info

Combustion managersW-FM50, W-FM100, W-FM200

infoThe capabilities of Weishaupt combustion managers

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Weishaupt burners with digital combustion managementhave been operating on a wide variety of heat generatorsand thermal process plant for more than 15 years. Thetechnology’s universal adapatability to completely differentburner types and operating conditions is compelling.

Close collaboration in Weishaupt’s own R&D Centre with thecombustion manager manufacturers leads to the development of bespoke products that continually establish new benchmarks.

Today, it is possible to cover the full spectrum of combustiontechnology applications with just a few different types of combustion manager.

Combustion managers incorporate efficiency-increasing andemissions-reducing technologies, as well as connections for external control systems.

Weishaupt’s range also covers the whole gamut of modern controltechnology, including fully comprehensive solutions for complexbuilding automation projects; future-oriented, cost-effective, andflexible.

The W-FM50digital combustion managers

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M

W-FM50 system with optional components

Burner with digital combustion management

Alternative:Oil or gasmeter

W-FM50combustion manager

Control anddisplay unit

ACS 450 servicing software

Frequencyconvertor for variablespeed drive

Fanmotor

Speedsensor

Setpointinput

KS20 loadcontroller

Schematic representation with W-FM50

Gas feed Air feed Air pressureswitch

Gas pressureswitch

Double gasvalve

Oil valvesOil pressureswitch

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Digital combustion management hasbeen an innovative and fundamentalcomponent of Weishaupt gas, oil, anddual-fuel burners for more than a decade.

The W-FM50 combustion manager hasearned a secure place on WM10 to WM30monarch® burners. Their ease of use, stabilityand operational reliabilty is compelling.

Electronic compound regulationECR, one of the combustion manager’s systems, guarantees the precise and continually reproducible dosing of the burner’s fuel and combustion air. Particular attention is given to the combustion air.

Variable speed driveThe W-FM50 is VSD ready. Opt for a frequency convertor and benefit from all the advantages that variable speed driveprovides. The high potential for energy savings and the reduction of noise emissions are two known benefits. Lesswell known, but significant nevertheless,

is the minimisation of the starting current,which helps to reduce peak load. What ismore, a frequency convertor provides optimal motor protection.

Yet today’s combustion manager systemsoffer even more: digital and analogue inputto the optional load controller, control of external fuel safety valves, communicationwith superordinate control systems, and theintegration of sitespecific parameters suchas, for example, adjustable pre- and post-purge times.

It sounds good, and it is.

The W-FM100 and W-FM200 digital combustion managers

Setpoint 50.0 °C

Act Value 78.5 °C

Load 64.8 %

Flame 98.5 %

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W-FM100 / 200 system components

Schematic representation with W-FM200

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CA

N b

us

Aut

onom

ous

CO

mon

itorin

g (w

ithou

t O2

mod

ule)

Puls

e in

put f

or fu

el m

eter

ing

Inte

rnal

load

con

trol

ler

Setpointinput

Burner with digital combustion manager

W-FM200combustion manager

Burner-mounted /panel-mountedcontrol and display unit

CO probe

Gas feed

Oil feed

Air feed

Air regulating sleeve

Freq

uenc

y co

nver

tor

for

varia

ble

spee

d dr

ive

O2 probe

O2 module

CO moduleBurnermotor

Speed sensor

M

ACS 450 servicing software

Temperature sensor

Air pressureswitch

Gas pressureswitch

Double gasvalve

Oil valvesOil pressureswitch

Temp. / press.sensor

Setpoint 50.0 °C

Act Value 78.5 °C

Load 64.8 %

Flame 98.5 %

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The W-FM100 and W-FM200 digital combustion managers

Control and display unit withclear text display

EnglishGermanFrenchItalianPortugeseSpanishPolishSlovenianHungarianCzechCroatianDutchSwedishDanishNorwegianFinnishRussianTurkishBulgarianRomanianChinese

Burner-mounted W-FM100 or W-FM200combustion manager

Mounted in a control panel

Burner motor junction box

Integrated star-delta switchingwith optional motor protection switch

Optional burner-mounted frequency convertor

Variable systems technologyThe W-FM100 and W-FM200 combustion managers utilise CAN bustechnology and can be mounted neatlyonboard the burner or in a separatecontrol panel as required. The system’scontrol and display unit, which is alsoconnected by CAN bus, can be installedin any suitable location. The control anddisplay unit also houses a jack for interfacing with a BMS via Modbus RTUor eBus, and a port for connecting to awindows PC running ACS450 servicingsoftware.

