11-12-Bruner - FINAL27 12 23

Contents
Page 1 Contents
Page 2-50 Wiring diagram
Page 51-278 Installation and operating instruction combustion manager W-FM 100 und W-FM 200
Page 279-390 Manual Dual fuel burner WM - GL30/2-A / ZM-R (W-FM 100/200)
Page 391-398 Add. sheet position change high gas pressure switch
Page 399-404 Add. sheet supplement service plan dual fuel burners WM 10 ... 50
Page 405 Conformity certification burner
Page 406 Conformity certification control panel
Page 407-514 Manual controller KS 40-1 for Weishaupt-burner
Page 515-563 Manual Digital 280-1
Page 564 Drawing
Page 565-696 Safety temperature limiter
Page 697-756 Manual UNIFLEX CI 45 universal transmitter

1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
WIRING DIAGRAM weishaupt

B Item identification consists of the identification block Instructions according to the manual have to be B
installation' (group) an 'item number' taken into consideration before commissioning.
The explanation for the location in the Electric installation has to be done by
coprises sheet number / diagram section'. electrically trained person, only.
Respect the local rules.
In case of mistakes in this wiring diagram, responcibility will

only be accepted within the framework of our terms and conditions.
No responcibility will be accepted for control panels, which

are not produced by Weishaupt.
C C
Diagram explanation:
Reference
Numbering 1 2 3 4 5 6 7 8
This drawing is protected and must
D D
not be copied or made available
A1
to unauthorised persons.
=P2
-K3
Circuit diagram Complete
Item identification
=P2-K3
Q1 =M1-Q1
Switching contacts
E reference E
05.05.17 0844 GMA
=M1
71001/010034
1/09.10.13 BJ
Constr.-
F
group =B1 F
- - - Date Name Title

Commission Gebr. Pfeiffer - TURBACO-CO - - - Drawn 27.04.17 GMA
WM-GL30/2
Created
Status
Origin
1 Delivery status - Checked Drawing-No. Max Weishaupt GmbH

Location
Turbaco Order-No.
210965471.000255 . Change Day Name Norm
75478/020150 Bl.01/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Sheet Designation Sheet Designation Sheet Designation
B01/39 WM-GL30/2 B27/39 Capacity regulation
B02/39 Table of contents B28/39 Capacity regulation
B03/39 Door plan B29/39 Uniflex

Transducer
B B
B04/39 Mounting plate distribution B30/39 control circuit
Load running signal
B05/39 Panel version B31/39 Load position
Burner
B06/39 WM-GL30 ZM-R B32/39 Motor control
B07/39 Burner connection B33/39 Mixed Air Fan
B08/39 Burner connection B34/39 Mixed Air Fan

direkt starter
B09/39 Burner connection B35/39 Thermistor motor protection
Gas valve train Mixed Air Fan
C B10/39 Burner connection B36/39 Analogue signals C
Oil armature to/from DDC
B11/39 Burner connection B37/39 Messages
Servomotors to external DDC
Indicator unit/operating unit to external DDC
Internal capacity regulation to external DDC
B14/39 Burner connection
Flame monitoring
B15/39 Burner connection
Motor control
B16/39 Main power supply
D D
B17/39 Emergency stop

to unauthorised persons
B18/39 Temperature limit control
B19/39 Temperature limit control

Exhaust with Display
B20/39 Safety circuit
B21/39 Voltage supply

Safety circuit
B22/39 Prohibited start
E E
Gas
B23/39 Prohibited start
Oil
B24/39 Fuel selection
Gas/Oil
B25/39 Protocol data converting
Modbus / profibus-DP
B26/39 Lockout reset - Signalling
61001/000000
09.10.14 RD
Constr.-
F
Group = F
Date Name Title Table of contents

- Drawn -
Created
Status
Origin
Checked Drawing-No. Max Weishaupt GmbH

-
Nr. Change Day Name Norm
75478/020150 Bl.02/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
B B
120 (680)
175 (625)
230 (570)
285 (515)
340 (460)
395 (405)
450 (350)
505 (295)
560 (240)
655 (145)
0 (800)
800 (0)
0 (1200)
105 (1095)
195 (1005)
C 285 (915) C
=B1 =V1
-K1 -K21
375 (825)
465 (735)
=B1 =B1 =B1 =V1 =B1
-S3 -P6 -P1 -S1 -S4
555 (645)
=V1 =L1 =L1 =L1 =B1
-P7 -P2 -P1 -S1 -S15
645 (555)
=B1
-A2
ABE Innenseite Türe 735 (465)
D D
=V1 =A1
-S9 -Q1
825 (375)
915 (285)
1005 (195)
1095 (105)
1200 (0)
E E
06.04.17 0800 GMA
61001/000000
09.10.14 RD
Constr.-
F
Group =X99 F
Date Name Title Door plan

- Drawn -
Created
Status
Origin

-
75478/020150 Bl.03/39 88475 Schwendi
1 2 3 4 5 6 7 8
F
D
C
B
E
A
Origin 61001/000000
Created 09.10.14 RD not be copied or made available
Status
01.08.16 1337 VB
1
1
-
-
2
2
2
20170505_084835 100100104 634
3
3
Nr.
4
Change
4
4
Day Name
-A1
Norm
5
5
5
Drawn
-E10
Checked
=L1 -Q2 =A1 -F1
-Q3 =B1 -F1 =A1 -T1

-Q1
-K19 =L1 -F1
Date
=A1 -F10
=V1 -F1
Name
730
800
=V1 -K1
=A1 -K10
Title =V1 -K7
=B1 -K6
=L1 -K5 =B1 -K23
=V1 -K9 =B1 -K21
6
=V1 -K23 =B1 -K22
6
6
Drawing-No.
=V1 -K24 =L1 -K10
=B1 -T10 =B1 -T1 =B1 -A3
1170
1200
-
7
7
7
Mounting plate distribution
75478/020150 Bl.04/39
Group
Constr.-
8
8
8
=X99
88475 Schwendi
Max Weishaupt GmbH
F
E
D
C
B
A
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Panel version Wiring colors and cross sections
Panel type WSW-008-12-030
Type X Rittal
Main current
Häwa Phase L1,L2,L3 Black min. 2,5mm 2
Neutral wire (N) Blue min. 2,5mm 2
.....
Earth GN / YE min. 2,5mm 2
B B
Version Cabinet control

Phase Red 1,0mm 2
X Panel
Neutral wire Blue 1,0mm 2
Mounting plate Control transformer Red 1,0mm 2
Control transformer neutral wire red/white 1,0mm 2
Size B= 800 mm Low voltage <50VAC Grey 0,75mm 2
(Without base) H= 1200 mm Low voltage <50VAC (0V) Grey/white 0,75mm 2
T= 300 mm DC Voltage + Dark blue 0,75mm 2
DC Voltage - Dark blue/white 0,75mm 2
C Base 100mm 200mm ... C
Control 0/4-20mA / 0-10V White 0,75mm 2
Protection IP65 Sensor lines White 0,75mm 2
Paint RAL 7032 External voltage Orange min. 1,0mm 2
Mounting plate galvanized PLC-Connection (pot.-free) Brown 1,0mm 2
Safety circuit - SNA..-relay Pink 1,0mm 2
Panel designation Language: English / Spanish
Plexi labels
Terminal strip
X Resopal labels
D D
-X1 = Panel general
Hinge Left X Right

-X2 = Doorconnection (option)
Cable inlet X Below Up -X3 = Terminals at burner
-X10 = Terminals PLC / PLC-indications (pot.free)

Cable inlet with cablenipple
-X31 = Powerterminal 400V
X Cable gland set
-X32 = Powerterminal 230V
Marine cable gland
-X40 = Safety circuit - SNA..-relay
Clamp rubber -X41 = Terminals low voltage 24V AC/DC
E E
-X46 = Terminals sensor lines
Equipment Industrial designation Terminals current- voltage signal (0/4-20mA / 0-10V)
Cable racket -X50 = Terminals busconnection
X Cable duct -X80 = Terminals panel illumination
1/20.03.13 GMA
Terminals panel ventilation

61001/400001
Wire marking Ongoing Terminals panel horn
Terminals -X99 = Direct at instrument connect lines

-
F Potential identification Constr.-

= F
Group
Date Name Title Panel version
- Drawn -
Created
Status
Origin

-
NR. Change Day Name Norm
75478/020150 Bl.05/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
-B10 Legend:
- +
-M20 P B10 Air pressure switch
M
M1 Burner motor
M20 Servomotor air damper
B B
Air
M
-M1 3
-K14
UN/2
-X15
C C
-K11
B35 Max. pressure switch in oil return line

K11 Nozzle solenoid
-K15 K14 Solenoid valve additional
-B35
UN/2
-M17 K15 Solenoid valve additional
P> M17 Servomotor oil regulator
M
X15 Magnetic clutch
D D
Oil
E M B31 Low pressure switch gas E

(1 B32 Pressure switch valve proving
-B33 -M38
B33 Max. pressure switch gas (Option)
P> -K32 (1 Position B33 depends on type of gas valve train
-K33
K32 Solenoid valve main gas
1 2
K33 Solenoid valve gas external (Option)
1/24.09.13 KRE
M38 Servomotor gas-throttle

71001/010031
Gas
P< P
-
-B31 -B32 Constr.-

F
group =B1 F
Date Name Title WM-GL30 ZM-R

- Drawn -
Created
Status
Origin

-
75478/020150 Bl.06/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Burner
-T2
-X30-03 -X30-02
2 4
12V
12V
1
3
B B
2 FE
2
UN
12V
1 1
-X30-01
-X10-01
-X52
1
2
3
4
1
2
3
4
-A1 G G0 L N 12V M 12V FE
Jumper
Jumo Safety Loop Gas /Oil W-FM
W-FM100 /8.1
L PE N L PE N L L L PE L
C C
-X3-01
-X3-04
-X4-01
-X4-03
-X5-03
-X6-01
-X7-03
-X8-01
1
2
1
2
3
4
5
1
2
3
4
1
2
3
1
2
3
4
1
2
3
4
1
2
3
1
2
1
/15.1
FE
/13.2
D D
1: Oil Start conditions chain

24
2: Gas
3: Burner Fan RunFbk Connection control panel
1
/15.1
BR
E E
Start Command /21.1
Burner Fan M1
Q3
Legend: 4
71001/020009
1/26.09.13 ZN
/15.2
A1 Combustion manager
T2 Transformer Burner Fan RunFbk
FE Earth wire From Motor Page
-
Constr.-
F
group =B1 F
Date Name Title Burner connection

- Drawn -
Created
Status
Origin

-
75478/020150 Bl.07/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Burner
-B10 -S7 -T1
1 2 3
B B
3 2
/15.1 /15.2
-X3-02
-X3-03
-X4-02
1
2
1
2
1
2
3
L L PE N
W-FM W-FM
/7.8 /9.1
C C
D D
E Legend: E
B10 Air pressure switch

S7 Burner flange limit switch
T1 Ignition unit
71001/020013
1/27.09.13 ZN
Constr.-
F
group =B1 F

- Drawn -
Created
Status
Origin

-
75478/020150 Bl.08/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Burner
Legend:
B31 Low pressure switch gas

B32 Pressure switch valve proving
B B
B33 Max. pressure switch gas (Option)
K32 Solenoid valve main gas
K33 Solenoid valve gas external (Option)
K32.1
K32.2
W-FM W-FM
B31
B33
B32
K31
K33
/8.8 /10.1
L PE N
C C
-X9-03
-X9-02
-X9-01
4
3
2
1
2
1
4
3
2
1
PE
9
8
7
6
5
4
3
2
D D
Terminal box gas valve train
3
2
1
2
1
4
3
2
1
2
1
4
3
2
1
-X21-01
-X21-02
-X20-03
-X20-02
-X20-01
-X22-01
-X22-02
-X22-03
-X23-01
-X23-02
-X23-03
-X24-01
-X24-02
-X24-03
1
2
3
1
2
3
1
2
3
1
2
3
1
2
1
2
3
4
2
3
1
1
2
3
1
2
3
E E
PE
PE
PE
PE
L1
L2
L1
L2
L1
L2
L1
L2
X8 X8B X8A X9
N
N
1 2 3 1 2 3 1 2 3 2 1 3
71001/020023
1/01.10.13 ZN
Max. 2A
P< P> P 1 2
-
Constr.-
F -B31 -B33 -B32 -K32 -K33 group =B1 F

- Drawn Gas valve train
Created
Status
Origin

-
75478/020150 Bl.09/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Burner
-B35 -X15 -K11 -K14 -K15
UN/2 UN/2
P>
X1.4
X1.5
2 3 1 X12 1 2 PE 1 2 PE
1 2 PE
X35
B PE 2 3 1 -X17 B
-T10
-X5-02
-X6-02
-X8-02
-X8-03
1
2
1
2
3
1
2
3
4
1
2
3
4
PE L PE N N PE N PE
W-FM W-FM
/9.6 /11.1
N PE
C C
-X6-03
3
2
1
D D
Max. 1A
-K10
Legend:
E E
B35 Max. pressure switch in oil return line

K10 Non lift valve (Option)
K11 Nozzle solenoid
K14 Solenoid valve additional
K15 Solenoid valve additional
71001/020033
1/07.10.13 ZN
T10 Rectifier magnetic clutch

X15 Magnetic clutch
X17 Plug magnetic clutch
-
Constr.-
F
group =B1 F

- Drawn Oil armature
Created
Status
Origin

-
75478/020150 Bl.10/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Burner -M20 -M17 -M38
M M M
5 5
B 5 B
-X51
1
2
3
4
5
6
12VAC1
12VAC2
CANH
GND
Shield
CANL
W-FM W-FM
/10.8 /12.1
C C
D D
E Legend: E
M17 Servomotor oil regulator

M20 Servomotor air damper
M38 Servomotor gas-throttle
71001/020055.1
1/11.10.13 ZN
Constr.-
F
group =B1 F

- Drawn Servomotors
Created
Status
Origin

-
75478/020150 Bl.11/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Burner
B B
W-FM W-FM
/11.8 /13.1
C C
-X50
1
2
3
4
5
6
D D
WH
GN
BN
BK
YE
Connection control panel

ABE
/25.2
E E
71001/020048
1/10.10.13 ZN
Constr.-
F
group =B1 F

- Drawn Indicator unit/operating unit
Created
Status
Origin

-
75478/020150 Bl.12/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Burner
B B
External Setpoint
Actual value Actual value Capacity input Capacity output
Pt/Ni1000
0/4-20mA
0/4-20mA
0/4-20mA
W-FM W-FM
0/2-10V
0/2-10V
Sensor
Power
/12.8 Pt100 /14.1
FE
FE
FE
FE
0
0
C C
-X60
-X61
-X62
-X63
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
3
2
1
FE
/7.3 WE
/-28.
7
WE
+
/28.
7
D D
Connection control panel

/t.
LRM
/30.4
Analog Signal From Panel to Burner Black Box

E E
4
1
2
W10
0
-X46 LIYCY
2 0,75
- screened
.
.
X. +
71001/020595
1/04.03.15 ZN
- Set point from DCS.

De Rio a
Burner Move signal Here. Harwi
-
Constr.-
F
group =B1 F

- Drawn Internal capacity regulation
Created
Status
Origin

-
75478/020150 Bl.13/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Burner
-B1
QRI
BK
BN
BU
B B
-X10-02.2
2
3
4
5
QRI6
P/QRI
FSV/
N
L
PE
W-FM
/13.8
C C
D D
E Legend: E
B1 Flame sensor
71001/020016.1
1/27.09.13 ZN
Constr.-
F
group =B1 F

- Drawn Flame monitoring
Created
Status
Origin

-
75478/020150 Bl.14/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Burner -M1
U1 W2
V1 M U2
W1 3 V2
Terminal box burner motor

B B
17 (43)
W-FM100 -K19 -Q3
13
-Q1
13
-Q2
13
4 18 28 4 14 4 14 5 14
-X3-01
(44)
1
2
(32)
43 31 22 22
-Q3 -Q3 -Q3 -Q1 2 4 6 2 4 6 2 4 6
4 44 4 32 4 21 4 21 -Q2 -Q1 -Q3
star Delta (31) main 5 1 3 5 4 1 3 5 4 1 3 5
C A1 A1 A1 A1 C
1
-K19 -Q1 -Q3 -Q2
A2 A2 A2 A2
/7.2
2
/8.5
3
Line 28 1 2 1 2 1 2
/8.3 7 7 6
4 17 3 4 3 4 3 4
7 7 6
/7.3 4 18
7
5 6
7
5 6
6
5 6
13 14 13 14 13 14
5 5 6
21 22 21 22 21 22
D
1 - 20S
5 4 D
31 32 31 32 31 32
-X4-01
3
43 44 43 44 43 44
3
1
2
3
4
BURNER FAN RUNNING OK

W-FM100
PE
L1
L2
L3
E Legend: E
4
K19 Time relay Connection control panel

M1 Burner motor
Q1 Heavy duty contactor
Q2 Heavy duty contactor MOT
Q3 Heavy duty contactor /32.2
71001/020034
1/07.10.13 ZN
Constr.-
F
group =B1 F

- Drawn Motor control
Created
Status
Origin

-
75478/020150 Bl.15/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
L1
L2
L3
/32.1
-F10
Humidistat 6AB
B B
1 3 5 Cabinet heater 3
-F1 50-100% r.F. 1

I> I> I> -F12 -F11
2 4 6 2 1 10AB 2
1,87A
L10
(L1)
(L2)
(L3)
/17.1
-T1
480V
T1
T2
T3
800VA
Main switch
-X80 1 2
C C
110V
-Q1
L2
L3
L1
(T1)
(T2)
(T3)
Thermostat
Surface.
Attention
Heating 110V
Earthed control circuit
Cabinet
Open plug connection for
measurement purposes only M
150W
A1
D -K10 110 D
-E10
A2
V1N11
/17.1
14
/37.3 11 12
24
/37.7 21 22
34
E 1 /39.3 31 32
E
-X31
N0
N1
N2
N3
L1
L2
L3
PE W5
...
4 10
Main power supply
71001/030001
1/09.10.13 BJ
-F0
20kW / 40A
50A
-
Constr.-
F L1 L2 L3 PE group =A1 F
Date Name Title Main power supply

480V 3/N/PE 60HZ Drawn -
Created
Status
Origin
110V / N/PE 60HZ Checked Drawing-No. Max Weishaupt GmbH

-
75478/020150 Bl.16/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
L10
/16.7 V1F11.1
1
/24.3 V1F11
-F1 /18.1
6AgG
2
-X10 2/1 2/3 2/5

-X40 1/1 1/3
B B
-S16
-X.
23 -X10 2/2 2/4 2/6
-K1 -X40 1/2 1/4
/20.4 24
Emergency stop
C C
11 21 41
A1 S10 S11 S21 S14 S12 S13 -S9 12 22 42
Start
115V = Logic
-K9 SR3D
A2
V1N11 V1N11
/16.8 /18.1
D D
13 14
/20.7
23 24
/39.3
33 34
41 42
/20.4
ZANDER
SR3D
..
E 1 2 E
-X40 -X10
10
11
12
1
2
3
4
1
2
3
4
5
6
7
8
9
1 x Forward reporting PLC
PE PE W15 PE W20
W10 ... ...
... 7 1,5 7 1,5
2 x Emergency stop
03.08.16 0732 GMA
5 1,5
PE
PE
PE
Emergency stop
Emergency stop
Emergency stop
1/09.10.14 HR
71001/030172
escape door
Fa. AREND
Shutdown
Constr.-
F -X. -S16 -X. Group =V1 F
Date Name Title Emergency stop

- Drawn -
Created
Status
Origin

-
75478/020150 Bl.17/39 88475 Schwendi 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11 V1F11
/17.8 /19.1
13 33
B
-K1 -K1 B
/20.4 14 /20.4 34
-X40 1/5
TB1
P> /19.1
-F23 Jumo
TB2
-X40 1/6
/19.1
C C
A1 S10 S11 S21 S14 S13 S12 A1 S10 S11 S21 S14 S13 S12
Start Start
115V = Logic 115V = Logic

-K23 SR3D -K24 SR3D
A2 A2
V1N11 V1N11
/17.5 /19.1
D D
13 14 13 14
/20.7 /20.7
23 24 23 24
/38.3 /38.3
33 34 33 34
41 42 41 42
/20.5 /20.5
ZANDER ZANDER
SR3D SR3D
.. ..
E 1 E
-X40
5
6
PE W25
...
3 1,5
PE
1/05.11.14 HR
71001/000000
limiter 1 (RAZ)
Temperature-
P>
-
Constr.-
F -F23 Group =V1 F
Date Name Title Temperature limit control

- Drawn -
Created
Status
Origin

-
75478/020150 Bl.18/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11 V1F11
/18.8 /20.1
Temperature limit control L1
B 0...200°C B
STL VORALARM Jumo

AO1
...
-K21 INP1 INP2 - +
14 15 16 11 13 N 12 4 5 1 3 6 8 9 10
C TB1 C
/18.7
TB2
/18.7
D D
V1N11 V1N11
Temperature after Burner ( hot gas chamber)

/18.8 /20.1
to be used in the DCS. no additional sensor

need to be used. No extra cost for noboddy.
E 1 E
-X46
1
3
W30
LIYCY Replace this RTD for a Thermocouple
Exhaust STL (PT100)
3 0,75
withing 0 - 1200 Celcius Type K with
Temperatur sensor
11.07.12 1430 FJ
screened
1/30.03.12 HR
61001/070136
Configuration, see
Compensated cable
separate list
Constr.-
F -B21 Group =V1 F
Date Name Title Temperature limit control

- Drawn Exhaust with Display
Created
Status
Origin

-
75478/020150 Bl.19/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11 V1F11
/19.8 /21.1
Zander limiter??? Fault Relay

SK1
41 =B1
/21.4
-K23 -K6 32 34
/18.2 /26.3 31
B B
42
41 41
-K7 12 14 13
-K9 -K24 -K9 Emergency
1 - Lockout reset
5 11
/17.2 /18.5 /17.2
2 - Burner on
42 42 14
0 - Off
13
1 0 2 3 1 7 5 -K24 Jumo
V1S1 /18.5
C /27.4 C
2 6
-S1 14
13
-K23 Limiter 1???

/18.2
A1
-X1 2/1
-K1 -P7 -K7 110 -P8 14

SK2
A2 /21.4
V1N11
-X1 2/2
V1N11
/19.4 RD /21.1
D D
13 14
/18.3 14
23 24
/17.3 6 11 12
33 34
/18.6
43 44 24
/39.3 21 22
34
Safety circuit 31 32
Lockout
E 2 E
-X1
1
2
PE N
W35
...
3 1,5
PE
60001/040213
04.06.09 SMD
Audible alarm
Lockout/fault
22.04.98 EG
Constr.-
F -P8 Group =V1 F
Date Name Title Safety circuit

Fail safe circuit interlock redundant Drawn -
Created
Status
Origin

-
75478/020150 Bl.20/39 88475 Schwendi 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11 V1F11
/20.8 /25.4 -A1
W-FM100
L N PE L W-FM
/22.1
-X3-04
5 4 3 2 1
-X1 4/6 4/5 4/PE -X1 4/4 -X1 4/3

B B
Line from Fuse??? Jumo & other conditions
SK1
/20.7
C C
SK2
/20.7
V1N11 V1N11
/20.8 /25.4
D D
E 4 E
-X1
10
11
12
13
14
15
16
17
23
24
25
26
1
2
3
4
5
6
7
8
9
PE N
W40
BR ...
/7.4 21 1,5
X3-01:2
X3-04:1
X3-04:2
X3-04:3
X3-04:4
X3-04:5
X4-01:1
X4-01:2
X4-01:4
X4-03:3
X5-03:1
X5-03:2
X5-03:3
X5-03:4
X6-01:1
X6-01:2
X7-03:2
X7-03:3
X8-01:1
X8-01:2
Burner connection
71001/050008.23
1/10.10.13 BJ
X3-01 X3-04 X4-01 X4-03 X5-03 X6-01 X6-02 X6-03 X7-01 X7-03 X8-01
-
-A1
W-FM100 / W-FM200 Constr.-
F
group =B1 F
Date Name Title Voltage supply

- Drawn Safety circuit
Created
Status
Origin

-
75478/020150 Bl.21/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
Start inhibit 1
W-FM PE L W-FM
/21.8 /23.1
-X7-03
1 2 3
-X1 4/23 -X1 4/24

B B
LSOG
/23.2
-X1 5/1
-X1 5/2
C C
D D
E 5 E
-X1
1
2
PE
71001/050014
1/21.10.13 BJ
Prohibited start
-
Gas
Constr.-
F
group =B1 F
Date Name Title Prohibited start

- Drawn Gas
Created
Status
Origin

-
75478/020150 Bl.22/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
W-FM L L W-FM
/22.8 /24.1
-X6-01
1 2 3 4
-X1 4/16 -X1 4/17

B B
-X1 6/10
P>
-X1 6/1 -X1 6/3 -F25
13 21
-X1 6/9
-S19 14 22 -X1 6/8

-X1 6/2 -X1 6/4
P>
LSOG
C /22.4 -F26 C
-X1 6/7
=L1 53 -X1 6/6
-Q2 Mixer Fan Running -X1 6/5

54
/33.6
D D
E 6 E
-X1
10
1
2
3
4
5
6
7
8
9
W45 W50 W55
Isol. oil valves combination
PE PE PE PE
... ... ...
Combustion chamber
Combustion chamber
Main fan in operation
5 1,5 3 1,5 3 1,5

PE
PE
PE
pressure switch 1
pressure switch 2
13
14
21
22
71001/050024
1/24.10.13 ZN
Limit switch
P> P>
Reserve
-
F -S19 -F25 -F26

Constr.-
group =B1 F
Date Name Title Prohibited start

- Drawn Oil
Created
Status
Origin

-
75478/020150 Bl.23/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
W-FM W-FM
/23.8 /25.1
-X4-01 X4-01
1 2 /26.3
-X1 4/7 4/8

B B
3 - Combustion manager internal

Fuel selection
1 2 3 1 3 7
1 - Gas
2 - Oil
C C
-S16 2
V1F11.1 V1F11.1
/17.7 /28.1
D D
E E
71001/050025.1
1/24.10.13 ZN
Constr.-
F
group =B1 F
Date Name Title Fuel selection

- Drawn Gas/Oil
Created
Status
Origin

-
75478/020150 Bl.24/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11 V1F11
/21.2 /29.1
12VAC1
12VAC2
CANH
Shield
CANL
GND
W-FM W-FM
-X50
/24.8 /26.1 -T1 -T11
1
2
3
4
5
6
Phoenix complett unit
mini NR.217 706 12 682
B B
24VDC DCOK
40mA
+
2 1
L +
+
AC100-240V
+24VDC
GND
1/1
1/2
1/3
1/4
1/5
DC24V 1A
N - 9-pol.
-X50 -
Plug cable
Sub-D
output
NR.217 706 12 642
Input
WH
GN
BN
YE
BK
-
Modgate
- alternative
NR.217 706 12 652
NR.217 706 12 672
C C
Bus line -A3

Indicator unit/operating unit
Plug
9-pol.Sub-D
Bus connection
NR.716401
-X1
8
4
7
2
3
-X90 Sub-D
B1
A1
B2
A2
V1N11 V1N11 On/Off
CAN-Bus /21.8 /26.1
D D
RJ45
Sub-D
1
2 3
COM 1
COM 2
3 4/6
Businterface
5 5
Line length max. 5 meter
-X91 7
-X92
-A3.X1/MM
-A3.X1/MM
-A3.X1/B1
-A3.X1/A1
-A3.X1/B2
-A3.X1/A2
-A2
E 5 E
-X50 -X99
1
2
3
4
5
ABE W60 W65 W70

/12.4 Bus line e.g. FD P L2/FIP e.g. FD P L2/FIP
Order number 2 0,64 2 0,64
Bus line Bus line
MM
MM
743192 -X. -X.
B1
A1
B2
A2
Profibus-DP out
1/12.11.14 HR
71001/340180
X50:2
X50:3
X50:4
X50:5
X50:6
Profibus-DP in
X50:1
Connection
Burner
-
F -A1 W-FM100 Constr.-

=B1 F
Group
Date Name Title Protocol data converting
- Drawn Modbus / profibus-DP
Created
Status
Origin

-
75478/020150 Bl.25/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
W-FM PE N W-FM
/25.3 /27.1
-X3-01 X4-01 -X4-01 -X4-03 -X8-01
1 2 /24.5 3 4 1 2 3 1 2
-X1 4/2 -X1 4/10 -X1 4/11 -X1 4/25 -X1 =

B B
Combustion manager
13
Reset
C
-S3 14
C
A1 A1 A1 A1
-P6 -K6 110 Fault Relay -K23 110 -K21 110 -P1 -P2 -K22 110
A2 A2 A2 A2
V1N11 V1N11
/25.4 RD WH WH /28.1
D D
14 14 14 14
/38.4 11 12 /34.6 11 12 /37.3 11 12 /37.4 11 12

Combustion manager
24 24 24 24
/39.3 21 22 21 22 21 22 21 22
34 34 34 34
Operation gas
Operation oil
Interlocking
/20.6 31 32 31 32 31 32 31 32
Burner ON
E E
71001/050022
1/22.10.13 ZN
Constr.-
F
group =B1 F
Date Name Title Lockout reset - Signalling

- Drawn -
Created
Status
Origin

-
75478/020150 Bl.26/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634

START BURNER
A A
1 2 3 4 5 6 7 8
Parameter Konfig X5-03 LMV2/3 inv

Disconnect This signals or just deactivated from FM100
W-FM On/Off 2 3 L W-FM
/26.8 /30.1
-X5-03
1 2 3 4
-X1 4/12 -X1 4/13 4/14 -X1 4/15

B B
=V1
-S1
1 - Partial load
10
4 - Automatic
1 2 3 4
V1S1 V1S1 2
3 - Full load
/20.6 /37.2
2 - Stop
13 9
1 5 7 3
-S4
Automatic Mode Fixed
1 - Remote ( DDC)
C C
1 2
2
B1S15
2 - Local
/28.5
-S15 1 3
-X1 7/1
DP monitor,Flow Proof EXEIN1

/37.5
-X1
D 7/2 Mixer Fan Running fbk EXEIN2 D

Q2 from p/33.7 /37.5

LC1
/28.1
Dry Contact from DCS . Start Burner

41 42 LC2 AUT
/28.1 /28.2
GL
/28.2 Jumped
KL
/28.2
E 7 E
-X1
1
2
PE
PE
71001/050013
1/16.10.13 ZN
Reserve
-
Constr.-
F .. group =B1 F
Date Name Title Capacity regulation

- Drawn -
Created
Status
Origin

-
75478/020150 Bl.27/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11.1 V1F11.1
/24.5 /31.1
Capacity regulator
Burner KS40-108 26
input 1 Di2 + Di3 : 5v, 160ua input 2

-K1 10V
DI2 DI3 QUIC= OFF
OUT3 OUT1 OUT2 0/4-20mA mA/pt 0/4-20mA
(W1/W2) (DPS/SG)
- + - +
B 23 24b 24 19/21 20 22 1 2 3 9 10 11 6 7 8 27 B
LC1
/27.6 -S15 6
B1S15 B1S15
LC2
/27.6 /37.2
/27.6 5 7
AUT
Jumped /27.7
C GL HGG+ WE+ C
/27.7 /29.5 /36.2

Removed
KL HGG1 WE-
/27.7 /36.6 /36.2
Connected
V1N11 V1N11
/26.8 /29.1
D D
E E
01.08.16 1425 GMA
61001/070600
22.01.03 WU
Constr.-
F
Group =B1 F
Date Name Title Capacity regulation

- Drawn -
Created
Status
Origin

-
75478/020150 Bl.28/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11 V1F11
/25.4 /34.4
15
out1
INP 1
250VAC 2A
OUT 3
PMA
Uniflex CI45
-T10 90-260V AC
B U+ I+ U/I- B
3 2 1 17 18 13 11 12 16
Mill Outlet Temperature HGG+

/28.5
HGG-
/36.6
C C
-X46 1/1 1/2 1/3
PT100
-B3
V1N11 V1N11
/28.8 /31.1
D D
Do not connect any PT100 here

E 1 E
-X46
1
W75
LIYCY
3 0,75
Temperatur sensor
screened
61001/750007
04.06.09 SMD
14.07.06 KE
Temperature after mill

0-400°C
PT100
Constr.-
F -B3 Group =B1 F
Date Name Title Uniflex

- Drawn Transducer
Created
Status
Origin

-
75478/020150 Bl.29/39 88475 Schwendi 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
0/4-20mA
FE
W-FM
0
/27.8
-X63
1 2 3
B B
-X46 2/1 2/2
BL-
C /31.2 C
BL+
/31.2
D D
E 2 E
-X46
1
2
LRM W80
/13.7 LIYCY
2 0,75
Burner connection
X63:1
X63:2
X63:3
screened
1/05.03.15 HR
71001/050305
X63
-
-A1
W-FM100 Constr.-
F
Group =B1 F
Date Name Title control circuit

- Drawn Load running signal
Created
Status
Origin

-
75478/020150 Bl.30/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11.1
/28.8
Load position
Burner L 5
°C Digital 280-1
INP1 .... OUT3
OUT1
OUT2
4-20mA 4-20mA
B -K21 di1 + - + - B
12 15 13 14 N 8 7 4 6
BL+ ISW-
From FM100 /30.5 /36.4
BL- To Terminal Blocks. ZC01
ISW+
/30.5
/36.4
C C
V1N11 V1N11
/29.8 /33.4
D D
this Display can be used even when it shows Celsius, should be % of Load
or worst case 4-20 mA value
E E
1/11.02.14 HR
61001/740006
Constr.-
F
Constr.- =B1 F
Date Name Title Load position

- Drawn Burner
Status
Drawn
Origin

-
75478/020150 Bl.31/39 88475 Schwendi 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
L1 L1
L2 L2
L3 L3
/16.8 /33.1
1 3 5
B B
-F1 I> I> I>

19A 2 4 6
C C
D D
E 2 E
-X31
1
2
3
MOT PE W85
WM-D132/210-2/10K0
/15.6 ...
4 4
Main power supply
07.04.15 1022 Ne
PE
1
3
5
61001/080041
24.08.00 BJ
Burner motor
12KW / 18A
Star-delta
Constr.-
F
-Q1 Group =B1 F
Date Name Title Motor control

3 AC Direct - start Drawn -
Created
Status
Origin

-
75478/020150 Bl.32/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
L1 L1
L2 L2
L3 L3
/32.3
STEDRE
/34.5
B B
1 3 5
L1F1
/34.5
-F1 I> I> I>
13,5A 2 4 6
17
13 13 13
-K19 -Q3 -Q1 -Q2
C 6 5 6 C
5 18 28 14 14 14
1 3 5 1 3 5 1 3 5
-Q2 -Q3 -Q1
6 2 4 6 6 2 4 6 5 2 4 6
31 22 22
-Q3 -Q3 -Q1
6 32 6 21 5 21
A1 A1
-K19 -Q1 -Q3 -Q2
A2 A2
./1
./2
./3
./4
./5
./6
-X31 -X31 V1N11 V1N11

/31.8 /34.3
D D
U1 W2 28 1 2 1 2 1 2
3 3 1
V1 M U2 17 3
3 4
3
3 4
2
3 4
W1 3 V2 6 18
3
5 6
3
5 6
2
5 6
-M1 7
13 14
6
13 14
7
13 14
21 22 21 22 21 22
1 - 20s
6 5 TO DCS mixer fan running
31 32 31 32
5
43 44 41 42 X5-03 Start loop condition
53 54
/23.2
63 64
E 3 E
-X31
1
2
3
4
5
6
PE W90
...
7 4
W1
W2
PE
V1
V2
U1
U2
1/25.11.14 HR
71001/860041
6,6KW / 13,6A
-M1
Mixed Air Fan
M
3
-
Constr.-
F =L1 F
...
Group
Date Name Title Mixed Air Fan
- Drawn -
Created
Status
Origin

-
75478/020150 Bl.33/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11 V1F11
/29.8 Jump this Contact. /35.1
=B1 if the burner Fails Mix
-X1 8/1 -K23 12 14
Fan Will sop. this is not
/26.5 11 OK. Mix Fan Must Run
until the Chamber temp
-X1 8/2
is less than 250 Celcius
Mixed Air Fan
2 - automatic
1 - Manually
B B
1 0 2 3 1
-S1 6
0 - Off
-S1 2 7 5
Probably
-F1 (33)
13
-F1
(41)
21 remove this and
L1F1
/33.2 use the relay for
14 22
C
(34)
MV1
(42)
fault C
/35.3 PTC Mixed Fan OK

MV2 STOMIS
/35.3 /35.4
STEDRE
A1
/33.5
-P1 -P2 -K10 110
A2
V1N11 V1N11
/33.8 WH RD /35.1
D D
14
/38.5 11 12
24
21 22
34
Mixed Air Fan
Mixed Air Fan

31 32
Operation
Fault
E 8 E
-X1
1
2
PE Remove this jumper to connect singnal
Start /Stop Mixer Fan from MCC
PE
60001/860008
14.02.80 RD
03.12.10 PI
Reserve
Bau-
F .. group =L1 F
Date Name Title Mixed Air Fan

3 AC direkt - start Drawn direkt starter
Created
Status
Origin
Checked Drawing-No. MAX WEISHAUPT GMBH

-
75478/020150 Bl.34/39 88475 SCHWENDI 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
V1F11
/34.7
Thermistor motor protection
3RN10 13-1BW10
AC/DC 24...240V Reset sensor

B -K5 B
A1 A2 95 96 98 05 06 08 Y1 Y2 T2 T1
Remove
MV1
/34.5
MV2 STOMIS
C /34.5 /34.8 C
-X46 3/1 3/2
-B51
V1N11
PTC fault on Mixer Fan
/34.8
to report to DCS
D D
E 3 E
-X46
2
W95
...
2 1,5
at the mixed air blower

1/05.11.14 HR
71001/000000
PTC thermistor
-
F -B51 Constr.-
=L1 F
Group
Date Name Title Thermistor motor protection
- Drawn Mixed Air Fan
Created
Status
Origin

-
75478/020150 Bl.35/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
B B
2
4-20 From Jumo to DCS
C C
WE- ISW- /19.9 HGG-

/28.7 /31.6 /29.6
WE+ ISW+ HGG1

/28.7 /31.6
/19.10 /28.5
D D
E 4 E
-X46
1
2
3
4
5
6
W100 W105 W110
LIYCY LIYCY LIYCY
Burner load position
4 - 20mA/ 0 - 400°C
4 - 20mA/ 0 - 400°C
2 0,75 2 0,75 2 0,75
4-20mA=0-100%
-X. screened -X. screened -X. screened

external setpoint
TZ01
61001/950055
.
.
.
.
.
.
07.11.11 WU
analog signal
Temperature
+ - + - ZC02 + -
return signal
A56-HG01.C001.TZ01
De Rio a Burner SP
hot-gas
Capacity feedback Burner a Rio
-
A56-HG01.C001.ZC02
A56-HG01.C001.ZC01 Constr.-
F
Group =Z1 F
Date Name Title Analogue signals

- Drawn to/from DDC
Created
Status
Origin

-
75478/020150 Bl.36/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
B B
C C
EXEIN1
/27.5
=A1 =B1 =B1 =A1
-K10 12 14
-K21 12 14
-K22 12 14
EXEIN2 -K10 22 24
/16.6 11 /26.6 11 /26.8 11

/27.5 /16.6 21
=V1
-S1 14
V1S1
D /27.5 D
15 13
=B1
-S15 10
B1S15
/28.5
9 11
E 1 E
-X10
10
11
12
1
3
4
5
6
7
8
9
PE W115
...
13 0,75
ready for operation
PE
-X.
1/05.11.14 HR
71001/000000
.
.
.
.
.
.
.
.
.
.
Operation gas
voltage failure
Run indication
Operation oil
Burner start
A56-HG01.XB02
A56-HG01.XB03 A56-HG01.XB11 A56-HG01.XB04
Enabling
Reserve
Burner
Burner
Burner
to DDC
-
A56-HG01.XB01
Constr.-
=Z1
...
...
...
...
...
...
...
...
F F
Group
Date Name Title Messages
- Drawn to external DDC
Created
Status
Origin

-
75478/020150 Bl.37/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
B B
Jumo
C C
=V1 23
=V1 23
=B1 =L1
-K24
-K23 /18.5 -K6 12 14
-K10 12 14
/18.2
/26.3 11 /34.7 11
24
24
Connect this runing FBk from

Mix fan
Q2 /33.7
D D
PTC from Mixer Fan
22
21
E 1 E
-X10
13
14
15
16
17
18
19
20
21
22
23
24
W120
...
12 0,75
Max. temperature
Max. temperature
-X.
1/05.11.14 HR
71001/000000
.
.
.
.
.
.
.
.
.
.
.
.
Alarmindication
Mixed Air Fan
A56-HG01.XB06 A56-HG01.XB07 A56-HG01.XB08 A56-HG01.XB13 A56-HG01.XB14

A56-HG01.XB05
Reserve
Reserve
limiter 1
limiter 2
Burner
to DDC
-
Fault
Fault
Constr.-
=Z1
...
...
...
...
...
...
...
...
F F
Group
Created
Status
Origin

-
75478/020150 Bl.38/39 88475 Schwendi
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
A A
1 2 3 4 5 6 7 8
B B
C C
=V1 23 =B1
-K9 -K6 21
/17.2 /26.3 22 24
Fault Relay
24 /33.5 /33.5
=V1 `
-K7 21
/20.5 22 24
D D
Burner Ready Fbck Mix Fan Ready Fbck

=A1
-K10 31
/16.6 32 34
Relay new NO
Aux Motor
Protecor
E 1 8 E
-X10 -X1
25
26
27
28
29
30
31
32
1
2
W125
...
10 0,75 New Signal
-X.
Emergency stop
1/05.11.14 HR
71001/000000
.
.
.
.
.
.
mixer Fan start

Alarmindication
Collective fault
Enabling
A56-HG01.XB09 A56-HG01.XB10
Reserve
Reserve
to DDC
initatet
initatet
-
A56-HG01.XB12 Constr.-
=Z1
...
...
...
...
...
...
...
F F
Group
Created
Status
Origin

-
75478/020150 Bl.39/39 88475 Schwendi
1 2 3 4 5 6 7 8
20170505_084835 100100104 634
Cablelist For wiring diagramm:75478/020150 -weishaupt-
al
in
rm
al
.
r ip
gn
in
te
st
n
si
rm
o.
tio
sc xt
it
it
de
al
ge
o
un
un
lN
te
de te
rip
N
in
k/
pa
le
le
rm
ne
n
e
d
oc
ab
ab
ai
or
el
el
n
Pa
Te
Bl
Pl
Fi
Fi
O
C
C
Notes on list layout
--------------------
+- Number of cores
I
I +- Core cross-section
I I
I I +- Cable type
I I I
I I I +- Cable length
I I I I
3 x 1.5 NYSLYOE-J .... m
----------------------------------
+F1:W1.050:PE 189.208 X1: 2/PE =V1-X1:PE SHUTDOWN
+F1:W1.050:1 189.208 X1: 2/17 =V1-X1:2/3 GENERAL
+F1:W1.050:2 189.208 X1: 2/18 =V1-X1:2/4 BOILER 1
I I I I I I I I I I I I
I I I I I I I I I I I +- Plain text description
I I I I I I I I I I I
I I I I I I I I I I +- Destination terminal number
I I I I I I I I I +- Destination block number
I I I I I I I I +- Item No., destination terminal strip
I I I I I I I +- Group No., destination terminal strip
I I I I I I I
I I I I I I +- Terminal No. in control panel
I I I I I +- Terminal block No. in control panel
I I I I +- Terminal strip in control panel
I I I I
I I I +- Page No. (page 189 of 208 pages)
I I I
I I +- Cable core
I +- Cable designation
+- Field No. (in this instance the 1st field)
The relevant regulations of the electricity supplier must be observed.
The core cross-sections specified are the minimum for the prefusing!
It is the responsibility of the main contractor to check the information regarding cable
length and manner of running and to correct it if required.
Please advise us of any changes to core cross-sections.
Cables connecting to the burner must be flexible, and oil-proof where applicable. Cables
connecting to the gas valve train must likewise be flexible if the boiler door is to be
hinged open with the gas valve train in place.
Burners may hinge open to the left or right-hand side, depending on type. Cables must be of
sufficient length to accommodate this movement.
Consideration must be given to boiler doors that hinge open. Cables must be of sufficient
length and should not foul on the opening door.
Max. 120 degrees Celsius for third-party oil preheater connections. Use heat-resistant cables
(e.g. SIHF-J silicone-sheathed cable). Cables connecting to the boiler must also be suitably
heat resistant (e.g. NYSLYOE-J).
Sensor cables must be screened (e.g. LiYCY) or else run separately.
Sales Order No.:210965471.000255 1 / 10 05.05.17 VS-Martin Geiss

20170505_084835 100100104 634
al
in
rm
al
.
r ip
gn
in
te
st
n
si
rm
o.
tio
sc xt
it
it
de
al
ge
o
un
un
lN
te
de te
rip
N
in
k/
pa
le
le
rm
ne
n
e
d
oc
ab
ab
ai
or
el
el
n
Pa
Te
Bl
Pl
Fi
Fi
O
C
C
Consideration must always be given to the particular environmental conditions presented by
the equipment (LTHW, HTHW, steam, thermal fluid, etc.).
Legend:
Terminal strip: -X1 - General control panel wiring
Terminal strip: -X10 - PLC / potentialfree reporting
Terminal strip: -X31 - 400V terminals
Terminal strip: -X40 - low voltage <60V
Terminal strip: -X46 - sensor line / current-,voltage signals
Terminal strip: -X50 - Bus cables
Terminal strip: -X99 - directly to device
4 x10 ... .... m

1 W5 1 16.39 -X31 1/L1 =A1-F0 L1 Main power supply
1 W5 2 16.39 -X31 1/L2 =A1-F0 L2
1 W5 3 16.39 -X31 1/L3 =A1-F0 L3
1 W5 PE 16.39 -X31 1/PE =A1-F0 PE
5 x1,5 ... .... m
1 W10 PE 17.39 -X40 1/PE =V1-X. PE Emergency stop
1 W10 1 17.39 -X40 1/1 =V1-X. Shutdown
1 W10 2 17.39 -X40 1/2 =V1-X. Fa. AREND
1 W10 3 17.39 -X40 1/3 =V1-X.
1 W10 4 17.39 -X40 1/4 =V1-X.
7 x1,5 ... .... m
1 W15 PE 17.39 -X10 2/PE =V1-S16 PE Emergency stop
1 W15 1 17.39 -X10 2/1 =V1-S16 escape door
1 W15 2 17.39 -X10 2/2 =V1-S16
1 W15 3 17.39 -X10 2/3 =V1-S16
1 W15 4 17.39 -X10 2/4 =V1-S16
1 W15 5 17.39 -X10 2/5 =V1-S16
1 W15 6 17.39 -X10 2/6 =V1-S16
7 x1,5 ... .... m
1 W20 PE 17.39 -X10 2/PE =V1-X. PE Emergency stop
1 W20 1 17.39 -X10 2/7 =V1-X. 2 x Emergency stop
1 W20 2 17.39 -X10 2/8 =V1-X. 1 x Forward reporting PLC
1 W20 3 17.39 -X10 2/9 =V1-X.
1 W20 4 17.39 -X10 2/10 =V1-X.
1 W20 5 17.39 -X10 2/11 =V1-X.
1 W20 6 17.39 -X10 2/12 =V1-X.
3 x1,5 ... .... m
1 W25 PE 18.39 -X40 1/PE =V1-F23 PE Temperature-
1 W25 1 18.39 -X40 1/5 =V1-F23 limiter 1 (RAZ)
1 W25 2 18.39 -X40 1/6 =V1-F23
3 x0,75 LIYCY .... m
screened
1 W30 1 19.39 -X46 1/1 =V1-B21 Temperatur sensor
1 W30 2 19.39 -X46 1/2 =V1-B21 Exhaust STL (PT100)
1 W30 3 19.39 -X46 1/3 =V1-B21
3 x1,5 ... .... m

20170505_084835 100100104 634
al
in
rm
al
.
r ip
gn
in
te
st
n
si
rm
o.
tio
sc xt
it
it
de
al
ge
o
un
un
lN
te
de te
rip
N
in
k/
pa
le
le
rm
ne
n
e
d
oc
ab
ab
ai
or
el
el
n
Pa
Te
Bl
Pl
Fi
Fi
O
C
C 1 W35 PE 20.39 -X1 2/PE =V1-P8 PE Audible alarm

