17, 21
Display and operating unit .................................  26, 30, 90 Input X10-06........................................................................ 21
Display illumination ............................................................. 37 Input X3-02 ............................................  14, 15, 16, 17, 18
Disposal ..................................................................................  8 Input X3-03 .................................................... 14, 15, 16, 18
Input X3-04 ............................................  14, 15, 16, 17, 18
E Input X5-01 ............................................  14, 15, 16, 17, 19
eBUS ..................................................................................... 37 Input X5-02 .......................................................................... 19
Electrical connection.......................................................... 28 Input X5-03 ............................................  14, 15, 16, 17, 23
Emergency-Off .................................................................... 18 Input X9-04 ............................................  14, 15, 16, 17, 20
Engineer level....................................................................... 33 Input X75 .............................................................................. 23
Excess air.............................................................................. 86 Input X8-04 .......................................................................... 18
Exchanging the unit ............................................................ 91 Interface ...................................................................  102, 104

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 Installation and operating instruction
Combustion Manager W-FM 50
12 Key word index

Ionisation electrode ............................................................ 21 Point of ignition.................................................................... 41

Post burn time ..................................................................... 40
L Post-purge position............................................................ 41
Post-purge time................................................................... 40
Liability.....................................................................................  6
Pre-ignition phase................................................  16, 17, 24
Lifespan............................................................................ 7, 88
Pre-purge.............................................................................. 39
Limit switch........................................................................... 18
Pre-purge position......................................................  39, 41
Load change ........................................................................ 36
Pre-purge position ............................................................. 41
Load controller.............................................................  22, 23
Pre-purge time..................................................................... 39
Load limit............................................................................... 42
Pressure regulating screw ........................................  69, 81
Load signal ........................................................................... 22
Pressure regulator .............................................................. 23
Lockout..........................................................................  18, 90
Pressure switch relief......................................................... 24
Low gas pressure switch ...................................... 9, 19, 40
Program stop ....................................................................... 39
Low gas programme ............................................................  9
Programme sequence.........................................  14, 15, 16
Low impact start.................................................................. 23
Pump pressure ............................................................  69, 81
M
R
Mains frequency ..........................................................  26, 37
Ramp time............................................................................. 41
Mains voltage ...............................................................  18, 26
Referencing .......................................................................... 12
Manual load ..................................................................  35, 36
Repetition counter ............................................................. 39
Manual OFF.......................................................................... 35
Reset..............................................................................  18, 91
Max. oil pressure switch .................................................... 19
Restore.................................................................................. 36
Max. pressure switch ......................................................... 19
Min. oil pressure switch..................................................... 19
Min. pressure switch .......................................................... 19 S
Modbus ................................................................................. 37 Safety circuit ...................................  14, 15, 16, 17, 18, 39
Modulating....................................................................  22, 39 Safety measures....................................................................  7
Modulation limit ................................................................... 42 Safety shutdown ................................................................. 32
Motor..............................................................................  24, 28 Safety time limiter................................................................ 18
Multi-stage....................................................................  22, 23 Safety valve .................................................... 14, 15, 16, 17
Save ........................................................................  11, 33, 36
N Service................................................................................... 88
Service contract .................................................................. 88
Nozzle circulation ................................................................ 20
Service interval .................................................................... 88
Service level ......................................................................... 33
O Setting step.......................................................................... 36
OFF function ........................................................................ 30 Setting time .......................................................................... 26
Oil throughput...................................................................... 71 Smell of gas ...........................................................................  7
Operating mode ..........................................................  22, 23 Software version .........................................................  36, 44
Operating phase ...................................  13, 14, 15, 16, 17 Spares ................................................................................  107
Operating point ................................................................... 11 Special positions................................................................. 41
Operating setting ................................................................ 13 Speed alteration.................................................................. 97
Operating stage 1............................................................... 84 Speed measurement.......................................................... 24
Operating unit...................................................................... 30 Speed standardisation................................. 42, 49, 63, 77
Operating volume ............................................................... 87 Stabilisation time................................................................. 39
Output X3-05 ........................................  14, 15, 16, 17, 24 Standard volume ................................................................. 87
Output X4-02 ........................................  14, 15, 16, 17, 24 Standby position ................................................................. 41
Output X6-03 ................................................ 14, 15, 16, 17 Start prevention...........................................................  24, 39
Output X7-01 ................................................ 14, 15, 16, 17 Start-up ................................................................................. 38
Output X7-02 ................................................ 14, 15, 16, 17 STL ......................................................................................... 18
Output X3-05 ...................................................................... 24 Storage.................................................................................. 26
Output X74 ..................................................................  24, 25 Switch off behaviour........................................................... 39

P T
Parameter ........................................  36, 38, 41, 42, 43, 44 Temperature ......................................................................... 26
Parity ...................................................................................... 37 Thermostat............................................................................ 23
Partial load...................................................... 42, 59, 73, 84 Three stage .......................................................................... 39
Password ........................................................ 34, 47, 61, 75 Throughput ........................................................................... 71
Password level..................................................................... 33 Torque ................................................................................... 26
Photo resistor....................................................................... 21 Transport............................................................................... 26
Pilot ignition.......................................................................... 39 Tree stage............................................................................. 22

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 Installation and operating instruction
Combustion Manager W-FM 50
12 Key word index

Two stage .....................................................................  22, 39

Type of operation ................................................................ 39
Type of protection............................................................... 26

U
Unit address......................................................................... 37
UV cell ................................................................................... 21

V
Valve proving................................................................  10, 20
Valve proving gas pressure switch ................................. 20
Valve proving pressure switch ......................................... 20
Voltage supply ..................................................................... 18
VSD........................................................................................ 43

X
X5-02..................................................................................... 17

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 Max Weishaupt GmbH · 88475 Schwendi

Weishaupt close by? Addresses, telephone numbers etc. can be found

at www.weishaupt.de

We reserve the right to make changes. All rights reserved.

The complete program:

Reliable technology and prompt, professional service
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83250302 1/2018-08 La