Compact and capableAn analogue burner control box and adigital combustion manager are as different from one another as a typewriterand a PC. A combustion manager unifies diverse, conventional burner controlsystems within a very small amount ofspace. That provides all kinds of benefits.Switching contacts and connectionglines reduce mechanical sources oferror to a minimum. New monitoringsystems, such as the contact feedbacknetwork, increase reliability by recogni-sing improper voltage signals and re-acting accordingly to them.

There are external benefits too. A smallerequipment footprint, faster installation,and computer-assisted system checksboth reduce costs and increase quality;a win–win situation for the customerand the manufacturer.

Setpoint 50.0 °C

Act Value 78.5 °C

Load 64.8 %

Flame 98.5 %

Extreme precision withelectronic compound regulation

Maintaining the ideal mixing ratio offuel to air through a burner’s entireturndown range can only be achievedwith a state-of-the-art combustionmanagement system.

Such a system is limited not just to thecombustion manager, it incorporates allof the controls. Electronic and mechanicalparts have to be equally accurate inorder for the necessary degree of precision to be realised. Equally accurate,however, does not mean equally extensive.

It is not what has been added that isthe crucial factor, but rather what hasbeen left out. If you look at a Weishauptburner today, you will notice that themechanical components have been reduced to a minimum. In their placeare stepping motors, which are preciseto 0.1° at the shaft and have torsionallyresistant connecting pieces. These ensure that positioning is both exact

Freq

uenc

y co

nver

tor

Control anddisplay unit

Actuators

Air

dam

per

Oil

regu

lato

r

Mix

ing

asse

mbl

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but

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W-FM200

CAN bus

and reproducible; a prerequisite for theconstantly precise proportioning ofevery individual component and, by extenison, the electronic compound regulation system.This provides key benefits when makingadjustments for flame geometry and different damper characteristics. Up to15 load points per curve, which are positioned differently dependent on theload, enable optimal adustments to bemade.

Similarly worth mentioning is the easeof load apportionment. One throughputmeasurement per load point, and thecapacity percentage, are all that have tobe entered in order for an automaticapportionment of the load points frompartial to full load to take place. Eachcontrol signal from the load controllerwill then result in the same change inload. Optimisation of the load controllerbecomes simpler, the system operatesmore stably, and efficiency is further increased.

How does an electronic compoundregulation system work?When the burner is adjusted, flue gasmeasurements are used to create acurve for each of the correcting elementsthat are working in compound. The necessary amount of excess air frompartial to full load is established at thesame time. This has to be kept constantthroughout the whole capacity rangeduring burner operation.

As can be seen illustrated above, thecurves differ from one another: one issteeper, one is shallower, and one iscurved. To compensate for these characteristics, the combustion managermakes use of the variable runtimes ofthe stepping motors. It calculates theexact runtime for each actuator, basedon the change in load to be effected.Only in this way is it possible for thedamper settings and the speed to follow the curves exactly – monitoringincluded.

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<) ]

Spe

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]

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Optimal matching:the little things that matter

Data backupEverybody knows that nothing lasts forever, yet not everybody thinks aboutthe necessary precautions. So it is goodto know that all the control and displayunits of Weishaupt combustion managershave separate memory modules thatare protected against loss of data.

If, for whatever reason, it becomes necessary at some point to replace thecombustion manager, the entire dataset can be copied over to the new unit,quickly, easily, and without error. And foranyone who prefers to be doubly sure,the ACS450 software can make an additional copy of the data on a PC orexternal data storage medium.

Just getting to site quickly is notenough. Getting everything workingagain as quickly as possible is just as important.

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The optimal matching of burner loadto the heat demand of a plant helpsto ensure the efficient operation ofthe entire system.

Responsibility for this key operationalaspect lies with a system componentthat, alongside big features like O2 trim,CO control, and variable speed drive, isoften given too little attention – the loadcontroller. It makes sure that the burnerconverts only as much fuel into heat asis actually needed at that moment. Itstops the burner from continually switchingon and off and thus avoids unnecessarystartup emissions. The load controller isthe crucial component when it comes toimproving annual efficiency and savingfuel.