1 W35 1 20.39 -X1 2/1 =V1-P8 Lockout/fault
1 W35 2 20.39 -X1 2/2 =V1-P8
21 x1,5 ... .... m
1 W40 1 21.39 -X1 4/1 =B1-A1 Burner connection
1 W40 2 21.39 -X1 4/2 =B1-A1 X3-01:2
1 W40 3 21.39 -X1 4/3 =B1-A1 X3-04:1
1 W40 4 21.39 -X1 4/4 =B1-A1 X3-04:2
1 W40 PE 21.39 -X1 4/PE =B1-A1 X3-04:3
1 W40 5 21.39 -X1 4/5 =B1-A1 X3-04:4
1 W40 6 21.39 -X1 4/6 =B1-A1 X3-04:5
1 W40 7 21.39 -X1 4/7 =B1-A1 X4-01:1
1 W40 8 21.39 -X1 4/8 =B1-A1 X4-01:2
1 W40 9 21.39 -X1 4/9 =B1-A1
1 W40 10 21.39 -X1 4/10 =B1-A1 X4-01:4
1 W40 11 21.39 -X1 4/11 =B1-A1 X4-03:3
1 W40 12 21.39 -X1 4/12 =B1-A1 X5-03:1
1 W40 13 21.39 -X1 4/13 =B1-A1 X5-03:2
1 W40 14 21.39 -X1 4/14 =B1-A1 X5-03:3
1 W40 15 21.39 -X1 4/15 =B1-A1 X5-03:4
1 W40 16 21.39 -X1 4/16 =B1-A1 X6-01:1
1 W40 17 21.39 -X1 4/17 =B1-A1 X6-01:2
1 W40 18 21.39 -X1 4/23 =B1-A1 X7-03:2
1 W40 19 21.39 -X1 4/24 =B1-A1 X7-03:3
1 W40 20 21.39 -X1 4/25 =B1-A1 X8-01:1
1 W40 21 21.39 -X1 4/26 =B1-A1 X8-01:2
5 x1,5 ... .... m
1 W45 PE 23.39 -X1 6/PE =B1-S19 PE Limit switch
1 W45 1 23.39 -X1 6/1 =B1-S19 13 Isol. oil valves combination
1 W45 2 23.39 -X1 6/2 =B1-S19 14
3 x1,5 ... .... m
1 W50 PE 23.39 -X1 6/PE =B1-F25 PE Combustion chamber
1 W50 1 23.39 -X1 6/7 =B1-F25 pressure switch 1
1 W50 2 23.39 -X1 6/8 =B1-F25
3 x1,5 ... .... m
1 W55 PE 23.39 -X1 6/PE =B1-F26 PE Combustion chamber
1 W55 1 23.39 -X1 6/9 =B1-F26 pressure switch 2
1 W55 2 23.39 -X1 6/10 =B1-F26
5 x.... Bus line .... m
Order number743192
1 W60 1 25.39 -X50 5/1 =B1-A1 X50:2 Connection
1 W60 2 25.39 -X50 5/2 =B1-A1 X50:3 Burner
1 W60 3 25.39 -X50 5/3 =B1-A1 X50:4
1 W60 4 25.39 -X50 5/4 =B1-A1 X50:5
1 W60 5 25.39 -X50 5/5 =B1-A1 X50:6
2 x0,64 e.g. FD P L2/FIP.... m
Bus line

20170505_084835 100100104 634
al
in
rm
al
.
r ip
gn
in
te
st
n
si
rm
o.
tio
sc xt
it
it
de
al
ge
o
un
un
lN
te
de te
rip
N
in
k/
pa
le
le
rm
ne
n
e
d
oc
ab
ab
ai
or
el
el
n
Pa
Te
Bl
Pl
Fi
Fi
O
C
C 1 W65 1 25.39 -X99 ../-A3.X1/B1 =B1-X. B1 Profibus-DP in

1 W65 2 25.39 -X99 ../-A3.X1/A1 =B1-X. A1
1 W65 3 25.39 -X99 ../-A3.X1/MM =B1-X. MM
2 x0,64 e.g. FD P L2/FIP.... m
Bus line
1 W70 1 25.39 -X99 ../-A3.X1/B2 =B1-X. B2 Profibus-DP out
1 W70 2 25.39 -X99 ../-A3.X1/A2 =B1-X. A2
1 W70 3 25.39 -X99 ../-A3.X1/MM =B1-X. MM
3 x0,75 LIYCY .... m
screened
1 W75 1 29.39 -X46 1/1 =B1-B3 Temperatur sensor
1 W75 2 29.39 -X46 1/2 =B1-B3
1 W75 3 29.39 -X46 1/3 =B1-B3
2 x0,75 LIYCY .... m
screened
1 W80 1 30.39 -X46 2/1 =B1-A1 X63:1 Burner connection
1 W80 2 30.39 -X46 2/2 =B1-A1 X63:2
4 x4 ... .... m
1 W85 PE 32.39 -X31 2/PE =B1-Q1 PE Main power supply
1 W85 1 32.39 -X31 2/1 =B1-Q1 1 Burner motor
1 W85 2 32.39 -X31 2/2 =B1-Q1 3
1 W85 3 32.39 -X31 2/3 =B1-Q1 5
7 x4 ... .... m
1 W90 PE 33.39 -X31 3/PE =L1-M1 PE Mixed Air Fan
1 W90 1 33.39 -X31 3/1 =L1-M1 U1 ...
1 W90 2 33.39 -X31 3/2 =L1-M1 V1
1 W90 3 33.39 -X31 3/3 =L1-M1 W1
1 W90 4 33.39 -X31 3/4 =L1-M1 V2
1 W90 5 33.39 -X31 3/5 =L1-M1 W2
1 W90 6 33.39 -X31 3/6 =L1-M1 U2
2 x1,5 ... .... m
1 W95 1 35.39 -X46 3/1 =L1-B51 PTC thermistor
1 W95 2 35.39 -X46 3/2 =L1-B51 at the mixed air blower
2 x0,75 LIYCY .... m
screened
1 W100 1 36.39 -X46 4/1 =Z1-X. . analog signal
1 W100 2 36.39 -X46 4/2 =Z1-X. . external setpoint
1 W100 36.39 -X46 4/ 4 - 20mA/ 0 - 400°C
2 x0,75 LIYCY .... m
screened
1 W105 1 36.39 -X46 4/3 =Z1-X. . Burner load position
1 W105 2 36.39 -X46 4/4 =Z1-X. . return signal
1 W105 36.39 -X46 4/ 4-20mA=0-100%
2 x0,75 LIYCY .... m
screened
1 W110 1 36.39 -X46 4/5 =Z1-X. . Temperature
1 W110 2 36.39 -X46 4/6 =Z1-X. . hot-gas

20170505_084835 100100104 634
al
in
rm
al
.
r ip
gn
in
te
st
n
si
rm
o.
tio
sc xt
it
it
de
al
ge
o
un
un
lN
te
de te
rip
N
in
k/
pa
le
le
rm
ne
n
e
d
oc
ab
ab
ai
or
el
el
n
Pa
Te
Bl
Pl
Fi
Fi
O
C
C 1 W110 36.39 -X46 4/ 4 - 20mA/ 0 - 400°C

13 x0,75 ... .... m
1 W115 PE 37.39 -X10 1/PE =B1-X. PE Run indication
1 W115 1 37.39 -X10 1/1 =B1-X. . to DDC
1 W115 2 37.39 -X10 1/2 =B1-X. .
1 W115 3 37.39 -X10 1/3 =B1-X. .
1 W115 4 37.39 -X10 1/4 =B1-X. .
1 W115 5 37.39 -X10 1/5 =B1-X. .
1 W115 6 37.39 -X10 1/6 =B1-X. .
1 W115 7 37.39 -X10 1/7 =B1-X. .
1 W115 8 37.39 -X10 1/8 =B1-X. .
1 W115 9 37.39 -X10 1/9 =B1-X. .
1 W115 10 37.39 -X10 1/10 =B1-X. .
1 W115 11 37.39 -X10 1/11 =B1-X. .
1 W115 12 37.39 -X10 1/12 =B1-X. .
12 x0,75 ... .... m
1 W120 1 38.39 -X10 1/13 =Z1-X. . Alarmindication
1 W120 2 38.39 -X10 1/14 =Z1-X. . to DDC
1 W120 3 38.39 -X10 1/15 =Z1-X. .
1 W120 4 38.39 -X10 1/16 =Z1-X. .
1 W120 5 38.39 -X10 1/17 =Z1-X. .
1 W120 6 38.39 -X10 1/18 =Z1-X. .
1 W120 7 38.39 -X10 1/19 =Z1-X. .
1 W120 8 38.39 -X10 1/20 =Z1-X. .
1 W120 9 38.39 -X10 1/21 =Z1-X. .
1 W120 10 38.39 -X10 1/22 =Z1-X. .
1 W120 11 38.39 -X10 1/23 =Z1-X. .
1 W120 12 38.39 -X10 1/24 =Z1-X. .
10 x0,75 ... .... m
1 W125 1 39.39 -X10 1/25 =A1-X. . Alarmindication
1 W125 2 39.39 -X10 1/26 =A1-X. . to DDC
1 W125 3 39.39 -X10 1/27 =A1-X. .
1 W125 4 39.39 -X10 1/28 =A1-X. .
1 W125 5 39.39 -X10 1/29 =A1-X. .
1 W125 6 39.39 -X10 1/30 =A1-X. .
1 W125 7 39.39 -X10 1/31 =A1-X. .
1 W125 8 39.39 -X10 1/32 =A1-X. .

20170505_084835 100100104 634
xt
te
al
on
ti
di
Ad
cables

20170505_084835 100100104 634
xt
te
al
on
ti
di
Ad
20kW / 40A

20170505_084835 100100104 634
xt
te
al
on
ti
di
Ad

20170505_084835 100100104 634
xt
te
al
on
ti
di
Ad
PT100
0-400°C
12KW / 18A
WM-D132/210-2/10K0
6,6KW / 13,6A

20170505_084835 100100104 634
xt
te
al
on
ti
di
Ad

Installation and operating instruction
Combustion manager W-FM 100 und W-FM 200 83054802 1/2015-07

Conformity certification
Sprachschlüssel 6004000002
Manufacturer: Max Weishaupt GmbH
Address: Max-Weishaupt-Straße
D-88475 Schwendi
Product: Combustion Manager
W-FM 100 / 200
The product described above conforms with
the regulations of directives:
GAD 2009 / 142 / EC

PED 97 / 23 / EC
LVD 2006 / 95 / EC
EMC 2004 / 108 / EC
This product is labelled as follows:
CE-0085
Schwendi, 05.12.2014
ppa. ppa.
Dr. Schloen Denkinger
Manager Research Manager Production and

and Development Quality Management
Combustion manager W-FM 100 und W-FM 200
1 User instructions .............................................................................................................. 9

1.1 Target group ........................................................................................................... 9
1.2 Symbols ................................................................................................................... 9
1.3 Guarantee and Liability ..................................................................................... 10
2 Safety .................................................................................................................................. 11
2.1 Designated application ..................................................................................... 11
2.2 When gas can be smelled ............................................................................... 11
2.3 Safety measures ................................................................................................. 11
2.3.1 Normal operation ............................................................................................ 11
2.3.2 Electrical connection ..................................................................................... 11
2.3.3 Gas supply ....................................................................................................... 12
2.4 Alterations to the construction of the equipment ....................................... 12
2.5 Noise emission ................................................................................................... 12
2.6 Disposal ............................................................................................................... 12
3 Product description ..................................................................................................... 13

3.1 Variations ............................................................................................................. 13
3.2 Function ................................................................................................................ 14
3.2.1 Burner control .................................................................................................. 14
3.2.2 Low gas programme ...................................................................................... 14
3.2.3 Valve proving ................................................................................................... 15
3.2.4 Load controller ................................................................................................ 16
3.2.5 Variable speed drive ....................................................................................... 16
3.2.6 O2 trim / monitoring ....................................................................................... 16
3.2.7 Program sequence ......................................................................................... 17
3.2.7.1 Gas direct ignition ...................................................................................... 17
3.2.7.2 Gas with ignition pilot valve ..................................................................... 18
3.2.7.3 Light oil direct ignition ............................................................................... 20
3.2.7.4 Heavy oil direct ignition ............................................................................. 22
3.2.7.5 Heavy oil with gas pilot ignition ............................................................... 24
3.3 Inputs .................................................................................................................... 26
3.3.1 Voltage supply ................................................................................................. 26
3.3.2 Safety circuit .................................................................................................... 26
3.3.3 Reset ................................................................................................................. 26
3.3.4 Air pressure switch ......................................................................................... 26
3.3.5 Fan contactor contact ................................................................................... 27
3.3.6 Fuel selection ................................................................................................... 27
3.3.7 Minimum oil pressure switch ........................................................................ 27
3.3.8 Maximum oil pressure switch ....................................................................... 27
3.3.9 Start release Oil .............................................................................................. 28
3.3.10 Heavy oil immediate start .............................................................................. 28
3.3.11 Start release Gas ............................................................................................ 28
3.3.12 Valve proving gas pressure switch ............................................................. 28
3.3.13 High gas pressure switch ............................................................................. 29
3.3.14 Low gas pressure switch .............................................................................. 29
3.3.15 Flame sensor .................................................................................................... 30
3.3.16 External load controller (X5-03) .................................................................. 32
3.3.17 External load controller (X62) ...................................................................... 33
3.3.18 External load controller (Bus) ....................................................................... 33
83054802 1/2015-07 MaW 3-228

3.3.19 Setpoint switch-over ...................................................................................... 34

3.3.20 Temperature sensor ....................................................................................... 35
3.3.21 Speed measurement ...................................................................................... 35
3.3.22 Fuel meter ......................................................................................................... 36
3.3.23 Flue gas temperature sensor ....................................................................... 36
3.3.24 Combustion air sensor / CO resistance circuit board ........................... 36
3.3.25 O2 sensor ......................................................................................................... 37
3.4 Outputs ................................................................................................................ 38
3.4.1 Alarm .................................................................................................................. 38
3.4.2 Motor ................................................................................................................. 38
3.4.3 Oil pump / magnetic coupling ..................................................................... 38
3.4.4 Start signal, pressure switch relief .............................................................. 39
3.4.5 Ignition ............................................................................................................... 39
3.4.6 Anti syphon valve ............................................................................................ 40
3.4.7 Oil fuel valves ................................................................................................... 41
3.4.8 Fuel valves Gas ............................................................................................... 42
3.4.9 Operating display ........................................................................................... 42
3.4.10 Analogue output .............................................................................................. 43
3.4.11 Frequency converter ...................................................................................... 43
3.5 Technical data ..................................................................................................... 44
3.5.1 Electrical data .................................................................................................. 44
3.5.2 Ambient conditions ........................................................................................ 45
3.5.3 Dimensions ....................................................................................................... 46
4 Installation ........................................................................................................................ 48
4.1 Installing O2 sensor .......................................................................................... 48
5 Electrical connection .................................................................................................. 50
6 Operation .......................................................................................................................... 55
6.1 Operating interface ............................................................................................ 55
6.1.1 Operating panel .............................................................................................. 55
6.1.2 Display ............................................................................................................... 56
6.2 Displaying and adjusting parameters ............................................................ 57
6.2.1 Password .......................................................................................................... 58
6.3 Menu structure .................................................................................................... 59
6.4 Operation and system information ................................................................. 68
6.4.1 Normal operation ............................................................................................ 68
6.4.2 Fuel selection ................................................................................................... 68
6.4.3 Operating hours .............................................................................................. 69
6.4.4 Start-up counter .............................................................................................. 69
6.4.5 Fuel meter ......................................................................................................... 70
6.4.6 Number of lockouts ........................................................................................ 71
6.4.7 Flame signal ..................................................................................................... 71
6.4.8 Product identification ..................................................................................... 71
6.4.9 Software version ............................................................................................. 71
6.4.10 Burner identification ....................................................................................... 71
6.5 Setting the display ............................................................................................. 73
6.5.1 Setting the language ...................................................................................... 73
6.5.2 Set contrast ..................................................................................................... 73
83054802 1/2015-07 MaW 4-228

6.5.3 Date/Time ......................................................................................................... 74

6.5.4 Units ................................................................................................................... 74
6.6 Interfaces ............................................................................................................. 75
6.6.1 Select interfaces ............................................................................................. 75
6.6.2 eBus ................................................................................................................... 76
6.6.3 Modbus ............................................................................................................. 76
6.6.4 Trending data ................................................................................................... 77
6.7 Manual / Automatic / Off .................................................................................. 78
6.8 Burner control ..................................................................................................... 79
6.8.1 Times ................................................................................................................. 79
6.8.2 Signalling start prevention ............................................................................ 81
6.8.3 Normal or direct start ..................................................................................... 81
6.8.4 Oil pump ........................................................................................................... 82
6.8.5 Forced intermittent ......................................................................................... 82
6.8.6 Pre-purge Gas ................................................................................................ 82
6.8.7 Continuous running fan ................................................................................. 83
6.8.8 Additional air pressure switch ..................................................................... 83
6.8.9 Configuring input X5-03 ............................................................................... 84
6.8.10 Configuring output X4-03 ............................................................................ 85
6.8.11 Extraneous light ............................................................................................... 85
6.8.12 Repetition counter .......................................................................................... 85
6.9 Electronic compound ........................................................................................ 85
6.9.1 Actuator ramps ................................................................................................ 85
6.9.2 Shutdown behaviour ...................................................................................... 86
6.9.3 Operating behaviour of frequency converter ............................................ 87
6.9.4 SpecialPositions ............................................................................................. 88
6.9.5 Creating load points, modulating operation ............................................. 90
6.9.6 Operating and switch points, multi-stage operation .............................. 94
6.9.7 Load range ....................................................................................................... 96
6.9.8 Load limit .......................................................................................................... 98
6.9.9 Start point ......................................................................................................... 98
6.10 O2 controller ....................................................................................................... 99
6.10.1 O2 controller operating mode .................................................................. 100
6.10.2 O2 monitor .................................................................................................... 102
6.10.3 O2 trim ........................................................................................................... 104
6.10.4 O2 control parameters ............................................................................... 106
6.10.5 O2 start mode .............................................................................................. 110
6.10.6 Type of Fuel ................................................................................................... 111
6.10.7 O2 sensor ...................................................................................................... 112
6.10.8 Service interval for O2 sensor .................................................................. 112
6.10.9 Define temperature sensor ........................................................................ 113
6.10.10 Flue gas temperature warning threshold ................................................ 113
6.10.11 Combustion efficiency ................................................................................ 114
6.10.12 O2 controller control variable ................................................................... 114
6.10.13 Status O2 controller ................................................................................... 114
6.10.14 Air rating ......................................................................................................... 114
6.10.15 Diagnostic code ........................................................................................... 115
6.10.16 O2 content .................................................................................................... 115
6.10.17 O2 setpoint ................................................................................................... 116
83054802 1/2015-07 MaW 5-228

6.10.18 Combustion air temperature / CO switching threshold ..................... 116

6.10.19 Flue gas temperature .................................................................................. 116
6.10.20 O2 sensor temperature .............................................................................. 116
6.10.21 O2 sensor heating capacity ...................................................................... 117
6.10.22 O2 sensor wear and tear ........................................................................... 117
6.10.23 Activate / deactivate O2 controller .......................................................... 117
6.11 CO monitor and CO controller ..................................................................... 118
6.11.1 Operating mode CO function ................................................................... 120
6.11.2 Time delay limit value exceeded ............................................................... 120
6.12 Load controller .................................................................................................. 121
6.12.1 Setpoint .......................................................................................................... 121
6.12.2 Load controller operating mode ............................................................... 122
6.12.3 Sensor selection (actual value) ................................................................ 124
6.12.4 Analogue inputs ........................................................................................... 125
6.12.5 Measuring range .......................................................................................... 126
6.12.6 External setpoint .......................................................................................... 127
6.12.7 Analogue output ........................................................................................... 128
6.12.8 Control parameters of internal load controller ...................................... 130
6.12.9 Control variable calming ............................................................................ 131
6.12.10 Fault signal suppression ............................................................................ 131
6.12.11 Modulating switch differentials ................................................................. 132
6.12.12 Multi-stage switch differentials and switch thresholds ....................... 133
6.12.12.1 Multi-stage switch differentials ............................................................. 133
6.12.12.2 Multi-stage switch threshold ................................................................. 134
6.12.12.3 Low impact start ....................................................................................... 134
6.12.13 Temperature sensor .................................................................................... 135
6.12.14 Boiler cold start function ............................................................................ 136
6.12.15 Adaption ......................................................................................................... 139
6.13 Actuators ............................................................................................................ 140
6.13.1 Addressing .................................................................................................... 140
6.13.2 Delete curves ................................................................................................ 141
6.13.3 Position control ............................................................................................ 141
6.14 VSD / Frequency converter ........................................................................... 142
6.14.1 Frequency converter release contact ...................................................... 142
6.14.2 Speed measurement ................................................................................... 142
6.14.3 Speed standardisation ............................................................................... 142
6.14.4 Actual speed ................................................................................................. 143
6.14.5 Setpoint output ............................................................................................ 143
6.14.6 Speed deviation ........................................................................................... 143
6.15 Flue gas recirculation ...................................................................................... 144
6.15.1 FGR function ................................................................................................ 144
6.15.1.1 Fan on burner ............................................................................................ 144
6.15.1.2 Separate fan .............................................................................................. 146
6.15.2 FGR operating mode .................................................................................. 148
6.15.3 Define temperature sensor ........................................................................ 149
6.15.4 FGR sensor temperature ........................................................................... 149
6.15.5 FGR release .................................................................................................. 150
6.15.6 Temperature compensation ...................................................................... 150
6.15.7 Operating temperature ............................................................................... 151
83054802 1/2015-07 MaW 6-228

6.15.8 Position limit FGR damper ........................................................................ 151

6.16 Data backup ...................................................................................................... 152
6.16.1 Backup copy ................................................................................................. 152
6.16.2 Updating software ....................................................................................... 153
6.17 TÜV Test ............................................................................................................ 154
6.17.1 Flame failure .................................................................................................. 154
6.17.2 Safety temperature limiter .......................................................................... 154
7 Commissioning ............................................................................................................ 155

7.1 Prerequisite ....................................................................................................... 155
7.1.1 Adapting the motor to the frequency converter .................................... 155
7.2 Adjusting the burner ........................................................................................ 156
7.2.1 Preparatory measures ................................................................................. 156
7.2.1.1 Carry out speed standardisation .......................................................... 157
7.2.1.2 O2 module presetting ............................................................................. 158
7.2.1.3 Deactivate flue gas recirculation ........................................................... 159
7.2.2 Adjusting gas side ....................................................................................... 160
7.2.3 Adjust modulation oil side .......................................................................... 166
7.2.4 Adjust multi-stage oil side ......................................................................... 172
7.3 Load controller .................................................................................................. 176
7.3.1 Configure load controller ........................................................................... 176
7.3.2 Adjust load controller .................................................................................. 178
7.3.2.1 Modulating load control .......................................................................... 178
7.3.2.2 Modulating load control .......................................................................... 179
7.3.2.3 Boiler cold start function ......................................................................... 180
7.4 O2 controller ..................................................................................................... 182
7.4.1 Set O2 monitor ............................................................................................ 182
7.4.2 Set O2 trim ................................................................................................... 183
7.4.3 Check and optimise O2 trim ..................................................................... 184
7.5 CO controller .................................................................................................... 186
7.5.1 Set measurement amplifier LT3 ............................................................... 186
7.5.2 Set CO control ............................................................................................. 187
7.6 Flue gas recirculation (temperature compensated) ................................. 188
7.7 Set pressure switches .................................................................................... 190
7.8 Concluding work .............................................................................................. 190
7.9 Check combustion ........................................................................................... 191
7.10 Calculate gas throughput ............................................................................... 192
7.11 Ratings apportionment ................................................................................... 193
8 Servicing .......................................................................................................................... 194

8.1 Notes on servicing ........................................................................................... 194
8.2 Service plan ....................................................................................................... 195
9 Troubleshooting .......................................................................................................... 196

9.1 Procedures for fault conditions ..................................................................... 196
9.1.1 Deactivating an alarm ................................................................................. 197
9.2 Fault ..................................................................................................................... 198
9.3 Lockout ............................................................................................................... 199
9.4 Rectifying faults ................................................................................................ 200
83054802 1/2015-07 MaW 7-228

10 Technical documentation ....................................................................................... 218

10.1 Frequency converter ....................................................................................... 218
10.1.1 Frequency converter Nord size I ... III ...................................................... 218
10.1.2 Frequency converter Nord size IV ............................................................ 220
11 Key word index ............................................................................................................ 222
83054802 1/2015-07 MaW 8-228

1 User instructions
1 User instructions
These installation and operating instructions form part of the equipment and must
Translation of original be kept on site.
operating instructions Carefully read the installation and operating manual prior to working on the unit.
1.1 Target group

These installation and operating instructions are intended for the operator and qual-
ified 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 dam-
age, 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
83054802 1/2015-07 MaW 9-228

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 installation and operating instruction,
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.
83054802 1/2015-07 MaW 10-228

2 Safety
2 Safety
2.1 Designated application

The combustion manager W-FM 100/200 is suitable for use with:
oil burners
gas burners
dual fuel and triple fuel burners,
dual gas 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
[ch. 8.2].
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 BGV A3 and adhere to local dir-
ectives,
tools in accordance with EN 60900 should be used.
83054802 1/2015-07 MaW 11-228

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.
Pipe work 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 pipe work 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.
Changing from LPG to Natural Gas and visa versa requires a conversion.
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.
83054802 1/2015-07 MaW 12-228

3 Product description
3.1 Variations
Type Version Functions
W-FM 100 LMV51.0… Burner control
Low gas programme
Valve proving
LMV51.1… as type LMV51.0…
Load controller
W-FM 200 LMV52.2… as type LMV51.1…
Variable speed drive
O2 trim
LMV52.4… as type LMV52.2…
FGR with temperature compensation
CO monitor and CO controller func-
tion
83054802 1/2015-07 MaW 13-228

3.2 Function
3.2.1 Burner control

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

The low gas pressure switch monitors the gas connection pressure from phase 21.
If the gas pressure set at the low gas pressure switch is not achieved, the combus-
tion manager initiates a safety shutdown and starts the low gas programme.
In the low gas programme, the combustion manager initiates a restart after the low
gas waiting time (Parameter: DelayLackGas). This low gas waiting time doubles
after every unsuccessful start attempt. If the start attempts exceed the repetition
limit value (Parameter: StartRelease) the combustion manager goes to lockout.
The repetition counter and the low gas waiting time are automatically reset when
the burner starts.
83054802 1/2015-07 MaW 14-228

3.2.3 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 set value during these 10 seconds, valve 1 is
leaking. The combustion manager initiates a controlled shutdown.
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 set value during these 10 seconds, valve 2
is leaking. The combustion manager initiates a controlled shutdown.
3 sek 10 sek 3 sek 10 sek A 1 2

1 V1 V2
2
3
4
5 80 81 82 83 P P 4
B C
1 2 1 2
V1 V2 V1 V2
P P 4 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
A Direct ignition
B Ignition gas tube
C Gas ignition device
83054802 1/2015-07 MaW 15-228

3.2.4 Load controller

The W-FM 200 is equipped with an internal PID load controller as standard, with
the W-FM 100 the internal load controller is optional.
The load controller is suitable for multi-stage and modulating burners. In modulating
operation, control variables calming reduces the drive impulses and protects the
actuators.
It is possible to choose between two setpoints using an external contact.
The boiler cold start function reduces the thermal load of the heat exchanger during
burner start.
3.2.5 Variable speed drive

Only the W-FM 200 is equipped with a frequency converter module for variable
speed control.
Via an analogue output (0/4-20 mA), the W-FM 200 control the frequency con-
verter of the fan motor and matches the speed to the burner capacity. This reduces
electrical consumption.
The speed and the rotation direction are monitored by an inductive proximity switch
and an asymmetrical transmitter disc.
3.2.6 O2 trim / monitoring

Only the W-FM 200 is equipped with an O2 trim function. An additional O2 module
(PLL52…) is required for O2 trim.
A sensor measures the O2 content in the flue gas. During operation, the W-FM 200
compares the O2 content with the setpoints determined during commissioning. If
deviations occur, the W-FM 200 activates the air regulating devices and corrects
the O2 content. This increases the boiler efficiency.
83054802 1/2015-07 MaW 16-228

3.2.7 Program sequence
3.2.7.1 Gas direct ignition

Valve
Test without pressure
System pressure test

proving
Post-purge position
Partial load position
Operating setting 1
Operating setting 2
Pre-purge position
Drain valve train

Ignition position
Lockout phase
Post burn time
Fill valve train

Safety phase
Start release
Flame signal
Ignition OFF
Fuel release
Pre-ignition
Post-purge
Direct start
Pre-purge
Home run
Standby
Start-up
Fan ON
00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 54 60 62 70 72 74 76 78 79 80 81 82 83
Inputs
Fuel selection X4-01:1
Safety circuit X3-04:1 (1
Heat demand (1
Flame signal (2
X10-...
Air pressure switch X3-02:1 (3
Fan contactor contact X4-01:3 (3
Start release Gas X7-03:2

Low gas pressure switch X9-03:4
High gas pressure switch X9-03:3
VP gas pressure switch X9-03:2
Outputs 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 54 60 62 70 72 74 76 78 79 80 81 82 83
Burner motor / Fan X3-01:1 (3
Ignition X4-02:3
Start signal
X4-03:3(4
Pressure switch release
Safety valve X9-01:1
Fuel valve 1 X9-01:4
Actuators 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 54 60 62 70 72 74 76 78 79 80 81 82 83
Full load
Pre-purge position
1
Post-purge position
2
Partial load
3
Ignition position
Standby position
(1
Signal only required to jump to Phase 79 (direct start)
(2
with QRI / QRA7x: Input X10-02:6
with ionisation electrode: Input X10-03:1
(3
Only with continuous running fan
(4
Signal is dependent on parameter: Start/PS valve (start signal or pressure switch release)
Signal on input / output activated
No signal on input
Input without influence
Signal optional or depending on parameter settings
1 Fuel actuator
2 Actuators air, Aux1, Aux2 / frequency converter
3 Actuator flue gas recirculation
83054802 1/2015-07 MaW 17-228

3.2.7.2 Gas with ignition pilot valve
Stabilisation of the flame

Valve
Ignition pilot valve OFF
Test without pressure
System pressure test

proving
Post-purge position
Operating setting 1
Operating setting 2
Pre-purge position
Drain valve train

Ignition position
Lockout phase
Post burn time
Fill valve train

Safety phase
Start release
Flame signal
Ignition OFF
Fuel release
Pre-ignition
Post-purge
Direct start
Pre-purge
Home run
Standby
Start-up
Fan ON
00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79 80 81 82 83
Inputs
(1
Heat demand
Flame signal (2
X10-...
(3
Fan contactor contact X4-01:3
VP gas pressure switch X9-03:2
Outputs 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79 80 81 82 83
Ignition X4-02:3
Start signal
X4-03:3(4
Safety valve X9-01:1
Ignition pilot valve X9-01:2
Fuel valve 1 X9-01:4 (5

Actuators 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79 80 81 82 83
Full load
Pre-purge position
1
Post-purge position
2
Partial load
3
Ignition position
Standby position
(1
(2
with ionisation electrode: Input X10-03:1
(3
(4
Signal is dependent on parameter: Start/PS valve (start signal or pressure switch release)
(5
If a pilot valve is fitted between fuel valve 1 and 2: Signal from Phase 40
If a gas ignition device is fitted in front of fuel valve 1: Signal from Phase 50
83054802 1/2015-07 MaW 18-228


No signal on input
1 Fuel actuator
83054802 1/2015-07 MaW 19-228

3.2.7.3 Light oil direct ignition
Post-purge position
Operating setting 1
Operating setting 2
Pre-purge position
Ignition position
Lockout phase
Post burn time

Safety phase
Start release
Flame signal
Ignition OFF
Fuel release
Pre-ignition
Post-purge
Direct start
Pre-purge
Home run
Standby
Start-up
Fan ON
00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 54 60 62 70 72 74 76 78 79
Inputs
(1
Heat demand
Flame signal (2
X10-...
Fan contactor contact X4-01:3 (3
Minimum oil pressure switch X5-01:2

Maximum oil pressure switch X5-02:2
Start release Oil X6-01:1
Outputs 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 54 60 62 70 72 74 76 78 79
Magnetic coupling / Oil pump X6-02:3 (4 (5 (5 (5
Ignition X4-02:3 (4 (5
Start signal
X4-03:3(6
Anti syphon valve X6-03:3
Fuel valve 1 X8-02/03
Actuators 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 54 60 62 70 72 74 76 78 79
Full load
Pre-purge position
1
Post-purge position
2
Partial load
3
Ignition position
Standby position
(1
(2
with QRA2: Input X10-03:1
with QRB: Input X10-02:1
(3
(4
Signal depends on parameter: OnIgnPointOilIgnition (long or short pre-ignition)
(5
Signal depends on parameter: OilPumpCoupling (direct coupling)
(6
Signal depends on parameter: Start/PS valve
83054802 1/2015-07 MaW 20-228


No signal on input
1 Fuel actuator
83054802 1/2015-07 MaW 21-228

3.2.7.4 Heavy oil direct ignition
Post-purge position
Operating setting 1
Operating setting 2
Pre-purge position
Ignition position
Lockout phase
Post burn time

Safety phase
Start release
Flame signal
Ignition OFF
Fuel release
Pre-ignition
Post-purge
Direct start
Pre-purge
Home run
Standby
Start-up
Fan ON
00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 54 60 62 70 72 74 76 78 79
Inputs
(1
Heat demand
Flame signal (2
X10-...
(3
Heavy oil immediate start X6-01:3
Outputs 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 54 60 62 70 72 74 76 78 79
Start signal
X4-03:3(6
Anti syphon valve X6-03:3
Fuel valve 1 X8-02/03
Actuators 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 54 60 62 70 72 74 76 78 79
Full load
Pre-purge position
1
Post-purge position
2
Partial load
3
Ignition position
Standby position
(1
(2
with QRA2: Input X10-03:1
with QRB: Input X10-02:1
(3
(4
(5
(6
83054802 1/2015-07 MaW 22-228


No signal on input
1 Fuel actuator
83054802 1/2015-07 MaW 23-228

3.2.7.5 Heavy oil with gas pilot ignition
Stabilisation of the flame

Ignition pilot valve OFF
Post-purge position
Operating setting 1
Operating setting 2
Pre-purge position
Ignition position
Lockout phase
Post burn time

Safety phase
Start release
Flame signal
Ignition OFF
Fuel release
Pre-ignition
Post-purge
Direct start
Pre-purge
Home run
Standby
Start-up
Fan ON
00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79
Inputs
(1
Heat demand
Flame signal (2
X10-...
(3
Heavy oil immediate start X6-01:3
Outputs 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79
Start signal
X4-03:3(6
Safety valve Gas X9-01:1
Ignition pilot valve Gas X9-01:2
Anti siphon valve Oil X6-03:3
Fuel valve 1 Oil X8-02/03
Fuel valve 2 Oil X7-01:3
Fuel valve 3 Oil X7-02:3
Actuators 00 01 10 12 20 21 22 24 30 32 34 36 38 40 42 44 50 52 54 60 62 70 72 74 76 78 79
Full load
Pre-purge position
1
Post-purge position
2
Partial load
3
Ignition position
Standby position
(1
(2
with ionisation electrode on gas ignition device: Input X10-03:1
(3
(4
(5
(6
83054802 1/2015-07 MaW 24-228


No signal on input
1 Fuel actuator
83054802 1/2015-07 MaW 25-228

3.3 Inputs
3.3.1 Voltage supply

1 SAFETY
The voltage supply is connected to inputs X3-04:3-5.
2 L LOOP
X3-04
PE 3 PE
LINE
N 4 N VOLTAGE
L 5 L
3.3.2 Safety circuit

1 In the diagnostic code, the inputs X3-03:1/2 and X3-04:1/2 are combined as
X3-03
FLANGE
2 L safety circuit. If one of the inputs is open the W-FM carries out at least one safety
P
shutdown. If the repetition value is exceeded an open input leads to lockout. The
1 SAFETY
repetition value can be set in parameter RepetitCounter under
2 L LOOP SafetyLoop, see [ch. 6.8.12].
X3-04
3 PE At input X3-04:1/2 all external components of the safety circuit are switched in se-
LINE
4 N VOLTAGE quence, these include:
5 L 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.
3.3.3 Reset
1 GAS A reset button can be connected to input X4-01:4. Pressing this button in lockout
2 will reset the combustion manager.
X4-01
OIL
3
(1 (2
4 RESET With lockout function(1
1
X3-01
L MOTOR If the push button is also required for manual lockout, it must be connected to
2 L ALARM mains input X3-04:5 (L). If the combustion manager is in an operating phase press-
1
ing the button will initiate a manual lockout.
SAFETY
2 L LOOP
X3-04
PE 3 PE Without lockout function(2

LINE
N 4 N VOLTAGE If the push button is not required to carry out manual lockout it must be connected
L 5 L
to alarm output X3-01:2.
3.3.4 Air pressure switch

P Depending on the burner configuration, the input is activated at the factory in the
1
X3-02
OEM level.
2 L
The input is activated for:
gas burners
dual fuel burners,
oil burners with separately driven pump.
In these cases, the closing contact of the air pressure switch is connected to in-
put X3-02:1. The fan will only start, if no signal is present at the input during start
release. If the signal is missing once the fan has started, the combustion manager
initiates a lockout.
83054802 1/2015-07 MaW 26-228

3.3.5 Fan contactor contact

1 GAS The auxiliary contact (closer) of the fan contactor is connected to input X4-01:3.
2 The fan will only start, if no signal is present at the input during start release. If the
X4-01
OIL
3 signal is missing once the fan has started, the combustion manager initiates a lock-
4 RESET out.
(1
(1
1 Only with frequency converter:
X3-01
L MOTOR
2 L ALARM
For fans with frequency converter, the signal is generated via a bridge from out-
P put X3-01:1 (burner motor / fan).
1
X3-02
2 L
3.3.6 Fuel selection

1 ON/OFF The fuel selection switch is connected to input X4-01:1/2. The fuel selection
2 switch has priority over fuel selection via display and operating unit (ABE) or build-
X5-03
3
3 2 ing management system (BMS). Fuel selection via ABE or BMS is only possible if
4 L no signal is present at input X4-01:1/2. There is no priority between ABE and
BMS, the last fuel selection is valid and is retained after power failure.
1 GAS
2
X4-01
OIL
0 1 2 3
4 RESET
3.3.7 Minimum oil pressure switch

P
1 PE The closing contact of the minimum oil pressure switch is connected to in-
X5-01
2 min put X5-01. On burners without minimum oil pressure switch the input is deactiv-
3 L ated.
In oil operation the combustion manager expects a signal at input X5-01:2 from
Phase 38, in Phase 44 with heavy oil with gas ignition device. If the pressure falls
below the value set, the pressure switch contact opens and the combustion man-
ager initiates a lockout. In Phase 38 (in Phase 44 with heavy oil with gas ignition
device ) lockout occurs after a waiting time of 3 seconds, in the following phases
lockout is immediate.
To avoid a lockout caused by pressure fluctuations during fuel release, the input re-
acts time delayed in Phase 40 and 42. The time delay can be adjusted in parameter
PressReacTime, see [ch. 6.8.1].
3.3.8 Maximum oil pressure switch

1 PE The opening contact of the max. oil pressure switch is connected to input X5-02.
X5-02
P
On burners without maximum oil pressure switch the input is deactivated.
P
2 max
3 L In oil operation the combustion manager expects a signal at input X5-02:2 from
Phase 22. If the value set at the pressure switch is exceeded, the pressure switch
contact opens and the combustion manager initiates a lockout. In Phase 21 (start
release) lockout occurs after a waiting time of 120 seconds, in the following phases
lockout is immediate.
To avoid a lockout caused by pressure fluctuations during fuel release, the input re-
acts time delayed in Phase 40 and 42. The time delay can be adjusted in parameter
PressReacTime, see [ch. 6.8.1].
83054802 1/2015-07 MaW 27-228

3.3.9 Start release Oil

1 START The start conditions for the oil operation are interrogated via input X6-01:1, e. g.:
2 oil shut off combination limit switch,
X6-01
L
3 oil temperature release contact (for heavy oil),
4 L cooling air fan contact (WK burners with hot air, version ZMH).
For burners without start conditions, a bridge is connected between terminals 1
and 2.
In oil operation the combustion manager expects a signal at input X6-01:1from
Phase 21. If the signal is missing after Phase 21, the combustion manager initiates
a shutdown.
3.3.10 Heavy oil immediate start

1 START The input is only activates on heavy oil burners with return flow temperature sensor.
2 The release contact of the return flow temperature sensor is connected to in-
X6-01
L
3 put X6-01:3.
4 L In heavy oil operation, the combustion manager carries out a nozzle circulation for
maximum 45 seconds. If the signal is present at input X6-01:3 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.
Depending on the burner nozzle circulation is carried out in phase:
38 (with direct ignition),
44 (with gas ignition device).
If the signal fails after Phase 44, the combustion manager initiates a safety shut-
down.
3.3.11 Start release Gas

1 PE The input is activated in gas operation and in heavy oil operation with gas ignition
X7-03
2 START
CPI
device.
3 L The combustion manager expects a signal at input X7-03:2 from Phase 21. If the
signal is missing after Phase 21, the combustion manager initiates a shutdown.
3.3.12 Valve proving gas pressure switch

1 L The opening contact of the valve proving gas pressure switch is connected to in-
2 LT put X9-04:2. Input X9-04:2 is only activated during valve proving [ch. 3.2.3].
X9-03
P
(CPI)
P
3 max
P
If the pressure set is not achieved in Phase 81 (test without pressure), the contact
P
4 min
closes.
If the pressure set is exceeded in Phase 83 (test with system pressure), the contact
opens.
83054802 1/2015-07 MaW 28-228

3.3.13 High gas pressure switch

1 L The input is activated in gas operation and in heavy oil operation with gas ignition
2 LT device. The opening contact of the high gas pressure switch is connected to in-
X9-03
P
(CPI)
3 max
P put X9-03:3.
P P
4 min On burners without high gas pressure switch the input is deactivated.
The combustion manager expects a signal at input X9-03:3 from Phase 40. If the
value set at the pressure switch is exceeded, the pressure switch contact opens
and the combustion manager initiates a lockout.
To avoid lockouts caused by pressure fluctuations when the valves open, the input
reacts time delayed in Phase 40, 42 and 50. The time delay can be adjusted in
parameter PressSigReactTime see [ch. 6.8.1].
3.3.14 Low gas pressure switch

1 L The input is activated in gas operation and in heavy oil operation with gas ignition
2 LT device. The closing contact of the low gas pressure switch is connected in-
X9-03
P
(CPI)
P 3 max
P put X9-03:4.
P
4 min
In gas operation, the combustion manager expects a signal at input X9-03:4 from
Phase 21. If the pressure drops below the value set, the pressure switch contact
opens and the combustion manager starts the low gas programme [ch. 3.2.2].
To avoid lockouts caused by pressure fluctuations when the valves open, the input
reacts time delayed in Phase 40, 42 and 50. The time delay can be adjusted in
parameter PressSigReactTime see [ch. 6.8.1].
83054802 1/2015-07 MaW 29-228

3.3.15 Flame sensor

If the flame signal from Phase 44 does not correspond to the value required, the
combustion manager initiates safety shutdown with restart. The number of safety
shutdowns set in parameter LossOfFlame in sequence lead to lockout
[ch. 6.8.12].
Depending on parameter ReactionExtranL , a flame signal in Standby
(Phase 12) will lead to start prevention or lockout.
A flame signal during pre-purge (Phases 30 to 36) or post-purge (Phase 76
and 78) leads to lockout after one repetition and repeated occurrence.
The OperationalStat shows the current flame signal as a percentage value.
BN
1 QRB QRB…
2 POWER QRI The flame sensor QRB… (photo resistor) is connected to input X10-02:1/4.
X10-02
3 L The flame sensor QRB is not suitable for continuous operation.

BK
4 N
If the combustion manager is installed in a control panel, the sensor cable must be
5 PE
routed separately (max 100 m).
6 QRI / FSV
Flame signal Sensor current Display
Minimum flame signal DC 30 μA approx. 35 %
Maximum flame signal DC 70 μA approx. 100 %
Extraneous light detection DC 5 μA -
from
1 QRB QRI
QRI BN
2 POWER QRI The flame sensor QRI (infrared) is connected to input X10-02:2/4/6.
X10-02
3 L The flame sensor QRI is suitable for continuous operation. The combustion man-
BU
4 N ager tests the flame sensor in cycles in operating position (Phase 60) by simulating
5 PE a flame failure. The voltage at output X10-02:2 is increased from 14 V to 21 V for
BK
+ 6 QRI / FSV 0.5 seconds. The signal voltage at the flame sensor therefore drops to 0 V and the
combustion manager receives the expected Off signal at input X10-02:6.
If the combustion manager is installed in a control panel, the sensor cable must be
routed separately (max 100 m).
Flame signal Display
Min. signal voltage: DC 3.5 V (X10-02:6) approx. 50 %
83054802 1/2015-07 MaW 30-228

QRA73 QRA73
M UV +
The flame sensor QRA73 (UV cell) is connected to input X10-02:2-6 using
plug AGM23.
4
PE
5
6
1
3
AGM23 The flame sensor QRA73 is suitable for continuous operation. The combustion
manager tests the flame sensor in cycles in operating position (Phase 60) by simu-
1 QRB
lating a flame failure. The voltage at output X10-02:2 is increased 14 V to 21 V for
4
PE
5
2
1
3
2 POWER QRI
0.5 seconds. The signal voltage at the flame sensor therefore drops to 0 V
X10-02
3 L
and the combustion manager receives the expected Off signal at input X10-02:6.
4 N
5 PE
If the combustion manager is installed in a control panel, the connection must be
6 QRI / FSV
divided into 2 lines after the AGM23 plug and routed separately (max 100 m):
Supply line: Core 1, 2 and PE (L / N / PE),
Signal line (screened): Core 3, 4 and 5 (POWER QRI / N / QRI).
Flame signal Display
Min. signal voltage: DC 3.5 V (X10-02:6) approx. 50 %
Ionisation electrode
X10-03
The ionisation electrode is connected to input X10-03:2.

