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The Capabilities of Weishaupt Combustion Managers
The Capabilities of Weishaupt Combustion Managers
Combustion managers
W-FM50, W-FM100, W-FM200
Weishaupt burners with digital combustion management
have been operating on a wide variety of heat generators
and thermal process plant for more than 15 years. The
technology’s universal adapatability to completely different
burner types and operating conditions is compelling.
2
The W-FM50
digital combustion managers
3
W-FM50 system with optional components
ACS 450
servicing software
Alternative:
Oil or gas
meter
W-FM50
combustion manager
Gas feed Air feed Air pressure Gas pressure Oil pressure Double gas Oil valves
switch switch switch valve
Digital combustion management has Electronic compound regulation is the minimisation of the starting current,
been an innovative and fundamental ECR, one of the combustion manager’s which helps to reduce peak load. What is
component of Weishaupt gas, oil, and systems, guarantees the precise and more, a frequency convertor provides
dual-fuel burners for more than a continually reproducible dosing of the optimal motor protection.
decade. burner’s fuel and combustion air.
Particular attention is given to the Yet today’s combustion manager systems
The W-FM50 combustion manager has combustion air. offer even more: digital and analogue input
earned a secure place on WM10 to WM30 to the optional load controller, control of
monarch® burners. Their ease of use, stability Variable speed drive external fuel safety valves, communication
and operational reliabilty is compelling. The W-FM50 is VSD ready. Opt for a with superordinate control systems, and the
frequency convertor and benefit from all integration of sitespecific parameters such
the advantages that variable speed drive as, for example, adjustable pre- and post-
provides. The high potential for energy purge times.
savings and the reduction of noise
emissions are two known benefits. Less It sounds good, and it is.
well known, but significant nevertheless,
4
The W-FM100 and W-FM200
digital combustion managers
Setpoint 5 0.0 °C
Act Value 7 8.5 °C
Load 6 4.8 %
Fla m e 9 8.5 %
5
W-FM100 / 200 system components
O2 probe
Temperature sensor
CO probe
Setpoint
input
CO module
Burner
M motor
Autonomous CO monitoring (without O2 module)
Speed
Air regulating sleeve sensor
O2 module
Oil feed
Air feed
Pulse input for fuel metering
Burner-mounted /
for variable speed drive
Setpoint 5 0.0 °C
control and Act Value
Load
7 8.5 °C
6 4.8 %
Fla m e 9 8.5 %
display unit
CAN bus
ACS 450
servicing software
W-FM200
combustion manager
Temp. / press. Air pressure Gas pressure Oil pressure Double gas Oil valves
sensor switch switch switch valve
6
The W-FM100 and W-FM200
digital combustion managers
Variable systems technology
English
German
The W-FM100 and W-FM200
French combustion managers utilise CAN bus
Italian technology and can be mounted neatly
Setpoint 5 0.0 °C
Act Value 7 8.5 °C
Portugese onboard the burner or in a separate
L oad 6 4.8 % Spanish
Fla m e 9 8.5 %
Polish
control panel as required. The system’s
Slovenian control and display unit, which is also
Hungarian connected by CAN bus, can be installed
Czech in any suitable location. The control and
Croatian
Dutch
display unit also houses a jack for
Swedish interfacing with a BMS via Modbus RTU
Danish or eBus, and a port for connecting to a
Norwegian windows PC running ACS450 servicing
Finnish
Russian
software.
Turkish
Bulgarian Compact and capable Burner motor junction box
Control and display unit with Romanian An analogue burner control box and a
clear text display Chinese
digital combustion manager are as
different from one another as a typewriter
and a PC. A combustion manager unifies
diverse, conventional burner control
systems within a very small amount of
space. That provides all kinds of benefits.
Switching contacts and connectiong
lines reduce mechanical sources of
error to a minimum. New monitoring
systems, such as the contact feedback
network, increase reliability by recogni-
sing improper voltage signals and re-
acting accordingly to them.