Weishaupt has a highly adaptable integralload controller for its W-FM100 and W-FM200 combustion managers. In theforeground is the automatic adaption ofthe PID control parameters. Behind thatis hidden a measurement process, whichdetermines the dynamics of the systemand calculates control values fromthem – and always especially for thatparticular system.

Savings are good, but only in the rightplaces. Therefore, it is also important tobear the heat generator in mind. Heatingup too rapidly, or operating at too low atemperature, can damage an appliance.Parameters such as minimum boiler temperature, or thermal shock protection,help protect against this.

PE

N L

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(STA

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X6-03X6-02X4-03

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OIL

X3-04

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X7-03X6-01

LSta

rt

Gas

LSta

rt

Oil

LSta

rt

Oil-HO

InterlockingExternal electrical signals cannot always be incorporated into a controlsystem as a matter of course and theirinclusion can require additional effortand expenditure.

Weishaupt’s W-FM100 and W-FM200combustion managers, however, haveseparated inputs for their control andsafety loops. Furthermore, there arefuel-dependent start releases for gas,light oil, and HFO for a wide variety ofapplications. So it is possible, for example,to monitor whether fresh air and fluegas dampers are open, or to provideswitching signals for the fuel feed.

It all sounds rather unspectacular, butthese are the very things that increaseoperational readiness and safety.

Backup ➞ Info

W-FM ➞ ABE

ABE ➞ W-FM

Optimising efficiency and emissions

η

rpm

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Variable speed drive (VSD)

WM-GL 30 dual-fuel monarch® with CO/FGR-version W-FM200 and frequency convertor

The W-FM200 combustion managerhas a very considerable range ofcapabilities.

The system contains no fewer than 13different software components. Many ofthese are directly connected with oneanother. VSD is always an element ofthe compound regulation, which in turnis the basis for O2 trim and CO control.

These interlocked technologies arecontrolled by intelligent software, whichautomates, calculates, and adjusts manythings in the background. Alongsidethat are clearly structured control levelswith text displays that allow for fine adjustments to be made, with the aimof saving energy while achieving environmentally friendly combustionand optimal performance.

Reduced electrical consumption for a WM-G30/1-A ZM-3LN

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Air volume [% vol]

Mot

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peed

[%]

Mot

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atin

g [k

W]

Without VSD

With VSD

Curves based on measurements on aerodynamic equipment

How does VSD save energy, andwhat other benefits does it offer?Burners with modulating load controlhave a variable rate of fuel throughputfor which the corresponding volume ofcombustion air is required.

Combustion air volume is usually controlled mechanically by an air damperwhile the burner motor runs at a constantspeed. Running the motor at 100 % capacity when only 50 % is required isa waste of energy, which the use ofVSD could have saved.

VSD offers other benefits too. Reducedmotor speed results in quieter operation,smoother running, and perfect startingbehaviour.

O2 trim and CO control

Example: Combustion limit trend across the entire operating range of a gas burner and the associated air settings with and without O2 trim

WM-GL 30 dual-fuel monarch® with CO/FGR-version W-FM200 and frequency convertor

The availability of well-proven technology to combat increasingenergy prices means that it is alwaysbeneficial to change over to the latest equipment

With amortisation periods of just a fewyears, operating costs will be reduced ona continuing basis thereafter. And that isnot all. Continuous monitoring and controlto ensure combustion is CO free meansincreased operational safety.

Two independent measurement systemsfeed into the combustion manager’s compound regulation system, allowingcontinual real-time adjustments to bemade without affecting operational availability or safety.

How does O2 trim increase efficiency?The task of a burner is to mix air and fuelas homogeneously as possible, in theright proportions, so that optimal combustion can follow.

Combustion quality, in other words,how close one can get to stochiometric combustion with almost no CO, is onesign of the quality of a mixing assembly.This point is known as the combustionlimit and it ultimately determines theamount of excess air with which the burnermust be operated in order to counter-balance environmental influences, variations in fuel quality, pollution, and soon. Therefore excess air is ballast that increases the flue gas volume, causingthe flow rate to increase. This results inreduced heat transfer and thus a reductionin efficiency.