1 ION If the combustion manager is installed in a control panel, the sensor cable must be
routed separately:
Max. length: 100 m,
Line capacity: 100 pF/m.
Flame signal Sensor current Display
Minimum flame signal DC 6 μA approx. 50 %
Maximum flame signal DC 85 μA approx. 100 %
83054802 1/2015-07 MaW 31-228

3.3.16 External load controller (X5-03)

For operation with load controller via contacts, parameter LC_OptgMode must be
set to ExtLC X503 see [ch. 6.12.2]. The contact for heat demand is connected
to input X5-03:1 (burner ON/OFF).
1 ON/OFF Modulating operation with load controller

2
X5-03
3 If input X5-03:2 (CLOSED) is activated, the burner capacity reduces.

3 2 If input X5-03:3 (OPEN) is activated, the burner capacity increases.
4 L If none of the two inputs is activated, the burner capacity remains unchanged.
1 ON/OFF Modulating operation with thermostat

P
2
X5-03
3 If thermostats or pressure regulators are connected to inputs X5-03, the modulat-

P
3 2 ing fuel can only be operated in sliding two stage operation.
4 L
At heat demand input X5-03:2 (CLOSED) is activated and the burner drives to par-
P P
1 ON/OFF tial load. If the temperature drops below the value set, input X5-03:3 (OPEN) is ac-
2
X5-03
3
P tivated and the burner drives to full load.
P P
3 2
4 L
Multi-stage operation (fuel oil only)

1 ON/OFF Two and three stage:
2
X5-03
3
Input Operating mode
3 2
4 L
two stage three stage
X5-03:1 Stage 1 Stage 1
1 ON/OFF Low impact start:

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

P
2
X5-03
3 A bridge connects terminals 2 and 3. At heat demand the burner drives to stage 1.
P
3 2 If inputs X5-03:2/3 are then activated simultaneously the burner drives via stage 2
4 L to stage 3.
83054802 1/2015-07 MaW 32-228

3.3.17 External load controller (X62)

1 ON/OFF For operation with external load controller on the analogue input, parameter
2 LC_OptgMode must be set to Ext LC X62 see [ch. 6.12.2].
X5-03
3
3 2 The contact for heat demand is connected to input X5-03:1 (burner ON/OFF).
- +
4 L The analogue load signal is connected to terminals X62:2/4 (0/2-10 V) or
X62:3/4 (0/4-20 mA). In parameter Ext Inp X62 U/I the input must be
1
0/2 ... 10 V matched to the analogue signal [ch. 6.12.4].
2 0-10V
0/4 ... 20 mA
X62
3 4-20mA
4 0 Modulating operation
5 FE In modulating operation, parameter MinActuatorStep determines the minimum
correcting element step [ch. 6.12.9].
Signal on X62 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:
3 … 5 … 12 mA Stage 1
13 … 15 … 20 mA Stage 2
Three stage:
3 … 5 … 7 mA Stage 1
8 … 10 … 12 mA Stage 2
13 … 15 … 20 mA Stage 3
3.3.18 External load controller (Bus)

For the operation with external load controller via Bus connection, parameter
interface
LC_OptgMode must be set to ExtLC Bus see [ch. 6.12.2]. The building man-
agement system provides the load signal via the bus connection.
In modulating operation, parameter MinActuatorStep determines the minimum
X50
correcting element step [ch. 6.12.9].
83054802 1/2015-07 MaW 33-228

3.3.19 Setpoint switch-over

When operating with internal load controller it is possible to switch between 2 set-
points. To do this, a potential free contact is connected to terminal X62:1/2.
1 Operating mode IntLC
W2
2 0-10V
Two internal setpoints (W1/W2) are available in operating mode IntLC . The
X62
W1
3 4-20mA
contact is used to switch between the setpoints.
4 0
5 FE
Open: Setpoint W1 activated
Closed: Setpoint W2 activated
Operating mode IntLC X62

In operating mode IntLC X62 the building management system provides the
W1
1
setpoint for the internal load controller via the analogue input.
0-10V
2 0-10V
In parameter Ext Inp X62 U/I , the input has to be matched to the analogue
signal [ch. 6.12.4]. Parameters Ext Setpoint min/max can be used to limit
X62
4-20mA
3 4-20mA
4 0
the external setpoint [ch. 6.12.6].
5 FE The contact is used to switch from the external setpoint to the internal setpoint W1.
If a voltage signal is present at input X62:2, the voltage signal has to be separated
from input X62:2 when switching over to the internal setpoint W1.
Open: External setpoint activated
Closed: Internal setpoint W1 activated
Operating mode IntLC Bus

interface
In operating mode IntLC Bus the building management system provides the
setpoint for the internal load controller via the Bus connection. The contact is used
1
W1 to switch from the external setpoint to the internal setpoint W1.
2 0-10V
X62
3 4-20mA Open: External setpoint activated

4 0 Closed: Internal setpoint W1 activated
5 FE
X50
83054802 1/2015-07 MaW 34-228

3.3.20 Temperature sensor

Pt/Ni 1000 Pt100
1 If the internal load controller is activated in parameter LC_OptgMode , a temper-
Pt/Ni 1000
2 ature sensor has to be connected to input X60 or a temperature or pressure sensor
Pt100
TEMP.
3
X60 has to be connected to input X61.
4 On W-FM 200 with flue gas recirculation (FGR), the FGR temperature sensor is
5 FE connected to input X60:3/4 as standard and is not available for the load controller.
As an alternative, the flue gas temperature sensor on the O2 module (accessory)
P/ can be used as FGR temperature sensor [ch. 3.3.23]. The sensor used must be
1 Power Supply
TEMP./PRES. INPUT
IN Sensor defined in parameter FGRsensor, see [ch. 6.15.3].
0....10 V 2 0-10 V
On W-FM 200 with CO control the combustion air sensor is fitted to input X60:3/4
X61
4...20 mA 3 4-20 mA
and is not available for the load controller. Parameter AirTempX60PT1000
GND 4 0
5 FE
(OEM level) must be set to activated .
The internal temperature monitor function is only possible with temperature sensor
on input X60. If there is no external safety temperature limiter available in the safety
circuit, two temperature sensors (Pt100/Pt1000 or Pt100/Ni1000) must be con-
nected for the internal temperature monitor function.
With different cable resistances in the three-wire circuit (Pt100) line compensation
is required.
Depending on the circuitry, the inputs must be configured via the following para-
meters:
Sensor selection [ch. 6.12.3]
Ext Inp X61 U/I [ch. 6.12.4]
Measuring range [ch. 6.12.5]
Additional sensor for boiler start function [ch. 6.12.14].
The voltage supply (20 V DC) on terminal X61:1 can not be changed.
3.3.21 Speed measurement

BN BN
1 Usensor For operation with frequency converter (W-FM 200 only) the proximity switch for
2 wire
BK BU
2 Pulse-In speed measurement is connected to input X70.
BU 3 wire
X70
3 0 Via the transmitter disc, the proximity switch detects 3 impulses per rotation. The
4 RESERVE number of impulses must be defined in parameter Num Puls per R, see
5 FE [ch. 6.14.2]. The direction of rotation is detected by the asymmetrical transmitter
disc (60°, 120°, 180°).
83054802 1/2015-07 MaW 35-228

3.3.22 Fuel meter

1 Usensor It is possible to connect 2 fuel meters to the W-FM 200:
2 wire
2 Pulse-In Gas meter: X71
3 X71 0
3 wire
Oil meter: X72
GAS
4 FE
Supply (PIN 1) approx. 10 V DC / max 45 mA
1 Usensor
Input (PIN 2) max 10 V DC
2 wire High level: min 3 V DC
2 Pulse-In
X72
3 wire Low level: max 1.5 V DC

3 0
4 Sensor Inductive sensor to DIN 19234 (Namur)
OIL
FE
Open Collector (pnp)
Reed contact
Frequency max 300 Hz
The number of impulses per unit of volume must be set in parameter
PulseValue… .
3.3.23 Flue gas temperature sensor

1 The flue gas temperature sensor is connected to the O2 module input X86 (access-
FUEL GAS
Pt/Ni 1000
ory).
X86
2
3 The sensor has to be configured in parameter FlueGasTempSens, see
[ch. 6.10.9].
Alternatively, the flue gas temperature sensor can be used as FGR temperature
sensor (flue gas recirculation). In parameter FGR sensor X86PtNi1000
must then be defined as FGR temperature sensor [ch. 6.15.3].
3.3.24 Combustion air sensor / CO resistance circuit board

1 The combustion air temperature sensor is connected to the O2 module input X87
COMBUS-
Pt/Ni 1000
TION. AIR
(accessory).
X87
2
3 The sensor has to be configured in parameter SupAirTempSens, see
[ch. 6.10.9].
In conjunction with CO control, a resistance circuit board is connected to input
COx >max
1
COMBUS-
X87. The digital output 3 of the CO measurement amplifier is connected to the O2

Pt/Ni 1000
TION. AIR
X87
2 module via the resistance circuit board. The combustion air sensor then has to be
3 connected to input X60:3/4 [ch. 3.3.20].
83054802 1/2015-07 MaW 36-228

3.3.25 O2 sensor
QGO... GND The O2 sensor is connected to the O2 module (accessory).
B1 1 B1
Connect signal cable (3 x 2 x 0.25 mm2) twisted in pairs to X81. Fit the screen
M 2 M
single-sided to the screen clamp of the O2 module, cable length maximum 10 m.
B2 3 B2
Connect separate cable (3 x 0.75 mm2) for sensor heating to the pulsed
QGO...
X81
M 4 M
output X89-2:Q4/Q5.
G2 5 G2 The O2 sensor has to be configured in parameter O2 Sensor, see [ch. 6.10.7].
U3 6 U3
Terminal Function
Q4
1 PE B1 / M Nernst voltage depending on the current O2 content
X89-2
Q5
QGO...
2 N Q5 [ch. 6.10.16].
3 L Q4 B2 / M Thermo element of the O2 sensor (0 … 33 mV), 700 °C equal to
approx. 29.1 mV.
Current operating temperature [ch. 6.10.20].
G2 Voltage supply for temperature compensation
U3 Signal of temperature compensation
L (Q4) Pulsed voltage supply for sensor heating 230 V, N (Q5) is
N (Q5) switched. Parameter QGO HeatingLoad shows the current
heating capacity [ch. 6.10.21].
83054802 1/2015-07 MaW 37-228

3.4 Outputs
3.4.1 Alarm
1 In lockout position (Phase 00) a mains voltage signal is emitted at alarm out-
X3-01
L MOTOR
2 L ALARM put X3-01:2.
Additionally, it is also possible to signal prevention. To do this parameter
AlarmStartPrev is set to activated [ch. 6.8.2]. The time, before a start preven-
tion triggers an alarm is set in parameter AlarmDelay, see [ch. 6.8.1].
Parameter Alarm act/deact is used to deactivate the alarm signal [ch. 9.1.1].
The deactivation only affects the alarm output, lockout or start prevention are not
reset. Reset or burner start are reset automatically by the deactivation and the
alarm output is ready of use again.
3.4.2 Motor
1 The fan motor is connected to output X3-01:1 via contactor or star delta switching.
X3-01
L MOTOR
M 2 L ALARM Depending on parameter ContinuousPurge the output is controlled from
N L Phase 22 or continuously [ch. 6.8.7].
If an air pressure switch is fitted, continuous running fan is only possible via pres-
sure switch relief. To do this, a vent valve has to be fitted and connected to out-
put X4-03.
3.4.3 Oil pump / magnetic coupling

1 PE Either the magnetic coupling, a separate oil pump or the anti syphon valve are con-
X6-02
2 N nected to output X6-02.

M
3
~
L The type of oil pump coupling is set in parameter OilPumpCoupling, see

[ch. 6.8.4].
Magnetic coupling / separate oil pump

On dual fuel burners with magnetic coupling or on burners with separate oil pump,
parameter OilPumpCoupling is set to Magnetcoupl . The switch-on point
of the ignition should be set to short pre-ignition (on in Ph38). In light oil opera-
tion, the output is controlled from the start of pre-ignition (phase 38) to operating
setting 2 (phase 62). In heavy oil operation, the output is controlled in phase 36, to
ensure oil pressure is available for the subsequent nozzle circulation.
Direct coupling
On oil burners with the oil pump directly coupled to the burner motor, the anti sy-
phon valve is connected to output X6-02. Parameter OilPumpCoupling must
be set to Directcoupl, this means that long ignition is activated automatically.
The output is controlled together with the fan from phase 22 and remains activated
for a further 15 seconds after the fan has switched off.
83054802 1/2015-07 MaW 38-228

3.4.4 Start signal, pressure switch relief

Output X4-03 is controlled depending on parameter Start/PS valve, see
[ch. 6.8.10].
Start signal
If parameter Start/PS valve is set to PS Reli_Inv the output is con-
trolled in phase 21 to phase 79.
-P 1 PE Pressure switch relief

P
+
X4-03
2 N If an air pressure switch is fitted, continuous venting or direct start is only possible
3 L (START) via pressure switch relief. To do this, a normally open vent valve has to be fitted to
the air pressure switch and parameter Start/PS valve must be set to PS
M Reli_Inv The output is controlled together with the fan motor, except at start
release (phase 21) and direct start (phase 79). The output is not controlled in
P
1 PE phase 21 and 79, the air pressure switch de-energises via the open vent valve and
P
+
X4-03
2 N the signal at input X3-02:1 corresponds to the program sequence.

3 L (START)
3.4.5 Ignition
1 PE
IGNITION The ignition unit is connected to output X4-02.
X4-02
2 N
3 L Ignition behaviour Gas
In gas operation, the output is controlled in phase 38 and 40.
The pre-ignition time in phase 38 can be adjusted in parameter Preigni
tionTGas, see [ch. 6.8.1].
Ignition behaviour Oil

The switch-on point of the ignition is determined in parameter
IgnOilPumpStart, see [ch. 6.8.4].
The pre-ignition time in phase 38 can be adjusted in parameter Preigni
tionTOil, see [ch. 6.8.1].
Parameter IgnOilPumpStart Application
on in Ph38 Dual fuel burners with magnetic coup-
Output is controlled in phase 38 ling between burner motor and oil
and 40 (short pre-ignition). pump.
Burners with separate pump or pump
station.
on in Ph22 Burners with oil pump coupled directly
Output is controlled in phases 22 to 40 to the burner motor.
(long pre-ignition).
83054802 1/2015-07 MaW 39-228

3.4.6 Anti syphon valve

1 PE If an anti syphon valve is fitted in the oil supply, the valve can be connected to out-
X6-03
2 N put X6-03, X6-02 or X3-01.
SV
3 L Output X6-03:
Dual fuel burners with magnetic coupling between burner motor and oil pump
1 PE Oil and dual fuel burners with separately driven oil pump
X6-02
2 N
M Output X6-02:
3 L
Oil burners with oil pump coupled directly to the burner motor (without continu-
ous running fan)
1
X3-01
L MOTOR
2 L ALARM Output X3-01:
Dual fuel burners with oil pump coupled directly to the burner motor (without
continuous running fan)
Oil burners with oil pump coupled directly to the burner motor (with continuous
running fan)
83054802 1/2015-07 MaW 40-228

3.4.7 Oil fuel valves

The oil solenoid valves are connected to the outputs X7-01, X7-02, X8-02 and
X8-03. The outputs are controlled according to the program sequence [ch. 3.2.7].
EL MS 1 PE Multi-stage operation
X7-01
2 N Output Light oil (EL) Heavy oil (MS) two stage

2 1 V2
3 L Heavy oil (MS) three stage
1 PE X7-01 Stage 2 Stage 1
X7-02
2 N
X7-02 Stage 3 Stage 2
3 2 V3
3 L
X8-02 Stage 1 -
1 L
1 X8-03 Additional solenoid valve Additional solenoid valve
X8-02
2 V1
3 N Nozzle circulation via output X8-03 is not possible on three stage heavy oil burners,
4 PE as the combustion manager controls outputs X8-02 and X8-03 simultaneously. The
1 L
solenoid valve for nozzle circulation is connected to output X4-02 (ignition) and
parameter IgnOilPumpStart must be set to on in Ph22 (long pre-
X8-03
2 V1
3 N
ignition) [ch. 6.8.4].
4 PE
EL Modulating operation
1 L
Output Light oil (EL) Heavy oil (MS)
2 V1
X8-02
3 N X7-01 - Nozzle solenoid (nozzle head)

4 PE X8-02 Nozzle solenoid (nozzle head) Additional solenoid valves(1
1 L
-or- Bypass valve (only with separ-
2 V1
Solenoid valves(1 ate pump station)
X8-03
3 N X8-03 Additional solenoid valves(1

-
4 PE €€
(1
The solenoid valve in the supply is always switched electrically in series with the
MS 1 PE solenoid valve in the return.
X7-01
2 N
V2
3 L
1 L
2 V1
X8-02
3 N
4 PE
83054802 1/2015-07 MaW 41-228

3.4.8 Fuel valves Gas

The fuel valves are connected to output X9-01. The contacts are controlled in ac-
cordance with the program sequence [ch. 3.2.7].
SV Output Fuel valve
X9-02
1 N
2 PE X9-01:1 (SV) External gas solenoid valve (optional)
1 L SV X9-01:2 (PV) Ignition gas valve(1
2 - or -
X9-01
L PV
3 L V2 Gas ignition device(2
4 L V1 Main gas Double gas valve
X9-01:3 (V2) Valve 2
PV N PE
1 X9-01:4 (V1) Valve 1
X9-01
(1 L SV
2 L PV
€€
(1
Only for burners with ignition gas tube.
3 L V2 (2
Only for heavy oil burners with gas ignition
4 L V1
1
X9-01
(2 L SV
2 2 L PV
1 3 L V2
4 L V1
1 L SV
V2 / V1 N PE
2 L PV
X9-01
2 3 L V2
1 4 L V1
Valve lift monitoring

The actuators of double gas valves type VGD (from DN 125) are equipped with
X9-02
1 N
2 PE limit switches. The limit switches monitor the valve lift and are switched in se-
quence with the voltage supply of actuator V2.
1 L SV
At burner start, the limit switches are bridged via a timer relay for approx. 25
2
X9-01
L PV
seconds. If both limit switches are closed once this time has elapsed, valve V2 re-
3 L V2
mains open.
4 L V1
If a valve does not maintain the the minimum lift, the relevant limit switch opens and
interrupts the voltage from actuator V2. Valve V2 closes and the combustion man-
ager initiates a safety shudown with restart. The number of safety shutdowns in se-
quence set in parameter LossOfFlame result in a lockout [ch. 6.8.12].
2M
1M
3.4.9 Operating display

1 Output X8-01 is controlled together with valve 1 of the current fuel. The output may
X8-01
GAS
2 OIL only be used as the operating display.

N
83054802 1/2015-07 MaW 42-228

3.4.10 Analogue output

1 4-20 mA If the combustion manager is equipped with an internal load controller, a system
X63
2 0 value can be issued at output X63 via an analogue signal (0/4 … 20 mA). The out-
3 FE put can be configured in parameter Analog Output, see [ch. 6.12.7].
Load signal
If the parameter Selection analog output is set to Load the analogue
signal corresponds to defined values. For different scaling, the parameter has to be
set to Load 0 .
Modulating operation:
Burner rating OFF 0% 100 %
Analogue signal 4 mA 4 mA 20 mA
Multi-stage operation:
Burner rating OFF Stage 1 Stage 2 Stage 3
Analogue signal 4 mA 5 mA 10 mA 15 mA
3.4.11 Frequency converter

WH The frequency converter is connected to output X73 using a screened cable
1
BN Start OUT
2 (W-FM 200 only). The screen must be connected to ground on both sides.
GN
3 Terminal Function
X73
YE
4 (W-FM 200)
GY
5 0
6 FE
X73:1/2 Enable contact:
The enable contact for the frequency converter closes from a de-
sired speed greater than 0 %.
The switch status in phase 10 (home run) for the standby posi-
tion (0 %) can be specified via parameter
ReleasecontctVSD, see [ch. 6.14.1].
X73:3 Alarm input:
U1 A signal from the frequency converter (DC 12 … 24 V) results in
a safety shutdown.
X73:4/5 Setpoint output (0/4 … 20 mA):
The output and input (W-FM 200 / frequency converter) must be
matched. The output signal can be set in parameter Setpoint
Output, see [ch. 6.14.5].
83054802 1/2015-07 MaW 43-228

3.5 Technical data
3.5.1 Electrical data
Combustion Manager W-FM

Mains voltage / Mains frequency (120) 230 V / 50 … 60 Hz
Consumption max 30 W
Internal unit fuse 6.3 AT, IEC 127-2/V
External fuse max 16 AB
Type of protection IP 00
Total contact load outputs max 5 A

Fan motor (output X3-01:1) 1A
Alarm (output X3-01:2) 1A
Ignition (output X4-02) (1.6) 2 A
Pressure switch relief (output X4-03) 0.5 A
Magnetic coupling (output X6-02) (1.6) 2 A
Oil fuel valves (1.6) 1 A
Fuel valves Gas (1.6) 2 A
Display and operating unit (ABE)

Mains voltage AC 24 V
Consumption max 50 mW
Type of protection (front) IP54 to ICE 529
Type of protection (rear) IP00 to ICE 529
Transformer
Secondary 1 AC 12 V
Secondary 2 2 x AC 12 V
Actuator
SQM45… SQM48.497A SQM48.697A SQM91.391A9
Mains voltage AC 2 x 12 V AC 2 x 12 V AC 2 x 12 V AC 2 x 12 V
Consumption 9 … 15 VA 26 … 34 VA 26 … 34 VA approx. 40 VA
Torque 3 Nm 20 Nm 35 Nm 60 Nm
Setting time 10 s / 90° 30 s / 90° 60 s / 90° 30 s / 90°
Type of protection IP 54 IP 54 IP 54 IP 66
83054802 1/2015-07 MaW 44-228

O2 module
Consumption O2 module max 4 W
Consumption O2 sensor max 90 W
Internal unit fuse 2.5 T, IEC 60127-2/I
External fuse max 16 AB
O2 sensor
Consumption max 90 W
Permissible flue gas velocity 1 … 10 m/s
Flue gas temperature max 300 °C
Permissible fuels QGO 20:
Natural and Liquid Petro-
leum Gas
Fuel oil EL
QGO 21:
Natural and Liquid Petro-
leum Gas
Fuel oil EL
Heavy oil to
DIN 51603-3 and
DIN 51603-5
3.5.2 Ambient conditions

Temperature in operation -20 … +60 °C
Temperature during transport / storage -20 … +60 °C
Relative Humidity max 95 %, no dew point
83054802 1/2015-07 MaW 45-228

3.5.3 Dimensions
Combustion Manager
182 mm
200 mm
82 mm 232 mm
250 mm
260 mm

Recess dimension: 127 x 91 mm ± 0.5 mm
49 96
24 19 90,2
135,8
126
83054802 1/2015-07 MaW 46-228

Transformer
66,5 mm
87 mm
55,5 mm
40,5 mm
10,5 mm
79,5 mm 102,5 mm
9 mm
120 mm
83054802 1/2015-07 MaW 47-228

4 Installation
4 Installation
4.1 Installing O2 sensor
O2 trim is only possible with W-FM 200 with O2 module.

For O2 measurement, an O2 sensor must be fitted in the flue gas pipe and connec-
ted to the O2 module. The distance between O2 sensor and O2 module must be no
more than 10 m.
Flange dimensions
QGO 20 QGO 21
51 mm 53,5 mm 48 mm
90 mm 180 / 260 mm
Prerequisite
Damage to the O2 sensor caused by overheating

Flue gas temperature above 300 °C can damage the O2 sensor.
Avoid flue gas temperatures above 300 °C at the O2 sensor.
CAUTION
Install O2 sensor only with the corresponding flange.

It must not be possible for extraneous air to enter in front of the sensor and at a
distance of 2 x Ø of the flue gas pipe behind the sensor.
83054802 1/2015-07 MaW 48-228

4 Installation
Installation position
Install the sensor as close as possible to the flue gas outlet of the boiler, but at
least at a distance of 1 x Ø of the flue gas pipe.
Sensor in the horizontal part of the flue gas pipe:
QGO 20: vertically from above or at an angle of 45°.
QGO 21: horizontal
Sensor in the vertical part of the flue gas pipe:
With a downward inclination of approx. 5°.
min 1 x Ø QGO 20 QGO 21

5° 45°
45°
Installation
Weld flange gastight to flue gas pipe 1, with QGO 20 observe the position of
the flue gas outlet openings 4.
Install O2 sensor 2, ensuring correct alignment of the seal 3.
Cable entry must be made on the opposite side to the flue gas flow.
QGO 20 QGO 21
2 2
1 3 1 3
≥ 10 mm
83054802 1/2015-07 MaW 49-228

5 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 re-start.
Electric shock caused by frequency converter despite disconnection from the

voltage supply
It is possible that electrical components on burners with frequency converters con-
WARNING tinue to carry voltage and cause electric shock even after the voltage supply has
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 AT pre-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 pre-fusing (maximum 16 AT). All other cable connections must be suit-
able for the relevant internal unit fuse (6.3 AT).
Earthing and neutral conductor must conform to local regulations.
The following applies for cable length:
all cable lengths maximum 100 m,
use only original Weishaupt parts as Bus line,
install Bus line as line configuration.
83054802 1/2015-07 MaW 50-228

Bus connection / supply voltage

The CAN Bus line must not exceed a total length of 100 m. A second source trans-
former is required from a line length of 20 m between the combustion manager and
the last actuator (e. g. combustion manager fitted to control panel). In this case
transformer 1 feeds the combustion manager and ABE, transformer 2 feeds the ac-
tuators. In so doing, the power supply of the CAN bus line (AC1 and AC2)
between combustion manager and the first actuator must not be connected.
The ends of the bus line must be terminated with a bus termination resistor. The
bus termination is permanently installed in the ABE. On the last actuator or at the
O2 module, the bus termination must be set via a jumper. Bus termination must be
deactivated for all other participants.
The screen of the bus line must be terminated at both ends.
1
SQM... SQM... SQM...
M M M
5
5 5 2
N
O2 5
12AC2
12AC1
CANH
Shield
CANL
6,3 AT
GND
L
12V UN
12V 12V
1
4 AT
4
3
4 AT
SQM... SQM... SQM...
M M M
5
5 5
3 5 5
5
X52 X51 X51 X52 X51 X51

FE
12AC2
M
12AC1
GND
CANL
CANH
12AC2
12AC1
Shield
GND
CANL
CANH
12AC2
12AC1
Shield
FE
12AC2
M
12AC1
GND
CANL
CANH
12AC2
12AC1
Shield
GND
CANL
CANH
12AC2
12AC1
Shield
4 4
4 AT 4 AT
G G
12V
12V
12V
12V
G0 4 AT G0 4 AT
X10-01
X10-01
L L
12V
12V
UN
UN
6,3 AT 6,3 AT
N N
W-FM ... W-FM 200

PE
PE
N
N
L
X3-04 X3-04
1 Burner
2 Bus termination
3 Control panel
4 Transformer
5 O2 module
83054802 1/2015-07 MaW 51-228


The ABE is equipped with 3 interfaces.
CAN (X70): CAN Bus connection to the combustion manager
COM 1 (X71): RS-232 for PC connection
COM 2 (X72): RJ45 connection building management system via Bus interface
The COM interfaces can not be used at the same time
COM 1
6 7 8 9
X71 CAN COM 2
1 2 3 4 5
6 7 8 9
8 1
1 2 3 4 5
X70 X72
PIN CAN (X70) COM 1 (X71) COM 2 (X72)

1 - - TXD
2 CAN L RXD -
3 GND TXD RXD
4 VAC 2 - GND
5 - GND U1
6 - - GND
7 CAN H - U2
8 VAC 1 - -
83054802 1/2015-07 MaW 52-228

Connect burner / fan motor, pump station

The motor must be protected against thermal overload and short circuit. The use of
a motor protection switch is recommended.
Open terminal box on motor.
Connect voltage supply to wiring diagram enclosed, observe motor rotation.
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 designated screen clamp on frequency converter.
Use screen cable glands (metal) on the burner.
Connect gas valve train

Observe wiring diagram.
Connect double gas valve (plug K32 / Y2).
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 / Y1).
Connect low gas pressure switch (plug B31 / F11).
Connect valve proving gas pressure switch (plug B32 / F12).
If required, connect high gas pressure switch (plug B33 / F33).
Connect connection cable to burner (use cable entry W-FM).
83054802 1/2015-07 MaW 53-228

Connect O2 sensor
The O2 sensor is connected to the O2 module (accessory).
Connect signal cable (3 x 2 x 0.25 mm2) twisted in pairs to X81. Fit the screen
single-sided to the screen clamp of the O2 module, cable length maximum 10 m.
Connect separate cable (3 x 0.75 mm2) for sensor heating to the pulsed
output X89-2:Q4/Q5.
QGO... PLL...
GND
B1 1 B1
M 2 M
B2 3 B2
QGO...
X81
M 4 M
G2 5 G2
U3 6 U3
Q4
1 PE
Q5
X89-2
QGO...
2 N Q5
3 L Q4
83054802 1/2015-07 MaW 54-228

6 Operation
6 Operation
6.1 Operating interface
6.1.1 Operating panel
5 2
4 3
1 4 line display with scroll function

2 Dial knob to scroll through menus and/or to alter values
3 [ENTER] key for selection
4 [esc] key to return or abort
5 [info] key to return to operating display
OFF function
Press [ENTER] and [esc] simultaneously.
Immediate lockout.
The lockout is stored in the fault history.
83054802 1/2015-07 MaW 55-228

6 Operation
6.1.2 Display
The ABE is equipped with a 4 line display with 16 characters per line. The dial
knob is used to scroll through the display, the cursor 1 indicates the position se-
lected.
Normal operation
Status/Reset
Fault history
Lockout history
Operating display
##
Normal operation The [info] key is used to jump from any menu level to the
Status/Reset operating display menu. The [esc] key is used to return the
Fault history display to the menu point previously used.
Lockout history
Menu level 1
##
Operating display The [esc] key is used to leave any position and to go back
Operation all the way to menu level 1 [ch. 6.3].
Manual operation
Param & Display
Fault display
During a fault condition, the display alternately shows the shutdown behaviour and
the fault diagnosed as a plain text display.
##
The combustion manager is in lockout. Once the fault has

Lockout been rectified, the combustion manager has to be reset for
restart [ch. 9.1].
Air pressure is
off
##
The combustion manager initiates a safety shutdown.

Safety The burner restarts automatically once the fault condition
shutdown has been rectified.
Safety loop
is open
83054802 1/2015-07 MaW 56-228

6 Operation
6.2 Displaying and adjusting parameters

Call up menu level 1
Operating display Press [esc] key until menu level 1 is displayed.
Operation
Normal operation
Manual operation
Status/Reset
Param
Fault& Display
history
Lockout history
Navigating through the level

Operating display Turn dial knob.
Operation Cursor switches to the next menu point.
Manual operation
Param & Display If a level has more than 4 menu points, the display scrolls up and down.
Updating
Enter PW
TÜV Test
One level lower

Operating display Press [ENTER] key.
Operation
Boiler setpoint
Manual
User operation
Maxload
Param
Fuel& Display
Date/Time
One level higher

Operating display Press [esc] key.
Operation
Boiler setpoint
Manual
User operation
Maxload
Param
Fuel& Display
Date/Time
Change value
Auto/Manuel/Off Press [ENTER] key.
Time
Program stop Selected parameter is displayed.
SwitchOffBeh
Curr: deactivated Turn dial knob.
ProgramStop
New: 36 Ignpos New value is displayed.
Save value
Auto/Manuel/Off Press [ENTER] key.
Time
Program stop The value changed is applied and saved.
SwitchOffBeh
Curr: deactivated
ProgramStop Do not accept value:
New: 36 Ignpos Press [esc] without first confirming with [ENTER] key.
Exit parameter without changing the value.
83054802 1/2015-07 MaW 57-228

6 Operation
6.2.1 Password
Enter password
HE password: 9876
Select Enter PW in menu level 1 and press the [ENTER].
Select Access with HE and press [ENTER].
Set first character using the dial knob and confirm with [ENTER].
A star appears and the cursor moves to the next position.
Repeat procedure until the password has been entered.
Confirm password with [ENTER].
Display changes to menu level 1.
Enter PW
TÜV Test
Access without PW Enter
Access with HE Password
Access with OEM :9876••••
Access with SBT
Manual operation
Param & Display
Updating
Enter PW
Deactivating password
If no key is activated for 120 minutes, the combustion manager automatically deac-
tivates the password and blocks the password level.
Select Deactivate PW in menu level 1 and press [ENTER].
The display shows Password has been deactivated.
Press [esc] key.
Display changes to menu level 1.
Param & Display Password has

Updating been deactivated
Enter PW
Deactivate PW
Operating display
Operation
Manual operation
Param & Display
83054802 1/2015-07 MaW 58-228

6 Operation
6.3 Menu structure

Values in the square brackets show the factory setting.
##
Operating display
Normal operation
Status/Reset
Fault history
Lockout history
##
Alarm act/deact
##
Operation
Boiler setpoint
Setpoint W1
##
Setpoint W2
Load limitAB
UserMaxLoadMod [100 %]
##
UserMaxLoadStg [S3]
Fuel
CurrentFuel
##
FuelSelect
Date/Time
Display the clock
##
Date
Time
Weekday
Set the clock
Date
Time
##
Weekday
Hours run
Gas operation
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
TotalHours
##
SystemOnPower
StartCounter
GasStartCount
OilStartCount
TotalStartCountR
##
TotalStartCount
Fuel meter(1
Curr Flow Rate
Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset DateGas
##
Reset DateOil
##
Number of lockouts
83054802 1/2015-07 MaW 59-228

6 Operation
##
Operation (continued)
O2 module
Current O2 Value(1
O2 setpoint(1
SupplyAirTemp(1
FlueGasTemp(1
##
CombEfficiency(1
##
Burner identification
Operating mode selection
Interface PC
GatewayBASon
GatewayBASoff
##
Type of Gateway [Modbus]
##
O2Ctrl activate(1
##
Manual operation
SetLoad
##
Autom/Manual/Off [Automatic]
##
Param & Display
Burner control
Times(2
TimeStartup1
MinTimeStartRel [1 s]
FanRunUpTme [2 s]
PrepurgeTmeGas [20 s]
PrepurgeTmeOil [15 s]
PrepurgeSafeGas [20 s]
PrepurgeSafeOil [15 s]
PrepurgePtl1Gas [0.2 s]
PrpurgePt3Gas [0.2 s]
PrepurgePt1Oil
PrepurgePt3Oil [0.2 s]
PrepurgeTGas [2 s]
PrepurgeTOil [2 s]
MinOnTmeOilPump [1 s]
##
TimeStartup2
Interval1Gas [2 s]
Interval1Oil [2 s]
Interval2Gas [2 s]
Interval2Oil [2 s]
##
PressReacTime [2 s]
TimeShutdown
MaxTmeLowFire [45 s]
AfterburnTme [8 s]
PostpurgeT1Gas [0.2 s]
PostpurgeT1Oil [0.2 s]
PostpurgeT3Gas [5 s]
PostpurgeT3Oil [5 s]
PostpurgeT3long [0 s](1
##
DelayLackGas [10 s]
(1
W-FM 200 only
(2
only with HE password
83054802 1/2015-07 MaW 60-228

6 Operation
##
Param & Display (continued)
Times in general
AlarmDelay [35 s]
DelayStartPrev [35 s]
PostpurgeLockout [0.2 s]
##
MaxTmeStartRel [120 s]
Configuration
ConfigGeneral(2
AlarmStartPrev [deactivated]
StandbyError [deactivated]
NormDirectStart[NormalStart]
OilPumpCoupling
IgnOilPumpStart
ForcedIntermit [activated]
Skip PrepurgeGas [deactivated]
##
ContinuousPurge [deactivated]
ConfigIn/output(2
RotSpeed PS on(1 [80]
RotSpeed PS off(1 [50]
Config X503 [LMV5x hrs]
##
Start/PSValve
ConfigFlamDet
ReacExtranLight [Startblock]
##
FlameSignal
RepetCounter(2
LossOfFlame [2]
HeavyOil [3]
StartRelease [10]
##
SafetyLoop [16]
ProductID
ASN ProductionDate
SerialNumber
ParamSet Code
##
ParamSet Vers
##
SW Version
Ratio control
SettingGas / Oil(2
SpecialPositions
HomePos
PrepurgePos
IgnitionPos
PostpurgePos
ProgramStop [deactivated]
##
ResetIgnitPos
##
CurveParams
LoadLimits
MinLoad [0 %]
##
MaxLoad [100 %]
(1
W-FM 200 only
(2
83054802 1/2015-07 MaW 61-228

6 Operation
##
Load mask out
LoadMaskLowLimit [0 %]
LoadMaskHighLim [0 %]
##
FC(1 [activated]
##
StartPoint Op [1]
##
Autom/Manual/Off [Automatic]
Times(2
OperRampMod
OperRampStage
##
TimeNoFlame
ShutdownBehav(2 [Rest pos]
##
ProgramStop(2 [deactivated]
O2Contr/Alarm(1
Gas/Oil settings
Operating mode (2
O2 trim(2
##
O2 monitor(2
O2 Alarm
O2 MaxValue [15]
##
NumMinUntilDeact [1]
Controller parameter
PI
LowFireAdaptPtNo(2 [2]
O2CtrlThreshold(2 [0 %]
LoadCtrlSuspend(2 [5 %]
O2ModOffset(2 [0 %]
Type Air Change(2 [like theory]
O2MaxManVariable(2 [35%]
##
O2MinManVariable(2 [-35%]
Startmode
O2InitOffset(2 [0 %]
NoTauSuspend(2 [10]
##
Adjust. Temp O2 [20 °C]
Type of Fuel(2
Fuel user-def(2
V_LNmin
V_afNmin
V_atrNmin
A2
##
B/1000
COx(2
OptgMode COx Gas [deactivated]
OptgMode COx Oil [deactivated]
##
Time COx alarm [20 s]
(1
W-FM 200 only
(2
83054802 1/2015-07 MaW 62-228

6 Operation
##
Process data
CombEfficiency
Man Var O2Ctrl
State O2Ctrl
AirRelated Load
##
Diag Reg State
Load controller
Controller parameters
ContrlParamList
StandardParam
P Part (Xp) [15 %]
I Part (Tn) [320 s]
##
D Part (Tv) [40 s]
MinActuatorStep [1 %]
SW_FilterTmeCon [3 s]
SetpointW1
SetpointW2
Sd_ModOn [1 %]
Sd_ModOff [10 %]
Sd_Stage1On [-2 %]
Sd_Stage1Off [10 %]
Sd_Stage2Off [8 %]
Sd_Stage3Off [6 %]
ThreshStage2On[300]
##
ThreshStage3On [600]
TempLimiter(2
TL_ThreshOff [95 °C]
##
TL_SD_On [-5 %]
Cold start
ColdStartOn (2 [deactivated]
ThresholdOn(2 [20 %]
StageLoad(2 [15 %]
StageSetp_Mod(2 [5 %]
StageSetp_Stage(2 [5 %]
MaxTmeMod(2 [3 min]
MaxTmeStage(2 [3 min]
ThresholdOff(2 [80 %]
AdditionalSens(2 [deactivated]
Temp. ColdStart
SetpAddSensor(2
Release Stages(2 [Release]
Configuration
LC_OptgMode [Int LR]
Sensor Select(2 [Pt100]
MeasureRangePtNi(2 [150 °C / 302 °F]
var.RangePtNi(2 [850 °C]
Ext Inp X61 U/I(2 [0 … 10 V]
MRange TempSens(2 [90 °C]
MRange PressSens(2 [2 bar]
Ext Inp X62 U/I(2 [4 … 20 mA]
Ext MinSetpoint(2 [0 %]
##
Ext MaxSetpoint(2 [60 %]
(1
W-FM 200 only
(2
83054802 1/2015-07 MaW 63-228

6 Operation
##
Analogue output(2
OutValuSelection [Load]
CurrMod 0/4mA [4 … 20 mA]
Scale20mA perc [100 %]
Scale20mA temp [850 °C]
Scale20mA press [2 bar]
Scale20mA angle [90°]
##
Scale 0/4mA [0 %]
Adaption
StartAdaption
##
AdaptionLoad [100 %]
##
SW Version
ABE
Times
Sum/WinterTime[Automatic]
##
Time EU/US
Language
DateFormat
##
PhysicalUnits
eBUS
Address [1]
##
SendCycleBU [30 s]
Modbus
Address [1]
Baud rate [19200 bit/s]
Parity [none]
Timeout [30 s]
Local / Remote
Remote Mode
##
W3
##
Display contrast
ProductID
ASN
ProductionDate
SerialNumber
ParamSet Code
##
ParamSet Vers
##
SW Version
Actuators
Addressing(2
1 AirActuator
2 GasActuator (Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2(1
##
6 AuxActuator3
Rotation direction(2
##
DeleteCurves
(1
W-FM 200 only
(2
83054802 1/2015-07 MaW 64-228

6 Operation
##
ProductID
1 AirActuator
2 GasActuator (Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2(1
6 AuxActuator3
##
SW Version
1 AirActuator
2 GasActuator (Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2(1
##
6 AuxActuator3
VSD module(1
Configuration
Releasecontct.VSD(2 [closed]
##
Speed
Num Puls per R(2 [3]
Standardisation(2
StandardisedSp(2
Absolute Speed
##
Setpoint Output(2 [4 … 20 mA]
Fuel meter(2
PulseValueGas [1]
##
PulseValueOil [1]
Process data
Max Stat Dev
Max Dyn Dev
NumDev >0.3%
NumDev >0.5%
##
Absolute Speed
Product identification
ASN ProductionDate
SerialNumber
ParamSet Code
##
ParamSet Vers
##
SW Version
O2 module(1
Configuration(2
O2 Sensor [no sensor]
O2SensServTim [0]
O2SensServTimRes
SupAirTempSens [no sensor]
FlueGasTempSens [no sensor]
MaxTempFlGasGas [300 °C]
##
MaxTempFlGasOil [300 °C]
(1
W-FM 200 only
(2
83054802 1/2015-07 MaW 65-228

6 Operation
##
Process Data
Current O2 value
O2 Setpoint
SupplyAirTemp
FlueGasTemp
CombEfficiency
QGO SensorTemp
QGOHeatingLoad
QGO Resistance
##
ProductID
ProductionDate
SerialNumber
ParamSet Code
##
ParamSet Vers
##
SW Version
Flue gas recirculation(1
FGRMode [Aux3 Curve]
FGRsensor [X86PtNi1000]
actTmpFGRsensor
ThresholdFGR Gas
ThresholdFGR Gas [300 s]
FGR Factor Gas [100]
Operating temp Gas
ThresholdFGR Oil
ThresholdFGR Oil [300 s]
Factor FGR Oil [100]
Operation TempOil
FGR MinPos
##
FGR MaxPos Fact [10]
SystemConfig
LC_OptgMode [IntLC]
Ext Inp X62 U/I(2 [4 … 20 mA]
##
TempLimiter(2
TL_Thresh_Off [95 °C]
TL_SD_On [-5 %]
Sensor Select [Pt100]
##
MeasureRangePtNi [150 °C / 302 °F]
O2Ctrl/LimitrGas(2 [man deact]
O2Ctrl/LimitrOil(2 [man deact]
LC Analog output(2 [Load]
##
allowed Pot.diff(2 [15]
Hours run
GasFiring
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
TotalHours
##
SystemOnPower
(1
W-FM 200 only
(2
83054802 1/2015-07 MaW 66-228

6 Operation
##
Reset
GasFiring
OilStage1/Mod
OilStage2
OilStage3
##
TotalHoursReset
StartCounter
GasStartCount
OilStartCount
TotalStartCountR
##
TotalStartCount
Reset
GasStartCount
OilStartCount
##
TotalStartCountR
Fuel meter
Curr Flow Rate
Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset DateGas
##
Reset DateOil
##
Updating
ParamBackup
Backup info
Date
TimeOfDay
BU included?
AZL included?
LC included?
ACT1 included?
ACT2 included?
ACT3 included?
ACT4 included?
ACT5 included?
ACT6 included?
VSD included?
O2 included?
##
LMV5x -> AZL(2

##
AZL -> LMV5x(2
##
Load SW from PC(2
##
Enter PW
##
Deactivate PW(2
##
TÜV Test
LossFlameTest(2
SLT Test
SLT TestlloadMod [100 %]
##
SLT Testload Stg [S3]
(1
W-FM 200 only
(2
83054802 1/2015-07 MaW 67-228

6 Operation
6.4 Operation and system information

Operating display Normal operation
In menu Normal operation you can switch between the standard display and
the position display.
Press [ENTER] key.
Display changes.
Depending on the current operating phase, the standard display shows the follow-
ing information:
Setpoint and actual value
Fuel selected
Current operating phase (clear text and number)
Fuel and air actuator positions
Current burner capacity and flame signal
The position display shows the following information:
Actuator positions
Speed
O2 content
Burner capacity
6.4.2 Fuel selection

Operation Fuel Current fuel
Fuel selection
Current fuel
The fuel selected is shown in parameter CurrentFuel (read only).
Fuel selection
With dual-fuel burners you can switch between oil and gas operation. A fuel
change during operation will initiate a restart.
Fuel selection is possible via:
Fuel selection switch on input X4-01:1/2 [ch. 3.3.6]
Parameter fuel selection (ABE)
Building management system (BMS) on Bus connection
The fuel selection switch on input X4-01:1/2 has priority. Fuel selection via ABE or
BMS is only possible if no signal is present at input X4-01:1/2. There is not priority
between ABE and BMS, the last fuel selection is valid and is retained after power
failure.
83054802 1/2015-07 MaW 68-228

6 Operation
6.4.3 Operating hours

Operation HoursRun
or
Param & Display HoursRun
Access in menu Operation/HoursRun is read only.
The individual operating hours counters can be reset in Param & Display/
HoursRun/Reset/… .
Parameters Function
GasFiring Operating hours Gas (can be reset)
OilStage1/Mod Operating hours Oil stage 1 / modulating operation (can
be reset)
OilStage2 Operating hours Oil stage 2 (can be reset)
OilStage3 Operating hours Oil stage 3 (can be reset)
TotalHoursReset Total operating hours (can be reset)
TotalHours Total operating hours ( read only, can not be reset)
SystemOnPower Operating hours with voltage applied to device (read
only, can not be reset)
Reset Reset only possible under Param & Display /
HoursRun
6.4.4 Start-up counter

Operation StartCounter
or
Param & Display StartCounter
Access in menu Operation/StartCounter is read only.
The individual start counters can be reset via Param & Display/
StartCounter/Reset/… .
Parameters Function
GasStartCount Burner starts Gas (can be reset)
OilStartCount Burner starts Oil (can be reset)
TotalStartCountR Total burner starts Gas and Oil (can be reset)
TotalStartCount Total burner starts Gas and Oil (read only, can not be re-
set)
Reset Reset only possible under Param & Display /
StartCounter
83054802 1/2015-07 MaW 69-228

6 Operation
6.4.5 Fuel meter

Only possible with W-FM 200.
Configuring the inputs

Param & Display VSD module Configuration Fuel Meter
In menu Fuel Meter , the input for the relevant fuel meter is configured
[ch. 3.3.22].
Parameters Function
PulseValueGas Number of impulses per volume unit of the gas meter at
input X71
PulseValueOil Number of impulses per volume unit of the oil meter at
input X72
The impulses per volume unit are entered in parameter Pulse value… with
4 decimal places.
Using the number of impulses set in parameter Pulse value… the W-FM cal-
culates the current fuel throughput.
In full load, the impulse frequency must not exceed 300 Hz.
In partial load, the impulse frequency must be minimum 0.1 Hz. If the fuel meter
does not supply a signal for 10 seconds, no fuel throughput is detected.
Example
##
Gas meter: 100 impulses/m3

Full load throughput: 300 m3/h
##
Partial load throughput: 50 m3/h
Full load frequency: 100 Imp/m3 x 300 m3/h = 30000 Imp/h
30000 Imp/h ÷ 3600 s = 8.333 Hz
Partial load frequency: 100 Imp/m3 x 50 m3/h = 5000 Imp/h
##
5000 Imp/h ÷ 3600 s = 1.389 Hz
Fuel throughput
Operation Fuel Meter
or
Param & Display Fuel Meter
If a fuel meter is connected, the parameters show the fuel consumption.
Parameters Function
Curr Flow Rate Current fuel throughput (read only, can not be reset)
Volume Gas Total gas throughput (read only, can not be reset)
Volume Oil Total oil throughput (read only, can not be reset)
Volume Gas R Gas throughput (can be reset via ENTER)
Volume Oil R Oil throughput (can be reset via ENTER)
ResetDateGas Reset date fuel volume Gas
ResetDateOil Reset date fuel volume Oil
83054802 1/2015-07 MaW 70-228

6 Operation
6.4.6 Number of lockouts

Operation LockoutCounter
The parameterLockoutCounter shows the number of faults with lockout since
commissioning (can not be reset).
6.4.7 Flame signal

Param & Display BurnerControl Configuration ConfigFlameDet FlameSignal
The parameter FlameSignal shows the current flame signal [ch. 3.3.15].
6.4.8 Product identification

Param & Display BurnerControl ProductID
or
Param & Display AZL ProductID
or
Param & Display Actuators ProductID
or
Param & Display VSD module ProductID
or
Param & Display O2 module ProductID
In menu ProductID the following information is displayed for all components
selected:
ASN (type description)
Production date
Identification number
Customer code parameters
Version parameters
6.4.9 Software version

Param & Display BurnerControl SW Version
or
Param & Display LoadController SW Version
or
Param & Display AZL SW Version
or
Param & Display Actuators SW Version
or
Param & Display VSD module SW Version
or
Param & Display O2 module SW Version
In parameter SW Version the software version of the selected components is
shown.
6.4.10 Burner identification

Operation BurnerID
83054802 1/2015-07 MaW 71-228

6 Operation
The parameter BurnerID shows the burner specific serial number.

The burner identification serves as copy protection. Burner specific data in the
memory of the ABE can not be transferred to another W-FM.
If a W-FM is delivered without burner identification and the backup copy from the
ABE is installed, the W-FM adopts the burner identification of the backup copy
[ch. 6.16.1].
83054802 1/2015-07 MaW 72-228

6 Operation
6.5 Setting the display
6.5.1 Setting the language

Param & Display AZL Language
The language for the display can be set in parameter Language .
If the language required is not available, the display and operating unit (ABE) with
the relevant group of languages should be used.
Group of languages (ABE) Languages
Western Europe 1 English, German, French, Italian, Spanish, Por-
tuguese
Western Europe 2 English, Dutch, Danish, Swedish, Norwegian, Fin-
nish
Eastern Europe 1 English, Polish, Hungarian, Czech, Croatian, Slove-
nian
Eastern Europe 2 English, German, Russian, Bulgarian, Turkish, Ru-
manian
6.5.2 Set contrast

Param & Display AZL Display Contrast
The contrast of the display can be changed and saved using parameter Display
Contrast .
If the operating display is in normal operation, the contrast can be changed using
the dial knob of the ABE.
Press and hold [Enter].
Set the contrast using the dial knob.
The setting will remain until the power supply is interrupted
83054802 1/2015-07 MaW 73-228

6 Operation
6.5.3 Date/Time
Display date and time

Operation Date/TimeOfDay DisplayClock Date
Set time TimeOfDay
Weekday
The date, time and weekday can be displayed in menu DisplayClock.
The date, time and weekday are set using SetClock.
Summer/Winter time
Param & Display AZL Times Sum/WinterTime
Time EU/US
Parameter Sum/WinterTime is used to select manual or automatic changeover
from summertime to wintertime.
Parameter Time EU/US is used to select the European or American summer-
time or wintertime.
Date format
Param & Display AZL DateFormat
Parameter DateFormat is used to select the date format DD.MM.YY or
YY.MM.DD.
6.5.4 Units
Param & Display AZL PhysicalUnits
Parameter PhysicalUnits is used to select the formats °C / bar or °F / psi.
All relevant values will be displayed and adjusted in the unit selected.
83054802 1/2015-07 MaW 74-228

6 Operation
6.6 Interfaces
6.6.1 Select interfaces

Operation OptgModeSelect InterfacePC
Gateway BASon
Gateway BASoff
Type of Gateway
Menu OptgModeSelect is used to select the serial interface in the operating
and display unit (COM 1 or COM 2) [ch. 5].
The COM interfaces can not be used at the same time.
Interface for PC (COM 1)

The combustion manager can be programmed and operated via PC-Tool (Soft-
ware: ACS450). The display and operating unit serves as interface.
Select parameter InterfacePC and confirm with [ENTER].
The interface is activated until the [esc] key is used to exit from parameter In
terfacePC .
Interface for building management system (COM 2)

The building management system can be connected to the ABE using an external
Bus interface allowing it to access the W-FM.
Activating the interface:
Select parameter Gateway BASon and confirm with [ENTER].
The interface in the display and operating unit (ABE) has been activated and the
building management system can access the W-FM. The ABE remains func-
tional.
Deactivating the interface:
Select parameter Gateway BASoff and confirm with [ENTER].
The interface of the display and operating unit (ABE) for the building manage-
ment system is deactivated. Only the ABE can access the W-FM.
Select Bus protocol:
Select Bus protocol in parameter Type of Gateway and confirm with
[ENTER].
eBus [ch. 6.6.2]
Modbus [ch. 6.6.3]
Data output [ch. 6.6.4]
83054802 1/2015-07 MaW 75-228

6 Operation
6.6.2 eBus
Param & Display AZL eBus Address
SendCycleBU
For Bus communication, the interface has to be activated and the bus protocol has
to be defined.
eBus address
Parameter Address defines the eBus address, which is used to communicates
with the W-FM.
Send cycle
Parameter SendCycleBU defines the time for the send cycle. The W-FM trans-
mits its operating data to the eBus participants in the cycle set.
6.6.3 Modbus
Param & Display AZL Modbus
For Bus communication, the interface has to be activated and the bus protocol has
to be defined.
The display and operating unit (ABE) operates as Slave in the Modbus protocol.
The RTU-Modus is used for transfer.
Modbus address
Parameter Address determines the Modbus address of the display and operat-
ing unit (ABE).
Baud rate
Parameter Baudrate determines the transfer speed. The Baud rate of the dis-
play and operating unit (ABE) and the Modbus participant connected must be
identical.
Parity
Parameter Parity determines the type of parity protocols. The parity of the dis-
play and operating unit (ABE) and the Modbus participant connected must be
identical.
Time out
Parameter Timout determines how long after Modbus communication fails the
display and operating unit (ABE) switches from Remote to Local .
If building management is deactivated or the Modbus connection fails, the internal
load controller of the W-FM takes over the control and the internal setpoint (W1) is
activated. Prerequisite is that the W-FM is equipped with an internal load controller
and has been configured [ch. 6.12].
83054802 1/2015-07 MaW 76-228

6 Operation
Local / Remote
Setting Function
local The operating modes for the load controller via Bus Ex
tLC Bus or IntLC Bus have no influence
[ch. 6.12.2].
The internal load controller takes over the control and the
internal setpoint W1 is activated.
remote Setting for load control via Bus [ch. 6.12.2].
If the operating mode ExtLC Bus has been selected,
the building management system determines the load.
If operating mode IntLC Bus has been selected, the
building management system determines the setpoint.
If Modbus communication fails, the W-FM automatically
changes into local mode. When communication is
restored, the mode has to be set to remote either via
the ABE or via Modbus signal.
Remote mode
Parameter Remote mode is read only, the setting is made via Modbus (building
management system).
Setting Function
Auto Setpoint W3 is determined by the building management
system.
On Load is determined by the building management system.
Off The internal load controller takes over the control.
External setpoint W3
Parameter W3 is read only, the setting is made via Modbus (building management
system).
6.6.4 Trending data

Operation OptgModeSelect Type of Gateway Data output
In Bus protocol Data output the interface COM 2 sends trending data for data
recording.
Interface configuration in menu Modbus is required for data output [ch. 6.6.3].
Data recording is not possible for diagnostic purposes during servicing and without
peripherals and software.
83054802 1/2015-07 MaW 77-228

6 Operation
6.7 Manual / Automatic / Off

ManualOperation SetLoad
Autom/Manual/Off
or
Param & Display RatioControl Autom/Manual/Off
Operating mode
Parameter Autom/Manual/Off determines the operating mode. In Remote op-
eration the parameter is read only and can not be altered [ch. 6.6.3].
Setting Function
Automatic The burner starts if there is a heat demand at in-
put X5-03:1.
The load controller determines the burner capacity.
Manuel The burner starts if there is a heat demand at in-
put X5-03:1.
Parameter SetLoad determines the burner capacity.
Burner Off Burner drives to or remains in Standby (Phase 12). A
message, that the W-FM is set to Burner Off in
manual operation does not appear.
Target load
Load, to which the burner drives in Manuel operating mode.
In modulating operation, the target load can be set within the load limits [ch. 6.9.7].
In multi-stage operation, one of the stages can be selected as the target load.
83054802 1/2015-07 MaW 78-228

6 Operation
6.8 Burner control
6.8.1 Times
Param & Display BurnerControl Times TimesStartup1
TimesStartup2
TimesShutdown
TimesGeneral
TimeStartup1
Time Parameters Function
Start release MinTimeStartRel Minimum residence time in phase 21.
The W-FM remains at least the time set in phase 21,
even if the start criteria have already been met.
Fan run-up time FanRunupTime Residence time in phase 22.

