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infoProduct information on digital combustion managementThe intelligent control conceptW-FM 100 and W-FM 200 combustion managers

Digital combustion managementModern oil, gas and dual fuelburners use combustion processeswhich require precise andreproducible mixture of fuel andcombustion air.Weishaupt’s digital combustionmanagement system employsmonitoring and optimizingtechnology, which allows simple andsafe operation of heating plant.Alongside the possibilities forremote operation, remote diagnosticand monitoring, digital combustionmanagement also reducescommissioning and maintenancecosts.Simple connectionAll the necessary connections for theexternal components are available asplug-in terminal blocks and all functionsare integrated into the combustionmanager’s software and hardware.Optimal switching safetyOutputs are connected via relays, toguarantee optimal switching safety. TheW-FM 100 and W-FM 200’s inputs andoutputs operate at mains voltage, nointerlocking relays are required.User-friendly operationA separate control and display unit(AZL) is available for the operating andmonitoring of the burner by the plantoperator, as well as for commissioningby the technician or engineer. The AZLis connected to the W-FM unit by a bussystem (CAN bus cable). In this way, theAZL can be placed anywhere the userchooses within 300 feet (100 m) of themain unit.Extremely precise controlThe bus system enables the operationof up to six servomotors. They areconnected directly to the actuators forair, fuel and the head assembly. Thesehighly precise stepping motors arepowered via the CAN bus cable.Choice of flame sensorDifferent types of flame sensor can beconnected directly to the main unit. Forbasic oil burners the usual photoresistorcan be used. For continuousoperating dual fuel burners an infraredflicker-detector has been developed.Burners operating solely on gas can beequipped with an ionization probedeveloped for continuous operation.Numerous interfaces for ease ofcommunicationThe integrated Bus interface enables alloperational data to be relayed to acentral building management system.Similarly, all burner functions can becontrolled by the BMS, including themodulating operation. This interfacealso allows all diagnostic functions to becalled up remotely.There are ports available on the AZLcontrol and display unit for two digitalinterfaces. An RS 232 connection isreadily accessible on the exterior of theAZL, which can be used to connect aPC or laptop. A software program thenallows the burner to be easilycommissioned. The operational datathat has been set can be saved andprinted out for reference. Furthermore,plant operation can be recorded thanksto a special recording function.Advantages at a glance:• One unit for all burner versions• Precise control for optimalcombustion• Choice of flame sensor• Integral modulating controller• Integral speed control (WM-F200)• Easy to connect O 2 module for O 2trim function (WM-F200)• User friendly, separate control &display unit (WM-F200)• Clear text display for error freeoperation• Flexible communication possibilitiesthrough a variety of interfaces3

System overviewCombustion managerThe W-FM 100 and W-FM 200combustion managers control theoperation of the burner via an integrated“burner controller.” The W-FMs aresuitable for continuous operation and canbe connected to flame sensors for gas, oiland dual fuel burners.Seven different start-up programs for oil,gas and heavy oil are available. Variousparameters can be set (for example prepurgetime, post-purge time, ignition andsafety timings, pre- and post-purgepositions of the stepping motors) toensure an individual matching to the plant.Oil, gas, heavy oil and dual fuel burnerscan all be individually controlled. Thedirect connection of all valves to the baseunit means that external fuel selectionrelays are unnecessary.All the necessary pressure switches canbe connected to the main unit as required.Their function is set during theconfiguration of the unit at the factory.Electronic compoundThe error free CAN bus, which controlsthe servomotors (air damper, oil regulator,gas butterfly, mixing head), differentiatesthis electronic compound regulation fromprevious systems.Each servomotor is fitted with its ownmicroprocessor and is driven by a highlyaccurate stepping motor. An integratedregulation and monitoring circuit positionsthe drive shaft to within one tenth of adegree. The set position is transmittedfrom the main unit via the Bus and oncethe exact position has been reached thisis transmitted from the servomotor backto the main unit. Completely separate datapackages are used for each fuel.Commissioning has been much simplified.It is now only necessary to program asmany operating points as the setting ofthe burner requires. It is still possible toenter further points, or alter the existingones, as and when required later.Independent operating curves areavailable for oil and gas. Each operatingcurve can be individually programmed forup to 6 stepping motors and a variablespeed drive.Control and Display UnitThe AZL control and display unit isconnected to the base unit via CANbusand can be installed up to 300 feet awayfrom the main unit, giving the operator thefreedom to choose its optimal installationposition.All burner functions can be controlleddirectly from the AZL unit, no externalcontrol elements, such as buttons orswitches are necessary. All operationsand diagnostic functions are displayed inclear text and virtually any language canbe loaded via a PC. A separate datarecorder in the unit enables a completebackup copy of the onsite settings to besaved.The AZL unit also serves as the interfacewith a central building managementsystem and as a connection point for a PCduring commissioning.4

O 2 probeO 2 moduleGas butterflyMixing headOil regulatorSteppingmotorsAir damperImpulse senderVariableSpeedDriveCAN-BusW-FM 200combustion managerCAN-BusBMSvisualizationProGraf NTDDCAZL control anddisplay unit5