O2 trim can’t improve a mixing assembly,but it can have an influence on theamount of excess air. By continuallymeasuring the O2 content of the flue gas,the amount of excess air can be reducedto a minimum. Then, the flue gas volumedecreases, the flow rate reduces, heattransfer improves, and the efficiency increases.

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Burner rating [%]

O2

cont

ent [

vol %

wet

]

Air–

fuel

equ

ival

ence

rat

io [λ

]

Operation without O2 trim

Operation with O2 trim

(CO > 50 ppm)Combustion limit

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Reducing NOx with flue gas recirculation

WKmono G80 with flue gas recirculation

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Burner rating [%]

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The values are for the stated burner versions on three-pass combustion chambers with medium temperatures ≤ 110 °C. Weishaupt constraints based on the requirements of EN 676.

Flue gas recirculation – Weishaupt’sanswer to ultra-low NOx limits.It sounds so simple – you connect theburner’s air inlet to the flue of the boilerwith a hose, draw the flue gas off withthe burner fan, and feed it back into theflame with the combustion air. The result:extremely low NOx emissions.

As we said, it sounds easy. However,the critical factor is the precise dosingof the recirculated flue gas. The W-FM200 combustion manager is best placed to control this. With justtwo additional components – a flue gastemperature sensor and a butterflyvalve – and some additional software,the W-FM200 can control the flow offlue gas so that the correct amount isfed into the combustion air under all operating conditions, providing reliablestartup and operational behaviour – justas you would expect.

NOx emissions achievable when firing natural gas A heat generator’s NOx emissionsdepend on a lot of different factors.The design of the appliance alone – itscombustion chamber dimensions, thethermal load, and the temperature ofthe heat exchange medium – has avery large effect on NOx formation.

Take into account even more factors,such as air humidity and temperature,excess air, and the type of fuel, and it isclear that reducing NOx emissions tothe lowest possible level does not solelydepend on the burner.

Nevertheless, having developed differentburner versions and systems, Weishauptis in the position of being able to meetthe most stringent of emission limits.

Version:multiflam®

Version:1LN

Version:NR

Version:multiflam® with FGR

Compelling solutions

0110 1100 1001 0001 0011 0110 1001 11001100 1000 1000 1110

0010 0000 1111 01101000 1000 0011 01100111 1110 1010 0110

Monitoring

Igniting

Communicating

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Combusting

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WK-series burner in hot-air execution with gas ignition burner

Perfect ignitionHelping safety and environmental protection

Gas iginition burner

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Flame monitoring for demanding safety requirements

Flame monitoring plays a crucialrole when it comes to reliability andsafety.

Determination of the best method offlame monitoring takes into account notonly the burner and the fuel to be combusted, but also how the systemoperates and the conditions inside thecombustion chamber.

Heat generators with one flame percombustion chamber are easier to monitor than those with multiple flames.In the latter case, it also depends whether the flames are firing into thecombustion chamber from the same oropposing directions.

Biomass plant and waste incineratorsneed a flame monitoring system that isnot affected by extraneous flames.

Weishaupt offers flame monitoring systems for gas, oil, and dual-fuel burners operating under the widestrange of conditions.

Testing and optimisation using a software tool

The constructive alignment of the CFC3... allows the detection range to be optimised

CFC3... flame detector

CFC3..flame detector

QRA73flame sensor

Flame root

Amplitude

Frequency

Combustion zone

VLoadelectronic module

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W-FC: Weishaupt Flame Control

is for plant with multiple burners firing from the same directioninto a single combustion chamber. TheW-FC assembly utilises flame frequencyto monitor each flame separately via aload-independent on and off thresholdfor each fuel. The CFC3... flame detector functions in series with theQRA73 flame sensor on the W-FM100or W-FM200 combustion manager.

Note: If a turndown in excess of 4:1or single-burner operation is required,the higher-specification W-FC 5.0must be selected.

W-FC 4.0

For plant with extreme NOxrequirements, e.g. hot air, thermal fluid, etc

is for plant with multiple burners firing from different directionsinto a single combustion chamber, andfor process plant with various flamesources. The W-FC assembly monitorseach flame separately via up to ten load-dependent switching thresholds for eachfuel. The VLoad electronic module andits user-friendly software establishes adistinct differentiation from extraneouslight sources specific to that plant. TheCFC3... flame detector functions in parallelwith the QRA73 flame sensor on the W-FM200 combustion manager.