Once this time has elapsed the burner drives to pre-
purge position.
Pre-purge PrepurgeTmeGas Time from reaching the pre-purge position until driving to
PrepurgeTmeOil ignition position (phase 30 to 34).
PrepurgeSafeGas Pre-purge time after the following occurrences:
PrepurgeSafeOil Lockout or safety shutdown
Power failure
Standby longer than 24h
PrepurgePt1Gas Auxiliary actuator3 (FGR) remains in standby position in
PrepurgePt1Oil Phase 30 for the duration of this time.
PrepurgePt3Gas Time in phase 34 during which all actuators remain in
PrepurgePt3Oil pre-purge position.
Pre-ignition PreIgnitionTGas Residence time in phase 38.
Nozzle circulation PreIgnitionTOil Once this time has elapsed, fuel is released for ignition.
On heavy oil burners without return flow temperature
sensor, nozzle circulation can be extended via PreIg
nitionTOil .
Oil pump ON time MinONTmeOilPump Residence time in phase 36 (heavy oil operation only).
In heavy oil operation, the time in phase 36 can be exten-
ded to allow oil pressure to build-up for ignition.
TimeStartup2
Flame stabilisation Interval1Gas Residence time in phase 44.
Interval1Oil Once this time has elapsed the burner drives to partial
load.
Interval2Gas Residence time in phase 52.
Interval2Oil Once this time has elapsed the burner drives to partial
load.
Pressure switch PressReacTime Time delay in phase 40, 42 and 52.
reaction time The pressure switches are interrogated in phase 40, 42
and 52 by the time delay set.
Prevents shutdown caused by pressure fluctuation when
opening the fuel valves.
83054802 1/2015-07 MaW 79-228

6 Operation
TimeShutdown
Load shutdown MaxTmeLowFire Residence time in phase 62.
If there is no longer a demand for heat, the W-FM re-
duces the burner capacity and closes the fuel valves
after the time set has elapsed. If partial load is reached
before the time has elapsed, the fuel valves close imme-
diately.
Anti siphon valve AfterburnTme Residence time in phase 70.
Once the time has elapsed, the anti siphon valve at out-
put X6-03 closes and the actuators for air and fuel drive
to post-purge position.
Post-purge time PostpurgeT1Gas Residence time in phase 74.
PostpurgeT1Oil Post-purge time 1 in phase 74 is always executed. Once
this time has elapsed, the auxiliary actuator3 (FGR)
drives to post-purge position.
PostpurgeT3Gas Residence time in phase 78.
PostpurgeT3Oil Post-purge time 3 in phase 78 is interrupted at heat de-
mand. Once the time has elapsed without heat demand,
the W-FM goes to Standby.
PostpurgeT3long Additional residence time in phase 78.
(W-FM 200 only) The PostpurgeT3long is added to both fuel de-
pendent times PostpurgeT3Gas / Oil .
Times in general
Alarm delay during start pre- AlarmDelay Time delay until a start prevention at heat demand is is-
vention sued at output X3-01:2. The function Alarm during start
prevention must be activated in parameter
AlarmDelay.
Message start prevention DelayStartPrev Time delay until a start prevention at heat demand is
shown in the display of the ABE.
Post-purge time lockout PostpurgeLockout If lockout occurs, the fan motor at output X3-01:1 runs
on by the time specified.
Heavy oil immediate start MaxTmeStartRel Maximum waiting time for signal at input X6-01:3.
83054802 1/2015-07 MaW 80-228

6 Operation
6.8.2 Signalling start prevention
Alarm at start prevention

Param & Display BurnerControl Configuration ConfigGeneral AlarmStartPrev
If parameter AlarmStartPrev is activated, start prevention is also signalled at
output X3-01:2 [ch. 3.4.1].
Start prevention in Standby

Param & Display BurnerControl Configuration ConfigGeneral Standby Error
If parameter Standby error is activated, faults are also recognised as start
prevention in Standby and are displayed in the ABE.
6.8.3 Normal or direct start

Param & Display BurnerControl Configuration ConfigGeneral NormDirectStart
Start prevention at heat demand during shutdown in phase 78.
Normal start
If NormalStart is activated, the fan switches off and the burner only starts after
a home run in phase 10.
Direct start
If DirectStart is activated the fan continues to run and the W-FM jumps via
phase 79 to phase 24.
In conjunction with an air pressure switch direct start is only possible with a release
valve at output X4-03 [ch. 3.4.4]. In menu Config input /output the para-
meter Start/PSvalve must therefore be set to PS Reli_Inv .
83054802 1/2015-07 MaW 81-228

6 Operation
6.8.4 Oil pump

Param & Display BurnerControl Configuration ConfigGeneral OilPumpCoupling
IgnOilPumpStart
Control of oil pump and switch on point of pre-ignition in oil operation [ch. 3.4.3].
Magnetic coupling / separate oil pump

For burners with magnetic coupling or separate oil pump:
Set parameter OilPumpCoupling to Magnetcoupl.
Set parameter IgnOilPumpStart to On in Ph38 .
Direct coupling
For burners with oil pump coupled directly to the burner motor.
Set parameter OilPumpCoupling to Direct coupl .
The long pre-ignition (on in Ph22) is automatically activated in parameter
IgnOilPumpStart .
6.8.5 Forced intermittent

Param & Display BurnerControl Configuration ConfigGeneral ForcedIntermit
With ForcedIntermit activated, the W-FM initiates a controlled shutdown with sub-
sequent restart after 23 h 50 min uninterrupted burner operation. If the burner is
not suitable for continuous operation, forced intermittent has to be activated.
6.8.6 Pre-purge Gas

Param & Display BurnerControl Configuration ConfigGeneral Skip Prepur
geGas
If the parameter is activated, the W-FM skips pre-purge in gas operation (Phase 24
to 34). According to EN 676 only allowed with Class A valves in conjunction with
valve proving system.
Pre-purge is not skipped after:
Lockout
24 h Standby
Power failure
Safety shutdown due to low gas
83054802 1/2015-07 MaW 82-228

6 Operation
6.8.7 Continuous running fan

Param & Display BurnerControl Configuration ConfigGeneral ContinuousPurge
If ContinuousPurge is activated, the fan runs in each operating phase.
If an air pressure switch is fitted, continuous purge is only possible with a relief
valve at output X4-03 [ch. 3.4.4]. For this, parameter Start/PSvalve must be
set to PS Reli_Inv in menu Config Input /Output.
Setting Function
deactivated In phases 00 to 21, output X3-01:1 (fan) is not activ-
ated.
In Phase 00 to 21, the frequency converter is controlled
with the idle speed (HomePosVSD) set, even if the safety
circuit / burner flange is open.
activated Output X3-01:1 (fan) and the frequency converter are al-
ways activated, even if the safety circuit / burner flange
are open.
off Sloop Output X3-01:1 (fan) and the frequency converter are al-
ways activated, except if the safety circuit / burner flange
are open.
deact/VSDSL In phases 00 to 21, output X3-01:1 (fan) is not activ-
ated.
In Phase 00 to 21, the frequency converter is controlled
with the idle speed (HomePosVSD) set, except if the
safety circuit / burner flange is open.
6.8.8 Additional air pressure switch

Param & Display BurnerControl Configuration Config input/ RotSpeed PS on
output RotSpeed PS off
The speed range set is monitored by an additional air pressure switch.
In the OEM level, the additional air pressure switch is deactivated, the function is
not used in standard applications.
Parameters Function
RotSpeed PS on The additional air pressure switch must supply an ON
signal above the speed set.
RotSpeed PS off The additional air pressure switch must supply an OFF
signal below the speed set.
83054802 1/2015-07 MaW 83-228

6 Operation
6.8.9 Configuring input X5-03

Param & Display BurnerControl Configuration Config input/ Config X503
output
Parameter Config X503 determines how the W-FM reacts to signals at in-
put X5-03.
Load controller multi-stage operating mode

If a load controller is connected to input X5-03 [ch. 3.3.16], the parameter determ-
ines the control of the operating stages.
Setting Input X5-03 Operating mode
Pin 2 Pin 3 two stage three stage
LMV2/3 inv 0 0 Stage 1 Stage 1
(Standard) 1 0 Stage 1 Stage 2
0 1 Stage 2 Stage 3
1 1 Stage 2 Stage 3
LMV5x std 0 0 Stage 1 Stage 1
(with KS40 1 0 Stage 1 Stage 1
load control-
ler) 0 1 Stage 2 Stage 2
1 1 Stage 2 Stage 3
LMV2/3 std 0 0 Stage 1 Stage 1
(special ap- 1 0 Stage 2 Stage 3
plication)
0 1 Stage 2 Stage 2
1 1 Stage 2 Stage 3
Deactivate O2 trim / stop in phase 36

If function DeaO2/Stp36 is set in parameter Config X503 , input X5-03
can be used to deactivate O2 trim or to trigger a stop function. For this setting,
parameter LC_OptgMode must not be set to ExtLC X503 .
Input Function
Pin 2 (X5-03) Mains voltage input at X5-03:2 deactivates O2 trim and the
W-FM 200 operates to the compound curves. The function O2
alarm remains activated.
Pin 3 (X5-03) If no mains voltage is applied to input X5-03:3, the burner stops
at the start in phase 36. If the stop function is not used in con-
junction with the O2 deactivation, fit a bridge at input X5-03
between terminals 3 and 4.
Deactivate O2 trim via operating mode

If the function AutoDeactO2is set in parameter Config X503 and if mains
voltage is applied to input X5-03:2, the operating mode of the O2 controller
changes from conAutoDeac to auto deact. The O2 controller is deactivated
and the burner operates to the compound curves. The function O2 alarm remains
activated. No message will be shown on the display. If voltage is no longer applied
to input X5-03:2, the operating mode changes back to conAutoDeac and O2
trim is reactivated [ch. 6.10.1]. For this setting, parameter LC_OptgMode must
not be set to ExtLC X503 .
83054802 1/2015-07 MaW 84-228

6 Operation
6.8.10 Configuring output X4-03

Param & Display BurnerControl Configuration Config input/ Start/PS valve
output
Parameter Start/PS valve determines if output X4-03 is used for a start sig-
nal or for pressure switch relief [ch. 3.4.4].
Setting Function
Start signal Output X4-03:3 is activated in phase 21 to 79.
PS Relief Output X4-03:3 is activated in phase 79.
Function is not used.
PS Reli_Inv In phase 21 and phase 79 the relief valve at out-
put X4-03:3 is de-energised and the air pressure switch
is tested.
6.8.11 Extraneous light

Param & Display BurnerControl Configuration ConfigFlameDet ReacExtranLight
Parameter ReacExtranLight determines the reaction if extraneous light is
present in Standby (Phase 12).
Setting Function
Lockout Flame signal in phase 12 triggers a lockout.
Startblock A flame signal in phase 12 leads to start prevention.
6.8.12 Repetition counter

Param & Display BurnerControl Configuration RepetitCounter
The parameters in menu RepetitCounter determine the number of safety
shutdowns until shutdown with lockout is initiated. Changes in the repetition
counter are only adapted after a reset or if the voltage supply has been interrupted.
Parameters Function
LossOfFlame Number of safety shutdowns due to missing flame signal.
Range: (1 … 2)
HeavyOil Number of safety shutdowns caused by return temperat-
ure sensor for nozzle circulation not being released
[ch. 3.3.10].
Range: (1 … 3 … 16(1)
StartRelease Number of start preventions with display messages
nozzle circulation [ch. 3.3.10].
Range: (1 … 10 … 16(1)
SafetyLoop Number of safety shutdowns caused by the safety circuit
not being released [ch. 3.3.2].
Range: (1 … 16(1)
€€
(1
Repetition value 16 means not limited, no shutdown with lockout is initiated.
6.9 Electronic compound
6.9.1 Actuator ramps

Param & Display RatioControl Times OperatRampMod
OperatRampStage
Ramp
83054802 1/2015-07 MaW 85-228

6 Operation
The ramps determine the speed of the actuators for a distance of 90°. The ramp
times must not fall below the time of the slowest actuator, see actuator name plate.
Parameters Function
OperatRampMod Ramp time for modulating operation for phases 60 and
62. In operating position, all actuators operate at this
speed.
OperatRampStage Ramp time for multi-stage operation for phases 60 and
62. In operating position, all actuators operate at this
speed.
Ramp Ramp time outside the operating position for modulating
and multi-stage operation. All actuators operate at this
speed in pre-purge, ignition, post-purge and standby po-
sition.
Only in conjunction with frequency converter

The ramp time of the frequency converter must be less than the ramp time set in
the W-FM (recommendation: 30 %).
6.9.2 Shutdown behaviour

Param & Display RatioControl ShutdownBehav
Parameter ShutdownBehav determines the behaviour during lockout.
Setting Function
Unchanged The actuators remain in the position they were in at the
time of the lockout.
PostpurgeP If lockout occurs, the W-FM initiates a post-purge.
HomePos If lockout occurs, the actuators drive to standby position.
83054802 1/2015-07 MaW 86-228

6 Operation
6.9.3 Operating behaviour of frequency converter

Only possible with W-FM 200.
Param & Display RatioControl GasSettings VSD
OilSettings
Parameter VSD determines the operating behaviour of the frequency converter.
The operating behaviour can be set individually for each fuel.
Setting Function
deactivated No frequency converter available.
The inputs and outputs for variable speed drive are not
activated.
activated Only in conjunction with a frequency converter.
The inputs and outputs for variable speed drive are activ-
ated.
air influen Only in conjunction with a frequency converter.
The inputs and outputs for variable speed drive are activ-
ated and the frequency converter is included in O2 trim.
83054802 1/2015-07 MaW 87-228

6 Operation
6.9.4 SpecialPositions
Param & Display RatioControl GasSettings SpecialPosi Home Pos
OilSettings tions PrepurgePos
IgnitionPos
PostpurgePos
ProgramStop
ResetIgnitPos
If the burners is in operating position (phases 60 and 62), the actuators and the
speed are driven by the compound curves. Outside of the operating position, the
actuators and the speed are driven according to the SpecialPositions .
In the special positions, the actuators can be set independently.
Special positions are fuel specific and must be set separately for each fuel on dual
fuel burners.
Setting Actuator
…PosGas: Gas butterfly valve
…PosOil: Oil quantity regulator
…PosAir: Air dampers
…PosAux1: Adjustable mixing head
…PosAux2: Auxiliary actuator for special applications (W-FM 200
only)
…PosAux3: Auxiliary actuator for special applications,
damper for flue gas recirculation (W-FM 200 only)
…PosVSD: VSD (only in conjunction with frequency converter,
W-FM 200)
Standby positions
Parameter HomePos determines the positions for phases 00 to 22. If continuous
running fan is activated, only the fuel actuators drive to standby position in
phases 00 to 22, the air influencing actuators remain in the post-purge position.
Pre-purge position
Parameter PrepurgePos determines the positions of the air influencing actuat-
ors for pre-purge in phases 30 to 34. The exception is the auxiliary actuator3 (flue
gas recirculation), which only drives to pre-purge position from phase 32.
Ignition position
Parameter IgnitionPos determines the positions for the ignition process in
phases 36 to 54.
Individual ignition positions can be deleted in parameter ResetIgnitPos . If a
relevant ignition position is not defined, the W-FM initiates a start prevention at
heat demand. Se installation and operating manual of burner for the ignition posi-
tion.
83054802 1/2015-07 MaW 88-228

6 Operation
Post-purge position
Parameter PostpurgePos defines the positions for post-purge in phases 74
to 78. The exception is auxiliary actuator 3 (flue gas recirculation), which only drives
to the post-purge position after phase 76.
The speed PostpurgePosVSD must not be set below 10 %.
Program stop
Using parameter ProgramStop, the program sequence can be stopped in
defined phases. Parameter ProgramStop can also be called up in menu Param
& Display/RatioControl.
Setting Function
deactivated No program stop
24 PrePurgP Stop in phase 24, pre-purge position
32 PrePFGR Stop in phase 32, auxiliary actuator3 in pre-purge posi-
tion
36 IgnitPos Stop in phase 36, ignition position
44 Interv 1 Stop in phase 44, flame signal
52 Interv 2 Stop in phase 52, ignition pilot valve OFF
72 PostPPos Stop in phase 72, post-purge position
76 PostPFGR Stop in phase 76, auxiliary actuator3 in post-purge posi-
tion
83054802 1/2015-07 MaW 89-228

6 Operation
6.9.5 Creating load points, modulating operation

Param & Display RatioControl GasSettings CurveParams Point
OilSettings Man
Depending on the load signal, the W-FM controls the actuators in compound in
modulating operation. Each actuator has its own compound curve. The compound
curves are formed from defined load points. 15 load points can be defined for the
compound curves, a minimum of 5 load points are required. On dual fuel burners,
the compound curves for each fuel can be set separately. In menu Point 1,
load points can be adjusted or deleted to optimise combustion. In menu Manual
2 new load points are set.
Point|Load:15.0
1 |Fuel:10.0
Manual |Air :15.0
2 |Aux1: 0.0
During initial commissioning, set load points up to full load. Once full load has been
regulated, optimise combustion in load point 1. Load point 1 must be within the ca-
pacity graph and below below partial load. Now delete all load points between
point 1 and full load. Starting at point 1, set new load points until full load is
achieved. Optimise combustion in the current point before setting a new load point.
To ensure an even speed characteristic curve, the speed of the new load points
should not be altered.
To ensure that control is possible across the entire load range in conjunction with
O2 trim point 1 must be approx. 50 % below partial load (point 2).
P1 P2 P3 P4 P5 P6 P7 P8 P9
90 100
80 90
70 80
7 70
60
60
50
50
40
40
30
30
6
20 20
5
2 10 10 3
4
0 0
0 10 20 30 40 50 60 70 80 90 100
1 Burner capacity in %
2 Actuator position in degree of angle
3 Speed in %
4 Fuel Fuel
5 Air damper Air
6 Mixing head Aux1
7 Frequency converter VSD
83054802 1/2015-07 MaW 90-228

6 Operation
Setting new load points

Select Manual and confirm with [ENTER].
Increase burner rating using dial knob whilst observing combustion values (ex-
cess air) and flame stability.
Set load point using [ENTER] key if either:
the O2 content in the flue gas increases to above 7 %,
the soot limit is reached,
the CO content increases,
the flame reaches the limit of stability.
The new load point is displayed in menu Point and can be adjusted.
Point|Load:10.0
|Fuel:10.0
|Air|Load:10.0
Manual O2 :15.0 O2 |Load:15.0
XXXX|Fuel:10.0
|Aux1: 0.0 XXXX |Fuel:14.4
Manual|Air :20.0 Point
Manual |Load:15.0
|Air :23.8
:10.0 |Aux1: 0.0 : 2 |Fuel:14.4
:15.0 |Aux1: 5.0
O2 |Air :23.8
XXXX |Aux1: 5.0
Editing load points

Select Point and confirm with [ENTER].
Select load point using dial knob and confirm with [ENTER] key.
Confirm query Change point? with [ENTER].
Confirm query With start with [ENTER].
The curve points can be changed and the actuators are synchronised.
Select actuator using the dial knob and press [ENTER].
Change values using the dial knob and confirm with [ENTER].
Once combustion has been optimised, exit point using [esc] and save with
[ENTER].
Point |Load:15.0
|Fuel:14.4
ManualPoint |Load:10.0
|Air :23.8 Point |Load:15.0
:1 |Fuel:10.0
|Aux1: 5.0 : 2 |Fuel:14.4
O2 |Air :20.0 |Air |Change
O2 Point :23.8
XXXX |Aux1: 0.0 : 2|point?
XXXX |Aux1: 5.0
Manual|Actuator
|positions
With start
Without start
Point |Load:15.0
: 2 |Fuel:14.4
O2 |Air :23.8
XXXX Point
|Aux1:|Load:15.0
5.0
: 2 |Fuel:14.4
O2 |Air :28.5
XXXX Point
|Aux1:|Load:15.0
5.0
: 2 |Fuel:14.4
O2 |Air :28.5
XXXX Save
|Aux1: 5.0
point>ENTER
cancel>ESC
Point |Load:15.0
: 2 |Fuel:14.4
O2 |Air :28.5
XXXX |Aux1: 5.0
83054802 1/2015-07 MaW 91-228

6 Operation
Deleting load points

Select menu Point and confirm with [ENTER].
Select Delete point? and confirm with [ENTER].
Load point is deleted.
Load points above this will be renumbered. The display shows the next higher
load point in the current numbering. If the last load point was deleted, the actu-
ator positions show XXXX .
Point |Load: 0.0

|Fuel:0.0
: 1 |Fuel:10.0
|Aux1: 5.0 : 2 |Fuel:14.4
O2 Point :23.8
XXXX |Aux1: 5.0
Manual|delete?
|Point |Load:24.3
: 2 |Fuel:22.1
O2 |Air :32.9
XXXX |Aux1:27.6
83054802 1/2015-07 MaW 92-228

6 Operation
Ratings apportionment
The load points are automatically assigned relative to the capacity. Incorrect load
distribution can cause operating problems during the load control.
Assign rating in % for load point to the following formula.
Enter the calculated capacity for load point in Load.
Throughput load point

Load [%] = 100
Throughput full load

Confirm query With start with [ENTER].
Confirm line Load with [ENTER].
Calculate actual load.
Set load using dial knob and confirm with [ENTER].
Exit point using [esc] and save with [ENTER].
Point |Load:15.0
|Fuel:14.4
:1 |Fuel:10.0
|Aux1: 5.0 : 2 |Fuel:14.4
O2 Point :23.8
XXXX |Aux1: 5.0
Manual|Actuator
|positions
With start
Without start
Point |Load:15.0
: 2 |Fuel:14.4
O2 |Air :28.5
XXXX Point
|Aux1:|Load:29.3
5.0
: 2 |Fuel:14.4
O2 |Air :28.5
XXXX Point
|Aux1:|Load:29.3
5.0
: 2 |Fuel:14.4
O2 |Air :28.5
XXXX Save
|Aux1: 5.0
point>ENTER
cancel>ESC
Point |Load:15.0
: 2 |Fuel:14.4
O2 |Air :28.5
XXXX |Aux1: 5.0
83054802 1/2015-07 MaW 93-228

6 Operation
6.9.6 Operating and switch points, multi-stage operation

Param & Display RatioControl OilSettings CurveParams CurveSet
Two or three stage operation is specified depending on the burner execution. A
three stage burner can also be operated two stage with low impact start or
change-over release. The change-over behaviour between the operating stages is
optimised via separate switch on and off points.
Operating stages Excess air for the relevant fuel quantity is set in the operating stages.
BS1, BS2, BS3(1
Switch-on points In the switch-on point, the air quantity for the change-over process into the next
ES2, ES3(1 higher stage is set.
If the switch-on point is exceeded, the solenoid valve of the next stage opens.
If the switch-on point is activated directly the solenoid valve remains closed, only
the air influencing actuators drive to the switch-on position and the flame stability
can be checked prior to the change-over.
Switch-off points In the switch-off point, the air quantity for the change-over process into the next
AS2, AS3(1 lower stage is set.
If the switch-on point is not maintained, the solenoid valve of the previous stage
closes. Switch-off points must not be activated directly, as the solenoid valve of
the previous stage remains open and only the air influencing actuators drive to the
switch off position. This leads to soot formation caused by insufficient air.
€€
(1
BS3, ES3 and AS3 only with three stage operation
5 3
1 2
1 Air damper position

2 Operating stage 1 (BS1)
3 Switch-on point 2 (ES2), solenoid valve stage 2 opens above
4 Operating stage 2 (BS2)
5 Switch-off point 2 (AS2), solenoid valve stage 2 closes below
83054802 1/2015-07 MaW 94-228

6 Operation
Two options are available fort he setting of the operating and switch points.
With start:
The actuator and frequency converter follow the current adjustment via dial knob.
With this option, the operating stages and switch-on points are set during burner
operation.
In the operating stages, the combustion is optimised.
In the switch-on points, the excess air for the change-over process to the next op-
erating stage is determined. Excess air for the switch-on point is approx. 7 % O2
residual content.
The switch-off points must not be activated during burner operation, as this leads
to soot formation caused by insufficient air.
Without start:
With this option, the operating stages and change-over points can be pre-set
without the actuator and frequency converter following. Pre-setting values see in-
stallation and operating manual of burner.
Setting operating and switch points

Select menu CurveSet and confirm with [ENTER].
Choose appropriate option with the dial knob and confirm with [ENTER].
With start: Optimise operating stages and switch-on points
Without start: Pre-set values and optimise switch-off points
Select operating stage or switch point using dial knob and confirm with
[ENTER].
Select Air actuator and confirm with [ENTER].
The selection option VSD only appears in conjunction with a frequency con-
verter.
Use dial knob to change the value and confirm with [ENTER].
Pre-setting values see installation and operating manual of burner.
Exit entry using [esc] and save with [ENTER].
Exit level using the [esc] key.
CurveSet
Actuator
positions
With start
Without start
Point|Air :20.0 Point|Air :30.0
:BS1 ||VSD : 100 :AS2 |VSD : 100
O2 | O2 Point|Air :30.0
XXXX| XXXX :AS2 |VSD : 100
O2 Point|Air :25.0
|VSD
XXXX :AS2 Point : 100
O2 |Air :25.0
XXXX:AS2 |VSD : 100
O2 Save
XXXX point>ENTER
cancel>ESC
Point|Air :25.0
:AS2 |
|VSD : 100
O2 |
XXXX|
CurveSet
83054802 1/2015-07 MaW 95-228

6 Operation
6.9.7 Load range
LoadLimits
Param & Display RatioControl GasSettings LoadLimits MinLoad_…
OilSettings MaxLoad_…
In modulating operation, the load limits restrict the load range within the compound
curves programmed. On dual fuel burners, the load limits for each fuel can be set
separately.
Minimum load:
Parameter MinLoad_… limits the load range downward (partial load). Minimum
load can not be set below load point 1, in conjunction with O2 trim not below load
point 2.
Maximum load:
Parameter MaxLoad_… limits the load range upwards (full load).
P1
0% 1 2 100 %
1 Minimum load MinLoad_…

2 Maximum load MaxLoad_…
3 Load range
83054802 1/2015-07 MaW 96-228

6 Operation
Fade-out partial range

Param & Display RatioControl GasSettings Load mask out
OilSettings LoadMaskLowLimi
t
LoadMaskHighLim
Parameter Load Mask out can be used to fade out part of the load range,
which could lead to operating problems due to site conditions. On dual fuel burn-
ers, the partial range for each fuel can be set separately. The faded-out partial
range can be driven through but not started directly. The burner drives from the
bottom to the lower limit and passes through the partial range only when the load
setpoint reached the upper limit. From the upper range, the burner remains at the
upper limit and drives through the partial range only when the load setpoint has
reached the lower limit.
Lower limit partial range:
Parameter LoadMaskLowLimit determines the lower limit. The lower limit can
not be set above the upper limit.
Upper limit partial range:
Parameter LoadMaskHighLim determines the upper limit. The upper limit can
not be set below the lower limit.
P1
0% 1 2 100 %
1 Lower limit partial range LoadMaskLowLimit

2 Upper limit partial range LoadMaskHighLim
3 Faded-out partial range
83054802 1/2015-07 MaW 97-228

6 Operation
6.9.8 Load limit

Operation User Maxload User MaxLoadMod
User MaxLoad Stg
Parameters Function
User MaxLoadMod Load limit for modulating operation.
Further restricts full load within the load limits [ch. 6.9.7].
User MaxLoadStg Load limit for multi-stage operation.
The burner drives only to the stage set.
6.9.9 Start point

Param & Display RatioControl GasSettings StartPointOp
OilSettings
Parameter StartPointOp determines the load point for partial load position in
phase 54. In phase 54, the burner drives to the load point set, when the load point
is reached, the W-FM changes over to phase 60 and load control is released.
83054802 1/2015-07 MaW 98-228

6 Operation
6.10 O2 controller
O2 trim is only possible in modulating operation with W-FM 200 with O2 module.
O2 trim is fuel specific and must be set separately for each fuel on dual fuel burn-
ers.
O2 trim and O2 monitor in conjunction with the O2 residual content are at the com-
bustion limit and the resulting O2 compound curve.
An idealised minimum O2 value is advantages for the control behaviour. When op-
timising the minimum O2 value increase rather than decrease. In conjunction with
CO control (accessory) the minimum O2 value must be set to ap-
prox. 0.25 to 0.5 percentage points below the combustion limit.
6,5
6,0
5,5
6
5,0
4,5
4,0
3,5 5
3,0
2,5 4
2,0 3
1,5
1,0
2 0,5
0
0 10 20 30 40 50 60 70 80 90 100
1 Burner capacity [%]

2 O2 content in the flue gas [%]
3 O2 residual content at the combustion limit
4 Minimum O2 value for O2 monitor
5 O2 setpoint for O2 trim
6 O2 compound, excess air in the load points 20 to 25 %
With frequency converter

On burners with frequency converter, parameter VSD can be used to determine if
the frequency converter is to be included in O2 trim [ch. 6.9.3].
Pre-control
The O2 controller is equipped with a pre-control function. The pre-control calcu-
lates the air ratings reduction for the entire load range relative to the fuel on the
basis of measured values during commissioning. If the load is changed, the air influ-
encing actuators drive to the calculated position, whilst the fuel actuator drives to
its load position. O2 trim is only activated if temperature or air pressure deviations
occur and and then drives the air influencing actuators.
To ensure the pre-control operates correctly, the load apportionment must match
the fuel throughput in each load point [ch. 6.9.5].
83054802 1/2015-07 MaW 99-228

6 Operation
6.10.1 O2 controller operating mode

Param & Display O2Ctrl/Limit GasSettings OptgMode
OilSettings
or
Param & Display SystemConfig O2Ctrl/LimitGas
O2Ctrl/LimitOil
Using operating mode:
the O2 controller and O2-monitor can be activated or deactivated,
the behaviour when a fault occurs can be defined.
The operating mode can be set separately for each fuel.
Deactivating manually (man deact)

Parameter man deact deactivates the O2 controller and O2 monitor and the
burner operates to the compound curves. This parameter is only used to create the
compound curve during commissioning, it is not suitable for normal operation.
O2 monitor only (O2 Alarm)

Parameter O2 Alarm only activates the O2 monitor.
If the O2 sensor has not reached the operating temperature at burner start, a start
prevention is initiated. If the O2 monitor is triggered or if an O2 fault occurs, the
W-FM initiates a controlled shutdown with single repetition, then lockout occurs.
O2 controller and O2 monitor (O2Control)

Parameter O2Control activates the O2 controller and O2 monitor.
If the O2 sensor has not reached the operating temperature at burner start, a start
prevention is initiated. If the O2 monitor is triggered or if an O2 fault occurs, the
W-FM initiates a controlled shutdown with single repetition, then lockout occurs.
Automatically deactivate control (conAutoDeac)

Parameter conAutoDeac activates the O2 controller and O2 monitor.
The burner starts before the O2 sensor has reached operating temperature. O2 trim
only starts once the operating temperature has been reached and the sensor test
has been successfully carried out.
If the maximum O2 monitor is triggered or if an O2 fault occurs, the W-FM changes
over to operating mode auto deact.
If the minimum O2 monitor is triggered the W-FM drives back to the compound
curves. After a time of 3 times Tau the O2 content is tested again. The time con-
stant Tau is determined automatically during standardisation [ch. 6.10.4].
When the O2 content exceeds the minimum limit the W-FM releases O2 trim.
If the O2 content drops below the minimum limit, the W-FM initiates a safety
shutdown with repetition. The number of repetitions can be set in parameter
NumMinUntilDeact , see [ch. 6.10.2]. If the number of repetitions is ex-
ceeded, the W-FM changes over to operating mode auto deact.
83054802 1/2015-07 MaW 100-228

6 Operation
Automatic deactivation (auto deact)

Do not select this operating mode.
Parameter auto deact is automatically activated when a fault occurs in operat-
ing mode conAutoDeac . The O2 controller is deactivated and the burner oper-
ates to the compound curves. A fault message appears in the display. If the operat-
ing mode is changed over the fault message disappears [ch. 6.10.23].
The O2 controller can also be deactivated via a signal at input X5-03:2 [ch. 6.8.9].
83054802 1/2015-07 MaW 101-228

6 Operation
6.10.2 O2 monitor
Param & Display O2Ctrl/Limit GasSettings O2 Alarm O2 Alarm
OilSettings O2 MaxValue
NumMinUntilDe
act
The W-FM monitors the O2 content in the flue gas using a sensor on the O2 mod-
ule. The limit values for the O2 alarm are defined using parameters O2 MinValue
and O2 MaxValue .
O2 minimum monitor
In parameter O2 Alarm , the setting under O2 MinValue stipulates the lower
limit for the O2 monitor.
If the O2 content in the flue gas drops below this lower limit for more than
3 seconds, the W-FM reacts in accordance with the operating mode set
[ch. 6.10.1].
An O2 MinValue has to be defined as the lower limit in each load point. The
O2 MinValue results from the O2 content in the flue gas at the combustion limit.
The O2 MinValue can be entered direct at each load point or can be determ-
ined by reducing the air rating:
Select menu O2 Alarm and confirm with [ENTER].
Select entry type 1 or 2.
Operating mode
O2 trim
O2 monitor
O2 parameters
Control monitor
O2 MaxValue
Point: 1 13.9%
NumMinUntilDeact Point: 9 100%
O2 MinValue :XXXX O2 MinValue :XXXX
PAir manual: PAir Point:
manual:9 100%
O2 MinValue :XXXX
PAir manual: 1
Point: 9 100%
O2 MinValue :XXXX
PAir manual:
2
1 Direct entry (O2 MinValue)

If the O2 min value for the load point is known, the value can be assigned dir-
ectly.
2 Determine O2 min value (PAir Manual)
The air rating is reduced manually in the load point, the O2 content is determ-
ined and saved as O2 MinValue.
83054802 1/2015-07 MaW 102-228

6 Operation
Direct entry:
Select O2 MinValue and confirm with [ENTER].
Exit entry using [esc].
Point: 9 100%
O2 MinValue :XXXX
PAir Point:
manual:9 100% Point: 9 100%
O2 MinValue :XXXX O2 MinValue : 0.7
PAir manual: 0.0 PAir Point:
manual:9 0.0100%
O2 MinValue : 0.7
PAir manual: 0.0
Point: 9 100%
O2 MinValue : 0.7
PAir manual:
Determine O2 min value:

Select parameter PAir Manual and confirm with [ENTER].
The display shows the current O2 actual value and the burner drives to the load
point.
Reduce air rating using the dial knob until the combustion limit is reached
(CO content approx. 100 ppm or smoke number approx. 1).
Press [ENTER] to accept the O2 actual value.
The display shows the value determined as O2 MinValue.
Point: 9 100%
O2 MinValue :XXXX
PAir manual:
Point: 9 100% Point: 9 100%
O2 MinValue : 3.8 O2 MinValue : 0.7
PAir manual: 0.0 PAir manual:10.4
Point: 9 100%
O2 MinValue : 0.7
PAir manual:10.4
Point: 9 100%
O2 MinValue : 0.7
PAir manual:
O2-maximum monitor
Parameter O2 MaxValue determines the upper limit value for the O2 monitor.
The limit value is valid across the entire load range. If the O2 content in the flue gas
exceeds this limit value for more than 3 seconds, the W-FM reacts in accordance
with the operating mode set [ch. 6.10.1].
Repetition for O2 minimum monitor

Parameter NumMinUntilDeact determines the number of repetitions until the
O2 controller is deactivated. The parameter is only relevant, if the operating mode is
set to conAutoDeac, see [ch. 6.10.1].
If a rapid load change triggers the O2 minimum monitor, increase parameter
O2ModOffset, see [ch. 6.10.4].
83054802 1/2015-07 MaW 103-228

6 Operation
6.10.3 O2 trim
Param & Display O2Ctrl/Limit GasSettings O2 Control
OilSettings
The W-FM monitors the O2 content in the flue gas using a sensor on the O2 mod-
ule.
Moisture in the O2 sensor.

With new sensors or if the sensor has been switched off for extended periods,
moisture may form in the sensor and distort the measured value. A longer heat-up
process through the internal sensor heating displaces this moisture.
Heat up the sensor prior to adjusting the O2 trim.
Parameter LowFireAdaptPtNo can be used to set from which load point O2

trim is possible [ch. 6.10.4].
During commissioning, in parameter O2 Control standardisation is carried out
at each point from the load point determined up to full load and the O2 setpoint is
determined. During standardisation the air influencing actuators drive open on the
compound curve according to the standardised value and reduce the air quantity,
the fuel quantity remains unchanged.
No standardisation is carried out in load point 1, the reference line between load
point 1 and load point 2 only serves to reduce air. To ensure O2 trim is possible
across the entire load range, point 1 must be approx. 50 % below partial load
(point 2).
In the load point set under LowFireAdaptPtNo and the last load point (full load)
the W-FM carries out an adaption. In these two points, the W-FM drives back to
the compound curve after saving. The delay time before the O2 content at the
sensor changes is saved as time constant Tau.
The setpoint for O2 trim should be approx. 0.5 … 1 %point above the O2
MinValue of the O2 monitor.
The O2 value in the load points of the compound curve should be approx.
2 % points above the setpoint for O2 trim.
83054802 1/2015-07 MaW 104-228

6 Operation
Standardisation
Select O2 Control and confirm with [ENTER].
Burner drives to load point.
Once the O2 content has stabilised confirm with [ENTER].
Turn dial knob to the right.
The air influencing actuators drive open on the compound curve, reduce the air
quantity and thus the O2 content.
Confirm standardised value with [ENTER].
Carry out standardisation in all points, point 2 to full load.
Operating mode
O2 trim
Point: 2 25.0%
O2 monitor Point: 9 100%
O2 parameters
Control compound:XXXX O2 compound:XXXX
O2 setpoint:XXXX Point: 9
O2 setpoint:XXXX
Standard val:XXXX O2 compound:
Standard val:XXXX 3.8
If value is stable
continue w ENTER
Point: 9 Point: 9
O2 compound: 3.8 O2 compound: 3.8
O2 setpoint: 3.8 O2 setpoint: 1.7
Standard val:XXXX Standard val:10.2
Point: 9
O2 compound: 3.8
O2 setpoint: 1.7
Measurement * Delay time * Standard val:10.2
successful control is measured
param determined
Point: 9 100% Continue w ESC O2 actual value : 2.6Save
O2 compound: 3.8 point>ENTER
O2 setpoint: 1.7 cancel>ESC
Standard val:10.2
* Measurement of delay time (time constant Tau) only at 100 % and in the load point defined under LowFireAd
aptPtNo.
If the measurement fails in the defined load point, select the next higher load point [ch. 6.10.4].
Avoid changing the load points in menu CurveParams once standardisation has
been completed. If a load point is changed, the standardisation in this point is de-
leted and O2 trim is no longer possible. In this case the standardisation for this load
point has to be repeated.
83054802 1/2015-07 MaW 105-228

6 Operation
6.10.4 O2 control parameters

Param & Display O2Ctrl/Limit GasSettings ControlParam
OilSettings
The control parameters are fuel specific and must be set separately for each fuel on
dual fuel burners.
PI parameters and time constant Tau

This parameter influences the reaction behaviour of O2 trim.
Parameters Function
P LowFire Proportional part of O2 trim.
P HighFire The greater the value set, the faster the regulation will
commence. If the value set is too great the controller
tends to over-oscillate.
I LowFire Integral part of O2 trim.
I HighFire The smaller the value set, the faster the regulation will
commence. If the value is set too small, the controller
tends to oscillate.
Tau LowFire The flue gas reaction time measured during standardisa-
tion in the point set under LowFireAdaptPtNo .
Tau HighFire The flue gas reaction time measured during standardisa-
tion at 100 % burner capacity.
Partial load adaption point (LowFireAdaptPtNo)

Parameter LowFireAdaptPtNo determines the load point at which Tau Low-
Fire (flue gas reaction time) is measured. If the flue gas velocity in the current partial
load adaption point is too low, the measurement fails and the next higher point has
to be selected. O2 trim is not possible below the partial load adaption point set.
83054802 1/2015-07 MaW 106-228

6 Operation
O2 controller limit (O2 CtrlThreshold)

If reliable O2 trim is not possible in the lower capacity range, (e. g. flue gas velocity
at the O2 sensor insufficient), the O2 control limit can be increased in parameter
O2 CtrlThreshold .
At a burner capacity below the control limit O2 trim is deactivated. Once the burner
capacity increases again by 5 % points above the control limit, O2 trim is reactiv-
ated. If the O2 control limit is below the partial load adaption point, the O2 control
limit is ineffective.
The flue gas velocity at the O2 sensor may not be sufficient for reliable regulation
for capacities in the lower load range. Recognisable when the O2 sensor reacts
very slowly to changes in the O2 content in the flue gas. In this case increase the
O2 regulating limit accordingly.
Flue gas velocity [v]:
min: 1 m/s
max: 10 m/s
Formula: Rule of thumb:
T + 273
QB L λ
273 QB 0.0046 T + 273
v= v=
d2 0.785 3600 d2 273
v Flue gas velocity [m/s]

QB Fuel throughput [kg/h] [m3/h]
L Stoichiometric air requirement [m3/kg] [m3/m3]
λ Air number
T Flue gas temperature [°C]
d Flue gas pipe diameter [m]
Behaviour at load change (LoadCtrlSuspend)

Parameter LoadCtrlSuspend specifies the threshold at which the O2 trim locks
out when the load changes. With a change in load 2 the W-FM calculates an ad-
justed burner capacity 3. If the difference of the reference line exceeds the value
LoadCtrlSuspend 1 O2 trim is suspended 4 and parameter O2ModOffset
is activated. If the difference is not maintained, the W-FM releases O2 trim again
after a delay time (2 x Tau HighFire).
The lower the value set, the more often O2 trim will be suspended and driven to the
O2ModOffset set.
2
1 3
83054802 1/2015-07 MaW 107-228

6 Operation
O2-Offset (O2ModOffset)
Increase of the O2 content in percentage points, if O2 trim is suspended via para-
meter LoadCtrlSuspend when the load is changed. O2ModOffset en-
sures that the O2 min value is maintained in case of LoadCtrlSuspend.
If the threshold value LoadCtrlSuspend is exceeded when the load is
changed, the air influencing actuators operate and increase the O2 content by the
value set, then the fuel actuator operates.
In conjunction with CO trim the W-FM increases the O2 setpoint by O2 offset if the
CO limit value has been exceeded.
Pre-control (Type Air Change)

Parameter Type Air Change influences the calculation procedure of the pre-control
[ch. 6.10].
Parameters Function
like theory Recommended for fuel gas.
Temperature and air pressure fluctuations influence the
fuel throughput.
like P air Recommended for fuel oil.
Temperature and air pressure fluctuations do not influ-
ence the fuel throughput.
LambdaFact1 Not recommended.
Only for burners with stoichiometric fuel/air ratio
(Lambda factor 1).
83054802 1/2015-07 MaW 108-228

6 Operation
O2 control variable limit

The control variable can be limited to ensure that O2 trim reacts to faults during O2
measurement (e. g. false air in the flue gas, O2 sensor or air regulator blocked, etc.)
and does not try to compensate for these.
Upper limit: O2MaxManVariable
Lower limit: O2MinManVariable
The reaction when the control variable limit is reached depends on the operating
mode set [ch. 6.10.1].
Operating mode Reaction
O2 controller The W-FM carries out a safety shutdown with sub-
sequent lockout.
conAutoDeac The W-FM carries out a safety shutdown with sub-
sequent repetition and deactivated O2 controller. The
burner operates to the compound curves.
The control variable limit results from the maximum expected temperature or air
pressure fluctuations based on the conditions at the time of commissioning. If the
control variable is set too low this will lead to a safety shutdown if climatic fluctu-
ations are too great. The control variable limit can be determined using the follow-
ing diagram.
Example 3 Example 4
O2MaxManVariable O2MinManVariable
Expected temperature fluctuation(1 (-20 K … +30 K): +30 K -20 K
(1
Expected air pressure fluctuation (-60 mbar … +40 mbar): -60 mbar +40 mbar
Control variable limit from diagram = 14.7 % -11.6 %
€€
(1
Based on the air temperature and pressure during commissioning.
-100
-80
20
3 -60
-40
-20
0
+20
+40
10 +60
+800
+10
-60 -50 -40 -30 -20 -10 10 20 30 40 50 60
-10
0
-10
8 0
-
0
-6
-4
0 4 -20
-2 0
0
0
+2
4 0
+ -30
2 0
+6 +80 100
+
1 Temperature fluctuation [K]

2 Control variable limit [%]
83054802 1/2015-07 MaW 109-228

6 Operation
6.10.5 O2 start mode

Param & Display O2Ctrl/Limit GasSettings Startmode
OilSettings
O2 offset at burner start (O2InitOffset)

Parameter O2InitOffset is not used in the Weishaupt configuration and has
no function.
Release O2 trim (NumberTauSuspend)

Parameter NumberTauSuspend determines the factor for the calculation of O2
block time.
O2 block time = Tau LowFire x NumberTauSuspend
Due to the reaction and settling time of the O2 sensor, the O2 regulator is initially
blocked at burner start. The O2 block time starts in operating setting (phase 60).
After the block time the W-FM initialises the O2 regulator and releases O2 trim after
a further 4 x Tau LowFire.
As the two possible O2 sensors differ in reaction and settling time, Number
TauSuspend depends on the sensor used.
O2 sensor Recommended NumberTauSuspend
QGO 20 approx. 10 … 20
QGO 21 above 40
The block time also applies to the function CO monitor and CO controller
[ch. 6.11].
At burner start, the CO content is increased. Once the flame has formed and stabil-
ised, the CO content drops. If the block time is too short, the increased CO con-
tent at burner start will trigger a safety shutdown.
Combustion air temperature during commissioning (Adjust. Temp O2)

Parameter Adjust. Temp O2 determines the air temperature during commis-
sioning in conjunction with a supply air sensor, this is not used in the Weishaupt
configuration and has no function.
83054802 1/2015-07 MaW 110-228

6 Operation
6.10.6 Type of Fuel

Param & Display O2Ctrl/Limit GasSettings Type of Fuel
OilSettings Fuel userdef
The fuel used must be defined in parameter Type of Fuel . If the fuel used is
not available, set parameter Type of Fuel to Fuel userdef and set the
fuel values in menu Fuel userdef.
The type of fuel is used to calculate:
the pre-control
the combustion efficiency
User defined fuel values

