infoInformation on digital combustion management

The intelligent control conceptW-FM 100 and W-FM 200 combustion managers

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Digital combustion management

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Modern gas, oil and dual fuel burners use combustion processeswhich require a precise and reproducible mixture of fuel andcombsution air.

Weishaupt’s digital combustion management is the monitoring andoptimising technology which allowsthe simple and safe operation ofcombustion plant.

Alongside the possibilities for remote operation, diagnosis andmonitoring, digital combustion management also reduces commissioning and servicing costs.

Simple connection

All the necessary connections for theexternal components are made via plugin terminal blocks, and all functions areintegrated into the combustion manager’s hardware and software.

Optimal switching safety

Outputs are realised via relays to guarantee optimal switching safety. TheW-FM 100 and W-FM 200’s inputs andoutputs are at mains voltage, no interlocking relays are required.

User friendly operation

A separate control and display unit(ABE) is used both by the plant operator for the running and monitoringof the burner, and by the engineer forsetting and comissioning. The ABE islinked to the W-FM unit by a secure bussystem (CAN bus). In this way the ABEcan be fitted anywhere the user chooses within 100 m of the main unit.

Extremely precise control

The secure bus system enables theoperation of up to six servomotors. Theyare connected directly to the correctingelements for air, fuel and the mixinghead assembly. These highly precisestepping motors are supplied with power via the CAN bus.

Choice of flame sensor

Four different types of flame sensor canbe connected directly to the main unit.For oil burners, the usual photo-resistorcan be used. For continually operatingdual fuel burners an infra red flicker detector has been developed. Burnersoperating solely on gas can be equipped with an ionisation probe developed for continual operation.

Numerous interfaces for ease ofcommunication

The integrated eBus interface enablesall operational data to be relayed to asuperordinate PLC or BMS. Similarly,the PLC/BMS can control all burnerfunctions, including capacity regulation.This interface also allows all diagnosticfunctions to be called up remotely.

There are ports available on the ABEcontrol and display unit for two digitalinterfaces. An RS 232 connection,which can be used to connect a PC orlaptop, is readily accessible on the exterior of the ABE. A software programthen allows the burner to be easily commissioned. the operational data thathave been set can be saved and printedout for reference. furthermore, plantoperation can be recorded thanks to aspecial recording function.

Advantages at a glance:

• One combustion manager for all burner variants

• Precise control for optimal combustion figures

• Choice of flame sensor

• Integral gas valve proving

• Integral capacity controller

• Integral speed control module(WM-F200)

• O2 module can be easily connectedfor O2 trim (WM-F200)

• Display of combustion efficiency(WM-F200)

• User friendly, separate control anddisplay unit

• Clear text display for error free operation

• 16 languages available

• Various interfaces for ease of communication

• Digitally controlled, modulating gasburners equipped with variable speeddrive meet the requirements of HMGovernment’s Enhanced Capital Allowance Scheme.

• Digitally controlled, multi-staged oilburners meet the requirements ofHM Government’s Enhanced CapitalAllowance Scheme.

System overview

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Combustion manager

The W-FM 100 and W-FM 200 combustion managers control the startup and shut down of the burner via anintegral ‘burner controller.’ The W-FMsare suitable for continuous operationand can be connected to flame sensorsfor gas, oil and dual fuel burners.

Seven different start up programs foroil, gas and heavy oil are available. Diverse parameters can be set (for example pre-purge time, post-purgetime, ignition and safety timings, pre-and post-purge positions of the stepping motors) to ensure an individualmatching to the plant.

Gas, light oil, heavy oil and dual fuel burners can all be individually controlled.The direct connection of all valves to theunit 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 compound

The error free CAN bus, which controlsthe servomotors (air damper, oil regulator, gas butterfly, mixing head),differentiates this electronic compoundregulation from previous systems.

Each servomotor is fitted with its ownmicroprocessor and is driven by a highlyaccurate stepping motor - an integratedregulation and monitoring circuit positions the drive shaft to within onetenth of a degree.The set position istransmitted from the main unit via thebus and once the exact position hasbeen reached this is transmitted fromthe servomotor back to the main unit.Completely separate data packets areused for each fuel.

Commissioning is much simplified. It isonly necessary to program as many capacity points as the setting of theburner requires. Additional points canbe entered, or existing points altered, asand when subsequently required.

Independent operating curves are available for gas and oil. Each operatingcurve can be individually programmedfor up to six stepping motors and a frequency convertor.

Control and display unit

The ABE control and display unit isconnected to the system bus and canbe installed up to 100 m away from themain unit, giving the operator the freedom to choose its optimal installation position.

All burner functions can be controlleddirectly from the ABE. No external control elements, such as buttons orswitches, are necessary. All operationsand diagnosis functions are displayed inclear text. There are 16 languages available.

A separate data recorder in the unit enables a complete back-up copy of theon-site settings to be saved.

The ABE also serves as the interfacewith a superordinate PLC or BMS andas a connection point for a PC duringcommissioning.

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Gas feed

Air feed

Oil feed

Mixing assembly

O2 probe

O2 module

Control anddisplay unit

Plant monitoring& visualisation

Pro Graf NT

Impulse sender

Steppingmotors

CAN bus

CAN bus

DDC

W-FM 200combustion manager

Frequencyconvertor

Separate access levels for safety

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Plant operator level

All the necessary commands for operating 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• Reset

Examples of readable values:• Actual temperature/pressure• Current burner rating• Flame signal• Error messages such as

“Max. gas pressure exceeded”

Service level (password protected)

This level is used by the qualified service engineer to commission andservice the burner.