Burner-mounted W-FM100 or W-FM200 There are external benefits too. A smaller Integrated star-delta switching
combustion manager equipment footprint, faster installation, with optional motor protection switch
and computer-assisted system checks
both reduce costs and increase quality;
a win–win situation for the customer
and the manufacturer.
7
Extreme precision with
electronic compound regulation
90 100
Frequency convertor
Actuator [°<) ]
Speed [%]
80 90
70 P4 80
70
60 P3
60
50
P2 50
Actuators 40
40
30
P1
Mixing assembly
30
Gas butterfly
20
Oil regulator
20
Air damper
Air pos
Auxiliary 2
Auxiliary 3
10 Gas pos 10
FC pos
0 0
0 Rating [%] 100%
CAN bus
Control and
W-FM200 display unit
Maintaining the ideal mixing ratio of and reproducible; a prerequisite for the How does an electronic compound
fuel to air through a burner’s entire constantly precise proportioning of regulation system work?
turndown range can only be achieved every individual component and, by When the burner is adjusted, flue gas
with a state-of-the-art combustion extenison, the electronic compound measurements are used to create a
management system. regulation system. curve for each of the correcting elements
This provides key benefits when making that are working in compound. The
Such a system is limited not just to the adjustments for flame geometry and necessary amount of excess air from
combustion manager, it incorporates all different damper characteristics. Up to partial to full load is established at the
of the controls. Electronic and mechanical 15 load points per curve, which are same time. This has to be kept constant
parts have to be equally accurate in positioned differently dependent on the throughout the whole capacity range
order for the necessary degree of load, enable optimal adustments to be during burner operation.
precision to be realised. Equally accurate, made.
however, does not mean equally As can be seen illustrated above, the
extensive. Similarly worth mentioning is the ease curves differ from one another: one is
of load apportionment. One throughput steeper, one is shallower, and one is
It is not what has been added that is measurement per load point, and the curved. To compensate for these
the crucial factor, but rather what has capacity percentage, are all that have to characteristics, the combustion manager
been left out. If you look at a Weishaupt be entered in order for an automatic makes use of the variable runtimes of
burner today, you will notice that the apportionment of the load points from the stepping motors. It calculates the
mechanical components have been partial to full load to take place. Each exact runtime for each actuator, based
reduced to a minimum. In their place control signal from the load controller on the change in load to be effected.
are stepping motors, which are precise will then result in the same change in Only in this way is it possible for the
to 0.1° at the shaft and have torsionally load. Optimisation of the load controller damper settings and the speed to
resistant connecting pieces. These becomes simpler, the system operates follow the curves exactly – monitoring
ensure that positioning is both exact more stably, and efficiency is further included.
increased.
8
Optimal matching:
the little things that matter
SAFETY
Oil-HO Oil Gas
LOOP
100
80
60
40
Backup ➞ Info
Start
Start
Start
20 W-FM ➞ ABE
L
L
0 ABE ➞ W-FM
[t]
X6-01 X7-03 X3-04
SV
P
PE
PE
N
N
L
9
Optimising efficiency and emissions
rpm
10
Variable speed drive (VSD)
The W-FM200 combustion manager
has a very considerable range of
capabilities.
11
O2 trim and CO control
The availability of well-proven
technology to combat increasing
energy prices means that it is always
beneficial to change over to the
latest equipment
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.
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Compelling solutions
Igniting
Combusting
Communicating
15
Flame monitoring
for demanding safety requirements
Flame monitoring plays a crucial
role when it comes to reliability and
safety.
QRA73
flame sensor
Determination of the best method of
flame monitoring takes into account not
only the burner and the fuel to be
CFC3.. combusted, but also how the system
flame detector
operates and the conditions inside the
combustion chamber.