The fuel values have to be defined in menu Fuel userdef , if parameter
Type of Fuel is set to user def .
V_LNmin Stoichiometric air requirement (Lambda 1).
[m3 Air per m3 Gas or kg Oil].
V_afNmin Flue gas volume wet in stoichiometric combustion
(Lambda 1).
[m3 Flue gas wet per m3 Gas or kg Oil].
V_atrNmin Flue gas volume dry in stoichiometric combustion
(Lambda 1).
[m3 Flue gas dry per m3 Gas or kg Oil].
A2 Fuel factor for the calculation of combustion efficiency.
B/1000 Fuel factor for the calculation of combustion efficiency.
The parameter value corresponds to the resolution
1/1000.
Example: A value of 7 set corresponds to 0.007.
83054802 1/2015-07 MaW 111-228

6 Operation
6.10.7 O2 sensor
Param & Display O2 module Configuration O2 sensor
Parameter O2 sensor activates the O2 sensor connected.
Setting Function
no sensor No O2 sensor fitted, O2 trim not possible.
QGO20 QGO 20 fitted, for:
Gas burner
Oil burner (fuel oil EL)
Dual fuel burner (fuel oil EL)
QGO21 QGO 21 fitted, for:
Heavy oil burner (fuel oil MS and S)
Dual fuel burner (fuel oil MS and S)
The O2 sensor QGO 21 has an increased reaction and settling time. Due to this
behaviour, the release of O2 trim at burner start has to be delayed for longer. In
conjunction with QGO 21, the factor has to be set to minimum 40 in parameter
NumberTauSuspend , see [ch. 6.10.5].
6.10.8 Service interval for O2 sensor

Param & Display O2 module Configuration O2SensServTim
O2SensServTimRes
Setting the service interval

Parameter O2SensServTim stipulates the service interval in days for the the O2
sensor. The interval is deactivated if the setting is "0".
The interval is compared with the total operating hours counter. If the interval has
elapsed, a message appears in the ABE and O2 trim reacts according to the oper-
ating mode set [ch. 6.10.1].
O2 trim is deactivated in operating mode conAutoDeac, the O2 monitor re-
mains activated.
Lockout occurs in operating mode O2 Alarm or O2 controller.
Reset service interval

Parameter O2SensServTimRes resets the service interval.
If O2 trim is set to auto deact, the operating mode has to be reset to con
AutoDeac.
83054802 1/2015-07 MaW 112-228

6 Operation
6.10.9 Define temperature sensor

Param & Display O2 module Configuration SupAirTempSens
FueGasTempSens
Parameter SupAirTempSens is used to define the combustion air sensor fitted
[ch. 3.3.24].
Select Pt1000 in conjunction with CO control.
The flue gas sensor fitted is defined in parameter FueGasTempSens, see
[ch. 3.3.23].
The sensors have no influence on O2 trim, they are used to calculate combustion
efficiency.
6.10.10 Flue gas temperature warning threshold

Param & Display O2 module Configuration MaxTempFlGasGas
MaxTempFlGasOil
Parameter MaxTempFlueGas… determines a warning threshold for the flue gas
temperature. A flue gas temperature sensor has to be fitted for this function
[ch. 3.3.23].
The threshold is determined separately for oil and gas. Set the threshold approx.
20 % above the maximum flue gas temperature measured during commissioning
[ch. 6.10.19].
Damage to the O2 sensor caused by overheating

Flue gas temperature above 300 °C can damage the O2 sensor.
Avoid flue gas temperatures above 300 °C at the O2 sensor.
CAUTION
If the flue gas exceeds the temperature set, a message appears in the ABE.
The warning indicates an increased flue gas loss, the heat exchanger should be
cleaned.
CO function
In conjunction with the CO function the input of the combustion air sensor is used
for signal evaluation [ch. 6.11].
For the signal evaluation an apparent intake air temperature of up to 730 ° C is
generated. To ensure that the W-FM does not detect implausible values, the warn-
ing threshold in conjunction with the CO function must be set to 850 °C in para-
meter FlueGas… .
83054802 1/2015-07 MaW 113-228

6 Operation
6.10.11 Combustion efficiency

Param & Display O2 module Process Data CombEfficiency
or
Operation O2 module CombEfficiency
Combustion efficiency
Parameter CombEfficiency shows the combustion efficiency.
The following sensors must be fitted and configured for the combustion efficiency
to be shown:
O2 sensor [ch. 3.3.25]
Combustion air sensor [ch. 3.3.24]
Flue gas temperature sensor [ch. 3.3.23]
6.10.12 O2 controller control variable

Param & Display O2Ctrl/Limit Process Data ManVar O2 Ctrl
Parameter ManVar O2 Ctrl shows the current control variable of the O2 con-
troller.
6.10.13 Status O2 controller

Param & Display O2Ctrl/Limit Process Data Status O2 Ctrl
Parameter Status O2 Ctrl shows the current status of the O2 controller.
deactivated The O2 controller is deactivated. The burner operates to
the compound curves.
locked The O2 controller is blocked (sensor testing, partial load
not achieved, …).
LockTStart Blocked time in partial load elapses (Tau LowFire x
NumberTauSuspend).
InitContr Initialisation time elapses (4 x Tau LowFire).
LockTLoad The O2 controller is blocked due to a load adjustment.
activate The O2 controller is activated and controls to the O2 set-
point.
LockTCAct The O2 controller is blocked for a duration of 2 x Tau due
a control input.
LockCOx The CO limit value has been exceeded, the O2 controller
is blocked.
6.10.14 Air rating

Param & Display O2Ctrl/Limit Process Data Airrelated Load
Parameter Airrelated Load shows the current air rating of the fuel air ratio.
83054802 1/2015-07 MaW 114-228

6 Operation
6.10.15 Diagnostic code

Param & Display O2Ctrl/Limit Process Data Diag Reg State
Parameter Diag Reg State shows the diagnostic code when the controller is
blocked [ch. 9.4].
6.10.16 O2 content
Param & Display O2 module Process Data Current O2 Value
or
Operation O2 module Current O2 Value
Parameter Current O2 Value shows the O2 content currently measured in the
flue gas.
Depending on the O2 content in the flue gas and the temperature in the measuring
cell the O2 sensor generates Nernst voltage. The O2 module calculates the O2 con-
tent using the Nernst voltage and the sensor temperature.
It is possible for implausible values to be displayed whilst the sensor is being
heated up to operating temperature (700 °C). The sensor will only operate on the
reference line, which is required for an exact display once it has reached operating
temperature.
120
110
100
90
80
70
60
3
50
40
30
20
2 10
0
0,1 0,2 0,5 1 2 5 10 20
1 O2 content [%]
2 Nernst voltage [mV]
3 Reference line at 700 °C sensor temperature
83054802 1/2015-07 MaW 115-228

6 Operation
6.10.17 O2 setpoint
Param & Display O2 module Process Data O2 Setpoint
or
Operation O2 module O2 Setpoint
Parameter O2 Setpoint shows the O2 setpoint set for the current burner capa-
city.
The O2 setpoints are defined during commissioning.
6.10.18 Combustion air temperature / CO switching threshold

Param & Display O2 module Process Data Supply air temper
ature
or
Operation O2 module Supply air temper
ature
Parameter Supply air temperature shows the combustion air temperature
currently measured, if the relevant sensor is connected to the O2 module.
In conjunction with CO monitoring, the parameter shows the status of the CO
switching threshold [ch. 3.3.24].
6.10.19 Flue gas temperature

Param & Display O2 module Process Data Flue gas temperat
ure
or
Operation O2 module Flue gas temperat
ure
If a flue gas temperature sensor is connected to the O2 module, parameter Flue
gas temperature shows the current flue gas temperature [ch. 3.3.23].
6.10.20 O2 sensor temperature

Param & Display O2 module Process Data QGO SensorTemp
Parameter QGO SensorTemp shows the current temperature of the O2 sensor.
The temperature is detected by a thermocouple in the sensor, 700 °C corresponds
to approx. 29.1 mV.
O2 trim is activated at a sensor temperature of 700 °C (±15 °C). If the operating
temperature is not achieved, the W-FM reacts according to the operating mode set
[ch. 6.10.1].
If the temperature exceeds 750 °C, deactivate the sensor and check the electrical
connection.
83054802 1/2015-07 MaW 116-228

6 Operation
6.10.21 O2 sensor heating capacity

Param & Display O2 module Process Data QGO HeatingLoad
Parameter QGO HeatingLoad shows the current heating capacity.
The percentage display indicates the impulse / pause ratio based on 2 seconds.
60 % corresponds to 1.2 seconds impulse ad 0.8 seconds pause.
Heat capacity
Start capacity up to 100 °C: approx. 13 %
Heat-up process: approx. 60 %
At operating temperature: approx. 17 %
6.10.22 O2 sensor wear and tear

Param & Display O2 module Process Data QGO Resistance
Parameter QGO Resistance shows the internal resistance of the O2 sensor.
The internal resistance changes during the course of the operation. With an internal
resistance of less than 5 Ω or greater than 150 Ω the sensor is subject to aging. If
the parameter shows an internal resistance of 0 Ω, the W-FM has not yet carried
out the sensor test.
Sensor test
The W-FM carries out a sensor test every 23 hours. The O2 content must be con-
stant for the test, e. g. in pre-purge or at a static load. If a constant O2 content is
not achieved within 24 hours, the W-FM freezes the load and carries out the test. If
the burner is in standby, the W-FM carries out the test at the next burner start.
6.10.23 Activate / deactivate O2 controller

Operation O2Ctrl activate deactivated
activated
Parameter O2Ctrl activate activates or deactivates the O2 controller manu-
ally.
83054802 1/2015-07 MaW 117-228

6 Operation
6.11 CO monitor and CO controller

Components required for CO function:
Combustion manager W-MF 200 in version with FGR and CO (LMV52.4…)
O2 module
O2 sensor QGO 20, for fuels Gas and fuel oil EL
CO measurement amplifier LT3
Combi sensor KS1-D for CO measurement
Resistance board for connection CO measurement amplifier to O2 module
Additional information
Refer to the manual of the measuring amplifier LT 3 and combination sensor KS1-D
prior to commissioning.
The manual is available to download from the -w- Portal.
The function CO monitor and CO controller must only be activated in conjunction

with O2 trim.
Depending on the combustion system it is possible that soot particles at the CO
sensor can produce a false CO signal when using fuel oil EL. In this case, only use
the function CO monitor or deactivate the CO function in the operating mode for
oil. On dual fuel burners, there is no limitation for gas.
A CO sensor and a measurement amplifier with digital output for signal evaluation
is required for CO detection. The digital output 3 (Out3) of the measurement ampli-
fier is connected via a resistance board at the input of the combustion air sensor in
the O2 module [ch. 3.3.24].
Digital output 3 (Out3) is evaluated via the resistance board. In this case, the ABE
shows the switching status of the measurement amplifier via the combustion air
temperature.
Display Description
approx. 730 CO limit value exceeded.
°C Digital output 3 (Out3) open, resistance at input approx. 3.6 kΩ.
approx. 370 CO limit value not maintained.
°C Digital output 3 (Out3) closed, resistance at input approx.
2.4 kΩ.
The following settings have to be made in the configuration of the O2 module for
signal evaluation:
Set parameter MaxTempFlGas… to 850 °C [ch. 6.10.10]
In parameter SupAirTempSens select sensor Pt1000, see [ch. 6.10.9].
A combustion air sensor is required for the calculation and display of the combus-
tion efficiency. In conjunction with the CO function, the actual combustion air
sensor is connected to input X60:3/4. Parameter AirTempX60PT1000 (OEM
level) must be set to activated.
CO control is an extension of the O2 controller. The difference to the normal O2 trim
is that the O2 MinValue is set to approx. 0.25 … 0.5 percentage points below
the combustion limit. If CO control is only used for one fuel on dual fuel burners,
only the O2 MinValue for this fuel must be set below the combustion limit.
83054802 1/2015-07 MaW 118-228

6 Operation
4,5
4,0
3,5
3,0
3
2,5 5 6
2,0
4
1,5
1,0
2 0,5
0
0 10 20 30 40 50 60 70 80 90 100
1 Burner capacity [%]

2 O2 content in the flue gas [%]
3 O2 residual content at the combustion limit
4 Minimum O2 value for O2 monitor
5 O2 setpoint for O2 trim
6 O2 setpoint for O2 trim + Offset (O2ModOffset)
The digital output 3 (Out3) in the measurement amplifier is is interrogated once
after pre-purge. If the digital output is open, the W-FM carries out a safety shut-
down with repetition.
Following the release of O2 trim the digital output is permanently interrogated
[ch. 6.10.5].
If the CO content exceeds the limit value, the digital output in the measurement
amplifier opens and the value of the resistance board changes to approx. 3.6 kΩ.
The W-FM recognises that the limit has been exceeded and increases the O2 set-
point by the O2ModOffset set [ch. 6.10.4].
O2 trim is suspended. The air influencing actuators drive open, the O2 content in-
creases and reduces the CO content in the flue gas.
If the CO content drops below the limit value before the time delay of the CO mon-
itor Time COx monitor has elapsed, the digital output closes and O2 trim is
reactivated.
If the time delay is exceeded, the W-FM carries out a safety shutdown with
repetition [ch. 6.11.2].
83054802 1/2015-07 MaW 119-228

6 Operation
6.11.1 Operating mode CO function

Param & Display O2Ctrl/Limit COx OptgMode COx Gas
OptgMode COx Oil
On dual fuel burners, the CO monitor and CO controller can be activated or deac-
tivated for each fuel separately.
Setting Function
deactivated CO controller and CO monitor are deactivate.
COx Alarm Only the CO monitor is activated.
COx control CO controller and CO monitor are activated.
6.11.2 Time delay limit value exceeded

Param & Display O2Ctrl/Limit COx Time COx Alarm
Parameter Time COx Alarm determines the time delay until a safety shutdown
with repetition is carried out if the CO limit value is exceeded. If the number of re-
petitions is exceeded, the W-FM initiates a lockout. The number of repetitions de-
pend on the repetition counter of the O2 monitor (NumMinUntilDeact). see
[ch. 6.10.2].
If the CO content exceeds the limit value, the time delay must be long enough to al-
low the burner to drive to higher excess air.
83054802 1/2015-07 MaW 120-228

6 Operation
6.12 Load controller

6.12.1 Setpoint
Operation BoilerSetpoint SetpointW1
SetpointW2
or
Param & Display LoadController ControlParam SetpointW1
SetpointW2
Two setpoints (W1/W2) can be specified for the internal load controller using
parameters Setpoint … .
The setpoints can not be set via the temperature monitor TL_Thresh_Off , see
[ch. 6.12.13].
A potential free contact at input X62 can be used to switch between the setpoints
W1 and W2 or to switch from an external to the internal setpoint W1 [ch. 3.3.19].
83054802 1/2015-07 MaW 121-228

6 Operation
6.12.2 Load controller operating mode

Param & Display LoadController Configuration LC_OptgMode
or
Param & Display SystemConfig LC_OptgMode
The parameters in menu LC_OptgMode stipulates, wether the internal or an ex-
ternal load controller is used and which source specifies the setpoint.
External load controller

Setting Function
ExtLC X503 External load controller at input X5-03 [ch. 3.3.16].
ExtLC X62 External load controller with analogue load signal at input X62 [ch. 3.3.17]. In-
put X62 must be matched to the analogue signal in parameter Ext Inp X62
U/I , see [ch. 6.12.4].
The internal load controller converts the analogue signal into a digital load signal.
This operating mode is not possible without the internal load controller.
ExtLC Bus External load controller via Bus connection [ch. 3.3.18].
83054802 1/2015-07 MaW 122-228

6 Operation
Internal load controller

Setting Function
IntLC Internal Load controller with setpoint input (W1/W2) via ABE.
A contact at terminals X62:1/2 can be used to switch between setpoint W1 and
W2 [ch. 3.3.19].
IntLC Bus Internal load controller with setpoint input via Bus from the building management
system.
Parameters Ext Min/MaxSetpointcan be used to limit the setpoint range
[ch. 6.12.6].
A contact at terminals X62:1/2 can be used to switch to the internal setpoint W1
[ch. 3.3.19].
IntLC X62 Internal load controller with analogue setpoint from the building management sys-
tem at input X62 [ch. 3.3.17]. Input X62 must be matched to the analogue signal
in parameter Ext Inp X62 U/I , see [ch. 6.12.4]
The setpoint range results from the selected measuring range for the temperature
sensor in parameter Meas. range PtNi [ch. 6.12.5].
Parameters Ext Min/MaxSetpoint can be used to limit the setpoint range
[ch. 6.12.6].
A contact at terminals X62:1/2 can be used to switch to the internal setpoint W1
[ch. 3.3.19].
Changing over operating mode to internal load controller

A switch contact at terminal X62:1/2 can be used to switch over from an external
load controller to the internal load controller IntLC . If the contact is closed, the
internal load contactor is activated and controls on the internal Setpoint W1.
1
0/2...10 V For the operating mode change-over to function, LC_OptgMode has to be set to
2 0-10V
0/4...20 mA IntLC and the internal load controller has to be adjusted. Then LC_OptgMode
X62
3 4-20mA
has to be set to the external operating mode (ExtLC ...) required.
4 0
5 FE
83054802 1/2015-07 MaW 123-228

6 Operation
6.12.3 Sensor selection (actual value)

Param & Display LoadController Configuration Sensor select
or
Param & Display SystemConfig TempLimiter Sensor select
To determine the actual value for the internal load controller a sensor has to be
connected to input X60 or X61 [ch. 3.3.20].
The sensor connected is defined in parameter Sensor select.
Setting Function
Pt100(1 Pt100 sensor at terminal X60:1/2/4.
Pt1000(1 Pt1000 sensor at terminal X60:3/4
Ni1000(1 Ni1000 sensor at terminal X60:3/4
Pt100Pt1000(1 Pt100 sensor at terminals X60:1/2/4 for temperature
regulator function.
Pt1000 sensor at terminals X60:3/4 for temperature
monitor function.
Pt100Ni1000(1 Pt100 sensor at terminals X60:1/2/4 for temperature
regulator function.
Ni1000 sensor at terminals X60:3/4 for temperature
monitor function.
(2
TempSensor Temperature sensor at input X61
PressSensor(2 Pressure sensor at input X61
(2
NoSensor No sensor connected to W-FM (e. g. external load set-
ting without temperature monitor function).
€€
(1
The internal temperature monitor function is activated.
(2
The internal temperature monitor function is deactivated.
83054802 1/2015-07 MaW 124-228

6 Operation
6.12.4 Analogue inputs
Input X61
Param & Display LoadController Configuration Ext Inp X61 U/I
If a sensor is connected to input X61, the input has to be matched to the sensor in
parameter Ext Inp X61 U/I , see [ch. 3.3.20].
The voltage supply (20 V DC) on terminal X61:1 can not be changed.
Setting Function
4..20 mA Current signal with load monitoring
0..20 mA Current signal without load monitoring
2..10 V Voltage signal with load monitoring
0..10 V Voltage signal without load monitoring
Input X62
Param & Display LoadController Configuration Ext Inp X62 U/I
or
Param & Display SystemConfig Ext Inp X62 U/I
If an analogue setpoint or load signal is present at input X62, the input must be
matched to the analogue signal in parameter Ext Inp X62 U/I see
[ch. 3.3.17].
Setting Function
4..20 mA Current signal with load monitoring
2..10 V Voltage signal with load monitoring
0..10 V Voltage signal without load monitoring
83054802 1/2015-07 MaW 125-228

6 Operation
6.12.5 Measuring range

Param & Display LoadController Configuration MeasureRangePtNi(1
var.RangePtNi
MRange TempSensor
MRange PressSens
€€
(1
Parameter MeasureRangePtNi can also be called up via Param & Display / System config. /
Temp.Limiter.
The measuring range of the actual value sensor is specified in the parameters.
Temperature sensor (input X60)

The measuring range starts at 0 °C (32 °F) and can not be altered. The values are
available in parameter MeasureRangePtNi for the end of the measuring range.
150°C/302°F
400°C/752°F
850°C/1562°F
Parameter var.RangePtNi can be used to restrict the end of the measuring
range as required. Prerequisite is that the value in parameter Meas
ureRangePtNi is set to 850°C/1562°F . The scaling of the resistance curve
does not change.
Values approx. 10 % above the end of measuring range are interpreted as sensor
short circuit.
Sensor (input X61)

The measuring range starts at 0 °C (32 °F) or 0 bar (0 psi) and can not be altered.
The end of the measuring range can be set in the relevant parameter.
MRange TempSens: max 2000 °C (3632 °F)
MRange PressSens: max 100 bar (1450 psi)
Values 10 % outside of the measuring range are interpreted as sensor short circuit
or line break.
83054802 1/2015-07 MaW 126-228

6 Operation
6.12.6 External setpoint

Param & Display LoadController Configuration Ext MinSetpoint
Ext MaxSetpoint
Parameters Ext Min/MaxSetpoint can be used to limit the external setpoint.
Setpoints outside of the defined limits will not be included in the control by the in-
ternal load controller.
The limit applies only to operating mode:
IntLC Bus
IntLC X62
In operating mode IntLC X62 , the analogue signal is switched at input X62
(Ext Inp X62 U/I), see [ch. 3.3.17]. The internal load controller converts the
analogue setpoint signal in percentage to the measurement range [ch. 6.12.5] set
for the actual value sensor and generates the setpoint for the load control.
Measurement range Analogue signal Setpoint
set Ext Inp X62 U/I load controller
MeasureRangePtNi Current Voltage
0 … 150 °C 0/4 mA 0/2 V 0 °C
20 mA 10 V 150 °C
0 … 400 °C 0/4 mA 0/2 V 0 °C
20 mA 10 V 400 °C
0 … 850 °C 0/4 mA 0/2 V 0 °C
20 mA 10 V 850 °C
(1
0 … XX °C/bar 0/4 mA 0/2 V 0 °C
20 mA 10 V XX(1 °C/bar
€€
(1
Limit value depends on the end of the measuring range [ch. 6.12.5] set in para-
meter:
var.RangePtNi
MRange TempSensor or MRange PressSens
Example
##
Calculation Ext MaxSetpoint

##
Required upper setpoint limit: 80 °C

MeasureRangePtNi set: 150 °C
Analogue signal Ext Inp X62 U/I:
##
4 … 20 mA (analogue range 16 mA)
results in Ext MaxSetpoint =
##
80 °C / 150 °C ≈ 0.533 ≙ 53.3 %
Corresponds to a setpoint signal: 16 mA x 0.533 + 4 mAOffset ≈ 12.53 mA
83054802 1/2015-07 MaW 127-228

6 Operation
6.12.7 Analogue output

Param & Display LoadController Configuration Analog output
or
Param & Display SystemConfig LC Analog Output
The analogue output X63 is configured in menu Analog Output, see
[ch. 3.4.10].
Stipulate output value (OutValuSelection)

Parameter OutValuSelection stipulates the value that is output as a current
signal at output X63
Setting Function
(1
Load Load signal from internal load controller
Load 0
O2 Residual oxygen content in flue gas
Pos Air Position of the relevant actuator
Pos fuel
Pos Aux…
Speed VSD Setpoint speed
Flame Flame signal
Temp Pt… Temperature sensor input X60
Temp Ni1000
Temp X61 Temperature/ pressure sensor input X61
Press X61
€€
(1
Current range, output value and scaling are predefined and can not be changed
[ch. 3.4.10].
Current range (CurrMode 0/4mA 0/4mA)

Parameter CurrMode 0/4mA defines the current range at output X63.
0..20mA
4..20mA
83054802 1/2015-07 MaW 128-228

6 Operation
Output values
Defines the internal value (%, °C, bar or degree of angle) at which 20 mA flow at
output X63.
Setting Function
Scale20mA prec Internal percentage value (0 ... 999.9 %) at 20 mA, valid
for:
Load 0
O2
Speed VSD
Flame
Scale20mA temp Temperature at input X60/X61 (0 ... 2000 °C) at 20 mA,
valid for:
Temp Pt1000 / Temp Ni1000 / Temp Pt100
Temp X61
Press X61 Pressure sensor at input X61 (0 ... 99.9 bar) at 20 mA,
valid for Press X61.
Scale20mA angle Actuator position in degree of angle (0 ... 90°) at 20 mA,
valid for:
Pos Air
Pos fuel
Pos Aux…
Scaling (Scale 0/4mA)

Parameter Scale 0/4mA defines the internal value for the lower current limit.
Depending on parameter CurrMode 0/4mA 4 mA or 0 mA flow at the value set.
The relative value in percent refers to the output value set (Scale20mA … /
Press X61).
83054802 1/2015-07 MaW 129-228

6 Operation
6.12.8 Control parameters of internal load controller

Param & Display LoadController ControlParam ContrlParamList StandardParam
PPart (Xp)
IPart (Tn)
DPart (Tv)
To be able to use the internal load controller, it must be activated in parameter
LC_OptgMode, see [ch. 6.12.2].
The control behaviour of the load controller is set in menu ControlParamList .
Under StandardParam one of five standard parameter sets or the PID para-
meter set from the adaption can be selected.
Parameter set P-Part Xp [%] I-Part Tn[s] D-Part Tv [s]
StandardParam
##
Adaption Values determined during adaption [ch. 6.12.15].
very fast 42.5 68 12
fast 14.5 77 14
normal 6.4 136 24
slow 4.7 250 44
##
very slow 3.4 273 48
Adapting control parameters

The PID parameter can be altered manually.
Parameters Function
PPart (Xp) Proportional part
IPart (Tn) Integral part (integral action time)
DPart (Tv) Differential part (derivative action time)
Xp too small Xp too large Tn, Tv too small Tn, Tv too large
83054802 1/2015-07 MaW 130-228

6 Operation
6.12.9 Control variable calming

Param & Display LoadController ControlParam MinActuatorStep
In modulating operation, parameter MinActuatorStep determines the minimum
correcting element step.
The minimum correcting element step is used as control variable calming. If the dif-
ference between the new control variable and the current control variable is less
than MinActuatorStep, the current control variable is maintained. The actuators
are less stressed due to the reduced drive impulses.
If the control variable calming is too great, the control becomes inaccurate or be-
gins to oscillate.
6.12.10 Fault signal suppression

Param & Display LoadController ControlParam SW_FilterTmeCon
Parameter SW_FilterTmeCon weakens actual value fault signals.
Actual value fault signals mainly affect the D part. If the filter time selected is too
long it affects the actual value and negatively affects the control accuracy .
Set the filter time to 2 … 4 seconds for automatic adaption. If the time selected is
too long the automatic adaption can be interrupt. On steam plants, increase the fil-
ter time after the adaption to 6 … 8 seconds.
83054802 1/2015-07 MaW 131-228

6 Operation
6.12.11 Modulating switch differentials

Param & Display LoadController ControlParam Sd_ModOn
Sd_ModOff
Parameters for the On and Off switch points of the internal load controller for mod-
ulating operation.
Parameters Function
Sd_ModOn Switch-on point (controller ON)
Sd_ModOFF Switch-off point (controller OFF)
The on and off switch points are given as a percentage value and relate to the cur-
rent setpoint.
Example
##
On and off switch points at setpoint (W) = 70 °C

Sd_ModOn:
##
−10 % (of 70 °C = −7 °C)
Sd_ModOff +5 % (of 70 °C = 3.5 °C)
Controller ON
##
70 − 7 = 63 °C
Controller OFF 70 + 3.5 = 73.5 °C
With a positive switch differential Sd_ModOn the switch-on point is higher than
the current setpoint.
83054802 1/2015-07 MaW 132-228

6 Operation
6.12.12 Multi-stage switch differentials and switch thresholds
6.12.12.1 Multi-stage switch differentials

Param & Display LoadController ControlParam Sd_Stage1On
Sd_Stage1Off
Sd_Stage2Off
Sd_Stage3Off
Parameters for the On and Off switch points of the internal load controller for multi-
stage operation.
Parameters Function
Sd_Stage1On Switch-on point (controller ON)
Sd_Stage1Off Switch-off point stage 1 (controller OFF)
Sd_Stage2Off Switch-off point stage 2
Sd_Stage3Off Switch-off point stage 3
rent setpoint.
Example ##
On and off switch points at setpoint (W) = 70 °C
Sd_Stage1On = −10 % (of 70 °C = −7 °C)
Sd_Stage1Off = +5 % (of 70 °C = 3.5 °C)
Sd_Stage2Off = +2 % (of 70 °C = 1.4 °C)
##
Sd_Stage3Off = +1 % (of 70 °C = 0.7 °C)
##
Stage 1 (controller) ON 70 − 7 = 63 °C
Stage 1 (controller) OFF 70 + 3.5 = 73.5 °C
Stage 2 OFF 70 + 1.4 = 71.4 °C
##
Stage 3 OFF 70 + 0.7 = 70.7 °C
If stage 1 exceeds Sd_Stage3Off before stage 3 has switched, the controller
switches off.
Threshold for stage 2 not achieved Threshold for stage 2 and 3 not
Stage 1 already switches off at: achieved
Setpoint (W) + Sd_Stage3Off Stage 1 switches off at:
Setpoint (W) + Sd_Stage1Off
Sd_Stage1Off
Sd_Stage2Off
Sd_Stage3Off
Setpoint (W)
Sd_Stage1On
Stage 1 (controller ON)

Stage 2
Stage 3
83054802 1/2015-07 MaW 133-228

6 Operation
6.12.12.2 Multi-stage switch threshold

Param & Display LoadController ControlParam ThreshStage2On
ThreshStage3On
Parameter ThreshStage…On stipulates the switch threshold for stage 2 and
stage 3. The switch threshold influences the switching of the stages.
If the actual value drops below Sd_Stage1On the W-FM forms the integral from
control deviation x time. When the value reaches ThreshStage2On (Q2)
stage 2 switches.
If the value reaches ThreshStage3On (Q3) before Sd_Stage1On is not
achieved, stage 3 switches.
Sd_Stage1Off
Sd_Stage2Off
Sd_Stage3Off
Setpoint (W)
Sd_Stage1On
Q2 Q3 Q2
Stage 1 (controller ON)

Stage 2
Stage 3
6.12.12.3 Low impact start

If a three stage burner is to be operated two stage with low impact start:
Set parameter Sd_Stage2Off and Sd_Stage1Off to the same value.
When Sd_Stage2Off is reached, the W-FM initiates a shutdown.
Set parameter ThreshStage2On to 0.
if the W-FM releases the load control, stage 2 switches immediately. Stage 3
only switches once the switch threshold (Q3) has been reached.
83054802 1/2015-07 MaW 134-228

6 Operation
6.12.13 Temperature sensor

Param & Display LoadController ControlParam TL_ThreshOff
TL_SD_On
or
Param & Display SystemConfig TempLimiter TL_ThreshOff
TL_SD_On
The temperature monitor is only activated in conjunction with the sensors Pt100,
Pt1000 or Ni1000, see [ch. 6.12.3].
Parameter TL_ThreshOff stipulates the switch threshold for the temperature
monitor.
Parameter TL_SD_On stipulates the switch-on hysteresis. The switch-on hyster-
esis is given as a percentage value and relates to the switch threshold for the tem-
perature monitor.
Example TL_ThreshOff = 80 °C If the temperature exceeds the
threshold, the W-FM initiates a shut-
down and block the burner start.
TL_SD_On = −10 % If the temperature drops below the
80 °C − (80 °C x 0.1) = 72 °C switch-on hysteresis, the W-FM re-
moves the block.
83054802 1/2015-07 MaW 135-228

6 Operation
6.12.14 Boiler cold start function

Param & Display LoadController ControlParam ColdStart
The boiler cold start function reduces the thermal load of the boiler during burner
start.
If the boiler cold start function is activated and if the boiler temperatures is below
the switch-on threshold set for the boiler cold start function at burner start, the W-
FM carries out a cold start sequence. The burner starts with the lowest burner ca-
pacity. The capacity is increased, either after the residence time set or when the
boiler temperature exceeds the next setpoint step. When the boiler temperature
reaches the switch-off threshold set, the W-FM stops the cold start sequence and
the load control is activated.
Temperature
Setpoint (W)
ThresholdOff
Threshold_On
Step Setp_...
Boiler temperature
Modulating capacity
Step capacity
Partial load
Burner Off
Maxtime_mod
Multi-stage capacity
Stage 3
Stage 2
Stage 1
Burner Off
Maxtime_stage
83054802 1/2015-07 MaW 136-228

6 Operation
Activate boiler cold start function (ColdStartOn)

Parameter ColdStartOn activates or deactivates the boiler cold start function.
Switch-on threshold (ThresholdOn)

Parameter ThresholdOn stipulates the switch-on threshold for the boiler cold
start function.
If the boiler temperature is below the switch-on threshold at heat demand, the W-
FM carries out the cold start sequence.
The switch-on threshold is given as a percent value and relates to the current set-
point W1 or W2. If an additional sensor is connected to input X60, the switch-on
threshold relates to the setpoint set under Setp AddSensor .
Load stage (StageLoad)

Parameter StageLoad stipulates the stage for load increase in modulating oper-
ation.
When the boiler temperature reaches the next setpoint step StageSetp_…, the
burner capacity increases by the percentage point set.
If the next setpoint step is not reached, the capacity increases after the residence
time Maxtme_… set has elapsed.
Setpoint stage (StageSetp_…)

The parameters stipulate the step for the setpoint increase.
Parameters Function
StageSetp_Mod Setpoint step for modulating operation
StageSetp_Stage Setpoint step for multi-stage operation
The setpoint step is given as a percentage value and relates to to current set-
When the boiler temperature reaches the current cold start setpoint, the cold start
setpoint increases by the step set.
In addition, the burner capacity in modulating operation increases by the load step,
in multi-stage operation the next stage switches.
Residence time (MaxTme_…)

The residence time stipulates the minimum time after which the burner capacity is
increased.
If the boiler temperature does not reach the current cold start setpoint after this
time has elapsed, the burner capacity is increased and the time starts again. In
modulating operation, the burner capacity increases by the load step set, in multi-
stage operation the next stage switches.
Parameters Function
MaxTmeMod Minimum time for modulating operation after which the
burner capacity is increased.
MaxTmeStage Minimum time for multi-stage operation after which the
next stage switches, provided that the stages have been
released in parameter Release Stages.
83054802 1/2015-07 MaW 137-228

6 Operation
Switch-off threshold (ThresholdOff)

Parameter ThresholdOff stipulates the switch-off threshold for the boiler cold
start function.
The switch-off threshold is given as a percent value and relates to the current set-
When the boiler temperature reaches the switch-off threshold set, the W-FM stops
the cold start sequence and the load control is activated.
Additional sensor (AdditionalSens)

If a pressure sensor is connected to input X61, the cold start function requires an
additional sensor at input X60 [ch. 3.3.20].
The additional sensor connected is defined in parameter AdditionalSens .
If the additional sensor has been defined, the setpoint set under Setp Ad
dSensor is deemed as the reference value for the boiler cold start function.
Temperature at additional sensor (Temp. ColdStart)

Parameter Temp. ColdStart shows the current temperature at the additional
sensor.
Setpoint for additional sensor (Setp AddSensor)

Parameter Setp AddSensor stipulates the setpoint for the boiler cold start
function if an additional sensor is defined.
Release stages (Release Stages)

In parameter Release Stages , stage 2 and stage 3 can be blocked for boiler
cold start function. The parameter is only effective in multi-stage operation.
Setting Function
No release Boiler cold start function is only carried out with stage 1.
Stage 2 and stage 3 are blocked for the boiler cold start
function. Parameters MaxTmeStage and
StageSetp_Stage have no effect.
Release The boiler cold start function starts in stage 1. The next
stage switches, when the boiler temperature reaches the
current cold start setpoint or the residence time is ex-
ceeded.
83054802 1/2015-07 MaW 138-228

6 Operation
6.12.15 Adaption
Param & Display LoadController Adaption StartAdaption
AdaptionLoad
Start adaption
The load controller starts automatic adaption via parameter StartAdaption.
During adaption, the load controller identifies the controlled system and generates
the PID parameters from the data determined.
Adaption is only possible in modulating operation. It is possible to start in manual or
automatic operation, independent of operating status (burner ON, OFF or
Standby).
During adaption, the filter time SW_FilterTmeCon of fault signal suppression
must be 2 … 4 seconds [ch. 6.12.10].
Automatic adaption passes through 4 phases.
Phase Function
Temp setback Reduces actual value to 5 % below setpoint.
Stabilisation The course of the actual value is evaluated for 5 minutes.
phase If severe fluctuations occur, the time increases to
10 minutes.
Heating The course of the actual value during heat-up phase is
determined.
Adaption ok Adaption completed successfully, the PID parameters
are calculated.
Adaption capacity
Parameter AdaptionLoad stipulates the burner capacity for automatic adaption.
The adaption capacity should be chosen as large as possible. If the adaption in full
load (100 %) is interrupted due to insufficient heat demand, the adaption capacity
can be reduced by up to 40 %.
If the adaption capacity selected is insufficient, the setpoint temperature will not be
reached and the adaption will be aborted.
83054802 1/2015-07 MaW 139-228

6 Operation
6.13 Actuators
6.13.1 Addressing
Param & Display Actuators Addressing
If only one actuator is replaced, the W-FM addresses the new actuator automatic-
ally.
If two or more actuators are replaced at the same time, each new actuator has to
be addressed manually.
3
A B
1 Addressing key
2 LED
3 Jumper
A without Bus termination
B with Bus termination
Bus termination
On the last actuator or at the O2 module, the bus termination must be set via a
jumper [ch. ].
Addressing the actuator

Remove actuator cover.
In menu Param & Display / Actuator , select parameter Addressing
and confirm with [ENTER].
Select the relevant actuator using the dial knob:
1 AirActuator: Air damper
2 GasActuator (Oil): Gas butterfly valve
3 OilActuator: Oil quantity regulator
4 AuxActuator: Mixing head
5 AuxActuator2: Auxiliary actuator for special applications
6 AuxActuator3: Auxiliary actuator for special applications
Confirm with [ENTER].
The text Start address assignment with ENTER appears.
Start address assignment with [ENTER].
Text Address assignment being carried out changes to Please
press button on actuator after approx. 5 seconds.
Press addressing key on actuator.
LED on actuator flashes continually.
Text Address assignment carried out successfully appears.
LED on actuator displays flashing codes.
Exit address assignment using [esc]
83054802 1/2015-07 MaW 140-228

6 Operation
Flashing codes
LED Description
Continually ON unaddressed actuator
Flashing continually addressing being carried out
Flashing codes with pause Actuator is addressed:
1 impulse: Air damper actuator
2 impulses: Gas butterfly valve actuator
3 impulses: Oil quantity regulator actuator
4 impulses: Mixing head actuator
5 impulses: Actuator Aux2 (W-FM 200 only)
6 impulses: Actuator Aux3
Delete addressing
Press addressing key on actuator for 10 seconds.
The LED on the actuator changes to continually ON.
6.13.2 Delete curves

Param & Display Actuators DeleteCurves
Parameter DeleteCurves deletes the compound curves of all actuators, is re-
quired to change the rotation direction in the OEM level.
6.13.3 Position control

Param & Display SystemConfig Allowed Pot.diff
Each actuator transmits two independent position signals to the W-FM. The W-FM
compares the position signals to the setpoint position. The W-FM also compares
the two position signals. Parameter Allowed Pot.diff stipulates the max-
imum permissible deviation between the position signals.
The W-FM initiates a lockout, if:
an actuator does not reach the setpoint position,
the position signals exceed the difference set under Allowed Pot.diff .
Recommended setting: 15 (equal to 1.5°)
83054802 1/2015-07 MaW 141-228

6 Operation
6.14 VSD / Frequency converter

Only the W-FM 200 is equipped with a frequency converter module for variable
speed control.
6.14.1 Frequency converter release contact

Param & Display VSD module Configuration ReleasecontctVSD
The W-FM 200 is equipped with a release contact at output X73:1/2 for the fre-
quency converter [ch. 3.4.11].
Parameter ReleasecontctVSD stipulates the switch condition for the idle posi-
tion (0 %) in phase 10 (home run). The release contact closes from a setpoint
speed greater than 0 %, regardless of the parameter setting.
Setting Function
closed The release contact closes at idle position (0 %) in
phase 10 (home run), recommended setting.
open The release contact opens at idle position (0 %) in
phase 10 (home run), e. g. when using a DC brake.
6.14.2 Speed measurement

Param & Display VSD module Configuration Speed Num Puls perR
Parameter Num Puls perR stipulates the impulses per rotation at input X70
[ch. 3.3.21].
6.14.3 Speed standardisation

Param & Display VSD module Configuration Speed Standardisation
StandardisedSp
Speed standardisation (Standardisation)

Parameter Standardisation starts the automatic speed standardisation, to do
this set parameter to activated .
As a prerequisite for speed standardisation, the pre-purge position of the air influ-
encing actuators must be set to 90° [ch. 6.9.4].
During the standardisation, the air influencing actuators drive to the pre-purge posi-
tion and the W-FM issues a setpoint signal of 95 % (approx. 19.2 mA) to the fre-
quency converter. The maximum frequency set at the frequency converter is there-
fore only achieved to 95% e. g. 52.5 Hz x 0.95 ≈ 50 Hz). The standardised speed
is determined and saved in parameter StandardisedSp .
For the speed control, the standardised speed applies as 100 % value. If, during
operation at 100% standardised speed is not reached, a reserve of 5% is available.
The burner requires re-commissioning after each standardisation.
Standardised speed (StandardisedSp)

In parameter StandardisedSp the speed saved during standardisation can be
viewed and changed.
The burner requires re-commissioning after each change made to the standardised
speed.
83054802 1/2015-07 MaW 142-228

6 Operation
6.14.4 Actual speed

Param & Display VSD module Configuration Speed Absolute speed
or
Param & Display VSD module Process Data Absolute speed
Absolute speedParameter Absolute speed indicates the current speed
detected.
6.14.5 Setpoint output

Param & Display VSD module Configuration Speed Setpoint Output
Parameter Setpoint Output stipulates the current signal, which controls the
frequency converter [ch. 3.4.11].
The current signal from the W-FM must be matched to the frequency converter.
Setting Function
4..20 mA Current signal with load monitoring (standard)
6.14.6 Speed deviation

Param & Display VSD module Process Data
The process data can be found in the volatile memory and are reset during reset or
power failure.
Parameters Function
Max Stat Dev Shows the maximum speed deviation when changing a
control variable in modulating operation.
Max Dyn Dev Shows the maximum speed deviation between actual
speed and setpoint speed when accelerating.
Num Dev >0.3% Number of speed deviations when changing a control
variable with a difference greater than 0.3%.
Num Dev >0.5% Number of speed deviations when changing a control
variable with a difference greater than 0.5%.
83054802 1/2015-07 MaW 143-228

6 Operation
6.15 Flue gas recirculation

Only the W-FM 200 type LMV52.4… is equipped with the flue gas recirculation
(FGR) function.
Before the flue gas recirculation can be adjusted, burner commissioning with the
FGR damper closed must be carried out.
On burners with separate combustion air fan, the air dampers (Aux2) in front of the
FGR connection housing must also be slightly closed [ch. 6.15.1.2].
The FGR function is fuel specific and must be set separately for each fuel on dual
fuel burners.
If the FGR function is only used for one fuel on dual fuel burners, the actuator posi-
tion (Aux3) for the other fuel must be set to 0° (closed) in all load points and spe-
cial positions.
6.15.1 FGR function
6.15.1.1 Fan on burner

Through a pipeline, the fan draws the flue gas from the flue gas pipe. A flue gas
damper (FGR damper) 1 in the pipeline meters the recirculated flue gas quantity.
The FGR damper is driven load dependent, in compound by the actuator (Aux3).
The recirculated flue gas quantity dependents on the position of the FGR
damper 1 and the negative pressure in the FGR connector housing 2. With suffi-
cient negative pressure the FGR damper operates up to an opening angle of ap-
prox. 60°, above this the recirculated flue gas quantity increases marginally. If the
recirculated flue gas quantity is insufficient to reach the NOX limit value, the negat-
ive pressure in the FGR connector housing has to be increased, to do this either:
close air damper 3 further,
increase speed 4,
open mixing head 5 further.
The air quantity required for combustion must not be changed, to achieve this al-
ternately change the actuator positions and speed.
83054802 1/2015-07 MaW 144-228

6 Operation
4 5
3
2
M
M
W-FM 200
M
M
M
W-FM 200
M
Example Actuator Change Reaction

Air damper CLOSED decreased combustion air (-)
increased negative pressure (+)
increased flue gas recirculation (+)
Speed Increase increased combustion air (+)
FGR damper CLOSED decreased flue gas recirculation (-)
83054802 1/2015-07 MaW 145-228

6 Operation
6.15.1.2 Separate fan

Through a pipeline, the fan draws the flue gas from the flue gas pipe. A flue gas
damper (FGR damper) 1 in the pipeline meters the recirculated flue gas quantity.
The FGR damper is driven load dependent, in compound by the actuator (Aux3).
The recirculated flue gas quantity dependents on the position of the FGR
damper 1 and the negative pressure in the FGR connector housing 2. With suffi-
cient negative pressure the FGR damper operates up to an opening angle of ap-
prox. 60°, above this the recirculated flue gas quantity increases marginally. If the
recirculated flue gas quantity is insufficient to reach the NOX limit value, the negat-
ive pressure in the FGR connector housing has to be increased, to do this either:
Open burner air damper 3further,
increase speed 4,
open mixing head 5 further,
close air damper 6 in front of FGR connector housing further.
The air quantity required for combustion must not be changed, to achieve this al-
ternately change the actuator positions and speed.
M
3
W-FM 200
4 M
2
1 M
6
M
+
W-FM 200
83054802 1/2015-07 MaW 146-228

6 Operation
Example Actuator Change Reaction

Air dampers in CLOSED decreased combustion air (-)
front of FGR con- increased negative pressure (+)
nector housing increased flue gas recirculation (+)
Speed Increase increased combustion air (+)
FGR damper CLOSED decreased flue gas recirculation (-)
Initial commissioning without FGR

To ensure sufficient negative pressure for flue gas recirculation, slightly close the
air dampers in front of the FGR connector housing at each load point during the ini-
tial commissioning without FGR.
Once the combustion limit is determined and the excess air is set:
Close air dampers in front of FGR connector housing (Aux2) until the O2 content
reduces by approx. 0.4 % points.
Increase the O2 content again to the previous value using the air influencing ac-
tuators, whilst observing the flame stability.
83054802 1/2015-07 MaW 147-228

6 Operation
6.15.2 FGR operating mode

Param & Display Flue Gas Recirc. FGRMode
Parameter FGRMode stipulates how and when the actuator Aux3 is controlled
during flue gas recirculation.
Setting Function
Aux3onCurve Actuator Aux3 drives on its programmed compound curve.
Not recommended for FGR function.
If there is no flue gas recirculation installed, select this setting if the actuator is to
be used for another function.
time Actuator Aux3 initially remains in ignition position in phase 60 (operating posi-
tion 1). Only once the residence time set under DelaytimeFGR… has elapsed
will the actuator drive on the compound curve [ch. 6.15.5].
Temperature Actuator Aux3 initially remains in ignition position in phase 60 (operating posi-
tion 1). Once the FGR temperature sensor reaches the temperature set under
ThresholdFGR… will the actuator drive on the compound curve [ch. 6.15.5].
^^
Only for plant with FGR temperature sensor in the flue gas pipe.
Temp.comp. Temperature compensated FGR function. Only with W-FM type LMV 52.4xx.
During FGR commissioning the W-FM captures and saves the temperature at the
temperature sensor at each load point.
If, during operation, the FGR temperature differs from the saved temperature, the
W-FM recalculates the position for actuator Auxs3. Deviating from the compound
curve, the actuator drives to the calculated position and compensates the temper-
ature deviation.
How much the temperature deviation affects the actuator position can be set in
parameter FactorFGR… .
The FGR minimum position is always maintained [ch. 6.15.8].
In parameter DelaytimeFGR… the residence time for phase 60 (operating pos-
^^
ition 1) can be set [ch. 6.15.5].
TCautoDeact Temperature compensated FGR function and automatic deactivation. Only with
W-FM type LMV 52.4xx.
As with Temp.comp., the W-FM also monitors the FGR temperature sensor.
If a sensor fault occurs, the W-FM deactivates the FGR function and a warning
appears in the display. Actuator Aux3 then drives to FGR minimum position
^^
[ch. 6.15.8].
deactMinpos After ignition position, actuator Aux3 drives to FGR minimum position [ch. 6.15.8].
The temperature at the FGR temperature sensors is not recorded, the display
shows xxxx.
Operating mode for commissioning without FGR function, set FGR minimum pos-
ition to 0° .
auto deact Do not select this operating mode.
Parameter auto deact is automatically activated when a fault occurs in oper-
ating mode TCautoDeact . Actuator Aux3 drives to FGR minimum position
and a warning appears in the display.
€€
The temperature compensated AFR function is not possible when O2 trim is activ-
ated.
83054802 1/2015-07 MaW 148-228

6 Operation
6.15.3 Define temperature sensor

Param & Display Flue Gas Recirc. FGRsensor
The FGR sensor connected is defined in parameter FGRsensor .
The FGR temperature sensor is connected to input X60 as standard [ch. 3.3.20].
For temperature compensated operation, the FGR temperature sensor should be
positioned as close as possible to the FGR damper.
Parameters Function
X86PtNi1000 The temperature sensor connected to the O2 module is
also used for the FGR function [ch. 3.3.23].
Not suitable for temperature compensated operation.
X60 Pt10000 Ni1000 sensor at terminal X60:3/4
X60 Ni1000 Pt1000 sensor at terminal X60:3/4
The corresponding sensor must not be defined in the
menu Sensor Select of the load controller
[ch. 6.12.3].
6.15.4 FGR sensor temperature

Param & Display Flue Gas Recirc. actTmpFGRsensor
Parameter actTmpFGRsensor shows the current temperature at the FGR tem-
perature sensor.
83054802 1/2015-07 MaW 149-228