For classical parallel firing into acombustion chamber, with amaximum turndown of 4:1

For firing into a combustion chamber from opposing directions,and individual/staged firing ofmultiple burners

For plant with various flame sources,such as waste and biomass incineration, process plant, etc.

is required for plant withflue gas recirculation and a high re-circulation rate. This variant checksnot only for the presence of a flame,but also for its stability. Flame stabilityis monitored via an additional systemcomprising a CFC3.. flame detector, aVLoad electronic module, and a fluegas damper. Optimal detection of theflame throughout the entire loadrange is facilitated by load-dependentsetting points. If any flame irregularitiesoccur, the flue gas damper is adjustedto restore stability.

W-FC 6.0

Weishaupt Flame Control (W-FC) is areliable flame monitoring system designed to meet demanding safety requirements and comply with the

EN 298 standard for continuous operation.

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Special application:Simultaneous combustion

One of many solutions: Burner system with two W-FM200 combustion managers for separate or simultaneous combustion

The use of renewable fuels demands the implementation of increasingly specialised solutions.

Weishaupt has long been able to combusttwo or more fuels simultaneously. Depending on the particular arrangementof the fuel supply system, executionswith one or more combustion managers

are possible. One such variant with twoW-FM200s makes it possible for optimaladjustments to be made for each fuel,both when firing individually and duringsimultaneous combustion with anotherfuel.

Weishaupt can offer even more, such as“on-the-fly” fuel changeover. For biogas

in particular, which may not always beavailable in sufficient volume, a methodof changing over to natural gas without apause in firing has been established.This presents several advantages, suchas fewer burner starts, reduced start-upemissions, and more stable operatingtemperatures.

info esc

S o l l w e r t 8 0 . 0 ° CI s t w e r t 7 8 . 5 ° CL e i s t u n g 6 4 . 8%F l a mm e 9 8 . 5%

Separate firing

Simultaneousfiring

Biogas

Nat. gas

Fuel oil

Setpoint 50.0 °C

Act Value 78.5 °C

Load 64.8 %

Flame 98.5 %

Setpoint 50.0 °C

Act Value 78.5 °C

Load 64.8 %

Flame 98.5 %

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Special applications, like simultaneouscombustion, call for bespoke controlpanels.

Weishaupt, with its own in-house controlpanel design, production, and testingdepartments, can provide a full service.What is more, it can all be commissionedand serviced by Weishaupt’s very ownexperienced technicians.

A worry-free package from a singlesupplier. It doesn’t get better than that.

Special burner for the simultaneous combustion of two gas types

Weishaupt control panel with two W-FM200 combustion managers

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Digital combustion managers:The differencesCombustion manager W-FM50 W-FM100 W-FM200

Fuels

Gaseous l l l

Liquid l l l

Gaseous / liquid – l l

Gaseous / gaseous – – l 2)

Gaseous / gaseous / liquid – – l 2)

Gaseous / liquid / liquid – l 2) l 2)

Other fuel combinations available – – –

Simultaneous combustion

With fixed fuel volume ratio – l 3) l

With fixed fuel volume ratio + independent combustion – l 3) 4) l 4)

With multiple fuel volume ratios + independent combustion – – –

On-the-fly fuel changeover

Gaseous gaseous – – –

Gaseous liquid – –– –

Features

Continuous operation > 24 h l 5) l l

Integrated gas valve proving l l l

Maximum number of actuators 2 4 6

Maximum number of frequency convertors 1 – 1

Maximum number of compound adjustments 1 2 2

Multiple combustion managers can be networked – – –

Language-neutral control and display unit l – –

Multi-language control and display unit, clear text – l l

Multi-language control and display unit, colour graphics – – –

Removable control and display unit, max length of connecting line to W-FM 20 m < 100 m < 100 m

Data backup on control and display unit / servicing software l / l l / l l / l

1) Low-viscosity liquid fuels only2) External control required

3) Only with free AUX 1 output 4) Second W-FM required

5) Gaseous fuels only

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Combustion manager W-FM50 W-FM100 W-FM200