Commissioning examples: • Setting of the electronic compound• Matching the capacity regulator to

the plant• Setting of the VSD and O2 trim

Servicing examples:• Reading of error codes for early

diagnosis• Resetting the burner after

exchanging components• Reading the number of start ups and

hours run

OEM level (password protected)

Weishaupt use this level to configurethe combustion manager at their plant

Configuration examples:• Selection of connected pressure

switches• Setting the fuel type; gas, oil or heavy

oil• Program runtimes, e.g. pre- and post-

purge• Country specific settings• Presetting during QA checks

D r i v i n g t o

P r e p u r g e P o s . 2 4

F 0 5 . 1 . A 4 4 . 6 3 0 . 3

P o i n t ‡ L o a d : 2 3 . 5

‡ F u e l : 2 3 . 2

M a n ‡ A i r : 4 1 . 6

‡ V S D : 3 0 . 3

T i m e s S t a r t u p 1

T i m e s S t a r t u p 2

T i m e s S h u t d o w n

T i m e s G e n e r a l

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Function overview

Integrated gas valve proving

A valve proving program is integratedinto the system and requires only an additional pressure switch on the gasvalve train

Using a special control program, it ispossible to select whether valve provingtakes place at burner start, burner shut-down or on both occassions.

After a power failure or automatic shut-down, a valve proving test is always car-ried out at the next burner start.

Integrated capacity control

The integral capacity controller (included as standard with W-FM 200,optional extra with W-FM 100) can beconnected to various temperature andpressure sensors.

Two internal set values can be called upvia an external drive (heat retention function, night setback). If required, thecapacity controller can also be activatedby external set values and regulators.Switching back to internal set valuesand regulators is possible at any time

There is a separate start up program fora cold boiler start, which gently bringsthe heating appliance up to nominaltemperature or pressure.

Integrated speed control (VSD)

The burner can benefit from variablespeed drive by using a frequency convertor to control the speed of theburner fan. The frequency convertor iscontrolled directly by the W-FM 200combustion manager

If fuel meters are fitted (extra cost option), cumulative fuel consumptionand current throughput rates can bedisplayed.

Integrated O2 trim

Fitting an O2 probe and O2 module andconnecting them to the W-FM 200 viathe internal system bus is all that is required to equip the burner for O2 trim- a great simplification compared witholder systems.

The O2 module converts the signal fromthe O2 probe for the CAN bus. The module can be placed up to 10 m awayfrom the O2 probe.

The use of flue gas and air inlet temperature sensors enables combustion efficiency to be displayed.

Max Weishaupt GmbH, D-88475 SchwendiTel (0 73 53) 8 30, Fax(0 73 53) 8 33 58www.weishaupt.de

Print No. 83201402, August 2007Printed in Germany. All rights reserved.

Neachells Lane, Willenhall, WV13 3RGTel (01902) 609841, Fax (01902) 633343

Overview of digitalcombustion management

System overviewDigital combustion management W-FM 05 W-FM 10 W-FM 20 W-FM 21 W-FM 50 W-FM 100 W-FM 200

Burner controller for intermittent operation x x x x x x x

Burner controller for continuous operation x x x

Flame sensor for intermittent operation QRB, Ion QRB, Ion QRB, Ion QRB, Ion QRB, Ion QRB, Ion QRB, Ion

Flame sensor for continuous operation QRB, Ion1) QRI, Ion QRI, Ion

Servomotors in electronic compound 2 off 2 off 2 off 4 off 6 off

Servomotors with stepping motor x x x x x x

Frequency convertor in pneumatic compound x x

Frequency convertor in electronic compound x x

Input for O2 probe x

Integral O2 regulator x

Single fuel operation x x x x x x x

Dual fuel operation x x

Gas valve proving x x x x x x

Integral self adjusting PID-regulator fortemperature or pressure Optional

x

Removable control unit (max. distance) 30 m 30 m 20 m 100 m 100 m

Fuel consumption meter x x x2) x

Display of combustion efficiency x

eBUS interface x x x x x x x

Modbus interface x x x

PC supported commissioning x x x

Applicable burner types WL5 WL10 WL30 WL30 WM-L10 RL, G, GL, RGL RL, G, GL, RGLWL10 WL20 WL40 WL40 WM-L20 30–70 30–70WL20

1) In planning WG5 WG10 WG10 WG10 WM-G10 WM-GL10 WKL, WKG2) Not with variable speed drive WG 10 WG20 WG20 WG20 WM-G20 WM-GL201) WKGL

WG20 WG30 WG30 WKL, WKGWG 40 WG 40 WKGL

Single stage Two stage Two stage Two stage Two stage Two stage Two stageModulating Modulating Three stage Three stage Three stage

Modulating Modulating Modulating

Digital combustion management is available for nearly all Weishaupt burners.

All combustion managers operate via a digital eBus interface. Thisenables all the necessary informationand commands to be relayed to a superordinate PLC or BMS.

W-FM 100 and W-FM 200 –the advantages at a glance:

• One combustion manager for all industrial burner variants

• Precise control for optimal combustion figures

• Choice of flame sensor• Integral gas valve proving• Integral capacity controller• Integral speed control module• O2 module can be easily

connected• User friendly, separate control and

display unit

• Clear text display for error free operation

• Flexible communication possibilities through a variety of interfaces

• Digitally controlled, modulating gasburners equipped with variable speeddrive meet the requirements of HMGovernment’s Enhanced Capital Allowance Scheme.

• Digitally controlled, multi-staged oilburners meet the requirements ofHM Government’s Enhanced CapitalAllowance Scheme.