6 Operation
6.15.5 FGR release

Param & Display Flue Gas Recirc. ThresholdFGR…
DelaytimeFGR…
The parameters stipulate when the FGR function is released.
After entering phase 60 (operating position 1) actuator Aux3 initially remains in igni-
tion position. if the release criteria is met, Aux3 drives on the compound curve.
Depending on the FGR operating mode set, release is either effective via the time
or the temperature at the FGR sensor.
The release can be set separately for each fuel.
Parameters Function
ThresholdFGR Gas When the FGR sensor reaches the temperature set, the
ThresholdFGR Oil W-FM releases the FGR function. For this, the FGR
sensor must be placed in the flue gas pipe or the FGR
damper must be slightly open in ignition position.
Only for operating mode Temperature.
DelaytimeFGR Gas The W-FM releases the FGR function in phase 60 once
DelaytimeFGR Oil the time set has elapsed. The time depends on the the
warm-up phase of the plant. Criteria is consistent capa-
city and constant flue gas temperature.
For operating mode:
time
Temp.comp.
TCautoDeact
recommended setting: 60 seconds
6.15.6 Temperature compensation

Param & Display Flue Gas Recirc. FGR Factor Gas
FGR Factor Oil
During FGR commissioning the W-FM captures and saves the temperature at the
FGR temperature sensor at each load point. If, during operation, the FGR temperat-
ure differs from the saved temperature, the W-FM recalculates the position for ac-
tuator Aux3. If the FGR sensor drops below the temperature saved the FGR
damper is closed further.
Parameter FGR Factor … stipulates how much the temperature compensation
affects position of the FGR damper.
With a factor of 100%, the temperature compensation is fully effective. With values
below 100% the recirculated flue gas quantity is reduced.
The parameter is only effective in operating modes:
TCautoDeact
Temp.comp.
83054802 1/2015-07 MaW 150-228

6 Operation
6.15.7 Operating temperature

Param & Display Flue Gas Recirc. OperationTempGas
OperationTempOil
Parameter OperationTemp … displays the temperatures that were saved dur-
ing temperature compensated commissioning.
The temperature can be displayed at each load point. Invalid values or non-con-
figured operating points are displayed with XXXX .
6.15.8 Position limit FGR damper

The position limit restricts the setting of the flue gas damper up and down.
The Position limit is only effective in the temperature compensated operating
modes:
Temp.comp.
TCautoDeact
FGR minimum position

Param & Display Flue Gas Recirc. FGR MinPos
Parameter FGR MinPos limits the closing angle and ensures a minimum flow.
The minimum position is an absolute value (degree of angle) and applies to the
whole load range.
The FGR damper drives to minimum position if:
the W-FM calculates a smaller closing angles for the temperature compensation
then is defined in FGR MinPos ,
the operating mode deactMinpos or auto deact is activated.
FGR maximum position

Param & Display Flue Gas Recirc. FGR MaxPos Fact
Parameter FGR MaxPos Fact limits the opening angle upwards. The maximum
position is given as a percentage value and relates to the current position of the
compound curve (Aux3).
83054802 1/2015-07 MaW 151-228

6 Operation
6.16 Data backup
6.16.1 Backup copy

Updating Param backup BackupInfo
LMV5x > AZL
AZL > LMV5x
Information for backup

Menu BackupInfo displays the date, time and the contents of the last data
backup.
Parameters Function
Date Displays the date of the last backup copy.
TimeOfDay Displays the time of the last backup copy.
BU included? Indicates whether the information from the W-FM has
been transferred without errors.
AZL included? Indicates whether a display and operating unit was con-
nected during the last backup.
ACT… included? Shows the actuatros connected during the last data
back-up.
VSD included? Indicates whether a frequency converter module was
saved in the backup copy.
O2 included? Indicates whether an O2 module was saved in the
backup copy.
Creating a backup copy

Parameter LMV5x > AZL creates a backup copy of the W-FM in the display
and operating unit (ABE)
The existing data is overwritten.
The data from the W-FM can be backed up to any ABE.
Select parameter LMV5x > AZL and confirm with [ENTER].
Start process with [ENTER].
Param & Display

Updating
Enter Param
PW backup
Deactivate
Load SWPW from PC
BackupInfo
LMV5x > AZL
AZL >LMV5x
LMV5x> AZL Parmeters being
Start process updated
with ENTER Abort Backup
with ESC
being
Abort with ESC created
Parameters were
saved
Continue w ESC
Param backup
Load SW from PC
83054802 1/2015-07 MaW 152-228

6 Operation
Load backup copy to W-FM

Parameter AZL > LMV5x transfers the data of the display and operating unit
(ABE) to the W-FM.
The existing data is overwritten.
The data can only be transferred to the W-FM if either:
the burner identification is identical in the W-FM and in the backup copy
(backup) [ch. 6.4.10],
the W-FM does not contain a burner identification.
Select parameter AZL > LMV5x and confirm with [ENTER].
Start process with [ENTER].
The W-FM goes to lockout and displays the reason for the lockout.
Exit display using the [esc] key.
Reset burner using the [ENTER] key.
Param & Display

Updating
Enter Param
PW backup
Deactivate
Load SWPW from PC
BackupInfo
LMV5x > AZL
AZL > LMV5x
AZL > LMV5x Parmeters being
Start process updated
with ENTER Abort Backup
with ESC
Restore
Abort with ESC running
! Backup Restore
completed
Parameters
! GG: complete
Parameters
Backup Restore Lockout
Do you want to
reset system using
ENTER?
Reset
6.16.2 Updating software

Updating Load_SW_from_PC
ParameterLoad_SW_from_PC updates the software of the display and operating
unit (ABE). To do this, a PC with ASC450 Software must be connected at inter-
face COM 1, see [ch. 6.6.1].
The current file is available from Weishaupt.
83054802 1/2015-07 MaW 153-228

6 Operation
6.17 TÜV Test
6.17.1 Flame failure

TÜV Test LossFlameTest
Parameter LossFlameTest interrupts the flame signal and it is possible to
check if the W-FM initiates a lockout.
6.17.2 Safety temperature limiter

TÜV Test SLT Test
SLTTestload Mod
SLTTestload Stg
These parameters can be used to check if the safety temperature limiter (STL) re-
sponds.
Parameter SLT Test generates a heat demand, deactivates the internal temper-
ature monitor and the burner drives to the load or stage set under SLTTest
load….
83054802 1/2015-07 MaW 154-228

7 Commissioning
7 Commissioning
7.1 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 document 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.
7.1.1 Adapting the motor to the frequency converter
Frequency converter fitted to burner

If the frequency converter is fitted to the burner motor, the parameters have been
matched to the motor and motor adaption is therefore not required.
Separate frequency converter

On burners with separate frequency converter, the automatic motor adaptation
must be carried out on the frequency converter. For this, the motor parameters in
the frequency converter must match the specifications on the nameplate of the mo-
tor. Procedure for automatic motor adaptation see product manual for frequency
converter.
Separate frequency converter, which have been supplied with the burner, contain a
default parameter set a are supplied with a parameter list (MCT 10 Set-up Soft-
ware …). Automatic motor adaptation also has to be carried out in this instance.
83054802 1/2015-07 MaW 155-228

7 Commissioning
7.2 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 document contains detailed in-
formation about:
speeds (in in conjunction with frequency converter),
pump pressure,
flow and return pressure,
default settings,
mixing pressure.
7.2.1 Preparatory measures

In addition to this chapter, the information about adjustment in installation and oper-
ating manual of the burner should be observed.
Prerequisite
Remove mixing head drive rod (only on burners with adjustable mixing head).
Set fuel selection switch to Gas (only on dual fuel burners with heavy oil).
Switch on voltage supply.
1. Switch off burner

The ABE is in OperationalStat in the sub menu NormalOperation and dis-
plays current values.
Select ManualOperation.
Select Autom/Manual/Off.
Set Burner Off.
The burner switches off.
2. Enter password
Select Param & Display.
Select Access with HE (password for heating engineer).
Enter HE password using dial knob and confirm with [ENTER] [ch. 6.2.1].
3. Check drive rod of mixing head

Only on burners with adjustable mixing head.
Isolate burner motor from voltage supply.
Prevents fan starting during this step.
Select RatioControl.
Select GasSettings or OilSettings.
Select SpecialPositions.
Select HomePos.
Select HomePosAux1 and set 0.0°.
Refit drive rod and check stop (play 1 … 2 mm).
Remove drive rod again.
Select HomePosAux1 and set 90.0°.
Refit drive rod and check stop (play 1 … 2 mm).
Return HomePosAux1 to 0.0° setting.
Reconnect voltage to burner motor.
83054802 1/2015-07 MaW 156-228

7 Commissioning
4. Select fuel
Dual fuel burners only.
Fuel can be selected via:
external fuel selection switch,
the display and operating unit (ABE),
building management system (BMS).
The fuel selector switch has priority over fuel selection via the display and operating
unit (ABE) or building management system (BMS).
Select fuel via ABE:

Select Operation.
Select Fuel.
Select FuelSelect.
Select Fuel using the dial knob and confirm with [ENTER].
7.2.1.1 Carry out speed standardisation

Only on burners which are equipped with separate frequency converter
[ch. 6.14.3].
On dual fuel burner, standardisation should only be carried out during the commis-
sioning of the first fuel. The burner requires re-commissioning after each standard-
isation.
Skip this step on burners without frequency converter.
Select VSD module.
Select Configuration.
Select Speed.
Select Standardisation.
Select activated using the dial knob and confirm with [ENTER].
83054802 1/2015-07 MaW 157-228

7 Commissioning
7.2.1.2 O2 module presetting

Only for burners which are equipped with an O2 module.
Skip these steps on burners without O2 module.
1. Check configuration of O2 module

Select O2 Module.
Check settings of the following parameters:
O2 Sensor: Sensor used [ch. 6.10.7].
SupAirTempSens: Pt1000 or Ni1000, if connected [ch. 3.3.24],
FlueGasTempSens: Pt1000 or Ni1000, if connected [ch. 3.3.23],
MaxTempFlGas…: Pre-setting 400 °C [ch. 6.10.10].
Exit Configuration level using [esc].
2. Check O2 sensor temperature

Monitor sensor temperature regularly during heat up phase.
Select Process Data.
Select parameter QGO SensorTemp and check sensor temperature
[ch. 6.10.20].
Operating temperature: 700 ± 15 °C.
Exit level O2 Module , press [esc] twice.
3. Deactivating O2 trim
Deactivate the O2 trim prior to commissioning the compound curves. Deactivate the
O2 trim for both fuels (oil and gas) [ch. 6.10.1].
Select O2Control/Alarm .
Select OptgMode.
Select man deact using dial knob and confirm with [ENTER].
Exit level OptgMode using [esc].
4. Define fuel type

Define the fuel type for both fuels (gas and oil) on dual fuel burners [ch. 6.10.6].
Select Type of fuel.
Select fuel using the dial knob and confirm with [ENTER].
Exit level O2Control/Alarm , press [esc] three times.
83054802 1/2015-07 MaW 158-228

7 Commissioning
7.2.1.3 Deactivate flue gas recirculation

Only for burners which are equipped with flue gas recirculation.
Skip this step on burners without flue gas recirculation.
Deactivate flue gas recirculation prior to commissioning the compound curves
[ch. 6.15.2].
Select Flue Gas Recirc..
Select FGRMode.
Select deactMinpos using dial knob and confirm with [ENTER].
Exit level FGRModeusing [esc].
Select FGR MinPos.
Set 0° using dial knob and confirm with [ENTER].
Exit level Flue Gas Recirc. , press [esc] three time.
83054802 1/2015-07 MaW 159-228

7 Commissioning
7.2.2 Adjusting gas side
Prerequisite
Open gas isolating valve.
Pressure in gas valve train increases.
Close isolating valve.
1. Check load limits

Select GasSettings.
Select LoadLimits.
Select MinLoadGas and set 0.0%.
Select MaxLoadGas and set 100%.
Use [esc] key to return to the display LoadLimits.
2. Check ignition position

Select IgnitionPos.
Select IgnitionPosGas (gas butterfly valve setting in ignition position).
Check IgnPosGas , pre-setting values see installation and operating manual of
burner.
Select IgnitionPosAux1 (auxiliary motor setting in ignition position).
Check IgnitionPosAux1:
Standard: 0.0°
3LN (multiflam): 18.0°
Select IgnitionPosVSD (speed in ignition position, only in conjunction with
frequency converter).
Check IgnitionPosVSD.
50 Hz operation: 70% ≙ 35 Hz
55 Hz operation: 63.6%≙ 35 Hz
Use [esc] key to return to the display IgnitionPos.
83054802 1/2015-07 MaW 160-228

7 Commissioning
3. Check mixing pressure in ignition position

Select ProgramStop.
Select 36 IgnPos.
Use [esc] key to return to the display with GasSettings.
Select Manual (Burner On).
Check rotation direction of motor.
The burner starts and stops in ignition position without flame formation
Check mixing pressure in ignition position, see installation and operating manual
of burner.
Standard: 1.0 … 2.0 mbar
3LN (multiflam): 1.5 … 2 mbar
If necessary, adjust mixing pressure via air damper setting:
Select GasSettings.
Select IgnitionPos.
Select IgnitionPosAir and adjust.
4. Check gas valves

Set new program stop:
without ignition gas: 44 Interv 1
with ignition gas: 52 Interv 2
Ensure that the valves open and close correctly.
The burner tries to ignite.
The low gas pressure switch is activated.
5. Ignition
Open gas isolating valve.
The burner restarts the function sequence.
The burner ignites and the actuators stop in the ignition position.
Pre-set setting pressure on pressure regulator taking the expected combustion
chamber pressure into consideration, see installation and operating manual of
burner.
Determine combustion values at ignition position.
Set O2 content of approx. 4 … 5 % via gas butterfly valve setting (Igni
tionPosGas).
6. Adjusting low gas pressure switch
Risk of explosion due to falling gas supply pressure

Flame failure can lead to explosion.
Set low gas pressure switch to 70 % of the setting pressure.
DANGER
83054802 1/2015-07 MaW 161-228

7 Commissioning
7. Set intermediate load points

Set ProgramStop to deactivated.
Use [esc] key to return to the display SpecialPositions.
Select CurveParams.
Press [ENTER] key.
Point 1 is displayed.
Check combustion values
Only in conjunction with O2 trim

To ensure O2 trim is possible across the entire load range, point 1 must be approx.
50 % below partial load (point 2).
Excess air in all load points must be 20 … 25 %.
Press [ENTER] key.

Select Change point?.
Select Actuator positions with start.
Call up and change values with dial knob and [ENTER] key.

Reduce speed (VSD) step by step, whilst observing the combustion values and
adjust via air damper setting (Air). Minimum speed (see table) must be main-
tained.
Burner version Minimum speed

NR 40 %
LN, 1LN, 3LN 50 %
Exit point 1 using [esc] key and save with [ENTER] key.
Press [esc] key.
The menu displays Point, Manual and the current actuator positions.
In menu Point all load points can be adjusted.
In menu point Manual the current burner rating can be adjusted manually.
Correct combustion values via gas butterfly valve position (Fuel).
Exit setting using [esc] and save with [ENTER].
Exit load point using [esc].
Repeat steps until full load (Load: 100) has been reached.
83054802 1/2015-07 MaW 162-228

7 Commissioning
8. Adjust full load

When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
If the burner is equipped with an adjustable mixing head:
Set auxiliary actuator for mixing head (Aux1) to diagram, see installation and op-
erating manual of burner.
Adjust combustion values and, if necessary, speed (VSD) alternately via air
damper setting (Air).
Depending on the burner observe:
Mixing head position
Mixing pressure

Whilst observing the the combustion values and flame stability, keep speed as low
as possible, but not less than 80%.
Calculate gas throughput (operating volume VB) required [ch. 7.10].

Set the position of the gas butterfly valve (Fuel) to approx. 60 … 70° in the full
load point.
Adjust setting pressure at the pressure regulator until gas throughput (VB) is
achieved.
Determine combustion limit and set excess air [ch. 7.9].
Only in conjunction with flue gas recirculation

If the burner is later operated with flue gas recirculation, the recirculated flue gas
reduces the excess air.
Set excess air 25 % above the combustion limit to ensure sufficient combustion air
during the commissioning of flue gas recirculation.
Set excess air 25 % above the combustion limit.
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.
83054802 1/2015-07 MaW 163-228

7 Commissioning
9. Re-define point 1
Drive to point 1 in menu Point, whilst observing the combustion values.
Check combustion values and correct if necessary.
Carry out load apportionment [ch. 7.11].
To allow a reduction of MinLoad after commissioning, point 1 should be set below

the required partial load.
10. Delete intermediate load points

Delete all load points except for point 1 and full load (Load: 100).
When an intermediate load point is deleted, all points above this intermediate load
point are reduced by one number.
11. Set new intermediate load points

Starting at point 1, set new load points until full load is achieved.
A maximum of 15 load points can be programmed.

A minimum of 5 load points are required for modulating operation.

Increase burner rating in menu Manual, whilst observing combustion values.

Set new intermediate load point using [ENTER] key.
Optimise combustion at intermediate load point via air damper setting (Air).
12. Check start behaviour

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

Select LoadLimits.
Select MinLoad.
Define and set partial load whilst:
Observe data provided by boiler manufacturer.
Observe burner capacity graph.
83054802 1/2015-07 MaW 164-228

7 Commissioning
13. Set burner to automatic operation

Set Automatic.
If necessary set load controller and nd O2 trim.
14. Data backup

The display shows Create parameter backup?.
Start data backup by pressing [ENTER] key.
The display shows Parameters are being updated and the Para
meters have been saved.
The values have been backed up from the combustion manager to the ABE.
83054802 1/2015-07 MaW 165-228

7 Commissioning
7.2.3 Adjust modulation oil side
Prerequisite for fuel oil EL

Open oil shut off devices.
Prerequisite for medium and heavy fuel oil
Danger of getting burned on oil carrying components

The oil carrying components are heat up by the line heating and hot oil and could
cause burns if touched.
DANGER Do not touch the components.
Observe the enclosed installation and operating manual for the oil preheater (Print
No.18).
Prior to adjusting ensure that:
the oil supply is vented,
all oil shut off devices are open,
the oil supply has been preheated,
ring main pressure and oil flow is available.
Configure parameter C118 at the temperature regulator DR100 to wiring dia-
gram specification and set setpoints (only in conjunction with oil preheater type
WEV…).
Commission oil preheater.

Select OilSettings.
Select LoadLimits.
Select MinLoadOil and set 0.0%.
Select MaxLoadOil and set 100%.
Use [esc] key to return to the display LoadLimits.

The setting of the oil quantity regulator in ignition position is factory preset when
supplied, see burner data sheet.
Select IgnitionPos.
Select IgnitionPosOil (OilSettings quantity regulator in ignition position).
Check IgnitionPosOil , pre-setting values see installation and operating
manual of burner.
Select IgnitionPosAux1 (auxiliary motor setting in ignition position).
Check IgnitionPosAux1:
Standard: 0.0°
3LN (multiflam): 18.0°
Select IgnitionPosVSD (speed in ignition position, only in conjunction with
frequency converter).
Check IgnitionPosVSD.
50 Hz operation: 80% ≙ 40 Hz
55 Hz Operation: 72.7%≙ 40 Hz
83054802 1/2015-07 MaW 166-228

7 Commissioning

Select ProgramStop.
Select 36 IgnPos.
Use [esc] key to return to the display with OilSettings.
of burner.
Standard: 2.5 … 5.0 mbar
3LN (multiflam): 4.0 … 8.0 mbar
Select OilSettings
Select IgnitionPos.
4. Check pump pressure

The pump pressure in ignition position must be approx. 1 to 2 bar less than that of
the full load pressure listed in the 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
5. Ignition
Set Program stop to 44 Interv 1
The burner ignites and the stepping motors stop in the ignition position.
Determine combustion values at ignition position.
Set O2 content of approx. 5 % by positioning the oil quantity regulator (Igni
tionPosOil) whilst observing the return pressure:
Fuel oil EL: min 8 bar
Heavy oil: min 12 bar
83054802 1/2015-07 MaW 167-228

7 Commissioning

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 %.

Select CurveParams and CurveSet.
Press [ENTER] key.
Point 1 has been factory preset to a specific oil throughput, see burner data sheet.
Only in conjunction with O2 trim

To ensure O2 trim is possible across the entire load range, point 1 must be approx.
50 % below partial load (point 2).
Excess air in all load points must be 20 … 25 %.
Press [ENTER] key.

Select Change point?.
Select Actuator positions with start.
Call up and change values with dial knob and [ENTER] key.

Reduce speed (VSD) step by step, whilst observing the combustion values and
adjust via air damper setting (Air). The minimum speed (see table) must be
maintained:
Burner ver- Minimum speed

sion Pump driven separately Pump on burner motor
NR 50 % 70 %
LN, 1LN, 3LN 60 %
Exit point 1 using [esc] key and save with [ENTER] key.
Press [esc] key.
In menu Point all load points can be adjusted.
In menu point Manual the current burner rating can be adjusted manually.
the soot limit is reached,
Correct combustion values via oil quantity regulator position (Burn).
Exit setting using [esc] and save with [ENTER].
Exit load point using [esc].
83054802 1/2015-07 MaW 168-228

7 Commissioning
7. Adjust full load

When adjusting, the ratings data given by the boiler manufacturer and the capacity
graph of the burner should be observed.
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.
If the burner is equipped with an adjustable mixing head:
Set auxiliary actuator for mixing head (Aux1) to diagram, see installation and op-
erating manual of burner.
Adjust combustion values and, if necessary, speed (VSD) alternately via air
damper setting (Air).
Depending on the burner observe:
Mixing head position
Mixing pressure

Whilst observing the the combustion values and flame stability, keep speed as low
as possible, but not less than 80%.

Only in conjunction with flue gas recirculation

If the burner is later operated with flue gas recirculation, the recirculated flue gas
reduces the excess air.
Set excess air 25 % above the combustion limit to ensure sufficient combustion air
during the commissioning of flue gas recirculation.
Set excess air 25 % above the combustion limit.
The pump pressure must not be altered once this work has been completed.
Drive to point 1 in menu Point, whilst observing the combustion values.
Check combustion values and correct if necessary.

the required partial load.
83054802 1/2015-07 MaW 169-228

7 Commissioning

Delete all load points except for point 1 and full load (Load: 100).

Starting at point 1, set new load points until full load is achieved.


Increase burner rating in menu Manual, whilst observing combustion values.

Set new intermediate load point using [ENTER] key.
Optimise combustion at intermediate load point via air damper setting (Air).
If the burner is equipped with an adjustable mixing head, the combustion can be
optimised by utilising the interaction between air damper (Air) and Mixing head
(Aux1).

Define partial load

Select LoadLimits.
Select MinLoad.
Define and set partial load whilst:
Observe data provided by boiler manufacturer.
Maintain return pressure:
Fuel oil EL: min 8 bar
Heavy oil: min 12 bar
Observe burner capacity graph.
83054802 1/2015-07 MaW 170-228

7 Commissioning

Set Automatic.
If necessary set load controller and nd O2 trim.
13. Data backup

83054802 1/2015-07 MaW 171-228

7 Commissioning
7.2.4 Adjust multi-stage oil side

When using a frequency converter please note:
Ignition speed should be 100 %.
It is recommended that the speed at the on and off switch points is 100 %
Speed at operating point BS1 (and BS2 on three stage version) 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 for fuel oil EL

Open oil shut off devices.
Prerequisite for medium and heavy fuel oil
Danger of getting burned on oil carrying components

The oil carrying components are heat up by the line heating and hot oil and could
cause burns if touched.
DANGER Do not touch the components.
Observe the enclosed installation and operating manual for the oil preheater (Print
No.18).
the oil supply is vented,
all oil shut off devices are open,
the oil supply has been preheated,
ring main pressure and oil flow is available.
Configure parameter C118 at the temperature regulator DR100 to wiring dia-
gram specification and set setpoints (only in conjunction with oil preheater type
WEV…).
Commission oil preheater.
1. Select target rating

Target load is the load, which is started in manual operation with Manual.
Select SetLoad.
Set S1.
2. Check presetting of points

Select OilSettings.
Select Stepping motor positions Without Start.
Check presetting of points and adjust if necessary.
Value for operating points and on and off switch points see installation and operat-
ing manual of burner.
Use [esc] key to return to the display with CurveParams.
83054802 1/2015-07 MaW 172-228

7 Commissioning

Select ProgramStop.
Select 36 IgnPos.
Use [esc] key to return to the display with OilSettings.
of burner.
Select OilSettings
Select IgnitionPos.

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
5. Ignition
Set Program stop to 44 Interv 1
The burner starts and the stepping motor stops in ignition position.
Determine combustion values in ignition position.
Set O2 content of approx. 5 % via air damper setting (IgnitionPosAir) whilst
observing the mixing pressure.
6. Pre-set points
Select Actuator positions With Start.
Do not start switch-off points AS2 and AS3 , as this can lead to a deficiency of
air.
83054802 1/2015-07 MaW 173-228

7 Commissioning
7. Preset operating point BS1

Select BS1 with [ENTER].
The burner drives to operating point BS1.
Check combustion values and, if necessary, adjust via air damper setting (Air).
Exit BS1 using [esc] key and save with [ENTER] key.
8. Preset switch-on point ES2

Select ES2.
Set excess air (O2 content approx. 7 %) whilst observing flame stability.
For two stage burners only

Two stage burners do not have a switch-on point ES3 and no operating point BS3.
Operating point BS2 is full load and should be adjusted as full loaf point BS3 (full
load).
9. Pre-set operating point BS2

Select BS2.
Valve for nozzle 2 opens.
10. Pre-set switch-on point ES3

Select ES3.
Set excess air (O2 content approx. 7 %) whilst observing flame stability.
11. Adjust operating point BS3 (full load)

Select BS3.
Valve for nozzle 3 opens.
Determine oil throughput and if necessary adjust pump pressure.
Use [esc] key to return to the display CurveSet.
12. Define switch-off points AS2 and AS3

In menu CurveSet select option Without start.
Select switch-off point AS2.
Set air damper setting in switch-on point ES2 .
Select switch-off point AS3.
Set air damper setting in switch-on point ES3 .
Use [esc] key to return to the display CurveSet.
83054802 1/2015-07 MaW 174-228

7 Commissioning
13. Optimise operating points BS1 and BS2

Once full load has been adjusted and the pump pressure has been set to its final
value, the operating points should be optimised.
In menu CurveSet select option With start.
Select BS1.
Select BS2 and also adjust.
14. Check switch points

Activate operating points several times and observe switch-over behaviour.
If necessary optimise operating behaviour:
Adjust switch-off point in menu Without start whilst increasing the air
damper setting to avoid soot and CO formation
Adjust switch-on points in menu With start


Set Automatic.
Use [esc] key to return to the display with Param & Display.
Select SetLoad.
Set highest stage as the target load.
If necessary adjust load controller.
17. Data backup

83054802 1/2015-07 MaW 175-228

7 Commissioning
7.3 Load controller

7.3.1 Configure load controller
1. Enter password
2. Set operating mode

Select LoadController.
Select LC_OptgMode.
Set operating mode for the internal or external load controller using dial knob
and confirm with [ENTER] [ch. 6.12.2].
Use [esc] key to return to the display LC_OptgMode.
3. Define sensors
For operating mode with internal load controller and temperature monitor function,
the connected sensors must be defined [ch. 3.3.20].
Select Sensor Select.
Define connected sensor with the dial knob and confirm with [ENTER]
[ch. 6.12.3].
Use [esc] to return to the display Sensor Select.
To ensure the actual value is entered correctly, the measuring range of the sensors
must be defined [ch. 6.12.5].
Select menu for the sensor defined and confirm with [ENTER].
Sensor: MeasureRangePtNi / var.RangePtNi
Temperature sensor: MRange TempSens
Pressure sensor: MRange PressSens
Set end of measuring range using dial knob and confirm with [ENTER].
Use [esc] to return to the menu.
If a sensor is connected, input X61 has to be matched to the sensor [ch. 6.12.4].
Select Ext Inp X61 U/I.
Set analogue signal from the sensor.
Use [esc] to return to the display Ext Inp X61 U/I .
4. Configuring analogue input X62

If an analogue setpoint or load signal is present at input X62, the input must be
matched to the signal [ch. 6.12.4].
Select Ext Inp X62 U/I.
Match input to the analogue signal.
Use [esc] to return to the display Ext Inp X62 U/I .
83054802 1/2015-07 MaW 176-228

7 Commissioning
5. Limit external setpoint

It is possible to define limits for the setpoint for the operating mode with external
setpoint.
With an analogue setpoint signal the limit value relates to the measuring range set
[ch. 6.12.6].
Select Ext MinSetpoint or Ext MaxSetpoint .
Set the limit value using the dial knob and confirm with [ENTER].
Use [esc] to return to the menu.
6. Determine internal setpoint

Two setpoints can be set for the operating mode with internal load controller
[ch. 6.12.1].
Select ControlParam.
Select SetpointW1 .
Set setpoint using the dial knob and confirm with [ENTER].
Use [esc] to return to the display ControlParam.
If the second setpoint W2 is required:
Repeat procedure for SetpointW2.
7. Temperature sensor function

With an activated temperature monitor, the switch threshold and switch-on hyster-
esis can be set [ch. 6.12.13].
Select TempLimiter.
Select TL_ThreshOff.
Set threshold using the dial knob and confirm with [ENTER].
Use [esc] to return to the display TL_ThreshOff .
Select TL_SD_On.
Set switch-on hysteresis using the dial knob and confirm with [ENTER].
Use [esc] to return to the display TempLimiter.
83054802 1/2015-07 MaW 177-228

7 Commissioning
7.3.2 Adjust load controller
7.3.2.1 Modulating load control
1. Set switch differentials

The switch differentials determine the on and off switch point [ch. 6.12.11].
rent setpoint.
Set switch-on point (controller ON):
Select Sd_ModOn.
Set switch differential using the dial knob and confirm with [ENTER].
Use [esc] to return to the display Sd_ModOn .
Set switch-off point (controller OFF):
Select Sd_ModOFF.
2. Determine controller parameters

The control parameters can be determined in two ways:
An automatic adaption identifies the controlled system and forms the PID
parameters [ch. 6.12.15].
One PID parameter set can be selected from five standard parameter sets
[ch. 6.12.8].
Identifying the controlled system via adaption:
Select SW_FilterTmeCon using the dial knob and confirm with [ENTER].
The filter time must be 2 … 4 seconds [ch. 6.12.10].
Select Adaption .
Select AdaptionLoad.
Check adaption load and adjust if necessary.
If possible, the adaption load should be 100 % [ch. 6.12.15].
Use [esc] to return to the display AdaptionLoad.
Select StartAdaption using dial knob and confirm with [ENTER].
The display shows Start adaption with ENTER.
Confirm with [ENTER].
Adaption starts, the display shows the individual phases:
Temp setback
Stabilisation phase
Heating
Adaption ok
Use [esc] to return to the display Adaption.
Select PID parameter set immediately:
Select ContrlParamList.
SelectStandardParam .
Select PID parameter set using dial knob and confirm with [ENTER] [ch. 6.12.8].
Use [esc] to return to the display StandardParam.
83054802 1/2015-07 MaW 178-228

7 Commissioning
3. Edit controller parameters

The PID parameters can be edited individually and the control behaviour can be
optimised [ch. 6.12.8].
Observe control behaviour over a longer period and optimise if necessary.
Select P, I or DPart.
Change values using the dial knob and confirm with [ENTER] [ch. 6.12.8].
Use [esc] to return to the display ContrlParamList.
4. Check fault signal suppression

Select SW_FilterTmeCon.
Check filter time [ch. 6.12.10]:
Temperature sensor (Pt100): 2 … 4 seconds
pressure sensor (steam plant): 6 … 8 seconds
7.3.2.2 Modulating load control
1. Set switch differentials

The switch differentials determine the on and off switch points [ch. 6.12.12.1].
rent setpoint.
Set switch-on point (controller ON):
Select Sd_Stage1On .
Use [esc] to return to the display Sd_Stage1On .
Set switch-off point stage 1 (controller OFF):
Select Sd_Stage1Off.
Use [esc] to return to the display Sd_Stage1Off.
Set switch-off point stage 2:
Set switch-off point stage 3:
2. Set switch thresholds

The switch threshold specifies from which control deviation the W-FM activates the
next stage [ch. 6.12.12.2].
Set switch threshold stage 2:
Select ThreshStage2On .
Use [esc] to return to the display ThreshStage2On .
Set switch threshold stage 3:
Select ThreshStage3On .
83054802 1/2015-07 MaW 179-228

7 Commissioning
7.3.2.3 Boiler cold start function

The boiler cold start function reduces the thermal load of the boiler during burner
start [ch. 6.12.14].
1. Activate boiler cold start function

Select ColdStart.
Select ColdStartOn.
Select activated using the dial knob and confirm with [ENTER].
Use [esc] to return to the display ColdStartOn.
2. Define additional sensor

Only if an additional sensor for boiler cold start function is connected (e. g.
steam plant):
Select AdditionalSens.
Define the sensor connected with the dial knob and confirm with [ENTER].
Use [esc] to return to the display AdditionalSens.
Select Setp AddSensor.
Set setpoint using the dial knob and confirm with [ENTER].
Use [esc] to return to the display Setp AddSensor.
3. Set switch thresholds

The switch thresholds relate to the current setpoint or if an additional sensor is
connected to Setp AddSensor.
ON threshold:
Select ThresholdOn .
Use [esc] to return to the display ThresholdOn .
OFF threshold:
Select ThresholdOff.
Use [esc] to return to the display ThresholdOff.
4. Set StageLoad
Determines the load increase in modulating operation.
Select StageLoad.
Set StageLoad using the dial knob and confirm with [ENTER].
Use [esc] to return to the display StageLoad.
83054802 1/2015-07 MaW 180-228

7 Commissioning
5. Set setpoint step

For modulating operation:
Select StageSetp_Mod.
Set setpoint step using the dial knob and confirm with [ENTER].
Use [esc] to return to the display StageSetp_Mod.
For multi-stage operation:
Select StageSetp_Stage.
Use [esc] to return to the display StageSetp_Stage.
6. Set residence time

For modulating operation:
Select MaxTmeMod .
Use [esc] to return to the display MaxTmeMod.
For multi-stage operation:
Select MaxTmeStage.
Use [esc] to return to the display MaxTmeStage.
7. Data backup
83054802 1/2015-07 MaW 181-228

7 Commissioning
7.4 O2 controller
O2 trim is only possible in modulating operation with W-FM 200 with O2 module.
O2 trim is fuel specific and must be set separately for each fuel on dual fuel burn-
ers.
Moisture in the O2 sensor.

With new sensors or if the sensor has been switched off for extended periods,
moisture may form in the sensor and distort the measured value. A longer heat-up
process through the internal sensor heating displaces this moisture.
Heat up the sensor prior to adjusting the O2 trim.
7.4.1 Set O2 monitor

The O2 limit values are defined in the O2 alarm [ch. 6.10.2].
The operating mode of O2 trim must be set to man deact .
1. Select fuel
Select O2 Contr/Alarm.
Select O2 Alarm and confirm with [ENTER].
2. Set O2 minimum monitor

An O2 MinValue has to be defined as the lower limit in each load point, either
by:
driving to combustion limit and take over the value determined,
direct input, only possible if the O2 minimum value at the combustion limit is
already known.
Only in conjunction with CO control

Determine the combustion limit using the CO measurement amplifier whilst ob-
serving flue values in the reference measuring device.
Set O2 minimum monitor to approx. 0.25 … 0.5 percentage points below the com-
bustion limit.
Driving to combustion limit and take over the value determined:

Select O2 Alarm.
Select PAir Manual and confirm with [ENTER].
point.
Reduce air rating using the dial knob until the combustion limit is reached
(CO content approx. 100 ppm or smoke number approx. 1).
Press [ENTER] to accept the O2 actual value.
The display shows the value determined as O2 MinValue.
Note down O2 MinValue and load point, required in the later stages.
Repeat procedure in each load point.
Use [esc] to return to the display O2 Alarm.
Direct entry:
Select O2 Alarm.
Select O2 MinValue and confirm with [ENTER].
Use [esc] to return to the display O2 Alarm.
83054802 1/2015-07 MaW 182-228

7 Commissioning
7.4.2 Set O2 trim

Standardised values must be defined for O2 trim from a pre-determined load point
[ch. 6.10.3].
1. Select fuel
2. Define O2 setpoints
The setpoint for O2 trim should be approx. 0.5 … 1 %point above the O2
MinValue of the O2 monitor.
The O2 value in the load points of the compound curve should be approx.
2 % points above the setpoint for O2 trim.
Select O2 Control and confirm with [ENTER].

Burner drives to load point.
Once the O2 content has stabilised confirm with [ENTER].
Turn dial knob to the right.
The air influencing actuators drive open on the compound curve, reduce the air
quantity and thus the O2 content.
The O2 Setpoint should be approx. 0.5 … 1 % points above the 02
MinValue at the combustion limit.
Confirm standardised value with [ENTER].
In the load point set under LowFireAdaptPtNo and the last load point (full
load) the W-FM carries out an adaption.
If the measurement fails in the specified load point, select the next higher load
point [ch. 6.10.4].
Carry out standardisation in all points, point 2 to full load.
83054802 1/2015-07 MaW 183-228

7 Commissioning
7.4.3 Check and optimise O2 trim
1. Bridge load control

In order to monitor the O2 value via display and operating unit, the load must be in-
fluenced manually via an external signal (e. g. 3 pole switch at input X5-03).
It is preferential to monitor O2 trim with software ACS450.
Switch off burner and isolate W-FM from voltage supply.

Connect 3 pole switch to input X5-03.
Switch on voltage supply.
Set load controller operating mode to ExtLC X503, see [ch. 6.12.2].
Use [esc] to return to the display LoadController.

Select current fuel GasSettings or OilSettings.
Select OptgMode.
Set conAutoDeac using the dial knob and confirm with [ENTER].
Use [esc] to return to the display Param & Display.

Set Automatic using dial knob and confirm with [ENTER].
Use [esc] to return to the display Autom/Manual/Off.
Use [info] to return to OperationalStat.
Select NormalOperation.
4. Check O2 trim
Close control circuit and drive to full load via 3 pole switch.
Check control behaviour whilst monitoring O2 value in the display and operating
unit.
The burner drives on the compound curves to full load.
Once the O2 sensor has reached operating temperature and the blocking time
has elapsed, the W-FM goes to pre-control [ch. 6.10].
Only the air influencing actuators are operating, the fuel actuator remains in its
position and the O2 actual value approaches the O2 setpoint.
If O2 setpoint is not reached via the pre-control, O2 trim reacts and controls the
O2 actual value.
Change load using the 3 pole switch.
O2 trim is suspended and the burner drives to the new load.
Pre-control is activated and the compound almost maintains the O2 setpoint.
If no changes were made to the load before the blocking time has elapsed, O2
trim is activated and controls the O2 actual value.
Drive through the entire load range and monitor the control behaviour.
If necessary, optimise O2 trim via the settings in menu ControlParam, see
[ch. 6.10.4].
83054802 1/2015-07 MaW 184-228

7 Commissioning
Observation Action
O2 actual value fluctuates, at constant Change parameter PI see [ch. 6.10.4].
load In the lower load range:
Increase I LowFire
or
reduce P LowFire .
In the upper load range:
Increase I HighFire
or
decrease P HighFire.
O2 sensor reacts very slowly to Increase O2 regulating limit [ch. 6.10.4].
changes in the O2 content in the flue
gas.
O2 trim remains suspended, despite a Check status of O2 controller
prolonged period of constant load. [ch. 6.10.13].
Increase parameter LoadCtrlSus
pend, see [ch. 6.10.4].
O2 monitor reacts to load change. Check setting of O2 monitor [ch. 7.4.1].
Increase parameter O2ModOffset .
5. Set flue gas temperature warning threshold

Drive to full load.
Check flue gas temperature
Select O2 Module.
Select MaxTempFlGas… .
Set threshold 20 % above the measured temperature using the dial knob and
confirm with [ENTER].
6. Next fuel (dual fuel burners only)

In modulating operation for both fuels:
Repeat setting for second fuel [ch. 7.4.1].
83054802 1/2015-07 MaW 185-228

7 Commissioning
7.5 CO controller
Additional information
Refer to the manual of the measuring amplifier LT 3 and combination sensor KS1-D
prior to commissioning.
The manual is available to download from the -w- Portal.
The release of level 2 in the measuring amplifier is password protected.

Password: 8F3W
7.5.1 Set measurement amplifier LT3

The handheld operating unit is required for the settings on the measurement ampli-
fier LT3. For detailed information, see instructions Lambda Transmitter LT3 and
combination sensor KS1-D.
Setting the language:
Select language in main menu F3.
Enter password:
Select Enter Password in main menu F3.
Enter password 8F3W and confirm.
Set CO limit value:
Select Config LimitValue in main menu F3.
Select Config LimitValue 1.
Select LV fuel 1 .
Select Config fixed value and set 100 ppm .
Return to main menu F3
Set standby position of digital output 3 (Out3):
Select Digital Outputs in main menu F3.
Select Digital Output 3 .
Select Standby and set activated .
Return to main menu F3
Set trip delay for CO limit value:
Select Config LimitValue in main menu F3.
Select Config LimitValue 1.
Select Trip delay and set 03 s.
Return to main display.
83054802 1/2015-07 MaW 186-228

7 Commissioning
7.5.2 Set CO control

Commissioning of the O2 controller must be completed for the CO control.
1. Define combustion air sensors

Select O2 Module.
Select SupAirTempSens.
Select Pt1000 using dial knob and confirm with [ENTER].
2. Set flue gas temperature warning threshold

SelectMaxTempFlueGas … .
Set 850 °C using dial knob and confirm with [ENTER].
Use [esc] to return to the display O2 Module.
On dual fuel burners, set both MaxTempFlGasGas and MaxTempFlGasOil.
3. Set blocking time

To ensure that an increased CO content during burner start does not initiate a
safety shutdown, the factor for the blocking time must be set to a minimum of 10
[ch. 6.10.5].
Select NumberTauSuspend.
Set a minimum of 10 using dial knob and confirm with [ENTER].
Use [esc] to return to the display O2 Module.
On dual fuel burners repeat procedure.
83054802 1/2015-07 MaW 187-228

7 Commissioning
7.6 Flue gas recirculation (temperature compensated)
Prerequisite
the burner was initially adjusted with FGR damper closed,
excess air in each load point without FGR is approx. 25 %,
the FGR sensor is connected and defined.
1. Enter password

Select Flue Gas Recirc..
Select FGRMode.
Set operating mode TCautoDeact using dial knob and confirm with [ENTER].
Use [esc] key to return to the display FGRMode.
3. Set release time

The time depends on the the warm-up phase of the plant [ch. 6.15.5].
Select DelaytimeFGR … for the relevant fuel.
Set operating mode 60s using dial knob and confirm with [ENTER].
Use [esc] to return to the display Flue Gas Recirc .
4. Set recirculated flue gas quantity

Select CurveParams.
Press [ENTER] key.
Press [ENTER] key.
Select Actuator positions With Start.
Select Aux3 using dial knob and confirm with [ENTER].
The display shows the current temperature at the FGR sensor under FGRT .
Once the temperature and the NOX value in the load point have stabilised, the re-
circulated flue gas quantity can be set.
Open the flue gas damper (Aux3) using the dial knob whilst monitoring combus-
tion values (excess air min 15 %) and flame stability.
Confirm with [ENTER] when:
the required NOX value has been reached,
the FGR temperature is stable.
Exit point using [esc] and save with [ENTER].
The recirculated flue gas quantity dependents on the position of the FGR damper
and the negative pressure in the FGR connector housing. If the recirculated flue
gas quantity is insufficient, increase the negative pressure in the FGR connector
housing [ch. 6.15.1].
83054802 1/2015-07 MaW 188-228

7 Commissioning
5. Next fuel (dual fuel burners only)

In modulating operation for both fuels:
Repeat setting for second fuel.
83054802 1/2015-07 MaW 189-228

7 Commissioning
7.7 Set pressure switches

Observe chapter 'Set pressure switches' in the installation and operating manual of
the burner.
Air pressure switch for variable speed drive and O2 trim

On burners with variable speed drive and O2 trim the air pressure switch is set dif-
ferently to the standard method.
O2 trim regulates the O2 content in the flue gas via the combustion air quantity. This
facilitates positions below partial load for the air influencing actuators. To determine
the lowest differential pressure, the burner must drive to the combustion limit in
point 2.
On dual fuel burners carry out the setting with fuel Gas.
Call up function O2 Alarm, see [ch. 6.10.2].
Select menu O2 Alarm and confirm with [ENTER].
Select load point 2 using dial knob and confirm with [ENTER] key.
Select parameter PAir Manual and confirm with [ENTER].
point.
Rotate setting cam on air pressure switch to the right, until the W-FM triggers a
lockout.
Turn back setting cam by approx. 1 mbar.
7.8 Concluding work

Observe chapter Concluding work in the installation and operating manual of the
burner.
83054802 1/2015-07 MaW 190-228

7 Commissioning
7.9 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.
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 rating in partial load to avoid condensation in the flue gas
ducts, except on condensing units.
Reduce burner rating 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
83054802 1/2015-07 MaW 191-228

7 Commissioning
7.10 Calculate gas throughput

Formula symbol Explanation Example values
VB Operating volume in m3/h -
Volume measured at gas meter at current pressure and
temperature (gas throughput).
VN Standard volume in m3/h -
Volume gained by gas at 1013 mbar and 0 C.
f Conversion factor -
QN Heat rating in kW 6000 kW
η Boiler efficiency (e. g. 92 % ≙ 0.92) 0.92
Hi Calorific value in kWh/m3 (at 0 °C and 1013 mbar) 10.35 kW/m3 (Natural Gas
E)
tGas Gas temperature at gas meter in °C 10 °C
PGas Pressure at gas meter in mbar 250 mbar
PBaro Barometric air pressure in mbar, see table 500 m ≙ 955 mbar
VG Gas throughput determined at gas meter 18.2 m³
TM Time measured during gas throughput (VG) 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 = = 549.1 m³/h
f 0.933
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
83054802 1/2015-07 MaW 192-228

7 Commissioning
7.11 Ratings apportionment

The load points are automatically assigned relative to the capacity. Incorrect load
distribution can cause operating problems during the load control.
Assign rating in % for load point to the following formula.
Enter the calculated capacity for load point in Load.
Throughput load point

Load [%] = 100
Throughput full load
83054802 1/2015-07 MaW 193-228

8 Servicing
8 Servicing
8.1 Notes on servicing
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.
Tightly close the screws on the test points ensuring the tests points are sealed.