Amplitude
VLoad
electronic module
Frequency
The constructive alignment of the CFC3... allows the detection range to be optimised
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W-FC: Weishaupt Flame Control
Weishaupt Flame Control (W-FC) is a EN 298 standard for continuous
reliable flame monitoring system operation.
designed to meet demanding safety
requirements and comply with the
W-FC 4.0 is for plant with multiple is for plant with multiple W-FC 6.0 is required for plant with
burners firing from the same direction burners firing from different directions flue gas recirculation and a high re-
into a single combustion chamber. The into a single combustion chamber, and circulation rate. This variant checks
W-FC assembly utilises flame frequency for process plant with various flame not only for the presence of a flame,
to monitor each flame separately via a sources. The W-FC assembly monitors but also for its stability. Flame stability
load-independent on and off threshold each flame separately via up to ten load- is monitored via an additional system
for each fuel. The CFC3... flame dependent switching thresholds for each comprising a CFC3.. flame detector, a
detector functions in series with the fuel. The VLoad electronic module and VLoad electronic module, and a flue
QRA73 flame sensor on the W-FM100 its user-friendly software establishes a gas damper. Optimal detection of the
or W-FM200 combustion manager. distinct differentiation from extraneous flame throughout the entire load
light sources specific to that plant. The range is facilitated by load-dependent
Note: If a turndown in excess of 4:1 CFC3... flame detector functions in parallel setting points. If any flame irregularities
or single-burner operation is required, with the QRA73 flame sensor on the occur, the flue gas damper is adjusted
the higher-specification W-FC 5.0 W-FM200 combustion manager. to restore stability.
must be selected.
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Special application:
Simultaneous combustion
Setpoint 5 0.0 °C
Act Value 7 8.5 °C
L oad 6 4.8 %
Fla m e 9 8.5 %
Biogas
Separate
firing
Nat. gas
Simultaneous
firing Fuel oil
S o l l we r t
Setpoint 85 0.0
0 . 0 °C
°C
I stw
Act er t
Value 77 8.5
8 . 5 °C
°C
L oad
L e i s t ung 66 4.8
4 . 8%%
F l ammem e
Fla 99 8.5
8 . 5%%
info esc
One of many solutions: Burner system with two W-FM200 combustion managers for separate or simultaneous combustion
The use of renewable fuels demands are possible. One such variant with two in particular, which may not always be
the implementation of increasingly W-FM200s makes it possible for optimal available in sufficient volume, a method
specialised solutions. adjustments to be made for each fuel, of changing over to natural gas without a
both when firing individually and during pause in firing has been established.
Weishaupt has long been able to combust simultaneous combustion with another This presents several advantages, such
two or more fuels simultaneously. fuel. as fewer burner starts, reduced start-up
Depending on the particular arrangement emissions, and more stable operating
of the fuel supply system, executions Weishaupt can offer even more, such as temperatures.
with one or more combustion managers “on-the-fly” fuel changeover. For biogas
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Weishaupt control panel with two W-FM200 combustion managers
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Digital combustion managers:
The differences
Combustion 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 – – –
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) 3) 5)
Low-viscosity liquid fuels only Only with free AUX 1 output Gaseous fuels only
2) 4)
External control required Second W-FM required
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Combustion manager W-FM50 W-FM100 W-FM200
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
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Digital combustion managers:
The differences
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
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The Weishaupt group
stands for reliability
Heating system production Facility in Sennwald, Neuberger Building automation in Rothenburg o.d.T. Ground drilling with BauGrund Süd
Switzerland
The Weishaupt group with 3400 In the sister company, Pyropac, located
employees belongs to leading compa- in Swiss Sennwald, heating systems are
nies for condensing technology, heat manufactured.
pumps, solar, burner and building auto-
mation. Neuberger building automation (energy
management), located in Rothenburg
The group which established in 1932 ob der Tauber, belongs to the group
consists of three sub-companies which since 1995.
operates in the field of energy techno-
logy, energy recovery and energy The BauGrund Sued Geothermal
management. (energy recovery) in Bad Wurzach,
responsible for drilling of ground sen-
The core business unit is sors and wells, joint the group in 2009.
Max Weishaupt GmbH (energy techno-
logy) which located in Upper Swabian
town of Schwendi, where all burners
are manufactured, the main administra-
tion is located and where the research
and development institute can be
found.
Weishaupt Corporation
6280 Danville Road
Mississauga, ON L5T 2H7, Canada
Ph: (905) 564 0946
Fax: (905) 564 0949
www.weishaupt-corp.com