Efficiency and emission optimisations

Variable speed drive l – l

O2 trim – – l

CO monitoring – –

O2 trim and CO control – –

Flue gas recirculation – –

Non-system-specific sensors – – –

Fuel consumption meter (switchable) l 6) – l

Combustion efficiency display available – – l

Flame monitoring

Duplicate flame monitoring – – l 2) l Extraneous light supression – unidirectional flames + turndown ≤ 4:1 – l l

Extraneous light supression – unidirectional flames + turndown > 4:1 – – l 2) Extraneous light supression – opposing flames – – l 2)

Extraneous light supression – Biomass (ignition and ancillary burners) – – l 2)

Flame monitoring systems for heightened requirements – – –

Ignition systems

Electrical ignition unit l l l

Gas pilot ignition – l l

Gas ignition burner – – l

Light-oil ignition burner – – l

Control and regulation

Three-term switching signal input l l

Analogue signal input (0 / 4–20 mA / 0 / 2–10 V) l / – / l / l

Setpoint input (temperature / pressure) – l

Load signal output (0 / 4–20 mA / 0 / 2–10 V) – / l6) / l / l

Integrated load controller – l

Control of multiple burners on a single combustion chamber – l 2) l 2)

2) External control required6) In lieu of variable speed drive

○ Optional

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Combustion manager W-FM50 W-FM100 W-FM200

Bus systems

eBus l l l

Modbus RTU l l

Modbus TCP/IP Gateway Gateway Gateway

Profibus DP Gateway Gateway Gateway

Mounting position

Burner-mounted combustion manager l l 7) l 7)

Panel-mounted combustion manager available – l l

Power supply

24 V, DC – – –

120 V, 50 Hz / 60 Hz l l l

230 V, 50 Hz / 60 Hz l l l

Approvals

Europe CE (230 V / 50 Hz) l l l

Australia AGA (240 V / 50 Hz) l l l

USA / Canada CSA (120 V / 60 Hz) l l l

USA / Canada ETL (120 V / 60 Hz) l l l

Maritime applications

Lloyd's Register – l l

DNV-GL – l l

Integration of customer-specific controls

Boiler controls (steam and HTHW) – – –

Burner sequencing – – –

Time-dependent pump switching – – –

Control of the fuel supply – – –

Trace heating control – – –

Switchable safety loops (fail-safe) – – –

Customer-specific control and regulation processes – – –7) Panel-mounted combustion manager required with preheated combustion air

Digital combustion managers:The differences

The Weishaupt group stands for reliability

The Weishaupt group with 3400employees belongs to leading compa-nies for condensing technology, heatpumps, solar, burner and building auto-mation.

The group which established in 1932consists of three sub-companies whichoperates in the field of energy techno-logy, energy recovery and energymanagement.

The core business unit is Max Weishaupt GmbH (energy techno-logy) which located in Upper Swabiantown of Schwendi, where all burnersare manufactured, the main administra-tion is located and where the researchand development institute can befound.

In the sister company, Pyropac, locatedin Swiss Sennwald, heating systems aremanufactured.

Neuberger building automation (energymanagement), located in Rothenburgob der Tauber, belongs to the groupsince 1995.

The BauGrund Sued Geothermal(energy recovery) in Bad Wurzach,responsible for drilling of ground sen-sors and wells, joint the group in 2009.

Heating system production Facility in Sennwald,Switzerland

Neuberger Building automation in Rothenburg o.d.T. Ground drilling with BauGrund Süd

Weishaupt Corporation6280 Danville RoadMississauga, ON L5T 2H7, CanadaPh: (905) 564 0946 Fax: (905) 564 0949www.weishaupt-corp.com

Weishaupt America Inc.2587 Millenium Drive, Unit AElgin, IL 60124, USAPh: (847) 531 5800Fax: (847) 531 5855www.weishaupt-america.com

Print No. 83217116, January 2017Printed in Germany. All rights reserved.

Regular maintenance reduces heatingcosts and environmental pollution. Only aproperly adjusted burner can save energyand be environmentally friendly. Behindeach Weishaupt burner stands the wholeWeishaupt customer service organization.The outstanding efforts made inmaintenance and service justify theenormous trust placed in Weishaupt’sburners, for at Weishaupt, product andcustomer service belong together.

Weishaupt customer service is there foryou all year round. Whenever you needhelp, be it the supply of spare parts,technical advice or a site visit. We arethere when you need us.