Isolate the device from the power supply prior to starting any work.
DANGER Safeguard against accidental re-start.
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.
will be exceeded prior to the next service should be replaced as a precaution
[ch. 8.2].
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 (stepping motor)
gas valve
oil solenoid valve,
nozzle shut off (closing 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.
83054802 1/2015-07 MaW 194-228

8 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
safety interlock circuit.
Check combustion values, if necessary re-adjust the burner.
Enter combustion values and settings in the commissioning record and/or test
sheet.
8.2 Service plan

For detailed information see installation and operating manual of burner.
83054802 1/2015-07 MaW 195-228

9 Troubleshooting
9 Troubleshooting
9.1 Procedures for fault conditions

Check prerequisites for operation:
Voltage supply available
Heating switch is set to On.
Temperature regulator or pressure regulator on heat exchanger has been set
correctly.
Boiler or heating circuit control is functioning and set correctly.
The combustion manager recognises irregularities of the burner and displays these
on the display and operating unit.
The following conditions can occur:
Fault
Lockout
Resetting
OperationalStat Status/Reset
The display and operating unit alternately shows the shutdown behaviour and the
fault diagnosed as a plain text display.
Damage resulting from incorrect servicing

The combustion plant could be damaged.
Do not carry out more than 2 lockout resets successively.
CAUTION Faults must be rectified by qualified personnel.
If the ABE displays a fault:

If the [esc] key has been pressed twice, reset can only be carried out via the menu.
Select OperationalStat.
Select Status/Reset.
Current lockout is displayed.
Via reset key on input X4-01:4:
Press reset 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.
83054802 1/2015-07 MaW 196-228

9 Troubleshooting
9.1.1 Deactivating an alarm

OperationalStat Alarm act/deact
Parameter Alarm act/deact deactivates or activates the alarm output
X3-01:2.
A reset or a burner start automatically resets the deactivation and the alarm output
is ready for use again.
83054802 1/2015-07 MaW 197-228

9 Troubleshooting
9.2 Fault
If a fault occurs, the combustion manager initiates a controlled shutdown.
Example
Safety loop
Safety is open
shutdown
The burner restarts automatically as soon as the fault condition has been rectified.
Fault history
OperationalStat FaultHistory
Parameter FaultHistory alternately shows the last 21 faults as plain text or
diagnostic display [ch. 9.4].
Select History using dial knob and confirm with [ENTER].
Browse history with the dial knob.
The display changes every 5 seconds between plain text and diagnostic display.
The [ENTER] key can be used to manually change the display.
Exit History using [esc] key.
Normal operation
Status/Reset
Fault history
Lockout1 history
Class:00 Oil 5 sec Safety loop
Code:21 Phase:24 is open
Diag:00 Load: 100
Start No. 18
21 Class:00 Oil
Code:26 Phase:60
Diag:00 Lst:42.5
Start No. 1232
The diagnostic display provides information about:

Fault number (1 … 21)
Fault class (Class:)
Current fuel when fault occurred (Oil or Gas)
Fault code (Code:)
Operating phase when fault occurred (Phase:)
Diagnostic code (Diag:)
Load setting or stage when fault occurred (Load:)
Number of burner starts (Start No.)
83054802 1/2015-07 MaW 198-228

9 Troubleshooting
9.3 Lockout
If a lockout condition occurs, the combustion manager initiates a fault shutdown
and burner lockout.
Once the fault has been rectified, the combustion manager has to be reset for re-
start.
Example
Air pressure is
Lockout off
Lockout history
OperationalStat LockoutHistory
Parameter LockoutHistory alternately displays the last 9 faults as plain text or
diagnostic display [ch. 9.4].
Select History using dial knob and confirm with [ENTER].
Browse history with the dial knob.
The display changes every 5 seconds between plain text and diagnostic display.
The [ENTER] key can be used to manually change the display.
Exit History using [esc] key.
Normal operation
Status/Reset
Fault history
Lockout history
1 01.04.15 13:22 5 sec Air pressure is
C:28 D:00 P:62 off
Start No. 22
Load:79.6 Gas
9 06.11.15 08:15
C:31 D:00 P:81
Start No. 4711
Load:25.0 Gas
The diagnostic display provides information about:

Fault number (1 … 21)
Date when fault occurred (dd.mm.yy)
Time when fault occurred (hh.mm)
Fault code (C:)
Diagnostic code (D:)
Operating phase when fault occurred (P:)
Number of burner starts (Start No.)
Load setting or stage when fault occurred (Load:)
Current fuel when fault occurred (Oil or Gas)
83054802 1/2015-07 MaW 199-228

9 Troubleshooting
9.4 Rectifying faults

Fault Diagnostic Cause Rectification
codes code
01 01 ROM error Internal fault(1
02 01 … 07 RAM error Internal fault(1
03
^^
01 … 60 Error during internal data comparison Internal fault(1
04
^^
– Synchronisation error Internal fault(1
05 01 … 03 Error flame signal amplifier test Check electrical connection
^^
Replace flame sensor.
06
^^
01 … 04 Error internal hardware test Internal fault(1
10 01 … 1B Error on input or output The diagnostic code indicates which input or
output is affected.
01 Load controller external on / off Check neutral conductor to W-FM.
02 Fan contactor contact Check electrical connection
Check if a capacitive load is connected.
03 Fuel selection Oil A fault could be triggered if the internal
04 Fuel selection Gas relay switches off and the capacitive load
05 Reset delays the voltage drop by 10 ms.
06 Maximum oil pressure switch Internal fault(1
07 Minimum oil pressure switch * Depending on the operating phase an im-
08 Valve proving gas pressure switch permissible voltage signal is present at the
corresponding output. This could be
09 Anti syphon valve / safety valve Oil SV return triggered by reverse voltage caused by an
signal X6-03* operating signal (e. g. during a lamp test).
0A Fuel valve Oil V1 return signal
X8-02 / X8-03*
0B Fuel valve Oil V2 return signal X7-01*
0C Fuel valve Oil V3 return signal X7-02*
0D Safety valve Gas SV return signal X9-01:1*
0E Fuel valve Gas V1 return signal X9-01:4*
0F Fuel valve Gas V2 return signal X9-01:3*
10 Ignition gas valve PV return signal X9-01:2*
11 Safety circuit, burner flange limit switch
12 Internal safety relay return signal
13 Low gas pressure switch
14 High gas pressure switch
15 Ignition return signal
16 Air pressure switch
17 Start release Oil
18 Heavy oil immediate start
19 External load controller open
1A External load controller closed
^^
1B Start release Gas
11 01 Contact return signal network short circuit Internal fault(1
€€
(1
If occurring sporadically: Optimise EMC measures. If occurring continuously replace defective component.
83054802 1/2015-07 MaW 200-228

9 Troubleshooting

codes
^^
code
15 03 … 7F Actuator position or speed not achieved If several faults occur, the diagnosis codes
are add up.
01 Position error air actuator Check mechanics after the actuator for
02 Position error fuel actuator freedom of movement.
04 Position error auxiliary actuator1 Internal fault(1
08 Position error auxiliary actuator2
20 Position error auxiliary actuator3
10 Speed not achieved Check ramp time [ch. 6.9.1].
40 Speed difference between setpoint and ac- Check signal line between W-FM and fre-
tual has exceeded tolerance quency converter.
Check signal line of speed measurement
[ch. 3.3.21].
^^
Check speed standardisation [ch. 6.14.3].
16 00 Fault compound curve air actuator Check compound curve of relevant actu-
01 Fault compound curve fuel actuator ator, if necessary adjust [ch. 6.9.5].
02 Fault compound curve auxiliary actuator1
05 Fault compound curve frequency converter
0A P- part outside of permissible range Check O2 control parameters, if necessary
0B I- part outside of permissible range adjust [ch. 6.10.4].
0C Tau outside of permissible range
0D O2 setpoint outside of permissible range Check values, if necessary readjust O2
0E O2 min value outside of permissible range trim [ch. 6.10.2].
0F O2 compound value outside of permissible
range
13 Presetting of ABE outside of permissible Internal fault(1
range
14 Standardisation value outside of permissible Check values, if necessary readjust O2
range trim [ch. 6.10.2].
20 Exceeding permissible setpoint position Internal fault(1
range
21 Presetting of ABE outside of permissible
range
22 None of the def. cases were met during
switch instruction
23 No defined ELR phase detected during
switch instruction
^^
40 Implausible setpoint position
17 01 Timeout during program run synchronisation Internal fault(1
prior to data transfer
02 Timeout during data transfer
03 CRC error during data transfer
3F Difference detected during data comparison.
€€
(1
83054802 1/2015-07 MaW 201-228

9 Troubleshooting

codes
^^
code
18 – Invalid value in a compound curve Check compound curves.
Valid load range: 0 … 100 %
Valid position range: 0 … 90°
Valid speed range: 0 … 100 %
During initial commissioning:
Correct value.
After previously correct operation:
^^
Replace W-FM.
19 01 … 2F Actuator error during comparison between If several faults occur, the diagnosis codes
potentiometer channel A and B are add up.
01 Air actuator fault Set allowed Pot.diff to 15, see
02 Fuel actuator fault [ch. 6.13.3].
Check CAN Bus connection [ch. 5].
04 Auxiliary actuator1 fault
Internal fault(1
^^
1A 1 Curve gradient between two load points too Change load assignment in the load
great. points to fall below the maximum permiss-
Maximum permissible gradient at 0.1 % load ible gradient [ch. 6.9.5].
change:
3.6° (with 30 s ramp time)
^^
1B – The burner shuts down during the setting of Set compound curves in Manual op-
the compound curves due to lack of heat de- erating mode [ch. 6.7].
mand. Prevents shutdown by the load controller.
Shutdown only occurs if the temperature
monitor responds. The current load point
^^
being adjusted can still be saved.
1C 01 … 3F Ignition position for the relevant actuator is
If several faults occur, the diagnosis codes
missing. are add up.
01 Air actuator ignition position missing Set ignition position [ch. 6.9.4].
02 Fuel actuator ignition position missing
04 Auxiliary actuator1 ignition position missing
10 Frequency converter ignition position miss-
ing
^^
1D 01 … 3F Run time fault actuators / frequency con- If several faults occur, the diagnosis codes
verter are add up.
01 Air actuator run time fault Check mechanics after the actuator for
02 Fuel actuator run time fault freedom of movement.
Check actuator voltage supply.
04 Auxiliary actuator1 run time fault Check actuator ramp time [ch. 6.9.1].
08 Auxiliary actuator2 run time fault Ramp time should not be less slowest ac-
10 Frequency converter run time fault tuator
20 Auxiliary actuator3 run time fault
€€
(1
83054802 1/2015-07 MaW 202-228

9 Troubleshooting

codes
^^
code
1E 01 … 3F At least one actuator has not reached the If several faults occur, the diagnosis codes
specified special position. are add up.
01 Air actuator has not reached the special po- Check mechanics after the actuator for
sition freedom of movement.
02 Fuel actuator has not reached the special Check actuator voltage supply.
position
04 Auxiliary actuator1 has not reached the spe-
cial position
cial position
10 Frequency converter has not reached the
special position
cial position
40 Speed has not reached the special position Check ramp time [ch. 6.9.1].
Check signal line between W-FM and fre-
quency converter.
Check signal line of speed measurement
[ch. 3.3.21].
^^
Check speed standardisation [ch. 6.14.3].
1F 01 Internal test of frequency converter module Internal fault(1
failed
02 Rotational direction of fan incorrect Check rotation direction of motor.
Check transmitter disc for speed
measurement [ch. 3.3.21].
Check rotational direction of frequency
converter.
03 Impulse fault during speed measurement Check transmitter disc and proximity
switch for speed measurement
[ch. 3.3.21].
04 Speed is not stable during speed standard- Check motor.
isation Check transmitter disc and proximity
switch for speed measurement
[ch. 3.3.21].
05 Air actuator has not reached pre-purge posi- Check mechanics after the actuator for
tion freedom of movement.
Check actuator voltage supply.
06 Internal speed test failed Internal fault(1
07 Safety circuit not closed during speed Check safety circuit
^^
standardisation
21
^^
– Safety circuit not closed Check safety circuit
22 – Threshold of temperature monitor exceeded Check temperature of plant.
Check setting of temperature limiter
^^
[ch. 6.12.13].
23
^^
01 … 03 Extraneous light during start-up Find and eliminate extraneous light source
24 01 … 03 Extraneous light during shutdown Check flame sensor
^^
Fuel valves leaking, check.
25 01 … 03 No flame at the end of the safety time Check ignition.
Check burner setting
Check flame sensor
Check fuel valves.
€€
(1
83054802 1/2015-07 MaW 203-228

9 Troubleshooting

codes
^^
code
26 01 … 03 Flame failure during operation Check burner setting
Check fuel supply
^^
Check flame signal [ch. 6.4.7].
27 – Impermissible ON signal from air pressure Check air pressure switch [ch. 3.3.4].
switch Check pressure switch release [ch. 3.4.4].
28 – Impermissible OFF signal from air pressure
^^
switch
29 – Impermissible ON signal from fan contactor Check electrical connection and fan con-
contact tactor contact [ch. 3.3.5].
2A – Impermissible OFF signal from fan contactor Supply for contactor contact X3-02:1
^^
contact
2B – Impermissible ON signal from FGR air pres-
^^
sure switch
2C – Impermissible OFF signal from FGR air pres-
^^
sure switch
2D – Impermissible ON signal at input start re-
^^
lease Gas
2E – Impermissible OFF signal at input start re-
^^
lease Gas
2F – Low gas pressure switch has reacted Check gas connection pressure.
30
^^
– High gas pressure switch has reacted Check gas pressure switch
31 – Valve proving gas pressure switch has re- Check gas pressure switch
acted, contact open, V1 leaking or V2 does Check double gas valve
not open.
32 – Valve proving gas pressure switch has
dropped out, contact closed, V2 or ignition
^^
gas valve leaking or V1 does not open.
33 – Unexpected oil pressure, min. oil pressure
switch has triggered, contact closed
34 – Min. oil pressure switch has not reacted, Check pump pressure.
contact open Check oil supply
35 – Max. oil pressure switch has triggered, con- Check min. oil pressure switch.
^^
tact closed
36
^^
– No signal at input start release Oil [ch. 3.3.9]
37 – No signal at input heavy oil immediate start
^^
[ch. 3.3.10]
38
^^
– Low gas programme activated Check gas connection pressure.
39
^^
– Internal safety time error
3A – No burner identification is saved in the Transfer data from the ABE [ch. 6.16.1].
^^
W-FM.
3B
^^
– No HE password defined
40
^^
– Internal safety relay fault
41 – Internal ignition contact setting fault Check electrical connection at output.
€€
(1
83054802 1/2015-07 MaW 204-228

9 Troubleshooting

codes
^^
code
42 01 … FF Internal fuel valve relay contact setting fault If several faults occur, the diagnosis codes
are add up.
01 Anti syphon valve / safety valve Oil SV Check electrical connection at output.
X6-03* Depending on the operating phase an imper-
02 Fuel valve Oil V1 X8-02 / X8-03 missible voltage signal is present at the cor-
04 Fuel valve Oil V2 X7-01 responding output. This could be triggered
by reverse voltage caused by an operating
08 Fuel valve Oil V3 X7-02 signal (e. g. during a lamp test).
10 External solenoid valve Gas / safety valve
Gas SV X9-01:1
20 Fuel valve Gas V1 X9-01:4
40 Fuel valve Gas V2 X9-01:3
^^
80 Ignition gas valve PV X9-01:2
43 01 No fuel or both selected via input X4-01 Check electrical connection [ch. 6.4.2].
02 Fuel supply without compound curves Set fuel.
03 Variable "Supply" not defined Transfer data from the ABE [ch. 6.16.1].
04 Variable "Fuel" not defined Check fuel selection [ch. 6.4.2].
05 Undefined operating mode with load control- Check operating mode [ch. 6.12.2].
ler
06 Pre-purge time Gas too short Internal fault(1
07 Pre-purge time Oil too short
08 Safety time 1 Gas too long
09 Safety time 1 Oil too long
0A Time ignition Off greater than safety time 1
Gas
0B Time ignition Off greater than safety time 1
Oil
0C Safety time 2 Gas too long
^^
0D Safety time 2 Oil too long
44 01 … 04 Deactivated input connected. Activate input or connect nothing.
01 Load controller input X62 Some inputs can only be activated in the
02 Air pressure switch input X3-02 OEM level.
03 Fan contactor contact input X4-01:3
04 Low gas pressure switch input X9-03:4
05 High gas pressure switch input X9-03:3
06 Min. oil pressure switch input X5-01
07 Max. oil pressure switch input X5-02
08 Start release Oil input X6-01:1
09 Heavy oil immediate start input X6-01:3
0A Start release Gas input X7-03:2
0B Safety temperature monitor for high temper-
^^
ature input X6-01:3
45 – Safety shutdown during safety temperature
limiter test
€€
(1
83054802 1/2015-07 MaW 205-228

9 Troubleshooting

codes
^^
code
46 01 … 07 Program stop is activated, the program se- Deactivate the program stop if it is no
quence stops in the defined phase longer required [ch. 6.9.4].
01 Stop in phase 24, pre-purge position
02 Stop in phase 32, auxiliary actuator3 in pre-
purge position
03 Stop in phase 36, ignition position
04 Stop in phase 44, flame signal
05 Stop in phase 52, ignition pilot valve OFF
06 Stop in phase 72, post-purge position
07 Stop in phase 76, auxiliary actuator3 in post-
^^
purge position
47 – Signal start release Gas input X7-03:2 miss-
^^
ing
48
^^
00 2 flame signals instead of one present
49 01 External flame detector connected via con- If an external flame detector is connected to
tact and flame sensor X6-01:3, no flame sensor must be connec-
ted to X10.
02 External flame detector for high temperature If an external high temperature monitor is
connected via contact and 2 flame sensors connected to X6-01:3, only one flame
sensor may be connected to X10 for low-
^^
temperature operation.
50
^^
00 … 07 Error in key value test Internal fault(1
51
^^
00 … 07 Time block overrun Internal fault(1
52
^^
00 … 03 Stack fault Internal fault(1
53
^^
01 Incorrect reset condition Internal fault(1
57 00 … 05 Prohibited setting "and not" (&/) The diagnostic code indicates the appropri-
ate parameter.
00 In SensExtranlGas Change setting (OEM level).
01 In SensExtranlOil
02 In SensPilotPhGas
03 In SensPilotPhOil
04 In SensOperPhGas
05 In SensOperPhOil
€€
(1
83054802 1/2015-07 MaW 206-228

9 Troubleshooting

codes
^^
code
57 06 FGR mode temp.contr. is not permit- Function is only available for type
ted LMV52.4…
07 Prohibited setting HTempGuard Change setting (OEM level).
08 Prohibited setting ext.FlameGd
09 FGR mode deviating from Aux3onCurve Set Aux3onCurve.
is not permitted
0A Prohibited setting in AuxActuator, VSD Change setting (OEM level).
and Aux3 not permitted
0B Config X5-03 CoolFctStby is not per- Change setting [ch. 6.8.9].
mitted
0C Double assignment input X5-03 Change LC_OptgMode or Config
X503, see [ch. 6.8.9].
0D Prohibited setting HT/FGRedCo Change setting (OEM level).
0E Prohibited setting in COx , OptgMode Change setting [ch. 6.11.1].
COx Gas and OptgMode COx Oil are Function is only available for type
deactivated unequally LMV52.4…
^^
58 – Parameter set is corrupted Reset W-FM, see [ch. 9.1].

59 – Parameter set is corrupted If the error occurred during a parameter
5A – Parameter set is corrupted change:
Check parameter that was last changed
5B – Parameter set is corrupted for plausibility.
If the reset does not achieve a fault free con-
dition:
^^
Load data from the ABE [ch. 6.16.1].
5C – Data from the ABE was transferred to the Reset W-FM, see [ch. 9.1].
^^
W-FM
5D – Internal fault W-FM Reset W-FM, see [ch. 9.1].
5E – Internal fault W-FM If the error occurred during a parameter
change:
for plausibility.
dition:
^^
5F
^^
– Data backup was interrupted Repeat data backup [ch. 6.16.1].
60 – Internal fault W-FM Reset W-FM, see [ch. 9.1].
61 01 … 23 Internal fault W-FM If the error occurred during a parameter
change:
for plausibility.
dition:
^^
70
^^
01 … 04 Failed to restore lockout information Internal fault(1
71
^^
– W-FM locked out manually via input X4-01:4 Reset W-FM, see [ch. 9.1].
72 01 … 04 Implausible fault entry Internal fault(1
€€
(1
83054802 1/2015-07 MaW 207-228

9 Troubleshooting

codes
^^
code
80 01 … 03 Prohibited condition auxiliary actuator3 Check CAN Bus connection and Bus
81 01 … 03 Prohibited condition air actuator termination [ch. 5].
82 01 … 03 Prohibited condition fuel actuator Gas Internal fault(1
83 01 … 03 Prohibited condition fuel actuator Oil
84 01 … 03 Prohibited condition auxiliary actuator1
85
^^
01 … 03 Prohibited condition auxiliary actuator2
86
^^
01 … 03 Prohibited condition internal load controller Internal fault(1
87 01 … 03 Prohibited condition ABE Check CAN Bus connection and Bus
termination [ch. 5].
^^
Internal fault(1
88 01 Plausibility fault actuators Internal fault(1
02 Plausibility fault load controller
03 Plausibility fault ABE
04 Plausibility fault frequency converter module
^^
05 Plausibility fault O2 module
90 – ROM-CRC error auxiliary actuator3 Check CAN Bus connection and Bus
91 – ROM-CRC error air actuator termination [ch. 5].
92 – ROM-CRC error fuel actuator Gas Internal fault(1
93 – ROM-CRC error fuel actuator Oil
94 – ROM-CRC error auxiliary actuator1
95 – ROM-CRC error auxiliary actuator2
96 – ROM-CRC error auxiliary actuator2 Internal fault(1
97 – ROM-CRC error ABE Check CAN Bus connection and Bus
Internal fault(1
98 – At least two actuators with the same ad- Check address [ch. 6.13.1].
dress on the CAN-Bus
99 – CAN-Bus connection error Check CAN Bus connection and Bus
9A CAN-Bus connection error, error often oc- termination [ch. 5].
curs when a bus user is connected or dis- Internal fault(1
connected
9B Queue overflow CAN-Bus
€€
(1
83054802 1/2015-07 MaW 208-228

9 Troubleshooting

codes
^^
code
A0 01 … 1F Auxiliary actuator3 has signalled a fault Check CAN Bus connection and Bus
01 CRC error during ROM test termination [ch. 5].
02 CRC error during RAM test Internal fault(1
04 Error in key value test
05 Time block overrun
07 Synchronisation or CRC error
08 Cycle counter error
09 Error during stack test
0C Temperature in the actuator too high Check housing temperature (max. 60°C), if
necessary supply with cooling air.
0D Rotational direction of actuator incorrect Check mechanics after the actuator for
freedom of movement.
Check rotation direction, change if re-
quired (OEM level).
0E Ramp time for path insufficient Check actuator ramp time [ch. 6.9.1].
Ramp time should not be less slowest ac-
tuator
Reduce path between special positions.
10 Timeout during analogue to digital conver- Internal fault(1
sion
11 Error during test analogue to digital con-
verter
12 Error during analogue to digital conversion
13 Actuator position outside of permissible Check actuator position, if necessary turn
range (0 … 90°) back mechanically.
15 CAN-Bus connection error Check CAN Bus connection [ch. 5].
16 CRC error of parameter page
17 Page was open too long Reset W-FM, see [ch. 9.1].
18 Page has been corrupted If the error occurred during a parameter
19 Invalid access to parameters change:
1B Error when copying a parameter page for plausibility.
dition:
If none of the actions listed leads to a fault
free condition:
Replace W-FM.
1E Invalid position range in drive command Check SpecialPositions.
^^
1F Internal plausibility fault Optimise EMC measures.
A1
^^
See A0 Air actuator has signalled a fault See A0
A2
^^
See A0 Fuel actuator Gas has signalled a fault See A0
A3
^^
See A0 Fuel actuator Oil has signalled a fault See A0
A4
^^
See A0 Auxiliary actuator1 has signalled a fault See A0
A5 See A0 Auxiliary actuator2 has signalled a fault See A0
€€
(1
83054802 1/2015-07 MaW 209-228

9 Troubleshooting

codes
^^
code
A6 10 … 32 Internal load controller has signalled a fault Internal fault(1
10 No actual value gradient
12 Invalid proportional part (Xp) Check O2 control parameters, if necessary
13 Invalid integral part (Tn) adjust [ch. 6.10.4].
14 Invalid delay time (Tu) Internal fault(1
15 Invalid differential part (Tv)
16 Timeout during observation phase of auto- Internal fault(1
matic adaption
17 Boiler cold start function is activated
18 Timeout during automatic adaption
22 Setpoint exceeds limit value
^^
30 … 32 Internal memory fault
A6 33 CRC error during data transfer Reset W-FM, see [ch. 9.1].
^^
Repeat data backup [ch. 6.16.1].
A6
^^
34 … 3B Internal load controller fault Internal fault(1
A6 40 Page was open too long Reset W-FM, see [ch. 9.1].
If the error occurred during a parameter
change:
for plausibility.
dition:
free condition:
^^
Replace W-FM.
A6
^^
41 … 43 Internal load controller fault Internal fault(1
A6 41 … 46 Error in the data set from the internal load
controller
44 Page was set to ABORT Reset W-FM, see [ch. 9.1].
45 Page was set to RESTO If the error occurred during a parameter
46 Page has invalid status change:
for plausibility.
dition:
free condition:
^^
Replace W-FM.
A6 4A … 4E Internal load controller connection error Internal fault(1
CAN-Bus
€€
(1
83054802 1/2015-07 MaW 210-228

9 Troubleshooting

codes
^^
code
A6 50 … 5A Load controller input error The diagnostic code indicates which input is
affected.
50 Short circuit at input X60:1/4 Check electrical connection and sensor.
51 Break at input X60:1/4
53 Short circuit at input X60:3/4
55 Short circuit at input X60:3/4
57 Excess voltage at input X61
58 Break or short circuit at input X61
59 Excess voltage at input X62
^^
5A Break or short circuit at input X62
A6 5B The output value is not available for output Change setting [ch. 6.12.7].
^^
X63 in the current configuration.
A6 5C FGR sensor is not available in the current Change setting [ch. 6.15.3].
^^
configuration.
A6
^^
60 … 6F Internal load controller fault Internal fault(1
A6 70 … 77 Load controller input signals fluctuate too The diagnostic code indicates which input is
much affected [ch. 3.3.20].
70 Signal fluctuation input X60:1/4 Check electrical connection
71 Signal fluctuation input X60:2/4 Check signal (ripple voltage).
72 Signal fluctuation input X60:3/4
73 Signal fluctuation PWM
74 Signal fluctuation U-input X61:2
75 Signal fluctuation I-input X61:3
76 Signal fluctuation U-input X62:2/4
^^
77 Signal fluctuation I-input X62:3/4
A6 78 … 7F Load controller input signals too great or in- The diagnostic code indicates which input is
correct polarity. affected [ch. 3.3.20].
78 Excess voltage or incorrect polarity input Check electrical connection
X60:1/4 Check voltage or current.
79 Excess voltage or incorrect polarity input
X60:2/4
7A Excess voltage or incorrect polarity input
X60:3/4
7B Excess voltage or incorrect polarity PWM
7C Excess voltage or incorrect polarity input
X61
7D Current flow is too high or incorrect polarity
input X61
7E Excess voltage or incorrect polarity input
X62
7F Current flow is too high or incorrect polarity
^^
input X62
A6 80 … A6 Internal load controller fault Internal fault(1
€€
(1
83054802 1/2015-07 MaW 211-228

9 Troubleshooting

codes
^^
code
A6 A7 Incorrect or no additional sensor for boiler Change setting [ch. 6.12.14].
^^
cold start function defined.
A6
^^
B0 … FF Internal load controller fault Internal fault(1
A7 01 … 08 Internal fault ABE Check CAN Bus connection and Bus
Internal fault(1
09 Burner is locked out via OFF function of Reset W-FM, see [ch. 9.1].
ABE.
0A Internal fault ABE
0B Service message through burner starts Carry out service, reset start counter
[ch. 6.4.4].
0C Save parameters failed
0D OilSettings was selected in the menu, Select fuel Gas [ch. 6.4.2].
the fuel selection is set to Gas.
0E GasSettings was selected in the menu, Select fuel Oil [ch. 6.4.2].
the fuel selection is set to Oil.
15 … 1A Internal fault ABE Internal fault(1
1B Error during data backup Reset W-FM, see [ch. 9.1].
Repeat data backup [ch. 6.16.1].
1C … 28 Internal fault ABE
30 Bus communication error Check connection and settings
[ch. 6.6.2].
38 Interface mode could not be completed
[ch. 6.6.1]
40 Configuration error via software (PC tool)
88 … 8A Internal fault ABE
€€
(1
83054802 1/2015-07 MaW 212-228

9 Troubleshooting

codes
^^
code
A9 01 … 1F Internal frequency converter module has sig-
nalled a fault
01 … 09 Internal frequency converter module fault Internal fault(1
0A Speed or fuel meter not plausible, interfer- Check line installation.
ence on the line Use screened line.
Internal fault(1
0C Signal from frequency converter at alarm in- Read fault code from frequency converter
put X73:3 [ch. 3.4.11]
0D Frequency converter module can not com- Check current signal for frequency
pensate the speed difference converter [ch. 6.14.5].
The current signal of the W-FM must be
matched to the frequency converter.
Carry out speed standardisation
[ch. 7.2.1.1].
The burner requires re-commissioning after
each standardisation.
0E Error internal speed calculation Internal fault(1
15 CAN-Bus connection error Check CAN Bus connection and Bus
16 CRC error of parameter page Reset W-FM, see [ch. 9.1].
17 Page was open too long If the error occurred during a parameter
18 Page has been corrupted change:
19 Invalid access to parameters for plausibility.
1B Error when copying a parameter page
dition:
free condition:
Replace W-FM.
1E Invalid position range in drive command Check SpecialPositions.
1F Internal plausibility fault Internal fault(1
€€
(1
83054802 1/2015-07 MaW 213-228

9 Troubleshooting

codes
^^
code
AB 01 … 3F O2 module has signalled a fault
01 … 0A Internal O2 module fault Internal fault(1
10 Nernst voltage of O2 sensor outside of per- Check electrical connection [ch. 3.3.25].
missible range
12 Voltage thermocouple of O2 sensor outside
of permissible range
13 Voltage temperature compensation of O2
sensor outside of permissible range
15 Temperature combustion air sensor outside Check electrical connection and sensor
of permissible range (-20 … +800°C) [ch. 6.10.9].
16 Temperature flue gas temperature sensor Check temperature.
outside of permissible range
(-20 … +800°C)
17 … 1F Internal fault O2 module in test phase Internal fault(1
20 Sensor temperature of O2 sensor too low Check voltage supply and unit fusing of
internal O2 module.
Check voltage supply sensor heating
(Q4/Q5) [ch. 3.3.25].
21 Sensor temperature of O2 sensor too high Check sensor temperature [ch. 6.10.20].
22 Errors during calculation test Internal fault(1
23 Internal resistance of O2 sensor less than Check electrical connection [ch. 3.3.25].
5 Ω or greater than 150 Ω Replace O2 sensor [ch. 6.10.22].
24 Reaction time of O2 sensor greater than Check installation position of O2 sensor
5 seconds [ch. 4.1].
25 Error during sensor test [ch. 6.10.22]. O2 Clean O2 sensor.
value fluctuates, flow too low. Replace O2 sensor (sensor ageing).
If necessary increase O2 control limit.
30 CAN-Bus connection error Check CAN Bus connection and Bus
Internal fault(1
31 CRC error of parameter page Reset W-FM, see [ch. 9.1].
32 Page was open too long If the error occurred during a parameter
33 Page has been corrupted change:
34 Invalid access to parameters for plausibility.
38 Error when copying a parameter page
3E Invalid external default dition:
free condition:
Replace W-FM.
^^
3F Internal plausibility fault Internal fault(1
B0
^^
01, 02 Fault during output test Internal fault(1
B1 01 Internal fault(1
Error in short circuit testing of inputs to out-
puts
€€
(1
83054802 1/2015-07 MaW 214-228

9 Troubleshooting

codes
^^
code
B5 01 O2 min. value not maintained [ch. 6.10.2] Check setting of compound curve
[ch. 6.10.3].
Increase O2 Offset [ch. 6.10.4].
increase distance O2 min. value to O2 set-
point value [ch. 6.10].
02 At least one O2 min. value is missing Check O2 min. values [ch. 6.10.2].
03 At least one O2 setpoint is missing Check O2 setpoints [ch. 6.10.3].
04 Adaption error in the load point defined un- Repeat standardisation in both load points
der LowFireAdaptPtNo or in full load [ch. 6.10.3].
Increase LowFireAdaptPtNo, see
[ch. 6.10.4].
05 No valid O2 value for at least 3 seconds Check connection of O2 module and O2
sensor.
06 Air oxygen content not achieved in pre- Fully open air influencing actuators in pre-
purge (20.9 % ± 2 %) purge [ch. 6.9.4].
Increase pre-purge time [ch. 6.8.1].
Replace O2 sensor (sensor ageing).
07 O2 max. value not maintained [ch. 6.10.2] Check installation position and connec-
tion of O2 sensor [ch. 4.1].
08 O2 min. value or O2 max. value is missing Check O2 max. value.
[ch. 6.10.2] Check O2 min. value at each load point
Flue gas reaction time (Tau) is missing in the Repeat standardisation in the relevant
load point defined under LowFireAd load point [ch. 6.10.3].
aptPtNo or in full load [ch. 6.10.4]
09 Test time for O2 monitor missing Change setting (OEM level).
0A Internal W-FM fault in conjunction with O2 Internal fault(1
^^
trim
B6 01 CO signal outside of the permissible range Check CO resistance circuit board
[ch. 6.11] connection [ch. 3.3.24].
02 Prohibited setting Time COx Alarm Check setting [ch. 6.11.2].
03 Flue gas reaction time (Tau) is missing in the Repeat standardisation in the relevant
load point defined under LowFireAd load point [ch. 6.10.3].
aptPtNo or in full load [ch. 6.10.4]
04 CO limit value in operation exceeded Check combustion.
Check CO limit value of measurement
transducer LT3 [ch. 7.5.1].
Increase O2ModOffset, see [ch. 6.10.4].
Increase NumberTauSuspend, see
[ch. 6.10.5].
05 CO limit value in pre-purge exceeded Fully open air influencing actuators in pre-
purge [ch. 6.9.4].
^^
Increase pre-purge time [ch. 6.8.1].
B7 00 … 3F Error message from O2 module, no valid CO Check CO resistance circuit board
signal connection [ch. 3.3.24].
41 Connection between W-FM and O2 module Check CAN Bus connection [ch. 5].
interrupted
42 Connection error CAN Bus between W-FM Check CAN Bus connection [ch. 5].
and O2 module
^^
BA
^^
01 O2 module has aborted test of O2 sensor Internal fault(1
BB 00 Service interval for O2 sensor expired Clean or replace O2 sensor.
Reset service interval [ch. 6.10.8].
€€
(1
83054802 1/2015-07 MaW 215-228

9 Troubleshooting

codes
^^
code
BE 00 Operating mode O2 controller con Connect FGR sensor to input X60 and
AutoDeac is not permitted when define accordingly [ch. 6.15.3].
X86PtNi1000 is selected as FGR sensor. Set operating mode O2 controller to
O2Control or O2 Alarm, see
[ch. 6.10.1].
01 Current start mode of O2 trim is not permit- Deactivate CO function [ch. 6.11.1].
ted in conjunction with the CO function Set start mode to standard (OEM
^^
level).
BF – Fault in conjunction with O2 trim or O2 mon- Read fault history and rectify fault.
itor.
The fault history shows the cause just before
^^
fault "BF" (an error number in advance)
C5 01 … 2F The ABE has detected outdated versions If several faults occur, the diagnosis codes
whilst comparing the Software of individual are add up.
devices.
01 W-FM software version not current Restart system and wait approx. 1 min un-
02 Load controller software version in the til the display Parameters are be
W-FM not current ing updated disappears.
Reset W-FM, see [ch. 9.1].
04 ABE software version not current
08 Actuator software version not current
dition:
10 Frequency converter module software ver- Carry out software update of ABE.
sion in the W-FM not current Replace relevant component.
^^
20 Software version of O2module not current
D1 01 … 03 Prohibited condition of frequency converter Internal fault(1
^^
module in the W-FM
D3 01 … 03 Prohibited condition O2 module Check CAN Bus connection and Bus
^^
Internal fault(1
E1 – ROM-CRC error frequency converter mod- Internal fault(1
^^
ule in the W-FM
E3 – ROM-CRC error O2 module Check CAN Bus connection and Bus
^^
Internal fault(1
F0
^^
– Internal plausibility fault Internal fault(1
F1 01 … 07 Calculate internal fault during pre-control for Check compound curves [ch. 6.10].
^^
O2 trim Check fuel type setting [ch. 6.10.6].
F2 07 Invalid value of O2 module
08 Warning threshold for flue gas temperature Check flue gas temperature [ch. 6.10.19].
exceeded Check warning threshold for flue gas
temperature [ch. 6.10.10].
0A O2 sensor has not yet reached operating Wait until the O2 sensor has reached op-
temperature [ch. 6.10.20] erating temperature.
€€
(1
83054802 1/2015-07 MaW 216-228

9 Troubleshooting

codes
^^
code
F3 01 O2 trim PI parameter missing Check PI parameter [ch. 6.10.4].
02 No values defined for O2 control variable Define O2 control variable limit
limit [ch. 6.10.4].
03 O2 control variable limit has been activated Check O2 content in the flue gas and O2
sensor [ch. 6.10.16].
Check O2 control variable limit
[ch. 6.10.4].
Check O2 trim setting [ch. 6.10.2].

04 Curve parameters for O2 trim incomplete Check curve points for O2 trim
[ch. 6.10.2].
O2 compound values
O2 setpoints
O2 min. values
Standardisation values
05 Internal fault W-FM
06 Supply air temperature present is not valid Check supply air temperature sensor.
when setting O2 trim Check combustion air temperature during
commissioning [ch. 6.10.5].
07 Blocking time for the O2 sensor QGO 21 in- Increase factor NumberTauSuspend,
sufficient see [ch. 6.10.5].
08 O2 value above 135 during controller initial- Check O2 sensor (malfunction, secondary
isation in phase 60 air).
Increase factor NumberTauSuspend,
^^
see [ch. 6.10.5].
F4 01 Connection error CAN Bus between W-FM Check CAN Bus connection [ch. 5].
and O2 module
15 Temperature combustion air sensor outside Check electrical connection and sensor
of permissible range (-20 … +800°C) [ch. 6.10.9].
16 Temperature flue gas temperature sensor Check temperature.
outside of permissible range
^^
(-20 … +800°C)
F5 – Load controller return signal fault Check CAN Bus connection [ch. 5].
Internal fault(1
F6 01 FGR function was automatically deactivated Read fault history and rectify fault.
The fault history shows the cause just before
fault "F6" (an error number in advance)
02 Operating mode FGR TCautoDeact is Connect FGR sensor to input X60 and
not permitted when X86PtNi1000 is se- define accordingly [ch. 6.15.3].
lected as FGR sensor. Set FGR mode to temp.contr., see
[ch. 6.15.2].
€€
(1
83054802 1/2015-07 MaW 217-228

10 Technical documentation
10.1 Frequency converter

Detailed information see Frequency converter CD.
The construction and arrangement of diagnostic LEDs is dependent on the size of

the frequency converter.
10.1.1 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 (4 … 20 mA):
Switch 1: ON
Switch 2: ON
83054802 1/2015-07 MaW 218-228

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
83054802 1/2015-07 MaW 219-228

10.1.2 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
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
8 (DIN1) yellow Frequency converter start release (di-
gital input 1)
9 (BUS-S) OFF No Bus communication (system bus)
green Bus warning
flashing green Bus communication
0 (BUS-E) OFF System bus is operating correctly
flashing red Monitoring fault
red No system bus
83054802 1/2015-07 MaW 220-228

Status LED's
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
83054802 1/2015-07 MaW 221-228

11 Key word index
11 Key word index
Symbols Check O2 trim .................................................................. 184

Measurement amplifier.................................................... 186 Circulation time ................................................................... 79
CO content ....................................................................... 191
CO control blocking time............................................... 187
A
CO controller .................................................................... 118
ABE ................................................................................ 52, 55 CO function............................................................. 113, 120
Access with HE................................................................... 58 CO limit value ................................................................... 186
Actual speed ..................................................................... 143 CO limit value exceeded ................................................ 120
Actual value ................................................................ 68, 124 CO measurement amplifier.................................. 118, 186
Actuator....................................................................... 64, 140 CO monitor........................................................................ 118
Adaption............................................................ 64, 139, 178 CO resistance board ...................................................... 118
Additional air pressure switch.......................................... 83 CO resistance circuit board ............................................. 36
Additional sensor boiler cold start ..................... 138, 180 CO switching threshold ................................................. 116
Addressing ........................................................................ 140 Cold start .......................................................... 63, 136, 180
After burn time ............................................................. 60, 80 COM interface..................................................................... 52
Air influencing ...................................................................... 87 Combustion air sensor .................................... 35, 36, 113
Air number ......................................................................... 191 Combustion air temperature.......................................... 116
Air pressure ....................................................................... 192 Combustion control......................................................... 191
Air pressure fluctuation................................................... 109 Combustion limit .............................................................. 191
Air pressure switch........................................... 26, 39, 190 Commissioning....................................................... 155, 176
Air rating............................................................................. 114 Compound curve ................................................................ 90
Alarm...................................................... 38, 59, 61, 81, 197 Condensate.......................................................................... 12
Alarm delay ........................................................................... 80 Connection pressure ......................................................... 14
Alarm input ........................................................................... 43 Consumption........................................................................ 44
Ambient conditions............................................................. 45 Contact load ........................................................................ 44
Analogue input.................................................................. 125 Continuous running fan ............................................. 61, 83
Analogue output................................................ 43, 64, 128 Continuous venting............................................................. 39
Analogue signal................................................................ 125 Contrast ........................................................................ 64, 73
Anti siphon valve ................................................................. 80 Control behaviour ............................................................ 130
Anti syphon valve ........................................................ 38, 40 Control variable calming................................................. 131
Atomising pressure................................................ 167, 173 Control variable limit........................................................ 109
Automatic............................................................... 60, 62, 78 Control variables calming.................................................. 16
Auxiliary actuator3............................................................ 148 Controller limit O2 ........................................................... 107
Controller parameter O2................................................... 62
B Controller parameters .............................................. 63, 178
Backup ................................ 67, 152, 165, 171, 175, 181 Conversion factor ............................................................ 192
Backup copy ..................................................................... 152 Copy protection .................................................................. 72
Baud rate .............................................................................. 76 Correcting element step ......................................... 33, 131
Baudrate ............................................................................... 64 Counter ................................................................................. 69
Block time.......................................................................... 110 Current range.................................................................... 128
Boiler cold start ................................................................ 180 Current signal ................................................................... 125
Boiler cold start function ............................... 16, 136, 180 Current signal speed................................................ 43, 143
Boiler setpoint............................................................ 59, 121 Curve parameter ................................................................. 61
Boiler temperature .............................................................. 68 Customer code.................................................................... 71
Burner flange limit switch.................................................. 26
Burner identification ................................................... 60, 72 D
Burner motor ........................................................................ 38 Data backup ............................... 152, 165, 171, 175, 181
Burner Off............................................................................. 78 Data recording..................................................................... 77
Burner ON .................................................................... 32, 33 Date................................................................................ 59, 74
Burner starts ........................................................................ 69 Date format................................................................... 64, 74
Bus address ......................................................................... 64 Deactivate O2 trim ............................................................. 84
Bus connection ................................................................... 51 Deactivating O2 trim .......................................................... 84
Bus line.................................................................................. 51 Delete load point................................................................. 92
Bus protocol......................................................................... 75 Design lifespan .......................................................... 11, 194
Bus termination ......................................................... 51, 140 Diagnostic code ..................................................... 115, 200
Differential part ................................................................. 130
C Dimensions........................................................................... 46
CAN Bus............................................................................... 51 Direct coupling ............................................................ 38, 82
Change-over release.......................................................... 32 Direct start............................................................. 39, 61, 81
Changing over operation mode.................................... 123 Display ................................................................................... 56
Display and operating unit ...................................... 55, 196
83054802 1/2015-07 MaW 222-228

11 Key word index
Display contrast........................................................... 64, 73 Gas pressure switch reaction time ................................. 60

Disposal ................................................................................ 12 Gas temperature .............................................................. 192
Double gas valve................................................................. 42 Gas throughput ................................................................ 192
Gateway ................................................................................ 75
E Guarantee............................................................................. 10
eBus............................................................................... 64, 76
eBus address....................................................................... 76 H
Edit load point...................................................................... 91 HE Password ....................................................................... 58
Efficiency........................................................... 60, 111, 114 Heat demand ............................................................... 32, 33
Electrical connection.......................................................... 50 Heavy oil................................................................................ 41
Emergency-Off .................................................................... 26 Heavy oil immediate start .................................................. 80
Enable contact..................................................................... 43 Heavy oil intermediate start .............................................. 28
Excess air........................................................................... 191 High gas pressure switch ................................................. 29
Exchanging the unit ......................................................... 196 Hours run ...................................................................... 59, 66
External setpoint........................................................ 63, 127 Humidity ................................................................................ 45
Extraneous light .................................................... 30, 61, 85
I
F Identification number.......................................................... 71
Factory identification ............................ 61, 64, 65, 66, 71 Ignition ................................................................................... 61
Factory setting ..................................................................... 59 Ignition position ........................................................... 61, 88
Fan.......................................................................................... 79 Ignition unit ........................................................................... 39
Fan contactor contact........................................................ 27 Impulse ............................................................................... 142
Fan motor.............................................................................. 38 Input X10-02........................................................................ 30
Fault code.......................................................................... 200 Input X10-03........................................................................ 31
Fault history ................................................................ 59, 198 Input X3-02 .......................................................................... 26
Fault signal ........................................................................ 131 Input X3-03 .......................................................................... 26
FC setpoint........................................................................ 143 Input X3-04 .......................................................................... 26
FGR maximum position .................................................. 151 Input X4-01 .................................................................. 26, 27
FGR minimum position ................................................... 151 Input X5-01 .......................................................................... 27
FGR operating mode ...................................................... 148 Input X5-02 .......................................................................... 27
FGR release ...................................................................... 150 Input X5-03 .................................................... 32, 33, 61, 84
FGR temperature ................................................... 149, 151 Input X60 .............................................................................. 35
FGR temperature sensor ........................................ 35, 149 Input X6-01 .......................................................................... 28
Flame failure test ....................................................... 67, 154 Input X61 ............................................................ 35, 63, 125
Flame sensor........................................................................ 30 Input X62 .............................................. 33, 34, 63, 66, 125
Flame signal ................................................... 30, 31, 61, 71 Input X70 .............................................................................. 35
Flame stabilisation .............................................................. 79 Input X7-03 .......................................................................... 28
Flashing codes ................................................................. 141 Input X71 .............................................................................. 36
Flue gas damper .................................................... 144, 146 Input X72 .............................................................................. 36
Flue gas losses................................................................. 191 Input X81 ...................................................................... 37, 54
Flue gas measurement.................................................... 191 Input X86 .............................................................................. 36
Flue gas recirculation (FGR) ........................ 66, 144, 188 Input X87 .............................................................................. 36
Flue gas temperature .................... 45, 60, 113, 116, 191 Input X9-03 .......................................................................... 29
Flue gas temperature sensor.................................. 36, 113 Input X9-04 .......................................................................... 28
Flue gas velocity........................................................ 45, 107 Installation position ............................................................. 49
Forced intermittent ..................................................... 61, 82 Integral part ....................................................................... 130
Frequency converter . 16, 27, 62, 65, 87, 99, 142, 155, Interface ..................................................... 52, 75, 218, 220
218 Internal resistance O2 sensor....................................... 117
Fuel......................................................................................... 68 Interval time .......................................................................... 60
Fuel meter............................................... 36, 59, 65, 67, 70 Ionisation electrode ............................................................ 31
Fuel selection........................................................ 27, 59, 68
Fuel values......................................................................... 111 J
Fuel valve .............................................................................. 41
Jumper ......................................................................... 51, 140
Fuel valves ............................................................................ 42
Full load ................................................................................. 96
Fuse ....................................................................................... 44 L
Language ...................................................................... 64, 73
G Liability................................................................................... 10
Light oil .................................................................................. 41
Gas connection pressure.................................................. 14
Limit switch........................................................................... 26
Gas meter..................................................................... 36, 70
83054802 1/2015-07 MaW 223-228

11 Key word index
Load controller............. 16, 32, 33, 34, 63, 84, 121, 176 O2 controller.................................................... 60, 100, 117
Load controller operating mode ................................... 122 O2 controller manipulated variable.............................. 114
Load distribution ....................................................... 93, 193 O2 maximum value .......................................................... 103
Load limit....................................................................... 59, 98 O2 minimum value ........................................................... 102
Load limits..................................................................... 61, 96 O2 Module ................................................................... 16, 65
Load point............................................................................. 90 O2 monitor ........................................................................ 100
Load range ................................................................... 62, 96 O2 Offset........................................................................... 119
Load shutdown.................................................................... 80 O2 process data ................................................................. 66
Load signal ........................................................................... 43 O2 sensor.......................................... 37, 48, 54, 110, 112
Load stage......................................................................... 137 O2 sensor heating capacity .......................................... 117
Local ...................................................................................... 77 O2 sensor wear and tear ............................................... 117
Lockout......................................................... 26, 56, 86, 196 O2 setpoint ................................................................ 60, 116
Lockout history .......................................................... 59, 199 O2 trim ................................................................ 62, 99, 182
Low gas pressure switch .......................................... 14, 29 O2 trim function .................................................................. 16
Low gas programme .......................................................... 14 O2 trim limit....................................................................... 107
Low gas waiting time ......................................................... 60 O2 value................................................................................ 60
Low impact start.................................................................. 32 O2-Offset .......................................................................... 108
O2sensor temperature ................................................... 116
M Off........................................................................................... 62
OFF function ........................................................................ 55
Magnetic coupling ...................................................... 38, 82
Oil meter ....................................................................... 36, 70
Mains frequency .................................................................. 44
Oil pump ................................................................ 38, 79, 82
Mains voltage ............................................................... 26, 44
Oil pump coupling .............................................................. 61
Manual ........................................................................... 62, 90
Oil pump On Time .............................................................. 60
Manual operation ........................................................ 60, 78
Oil solenoid valve ................................................................ 41
Manuel ................................................................................... 60
Operating display.......................................... 42, 56, 59, 68
Max. oil pressure switch .................................................... 27
Operating hours .................................................................. 69
Max. pressure switch ................................................. 27, 29
Operating mode .......................................................... 32, 78
Maximum position FGR .................................................. 151
Operating mode CO function ....................................... 120
Measurement amplifier.......................................... 118, 186
Operating mode load controller ................................... 122
Measurement amplifier password ................................ 186
Operating mode O2 controller ..................................... 100
Measuring range ....................................................... 63, 126
Operating ramp ................................................................... 62
Menu level............................................................................. 57
Operating stage .................................................................. 94
Menu structure .................................................................... 59
Operating unit...................................................................... 55
Min speed ................................................................ 162, 168
Operating volume ............................................................ 192
Min. oil pressure switch..................................................... 27
Operation.............................................................................. 59
Min. pressure switch .................................................. 27, 29
Output values.................................................................... 129
Minimum O2 value.................................................... 99, 119
Output X3-01 ............................... 27, 38, 40, 80, 81, 197
Minimum position FGR ................................................... 151
Output X4-02 ...................................................................... 39
Minimum speed ...................................................... 162, 168
Output X4-03 .............................................................. 39, 85
Modbus ......................................................................... 64, 76
Output X6-02 .............................................................. 38, 40
Modbus address ................................................................. 76
Output X6-03 .............................................................. 40, 80
Modulating............................................................. 32, 33, 41
Output X63 ................................................................ 43, 128
Motor...................................................................................... 38
Output X7-01 ...................................................................... 41
Motor adaption ................................................................. 155
Output X7-02 ...................................................................... 41
Multi-stage...................................................... 32, 33, 41, 84
Output X73 ................................................................ 43, 142
Output X8-02 ...................................................................... 41
N Output X8-03 ...................................................................... 41
Nernst voltage................................................................... 115 Output X89 .................................................................. 37, 54
Normal operation......................................................... 59, 68 Output X9-01 ...................................................................... 42
Normal start.......................................................................... 81 Output X8-01 ...................................................................... 42
Nozzle circulation ................................................. 28, 41, 79
Number of lockouts ............................................................ 71 P
Parameter ..................................................................... 57, 59
O Parameter set....................................................................... 71
O2 adaption point............................................................ 106 Parity .............................................................................. 64, 76
O2 alarm ............................................................................ 102 Partial load.................................................................... 96, 98
O2 block time ................................................................... 110 Password ......................................... 58, 67, 156, 176, 188
O2 content ........................................................................ 115 PC-Tool................................................................................. 75
O2 control parameters ................................................... 106 Photo resistor....................................................................... 30
O2 control variable limit ................................................. 109 PLL52 .................................................................................... 16
83054802 1/2015-07 MaW 224-228