Separate access levels for safetyD rive toP re-purge 24F05.1.A44.6 30.3User/Operator level (AB)All the necessary commands foroperating the plant can be accessedfrom this level and all values can beread.Examples of commands:• Burner on/off control• Fuel changeover• Manual setting of the burner rating• ResetExamples of readable values:• Actual temperature or pressure• Current burner rating• Flame signal• Error messages such as“Max. gas pressure exceeded”P oint‡Load : 2 3 .5‡Fuel : 2 3 .2Man ‡Air :41.6‡Aux :30.3Service level (HF, passwordprotected)This level is used by the technician/engineer for commissioning andservicing the burner.Examples for commissioning:• Setting of the electronic compound• Matching the firing rate to therequired capacity of the plant• Setting the speed control and O 2 trimExamples for service:• Reading of error codes for earlydiagnosis• Resetting the burner after replacingcomponents• Reading the number of start-ups andhours runT imesT imesT imesT imesStartu p1Startu p2ShutdownGeneralWeishaupt level (OEM, passwordprotected)The configuration of the combustionmanager is carried out at the factoryusing this level.Examples for configuration:• Selection of connected pressureswitches• Setting the fuel type, gas, light oil, orheavy oil• Program runtimes, e.g. pre- and postpurge• Country specific settings• Presetting during QA checks6

Function overviewIntegral modulating controllerThe integral modulating controller canbe connected to various temperatureand pressure sensors.Two setpoints can be selected andactivated via an external signal (heatretention function, night setback). Ifrequired, the modulating controller canalso be activated by external set valuesor signals. Switching back to internal setvalues and internal modulatingcontroller is possible at any time.There is a separate start up program fora cold boiler start, which slowly bringsthe heating appliance up to nominaltemperature or pressure.Integral speed controlThe burner can also be equipped with avariable frequency drive. The frequencydrive is controlled directly by thecombustion manager.If fuel meters are installed (optional),cumulative fuel consumption andcurrent throughput rates can bedisplayed.Integral O 2 trimFitting an O 2 probe and O 2 module andconnecting them to the W-FM 200 viathe internal system bus is all that isrequired to equip the burner with O 2 trimfunction - a great simplificationcompared with older systems.The O 2 module converts the signal fromthe O 2 probe for the CAN bus. Themodule can be placed up to 30 feetaway from the O 2 probe.The use of flue and inlet temperaturesensors enables combustion efficiencyto be calculated and displayed.7

Weishaupt Corporation6280 Danville RoadMississauga, ON L5T 2H7, CanadaPh: (905) 564 0946Fax: (905) 564 0949www.weishaupt-corp.comOverview of digitalcombustion managementWeishaupt America Inc.2587 Millenium Drive, Unit AElgin, IL 60124, USAPh: (847) 531 5800Fax: (847) 531 5855www.weishaupt-america.comPrint No. 83201416, august 2007Printed in Germany. All rights reserved.System overviewDigital combustion management W-FM 05 W-FM 10 W-FM 20 W-FM 21 W-FM 50 W-FM 100 W-FM 200Burner controller for intermittent operation ● ● ● ● ● ● ●Burner controller for continuous operation ● ● ●Flame sensor for intermittent operation QRB, Ion QRB, Ion QRB, Ion QRB, Ion QRB, Ion QRB, Ion QRB, IonFlame sensor for continuous operation QRB, Ion QRI, Ion QRI, IonNumber of stepping motors in electronic compound 1 2 2 2 4 6Burner equipped with stepping motor ● ● ● ● ● ●Frequency converter in pneumatic compoundFrequency converter in electronic compound ● ●Input for O 2 probeIntegral O 2 TrimSingle fuel operation ● ● ● ● ● ● ●Dual fuel operation ● ●Gas valve proving ● ● ● ● ●Integral PID modulating controller fortemperature or pressure control●OptionalRemovable control unit (max. distance) 95 feet 95 feet 30 feet 300 feet 300 feetFuel consumption meter ● ● ● 2) ●Display of combustion efficiencyBus communication interface ● ● ● ● ● ●MOD-Bus Interface ● ● ●PC supported commissioning ● ● ●Applicable burner models WL5 WL10 C WL 30 C WL 30 C WM-L10 RL,G,GL,RGL RL,G,GL,RGLWL10 C WL20 C WL 40 C WL 40 WM-L20 30–70 30–70Z / T / R2) not by speed regulation WG5 WG10 C WG10 C WG 10 C WM-G10 WKL, WKG WKL, WKGWG10 C WG 20 C WG 20 C WG 20 C WM-G20 WKGL WKGLWG30 C WG30 C WG 40 C WG 40 CWG40 CSingle stage Two stage Two stage Two stage Two stage Two stage Two stageModulating Modulating Three stage Three stage Three stageModulating Modulating Modulating●●●●Digital combustion management isavailable for nearly all Weishauptburners.All combustion managers are ableto communicate via a digital Businterface. This enables all thenecessary information andcommands to be relayed to a centralbuilding management system.W-FM 100 and W-FM 200Advantages at a glance:• One combustion manager for allburner versions• Precise control for optimalcombustion results• Choice of flame sensor• Integral modulating controller• Integral variable speed control• O 2 module can be easilyconnected (W-FM 200)• User friendly, separate control &display unit• Clear text display for error freeoperation• Flexible communicationpossibilities through a variety ofinterfaces• New technology offers a priceadvantage