11 Key word index
Point ....................................................................................... 90 Sensor Select ................................................................... 124

Position control................................................................. 141 Sensor temperature......................................................... 116
Post purge ............................................................................ 61 Sensor test ........................................................................ 117
Post purge position ............................................................ 61 Service................................................................................ 194
Post purge time ................................................................... 60 Service interval ....................................................... 112, 194
Post-purge position............................................................ 89 Set load points .................................................................... 91
Post-purge time................................................................... 80 Setpoint............................................................... 59, 68, 121
Pre-control.................................................................. 99, 108 Setpoint external ................................................................. 63
Pre-ignition ................................................................... 79, 82 Setpoint output................................................................. 143
Pre-ignition switch on point.............................................. 82 Setpoint output speed....................................................... 43
Pre-ignition time .................................................................. 39 Setpoint stage .................................................................. 137
Preparing for adjustment................................................ 156 Setpoint switch-over .......................................................... 34
Pre-purge............................................................... 60, 79, 82 Setting time .......................................................................... 44
Pre-purge position...................................................... 61, 88 Settling time ...................................................................... 110
Pre-purge time..................................................................... 60 Shutdown behaviour .................................................. 62, 86
Pressure regulator .............................................................. 32 Smell of gas ......................................................................... 11
Pressure sensor ............................................................... 126 Software ACS450.................................................... 75, 153
Pressure switch reaction time.......................................... 79 Software version ................................................................. 71
Pressure switch relief................................... 38, 39, 61, 85 SpecialPositions.......................................................... 61, 88
Pressure switches ........................................................... 190 Speed .......................................................................... 65, 143
Production date................................................................... 71 Speed detection............................................................... 142
Program sequence ............................................................. 17 Speed deviation ............................................................... 143
Program stop ........................................................ 61, 62, 89 Speed measurement.......................................................... 35
Proportional part .............................................................. 130 Speed range ........................................................................ 83
Pump pressure ....................................................... 167, 173 Speed standardisation................................... 65, 142, 157
Pump station ................................................................ 38, 82 Standard display ................................................................. 68
Standard volume .............................................................. 192
Q Standardisation ................................................................ 157
Standardisation O2 Trim................................................ 105
QGO… ............................................................... 37, 54, 112
Standardisation VSD....................................................... 142
Standardising O2 trim .................................................... 105
R Standby ................................................................................. 81
Ramp.............................................................................. 62, 86 Standby positions ....................................................... 61, 88
Ramp time............................................................................. 86 Start counter ......................................................... 59, 67, 69
Reaction time .................................................................... 110 Start point ..................................................................... 62, 98
Release contact ........................................................ 65, 142 Start prevention............................................. 38, 61, 80, 81
Release O2 trim ............................................................... 110 Start release................................................................. 61, 79
Relief valve............................................................................ 85 Start release Gas................................................................ 28
Remote .................................................................................. 77 Start release Oil .................................................................. 28
Repetition counter ...................................................... 61, 85 Start signal ................................................................... 39, 85
Reset...................................................................................... 26 Status .................................................................................... 59
Reset fuel meter .................................................................. 70 Status O2 controller........................................................ 114
Reset start counter ............................................................. 69 STL ....................................................................... 26, 67, 154
Resetting operating hours ................................................ 69 Stop commissioning........................................................... 84
Residence time................................................................. 137 Stop function ....................................................................... 84
Resistance board............................................................. 118 Storage.................................................................................. 45
Resistance circuit board ................................................... 36 Summertime ................................................................. 64, 74
Restore............................................................................... 153 Supply voltage ..................................................................... 51
Restoring............................................................................ 153 Switch differential ............................... 132, 133, 178, 179
Rotation direction................................................................ 64 Switch threshold .............................................................. 134
Switch-off point........................... 94, 132, 133, 178, 179
S Switch-off threshold........................................................ 138
Switch-on point ........................... 94, 132, 133, 178, 179
Safety circuit ........................................................................ 26
Switch-on threshold ........................................................ 137
Safety measures.................................................................. 11
System configuration ......................................................... 66
Safety shutdown ................................................................. 56
Safety temperature limiter ....................................... 67, 154
Safety time limiter................................................................ 26 T
Scaling................................................................................ 129 Target load ................................................................... 60, 78
Send cycle.................................................................... 64, 76 Tau....................................................................................... 106
Sensor ................................................................................ 126 Temperature ......................................................................... 45
Sensor current............................................................. 30, 31 Temperature compensation................................. 148, 150
83054802 1/2015-07 MaW 225-228

11 Key word index
Temperature FGR ............................................................ 151

Temperature fluctuation.................................................. 109
Temperature limiter..................................................... 63, 66
Temperature monitor................................................ 35, 135
Temperature sensor ....................................... 35, 124, 126
Temperature sensor flue gas recirculation................. 149
Test O2 sensor................................................................. 117
Thermostat............................................................................ 32
Throughput ................................................................... 36, 70
Time................................................................................ 59, 74
Time constant Tau ................................................. 104, 106
Time delay.......................................................................... 120
Time out ................................................................................ 76
Timeout.................................................................................. 64
Times ............................................................................. 79, 86
Torque ................................................................................... 44
Transport............................................................................... 45
Tree stage............................................................................. 33
TÜV Test ............................................................................... 67
Two stage ............................................................................. 33
Type description.................................................................. 71
Type of Fuel....................................................................... 111
Type of protection............................................................... 44
U
Unit ......................................................................................... 64
Units ....................................................................................... 74
Updating ..................................................................... 67, 152
UV cell ................................................................................... 31
V
Valve lift ................................................................................. 42
Valve proving................................................................ 15, 28
Valve proving gas pressure switch ................................. 28
Valve proving pressure switch ......................................... 28
Variable speed drive................................................. 16, 142
Variations .............................................................................. 13
Voltage signal ................................................................... 125
Voltage supply ..................................................................... 26
VSD..................................................................................... 142
VSD module ...................................................................... 142
VSD setpoint........................................................................ 43
W
W1 ...................................................................................... 121
W2 ...................................................................................... 121
Warning threshold ........................................................... 113
83054802 1/2015-07 MaW 226-228

83054802 1/2015-07 MaW
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
W Burners up to 570 kW Wall-hung condensing boilers
for oil and gas up to 240 kW
The compact burners, proven millions of times
over, are economical and reliable. Available as The wall-hung condensing boilers WTC-GW
gas, oil and dual fuel burners for domestic and and WTC-OW have been developed to meet
commercial applications. the highest demands in ease of operation and
The purflam® burner version with special efficiency.
mixing head gives almost soot-free combustion Modulating operation means these units
of oil with greatly reduced NOx emissions. operate quietly and economically.
monarch® WM Burners Floor standing condensing boiler

and Industrial Burners up to 11,700 kW for oil and gas up to 1,200 kW
These legendary industrial burners are durable The floor-standing boilers WTC-GB and
and versatile. WTC-OB are efficient, low in emissions
Numerous variations of oil, gas and dual fuel and versatile. Higher capacities are achieved
burners meet a wide range of applications and by cascading up to four gas-fired condensing
capacity requirements. boilers.
WK Burners up to 28,000 kW Solar systems
These industrial burners of modular The stylish flat-plate collectors are the ideal
construction are adaptable, robust and complement for any Weishaupt heating
powerful. system. They are suitable for solar water
Even on the toughest industrial applications heating and for combined heating support.
these oil, gas and dual fuel burners operate With versions for on-roof, in-roof and flat roof
reliably. installations, solar energy can be utilised on
almost any roof.
multiflam® Burners up to 17,000 kW Water heaters / energy storage tanks
This innovative Weishaupt technology for This attractive program for domestic water
medium and large burners provides minimum heating includes classic water heaters,
emission values at capacities up to 17 MW. solar storage tanks, heat pump storage tanks
The burners with the patented mixing head are and energy storage tanks.
available for oil, gas and dual fuel operation.
MCR Technology / Building Automation Heat pumps up to 130 kW

from Neuberger
The heat pump range offers solutions for the
utilisation of heat from the air, the soil or
From control panels to complete building ground water.
management systems - at Weishaupt you can Some systems are also suitable for cooling
find the entire spectrum of modern control buildings.
technology. Future orientated, economical and
flexible.
Service Geothermal probe drilling
Weishaupt customers can be assured that With its daughter company, BauGrund Süd,
specialist knowledge and tools are available Weishaupt also offers geothermal probe and
whenever they are needed. Our service well drilling. With the experience of more than
engineers are fully qualified and have 10,000 systems and more than 2 million meters
extensive product knowledge, be it for burners, of drilling, BauGrund Süd offers a
heat pumps, condensing boilers or solar comprehensive service program.
collectors.
83054802 1/2015-07 MaW

Dual fuel burner WM - GL30/2-A / ZM-R (W-FM 100/200) 83263502 • 2/2014-12

Conformity certification
Sprachschlüssel 2183000002
Manufacturer: Max Weishaupt GmbH
Address: Max-Weishaupt-Straße
D-88475 Schwendi
Product: Dual fuel burner type
WM-GL 30/2-A
(W-FM 100/200)
The product described above conforms with
the regulations of directives:
GAD 2009 / 142 / EC

MD 2006 / 42 / EC
PED 97 / 23 / EC *
LVD 2006 / 95 / EC
EMC 2004 / 108 / EC
* With the appropriate choice of equipment.
This product is labelled as follows:
CE-0085
ppa. ppa.
Manager Research Manager Production and

and Development Quality Management
Dual fuel burner WM - GL30/2-A / ZM-R (W-FM 100/200)
1 User instructions ..................................................................................................................... 6

1.1 User guide ............................................................................................................. 6
1.1.1 Symbols ................................................................................................................. 6
1.1.2 Target group ......................................................................................................... 6
1.2 Guarantee and Liability ....................................................................................... 7
2 Safety ............................................................................................................................................ 8
2.1 Designated application ....................................................................................... 8
2.2 When gas can be smelled ................................................................................. 8
2.3 Safety measures .................................................................................................. 8
2.3.1 Normal operation ................................................................................................. 8
2.3.2 Electrical connection ........................................................................................... 8
2.3.3 Gas supply ............................................................................................................ 9
2.4 Alterations to the construction of the equipment ......................................... 9
2.5 Noise emission ..................................................................................................... 9
2.6 Disposal ................................................................................................................. 9
3 Product description ............................................................................................................. 10

3.1 Type key .............................................................................................................. 10
3.2 Serial number ..................................................................................................... 10
3.3 Function .............................................................................................................. 11
3.3.1 Air supply ............................................................................................................ 11
3.3.2 Gas supply ......................................................................................................... 12
3.3.3 Oil supply ............................................................................................................ 14
3.3.4 Electrical components ..................................................................................... 16
3.4 Technical data ................................................................................................... 17
3.4.1 Approval data ..................................................................................................... 17
3.4.2 Electrical data .................................................................................................... 17
3.4.3 Ambient conditions ........................................................................................... 17
3.4.4 Permissible fuels ............................................................................................... 17
3.4.5 Emissions ............................................................................................................ 18
3.4.6 Rating .................................................................................................................. 19
3.4.7 Dimensions ......................................................................................................... 20
3.4.8 Weight ................................................................................................................. 21
4 Installation ................................................................................................................................ 22
4.1 Installation conditions ...................................................................................... 22
4.2 Check rating ....................................................................................................... 23
4.3 Set mixing head ................................................................................................. 24
4.3.1 Setting diagram ................................................................................................. 24
4.3.2 Set flame tube ................................................................................................... 25
4.3.3 Adjust combustion head extension (optional) ............................................ 25
4.4 Burner installation ............................................................................................. 26
5 Installation ................................................................................................................................ 28
5.1 Gas supply ......................................................................................................... 28
5.1.1 Screwed valve train .......................................................................................... 29
5.1.2 Flanged valve train ............................................................................................ 30
5.1.3 Fitting gas pressure switch ............................................................................ 32
5.1.4 Carry out soundness test of gas supply line and vent ............................. 33
83263502 • 2/2014-12 • La 3-110

5.2 Oil supply ............................................................................................................ 34

5.3 Electrical connection ........................................................................................ 36
6 Operation .................................................................................................................................. 38
7 Commissioning ...................................................................................................................... 39
7.1 Prerequisite ........................................................................................................ 39
7.1.1 Connect measuring devices .......................................................................... 39
7.1.2 Check gas connection pressure ................................................................... 41
7.1.3 Check soundness of gas valve train ............................................................. 42
7.1.4 Check high pressure regulator type 06/1 … 09/1 and 1/1 … 5/1
................................................................................................................................ 44
7.1.5 Check high pressure regulator type 5/1-25/50 … 9/1-100/150 ........ 45
7.1.6 Venting the gas valve train .............................................................................. 46
7.1.7 Preset pressure regulator ............................................................................... 47
7.1.8 Preset gas and air pressure switch .............................................................. 48
7.2 Adjusting the burner ......................................................................................... 49
7.2.1 Adjusting gas side ............................................................................................ 50
7.2.2 Adjusting oil side ............................................................................................... 53
7.3 Set pressure switches ..................................................................................... 58
7.3.1 Set oil pressure switch .................................................................................... 58
7.3.2 Set gas pressure switch ................................................................................. 59
7.3.3 Set air pressure switches ............................................................................... 61
7.4 Concluding work ............................................................................................... 62
7.5 Check combustion ........................................................................................... 63
7.6 Calculate gas throughput ............................................................................... 64
7.7 Ratings apportionment .................................................................................... 65
8 Shutdown .................................................................................................................................. 66
9 Servicing .................................................................................................................................... 67
9.1 Notes on servicing ............................................................................................ 67
9.2 Service plan ....................................................................................................... 69
9.3 Hinge open the burner .................................................................................... 70
9.4 Removing and refitting nozzle assembly ...................................................... 71
9.5 Set nozzle distance .......................................................................................... 72
9.6 Removing the mixing head .............................................................................. 72
9.7 Set ignition electrodes ..................................................................................... 73
9.7.1 Set ignition electrodes nozzle assembly ..................................................... 73
9.7.2 Set ignition electrode diffuser ........................................................................ 73
9.8 Set nozzle tubes ................................................................................................ 74
9.9 Replacing the nozzle ........................................................................................ 74
9.10 Removing and refitting air damper stepping motor .................................. 75
9.11 Removing air regulator ..................................................................................... 76
9.12 Set air regulator ................................................................................................. 77
9.13 Removing and refitting gas butterfly stepping motor ............................... 78
9.14 Removing and refitting oil quantity regulator stepping motor ............... 79
9.15 Set pump coupling .......................................................................................... 80
9.16 Set magnetic coupling ..................................................................................... 80
9.17 Removing fan wheel ......................................................................................... 81
83263502 • 2/2014-12 • La 4-110

9.18 Check position of inlet nozzle ........................................................................ 81

9.19 Replace spring on pressure regulator ......................................................... 82
10 Troubleshooting .................................................................................................................... 83
10.1 Procedures for fault conditions ..................................................................... 83
10.2 Rectifying faults ................................................................................................. 84
11 Spares ......................................................................................................................................... 86
12 Technical documentation .............................................................................................. 102

12.1 Appliance categories ..................................................................................... 102
13 Project planning .................................................................................................................. 106

13.1 Oil supply .......................................................................................................... 106
13.1.1 Single pipe oil supply ..................................................................................... 107
13.1.2 Ring main operation ....................................................................................... 107
13.1.3 Oil circulation unit ........................................................................................... 107
13.2 Flue gas system .............................................................................................. 107
14 Key word index ................................................................................................................... 108
83263502 • 2/2014-12 • La 5-110

1 User instructions
1 User instructions
These installation and operating instructions form part of the equipment and must be
Translation of original kept on site. They are supplemented by the installation and operating instructions
operating instructions Combustion Manager W-FM 100/200.
1.1 User guide
1.1.1 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 equipment
and injury to personnel.
CAUTION
Important information
Requires direct action
Result after an action
Itemisation
Range of values
1.1.2 Target group

These installation and operating instructions are intended for the operator and quali-
fied personnel. They should be observed by all personnel working on the unit.
Work on the unit must only be carried out by personnel who have the relevant training
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 near or on the unit.
83263502 • 2/2014-12 • La 6-110

1 User instructions
1.2 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 installation and operating instruction,
▪ operation with faulty safety equipment,
▪ continual operation despite a fault,
▪ improper installation, commissioning, operation and service,
▪ 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 formation,
▪ repairs, which have been carried out incorrectly,
▪ the use of non original Weishaupt parts,
▪ unsuitable fuels,
▪ defects in the inlet lines,
▪ acts of God.
83263502 • 2/2014-12 • La 7-110

2 Safety
2 Safety
2.1 Designated application

The burner is suitable for continuous operation (only in conjunction with flame sensor
QRI) on heat exchangers to EN 303, EN 267 and EN 676.
If the burner is not used on combustion chambers to EN 303, EN 267 and EN 676,
a safety assessment of combustion and flame stability during individual process con-
ditions and of the shutdown limits of the combustion plant has to be carried out and
documented.
The combustion air must be free from aggressive compounds (e.g. Halogens). If the
combustion air in the boiler room is contaminated, increased cleaning and servicing
will be required. In this case ducted air intake is recommended.
The burner should only be used in enclosed rooms.
Improper use could:
▪ endanger the health and safety of the user or third parties,
▪ cause damage to the appliance 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 (see Ch.
9.2).

▪ All labels on the unit must be kept in a legible condition,
▪ the unit should only be operated with its cover in the closed position,
▪ do not touch moving parts during operation,
▪ stipulated settings, service and inspection work should be carried out at regular
intervals.
2.3.2 Electrical connection

For work carried out on live parts:
▪ Observe the accident prevention instructions BGV A3 and adhere to local direc-
tives,
▪ tools in accordance with EN 60900 should be used.
83263502 • 2/2014-12 • La 8-110

2 Safety
2.3.3 Gas supply

▪ Only the gas supply company or an approved agent may carry out installation,
alteration and maintenance work on gas appliances in buildings and properties.
▪ Pipe work must be subject to a combined load and valve proving test and usability
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 installation.
▪ Local regulations and guidelines must be observed during installation (e. g.
DVGW-TRGI, work sheet G 600; TRF Band 1 and Band 2).
▪ The gas supply pipe work 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. con-
densate). Observe vaporisation pressure and vaporisation temperature of liquid
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 operating
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.
83263502 • 2/2014-12 • La 9-110

3.1 Type key

WM - GL30/2-A / ZM-R
WM Type: Weishaupt Monarch
-G Fuel: Gas
L Fuel: Fuel oil EL
30 Size
/2 Ratings size
-A Construction
/ ZM Version: sliding two stage or modulating (Gas)
-R Version: sliding two stage or modulating (Oil)
3.2 Serial number

The serial number on the name plate identifies the product. This is required by Weish-
aupt's customer service department.
1 Name plate
Serial-No.
83263502 • 2/2014-12 • La 10-110

3.3 Function
3.3.1 Air supply
Air dampers
The air dampers regulate the air quantity required for combustion. The combustion
manager controls the air dampers via stepping motor. At burner shutdown the air
dampers close automatically. This reduces heat loss in the heat exchanger.
Fan wheel
The fan wheel supplies the air from the air intake housing to the combustion head.
Flame tube
The air gap between flame tube and diffuser is adjusted by positioning the flame tube.
This adjusts the mixing pressure and the air quantity required for combustion.
Air pressure switch

The air pressure switch monitors the fan pressure. If the fan pressure is insufficient,
the combustion manager initiates a lockout.
83263502 • 2/2014-12 • La 11-110

3.3.2 Gas supply
Double gas valve 1

The double gas valve opens and shuts off the gas supply.
Gas filter 2
The gas filter protects the subsequent valve train components from foreign particles.
Gas isolating valve 3

The gas isolating valve shuts off the gas supply.
Pressure regulator 4
The pressure regulator reduces the connection pressure and ensures a constant set-
ting pressure.
High gas pressure switch 5 (optional)

The high gas pressure switch monitors the setting pressure. If the gas pressure ex-
ceeds the value set, the combustion manager initiates a controlled safety shut-
down.
The combustion manager delays the operation of the high gas pressure switch during
the start-up of the burner. During this time any possible back pressure is reduced.
Low gas pressure switch 6

The low gas pressure switch monitors the gas connection pressure. If the preset gas
pressure is not achieved, the combustion manager initiates a start prevention and/or
re-start.
83263502 • 2/2014-12 • La 12-110

Valve proving gas pressure switch 7

The valve proving gas pressure switch checks the soundness of the valves. 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.
▪ valve 1 closes,
▪ valve 2 closes after a delay,
▪ the gas escapes and the pressure between valve 1 and valve 2 reduces,
▪ both valves remain closed for 10 seconds.
If the gas pressure increases to above the set value during these 10 seconds, valve
1 is leaking. The combustion manager initiates a controlled shutdown.
▪ valve 1 opens, valve 2 remains closed,
▪ the gas pressure between valve 1 and valve 2 increases,
▪ valve 1 closes again,
▪ both valves remain closed for 10 seconds.
If the gas pressure decreases to below the set value during these 10 seconds, valve
2 is leaking. The combustion manager initiates a controlled shutdown.
Gas butterfly valve 8

The gas butterfly valve regulates the gas quantity depending on the rating required.
The combustion manager drives the gas butterfly valve via stepping motor.
V2 V1
P P P
83263502 • 2/2014-12 • La 13-110

3.3.3 Oil supply
Oil pump
The pump draws the oil through the supply line and carries it under pressure to the
oil nozzle. The pressure regulating valve keeps the oil pressure constant.
Solenoid valves
The solenoid valves open and close the oil supply.
Nozzle assembly
The pump pumps the oil through the solenoid valves and the pressure lines to the
nozzle head, where the oil is atomised by the nozzle. The integrated nozzle shut off
opens or closes the oil supply directly at the oil nozzle.
Oil quantity regulator

The oil quantity regulator is driven by the combustion manager via stepping motor. An
oil metering vee slot in the oil quantity regulator changes the spill back quantity of the
fuel and thus the atomised quantity of the oil at the nozzle. The oil quantity regulator
has two metering slots. Each metering slot is matched with a specific oil throughput.
Two identity code numbers are located on the shaft of the oil quantity regulator, which
denote the oil throughput set.
1
2 2
1
Identity code Oil throughput

1 up to 280 kg/h
2 greater than 280 kg/h
Factory setting see burner data sheet.
Max. oil pressure switch

The maximum oil pressure switch monitors the pressure in the return. If the value set
is exceeded, the burner switches off.
Min. oil pressure switch (optional)

The minimum oil pressure switch monitors the pump pressure in the supply. If the
value set is not achieved, the burner switches off.
83263502 • 2/2014-12 • La 14-110

Sequence of operation
During the pre-purge time all shut off devices are closed. For burner ignition, the
combustion manager opens solenoid valves 4 and 8, as well as the shut off device
5 in the nozzle head. The oil quantity regulator 6 is in the open position (ignition
load position). Due to the low resistance of the oil quantity regulator in the return only
a small quantity of oil is atomised at the the nozzle, the larger quantity flows to the
pump return. If the load increases, the metering slot in the oil quantity regulator is
decreased, this reduces the oil flow in the return and thus increases the oil quantity
at the nozzle outlet.
P M
1 Oil pump
2 Strainers
3 Min. oil pressure switch (optional)
4 Solenoid valve supply (fitted in flow direction)
5 Nozzle head with shut off device
6 Oil quantity regulator
7 Maximum oil pressure switch
8 Solenoid valve return (fitted against flow direction)
The solenoid valve in the supply is always switched electrically in series with the
solenoid valve in the return. The voltage of the solenoid coil is therefore 115 V at
230 V/50 Hz mains voltage.
83263502 • 2/2014-12 • La 15-110

3.3.4 Electrical components
Combustion Manager
The combustion manager W-FM is the central control unit of the burner. It controls
the sequence of operation, monitors the flame and communicates with all compo-
nents.

The ABE is used to display and alter the operational values and parameters of the
combustion manager. It is connected by connection cable and can be remove from
the burner, e. g. when commissioning.
Burner motor
The burner motor drives the fan wheel and the oil pump.
On burners without speed control the combustion manager controls a star delta
combination.
On burners with speed control a frequency converter is connected in series.
Magnetic coupling
During gas operation, the magnetic coupling decouples the oil pump from the burner
motor.
Ignition unit
The electronic ignition unit creates a spark at the electrodes, which ignites the
fuel/air mixture.
Flame sensor
The combustion manager monitors the flame signal via the flame sensor. If the flame
signal becomes too weak, the combustion manager initiates a controlled shutdown.
See installation and operating manual Combustion Manager W-FM for flame signal
required.
Limit switch
The limit switch in the hinged flange stops the burner from operating in the open
position.
83263502 • 2/2014-12 • La 16-110

3.4 Technical data
3.4.1 Approval data

PIN 2009/142/EC CE-0085 BU 0360
PIN 97/23/EG Z-IS-TAF-MUC-10-05-376456-019
DIN CERTCO 5G1044/10M
Basic standards EN 267: 2011
EN 676: 2008
EN 60335-2-102 and EN 60335-1
EN 61000-6-2 and EN 61000-6-4
3.4.2 Electrical data
Burner control
Supply voltage / frequency 230 V/50 Hz
Consumption at start max 505 W
Consumption during operation max 195 W
Internal unit fuse 6.3 AT
External fuse max 16 AT
Burner motor WM-D132/210-2/10K0

Mains voltage/Mains frequency 380 … 415 V/50 Hz
Consumption max 10.8 kW
Power consumption max 22 A
Speed min 2940 rpm
External fuse 35 A (YΔ start)
3.4.3 Ambient conditions

Temperature in operation -15 … +40 °C (Gas)
-10(1 … +40 °C (Oil)
Temperature during transport / storage -20 … +70 °C
Relative humidity max 80 %, no dew point
(1
with the relevant suitable fuel oil and layout of oil supply.
3.4.4 Permissible fuels

▪ Natural Gas E/LL,
▪ Liquid Petroleum Gas B/P,
▪ Fuel oil EL to DIN 51603-1,
▪ Fuel oil EL A Bio 10 to DIN 51603-6
▪ Fuel oil EL to ÖNORM-C1109 (Austria)
▪ Fuel oil EL to SN 181 160-2 (Switzerland).
83263502 • 2/2014-12 • La 17-110

3.4.5 Emissions
Flue gas
▪ Emission Class 2 on fuel oil EL to EN 267,
▪ Emission Class 2 on Gas to EN 676.
The NOx values are influenced by:
▪ combustion chamber dimensions
▪ flue gas system
▪ fuel
▪ combustion air (temperature and humidity)
▪ medium temperature
For combustion chamber dimensions see leaflet "Conditions for attaining the NOx
emission values for Weishaupt burners (Print No. 1539 and 972)".
Sound levels
Dyad noise emission values to ISO 4871
Measured sound power level LWA (re 1 pW) 93 dB(A)(1
Uncertainty value KWA 4 dB(A)
Measured sound pressure level LpA (re 20 µPa) 85 dB(A)(2
Uncertainty value KpA 4 dB(A)
(1
Determined to noise level measurement standard ISO 9614-2.
(2
Determined at 1 metre distance in front of the burner.
The measured noise levels plus uncertainty values form the upper limit value, which
could occur when measuring.
83263502 • 2/2014-12 • La 18-110

3.4.6 Rating
Combustion heat rating

Natural Gas 450 … 4100 kW
Liquid Petroleum Gas 600 … 4100 kW
Fuel oil 900 … 4100 kW
75.6 … 344.5 kg/h(1
Combustion head WM-G(L) 30/2
(1
The oil throughput data relates to a calorific value of 11.9 kWh/kg for fuel oil EL.
Capacity graph
Capacity graph to EN 267 and EN 676.
The ratings data given relates to an installation elevation of 0 m above sea level. For
installation elevations above 0 m a ratings reduction of approx. 1 % per 100 m applies.
A limited capacity graph is valid for ducted air intake.
Combustion heat rating at combustion head setting:
Fuel oil Natural Gas Liquid Petroleum
Gas
Combustion head 3 5 7
OPEN
Combustion head 4 6 8
CLOSED
18
16
14
12
10
8
6
4
2
0
-2
-4
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500
0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375
1 Combustion heat rating [kW] or [kg/h]

2 Combustion chamber pressure [mbar]
83263502 • 2/2014-12 • La 19-110

3.4.7 Dimensions
Burner
300 mm
212 mm
695 mm
505 mm
128 mm
256 mm
248 mm
610 mm
mm
261 mm
38
10
301 mm
380 mm
548 mm
8 mm
11
37
m m
319 mm
1146 mm
1 349 … 374 mm without combustion head extension

499 … 524 mm with combustion head extension (150 mm)
649 … 674 mm with combustion head extension (300 mm)
83263502 • 2/2014-12 • La 20-110

Mixing head
260 mm
222 mm
45 mm
3.4.8 Weight
Burner
approx. 192 kg
83263502 • 2/2014-12 • La 21-110

4 Installation
4 Installation
4.1 Installation conditions
Burner type and capacity graph

Burner and heat exchanger must be matched.
▶ Check burner type and burner rating.
Installation location
▶ Prior to installation ensure that:
▪ the space for the burner hinging range is sufficient (see Ch. 3.4.7),
▪ sufficient combustion air is available, if necessary install ducted air intake.
Prepare heat exchanger
The refractory 3 must not protrude beyond the front edge of the combustion head,
it can, however, take a conical shape (min 60°).
Refractory may not be required on boilers with water-cooled front, unless the manu-
facturer gives other instructions.
Following installation, the aperture 4 between flame tube and refractory should be
filled with flame-proof, resilient insulating material (do not make solid).
Boiler constructions with deep refractories or thick doors, or boilers with reverse flame
combustion chambers may require a combustion head extension. Head extensions
of 150 and 300 mm are available. Dimension 2 then changes according to the head
extension used.
The burner has to be hinged open by approx. 70 … 80° to allow removal of the mixing
head.
M12
60°
45°
300 mm
360 mm
305 mm
330 mm
1 Flange gasket
2 min 349 mm (combustion head OPEN)
max 374 mm (combustion head CLOSED)
3 Refractory
4 Aperture
83263502 • 2/2014-12 • La 22-110

4 Installation
4.2 Check rating

The burner as delivered is equipped with an oil nozzle type -w- S4 50°. It has been
factory pre-sized for a specific oil throughput (factory presetting see burner data
sheet).
Alternatively an oil nozzle type W S5 50°V can be used.
Pump pressure setting

20 … 30
Spray characteristic and spray angle varies depending on pump pressure.
Determine exact oil throughput at oil meter or by weighing.
Nozzle selection diagram -w- S4 50°

20 bar 22 bar 24 bar 26 bar 28 bar 30 bar
Nozzle size kW(1 kW(1 kW(1 kW(1 kW(1 kW(1
160 kg/h 1488 1558 1628 1699 1769 1839
180 kg/h 1648 1725 1803 1880 1958 2035
200 kg/h 1868 1956 2044 2133 2221 2309
225 kg/h 2118 2217 2316 2414 2513 2612
250 kg/h 2344 2452 2561 2669 2778 2886
275 kg/h 2570 2688 2806 2923 3041 3159
300 kg/h 2862 2994 3126 3258 3390 3522
330 kg/h 3142 3286 3430 3574 3718 3862
360 kg/h 3421 3578 3735 3893 4050 4207
390 kg/h 3707 3877 4047 4218 4388 4558
(1
Guaranteed minimum rating of the relevant nozzle at an oil regulator setting of 90°.
Nozzle selection table -w- S5 50°V

20 bar 22 bar 24 bar 26 bar 28 bar 30 bar
Nozzle size kW(1 kW(1 kW(1 kW(1 kW(1 kW(1
160 kg/h 1488 1558 1628 1699 1769 1839
180 kg/h 1642 1719 1797 1874 1952 2029
200 kg/h 1797 1881 1966 2050 2135 2219
225 kg/h 2041 2136 2231 2327 2422 2517
250 kg/h 2273 2378 2483 2587 2692 2797
275 kg/h 2487 2601 2715 2830 2944 3058
300 kg/h 2725 2850 2975 3100 3225 3350
330 kg/h 3011 3150 3289 3429 3568 3707
360 kg/h 3308 3459 3610 3762 3913 4064
390 kg/h 3606 3770 3934 4099 4263 4427
(1
Guaranteed minimum rating of the relevant nozzle at an oil regulator setting of 90°.
83263502 • 2/2014-12 • La 23-110

4 Installation
4.3 Set mixing head
4.3.1 Setting diagram
Determine flame tube and air damper setting

Set mixing head relative to the combustion heat rating required. Therefore the flame
tube setting and air damper setting are matched.
Do not operate the burner outside of its capacity graph.
▶ Determine the required flame tube setting (dimension S1) and air damper setting
from diagram and note down.
Example Example 7 Example 8
Burner rating required 2375 kW 3375 kW
Combustion chamber pres-
5.0 mbar 7.5 mbar
sure
Flame tube setting
95 mm 75 mm
dimension S1
(233 mm) (213 mm)
(auxiliary dimension E)
Air damper setting 54° > 80°
18
50° 60° 70°
16 40°
14
30°
12
10
8 20°
6 10°
4
2
0 70
(208)
-2
95 90 85 80 75
-4 (233) (228) (223)(218)(213)
-6
-7
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500
1 Combustion heat rating in kW

2 Combustion chamber pressure in mbar
3 Air damper setting in ° (1
4 Flame tube setting dimension S1 in mm (1
(Auxiliary dimension E in mm) (1
5 Setting range of the air dampers with flame tube setting CLOSED (95 mm)
6 Setting range for flame tube with air damper setting > 80°
(1
Different settings may be required depending on site conditions.
83263502 • 2/2014-12 • La 24-110

4 Installation
4.3.2 Set flame tube

▶ Hinge open the burner (see Ch. 9.3).
▶ Remove nozzle assembly (see Ch. 9.4).
▶ Remove mixing head (see Ch. 9.6).
▶ If necessary, adjust to optimum combustion head extension position
(see Ch. 4.3.3).
▶ Undo screws 1.
▶ Adjust flame tube until the flame tube setting determined is reached at auxiliary
dimension E.
▶ Centralise flame tube whilst checking the distance at a minimum of 3 positions
(each offset by 120°).
▶ Re-tighten screws.
▶ Fit mixing head.
E S1
4.3.3 Adjust combustion head extension (optional)
Check flame tube length.

▶ Check total length of flame tube, dimension 2, and adjust if necessary.
Extension 150 mm 300 mm
Total length 539 mm (±1) 689 mm (±1)
▶ Undo hexagonal nuts 1 on flame tube.

▶ Adjust flame tube until total length has been reached at dimension 2.
▶ Centralise flame tube whilst checking the distance at a minimum of 3 positions
(each offset by 120°).
▶ Re-tighten hexagonal nuts 1, counter-holding at the screws.
83263502 • 2/2014-12 • La 25-110

4 Installation
4.4 Burner installation

▶ Isolate the device from the power supply prior to starting any work.
DANGER ▶ Safeguard against accidental re-start.
Only valid in Switzerland

When installing and operating in Switzerland the regulations of SVGW, VKF, local
and Cantonal regulations and the EKAS guideline (LPG Guideline Part 2) must be
observed.
▶ Screw studs 4 to boiler plate.

▶ Attach hinge flange 2 with flange gasket 3 to studs.
▶ Secure hinge flange to boiler plate with nuts 1.
▶ The aperture between flame tube and refractory should be filled with flame-proof,
resilient insulating material (do not make solid).
83263502 • 2/2014-12 • La 26-110

4 Installation
▶ Using suitable lifting equipment lift burner and, using hinge pins 4, fit into hinged
flange. Observe hinging direction.
▶ Check nozzle distance and adjust if necessary (see Ch. 9.5).
▶ Connect pressure hoses ensuring correct allocation.
▶ Place ignition cables into the burner housing, close the burner and secure with
dome nut 3.
1 Supply
2 Return
▶ Open view port cover.

▶ Plug diffuser ignition cable 1 into the left socket.
▶ Plug nozzle assembly ignition cables 4 into the two sockets on the right.
▶ Fit solenoid coil plug 2.
▶ Close view port cover.
▶ Plug in plug 3 on gas butterfly valve stepping motor.
83263502 • 2/2014-12 • La 27-110

5 Installation
5 Installation
5.1 Gas supply

Gas leaks can lead to a build-up of explosive gas/air mixture. With an ignition source
present this can result in an explosion.
DANGER ▶ Install gas supply with care.
▶ Observe all safety instructions.
Only an approved gas installer may carry out the gas side connection. Observe local
regulations.
The following should be obtained from the gas supply company:
▪ Type of gas
▪ Gas connection pressure.
▪ Maximum CO2 content in the flue gas.
▪ Calorific value in normal condition [kWh/m3].
Observe maximum permissible pressure of all components of the gas valve train.
▶ Close all fuel shut off devices prior to commencing work and protect from acci-
dental re-opening.
Observe general installation instructions

▪ The stepping motor of the gas butterfly valve must be located on the opposite side
to the gas valve train, if necessary rotate gas butterfly valve by 180°.
▪ Install manually operated shut off valve (gas isolating valve) in the supply.
▪ Ensure correct mounting alignment and cleanliness of sealing surfaces.
▪ Mount valve train free of vibration. It must not be allowed to swing. Suitable sup-
ports should be fitted.
▪ Mount valve train free of tension, if necessary fit compensator parallel to the burner
shaft.
▪ The distance between burner and double gas valve should be as small as possible.
If the distance is too great it could influence the burner start.
▪ The distance between pressure regulator and double gas valve should be as small
as possible. If the distance is too great, the function of the high gas pressure switch
cannot be guaranteed.
▪ Observe sequence and flow direction of gas valve train.
▪ If necessary fit high pressure regulator (see installation and operating manual Pres-
sure regulating devices).
Breather and vent lines for high pressure regulators without safety diaphragm
should be discharged to atmosphere.
▪ If necessary, fit thermal shut off device (TAE) in front of the gas isolating valve.
Installation position
Double gas valve and pressure regulator can be positioned with the actuator axis
angled from standing vertical to lying horizontal.
83263502 • 2/2014-12 • La 28-110

5 Installation
5.1.1 Screwed valve train

▶ Mount gas valve train free of stresses.
▶ Install disconnecting point between double gas valve and isolating valve.
✓ Boiler door can still be hinged open with valve train installed.
Installation examples
1 Double gas valve

2 Gas filter
3 Gas isolating valve
4 Pressure regulators
7 High gas pressure switch (optional)
83263502 • 2/2014-12 • La 29-110

5 Installation
5.1.2 Flanged valve train
Installation location VGD (from DN 125)

▶ Install stepping motors (connection to the front).
▶ Fit intermediate plug.
✓ Plug socket 1 must be plugged into stepping motor valve 1 (inlet side).
▶ For installation to the right, change over ignition gas plate 2 and pressure switch
plate 3.
Mount gas valve train

▶ Mount gas valve train free of stresses. Do not compensate for installation errors by
over-tightening the flange screws.
▶ Ensure correct alignment of flange seals.
▶ Tighten screws evenly diagonally across.
83263502 • 2/2014-12 • La 30-110

5 Installation
1 Double gas valve

2 Gas filter
4 Pressure regulators
83263502 • 2/2014-12 • La 31-110

5 Installation
5.1.3 Fitting gas pressure switch

▶ Remove closing plugs of test points 1.
▶ Fit sealing rings 2 supplied to low gas pressure switch 3 and valve proving gas
pressure switch 4, ensuring sealing surfaces are clean.
▶ Fix gas pressure switch to the double gas valve with the screws supplied.
W-MF DMV VGD
83263502 • 2/2014-12 • La 32-110

5 Installation
5.1.4 Carry out soundness test of gas supply line and vent
Only the gas supply company or a contract installation company may carry out a
soundness test and vent the gas line.
83263502 • 2/2014-12 • La 33-110

5 Installation
5.2 Oil supply

Observe EN 12514-2, DIN 4755, TRÖI and local regulations.
Check conditions for oil pump

Suction resistance max 0.4 bar(1
Supply pressure max 5 bar(1
Supply temperature max 140 °C(1
(1
Measured at the pump.
Check conditions for oil hoses

Length 1300 mm
Oil hose connection M38 x 1.5
Threaded socket connection M38 x 1.5 x G1"
Nominal pressure 10 bar
Thermal load max 100 °C
Connect oil supply
Damage to the oil pump due to incorrect connection

Mixing up supply and return can damage the oil pump.
▶ Ensure correct connection of oil hoses to the supply and return of the pump.
CAUTION
1 Supply
2 Return
83263502 • 2/2014-12 • La 34-110

5 Installation
▶ Connect oil supply and observe:

▪ Do not twist oil hoses,
▪ avoid mechanical tension,
▪ ensure sufficient hose length for the burner hinge range
▪ do not kink oil hoses (curve radius 1 of 165 mm must be maintained).
If these conditions for connection cannot be met:
▶ Adapt oil supply on site.
Purge oil supply and ensure it is tight
Damage to oil meter in oil circulating device resulting from purging

If an oil circulating device is fitted, the purging process could damage the integrated
oil meter.
CAUTION ▶ Replace oil meter with adapter during purging.
Oil pump seized due to running dry

The pump could be damaged.
▶ Fill oil supply with oil and purge.
CAUTION
▶ Check oil supply is tight.
83263502 • 2/2014-12 • La 35-110

5 Installation
5.3 Electrical connection

Electric shock caused by frequency converter despite disconnection from the

voltage supply
It is possible that electrical components on burners with frequency converters con-
WARNING tinue to carry voltage and cause electric shock even after the voltage supply has been
disconnected.
▶ Wait approx. 5 minutes before commencing work.
✓ Electric voltage has dissipated.
The electrical connection must only be carried out by qualified electricians. Observe
local regulations.
Carry out electrical connection in such a way that the burner can still be hinged open.
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 AT pre-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 supplied
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 current
of the pre-fusing (maximum 16 AT).
All other cable connections must be suitable for the relevant internal unit fuse
(6.3 AT).
Earthing and neutral conductor must conform to local regulations.
The following applies for cable length:
▪ all cable lengths maximum 100 m,
▪ use only original Weishaupt parts as Bus line,
▪ install Bus line as line configuration.
Connect gas valve train
Observe wiring diagram enclosed.
▶ Connect double gas valve (plug K32 / Y2):
▪ Solenoid coil on W-MF or DMV
▪ Stepping motor on VGD (see Ch. 5.1.2)
▶ Connect low gas pressure switch (plug B31 / F11).
▶ Connect valve proving gas pressure switch (plug B32 / F12).
▶ If required, connect high gas pressure switch (plug B33 / F33).
▶ Connect 10 core connection cable (use cable entry W-FM).
83263502 • 2/2014-12 • La 36-110

5 Installation
Connect burner motor

The motor must be protected against thermal overload and short circuit. The use of
a motor protection switch is recommended.
▶ Open terminal box on motor.
▶ Connect voltage supply to wiring diagram enclosed, observe motor rotation.
Speed control (optional)
If the frequency converter is located on the motor, the cable to the frequency converter
is not screened.
If the frequency converter is separate the control line and the motor connection must
be screened:
▶ Apply screen to the designated screen clamp on frequency converter.
▶ Use screen cable glands (metal) on the burner.
83263502 • 2/2014-12 • La 37-110

6 Operation
6 Operation
For further instruction see installation and operating manual Combustion Manag-
er W-FM 100/200.
Setpoint 80°C
ActValue 78°C
Load 100%
Flame 98.5%
1 4 line display with scroll function

2 Dial knob to scroll through menus and/or to alter values
3 [ENTER] key for selection
4 [esc] key (1 to return or abort
5 [info] key to return to operating display
(1
Escape
OFF function
▶ Press [ENTER] and [esc] simultaneously.
✓ Immediate lockout.
✓ The lockout is stored in the fault history.
83263502 • 2/2014-12 • La 38-110

7 Commissioning
7 Commissioning
7.1 Prerequisite
Only correctly carried out commissioning ensures the operational safety of the burner.
▶ Prior to commissioning ensure that:
▪ all assembly and installation work has been carried out correctly
▪ sufficient combustion air is available, if necessary install ducted air intake
▪ the annulus between flame tube and heat exchanger is filled
▪ the heat exchanger is filled with medium
▪ all regulating, control and safety devices are functioning and set correctly
▪ the flue gas ducts are unimpeded
▪ a measuring point conforming to standards is available to measure the flue gas
▪ the heat exchanger and flue gas ducting up to the test point are sound (extra-
neous air influences the test results)
▪ the operating instructions of the heat exchanger are complied with
▪ a heat demand is available
Additional system-related tests could be necessary. Please observe the operating
guidelines for the individual components.
On installations with process equipment, the conditions for safe operation and com-
missioning as detailed in worksheet 8-1 (Print No. 1880) must be met.
7.1.1 Connect measuring devices
Pressure measuring device for mixing pressure

▶ Open pressure test point in front of the mixing head 1 and connect pressure
measuring device.
83263502 • 2/2014-12 • La 39-110

7 Commissioning
Oil pressure measuring devices on oil pump
Oil leakage from oil pressure measuring devices due to constant load
Oil pressure measuring devices could be damaged and cause environmental pollution
through leakage.
WARNING ▶ Close or remove oil pressure measuring devices once commissioning is complete.
▪ Vacuum gauge for suction resistance/supply pressure.
▪ Pressure gauge for pump pressure.
▶ Close fuel shut off devices.
▶ Remove closing plug on the pump.
▶ Connect vacuum gauge 1 and pressure gauge 2.
-1 9
Oil pressure measuring device connected to the return line
through leakage.
Pressure gauge for return pressure.
▶ Remove bypass plug from the return line for pressure gauge 1.
▶ Connect pressure gauge.
83263502 • 2/2014-12 • La 40-110

7 Commissioning
7.1.2 Check gas connection pressure
Minimum connection pressure
Add the combustion chamber pressure in mbar to the minimum connection pressure.
The connection pressure should not fall below 15 mbar.
▶ Determine minimum connection pressure for low pressure installations from table
(see Ch. 7.1.7).
Maximum connection pressure

With low pressure supplies, pressure regulators to EN 88-1 with safety diaphragm
are used. Maximum connection pressure into isolating valve is 300 mbar.
With high pressure supplies high pressure regulators with safety assemblies are se-
lected from the following brochures:
▪ Pressure regulators up to 4 bar, Print No. 12
▪ Pressure regulators with safety devices, Print No. 1979.
Maximum connection pressure on high pressure installations see name plate.
Check connection pressure
Risk of explosion due to excess gas pressure

Exceeding the maximum connection pressure (see name plate) can damage the gas
valve train and lead to an explosion.
DANGER ▶ Check gas connection pressure.
▶ Fit pressure measuring device to gas filter (with high pressure supplies the inlet of
the pressure regulator is already equipped with a pressure measuring device).
▶ Slowly open isolating valve whilst checking the pressure increase.
If the measured connection pressure exceeds the maximum connection pressure:
▶ Immediately close isolating valve.
▶ Do not start plant.
▶ Inform system operator.
83263502 • 2/2014-12 • La 41-110

7 Commissioning
7.1.3 Check soundness of gas valve train
Soundness test
▶ Carry out soundness test:
▪ prior to commissioning,
▪ after servicing.
Valid for all test phases:
Test pressure 100 … 150 mbar
Waiting time for pressure equalisation 5 minutes
Test time 5 minutes
Permissible pressure loss max 1 mbar
First test phase

In the first phase the valve train section from the gas isolating valve up to the first valve
of the double gas valve is tested.
▶ Switch off burner.
▶ Connect test gauges to gas filter and inlet to valve 1 (low gas pressure switch).
▶ Open test point between valve 1 and valve 2.
▶ Carry out soundness test.
With high pressure regulators it is possible that the safety vent valve (SBV) responds
prior to the test pressure being achieved.
▶ Close vent line for soundness test.
▶ It is important to re-open vent line after commissioning.
Second test phase
In the second phase the interspace in the double gas valve is tested.
▶ Connect test gauge to test point between valve 1 and valve 2
(double gas valve).
▶ Carry out soundness test.
▶ Close all test points.
1 First test phase

2 Second test phase
83263502 • 2/2014-12 • La 42-110

7 Commissioning
Third test phase

In the third test phase, the valve train section from outlet of double gas valve to the
seal point between gas butterfly valve and hinge flange is checked. Carry out test
phase with the burner operating in partial and full load. Use an approved leak detecting
spray or gas detector for testing.
Use only leak detecting foam solutions, which do not cause corrosion (see
DVGW-TRGI, work sheet G 600).
▶ Check all components, intersections and test points of the valve train between
double gas valve and hinge flange.
▶ Document result of the soundness test on the engineers report.
Test points
W-MF 5xx DMV 525 DMV 5065 ... 5100 VGD 40
1 Pressure into valve 1

2 Pressure between valve 1 and valve 2
3 Pressure after valve 2
83263502 • 2/2014-12 • La 43-110

7 Commissioning
7.1.4 Check high pressure regulator type 06/1 … 09/1 and 1/1 …
5/1
The setting and function of the safety valves of the pressure regulating device must
be checked.
For detailed information see leaflet:
1. Check function of safety shut off valve (SAV)
▶ Seal vent line with sealing washer.
▶ Connect test equipment.
▶ Increase pressure to 350 mbar.
✓ SAV must respond.
If the SAV does not respond:
▶ De-energise spring until the SAV responds.
2. Check soundness of safety shut off valve (SAV)
The SAV has responded.
▶ Open and close isolating valve.
▶ Open test point between high pressure regulator and double gas valve.
The pressure enclosed between the gas isolating valve and the high pressure regu-
lator must not decrease.
▶ Close test point.
3. Check function of safety vent valve (SBV)
▶ Reset SAV.
▶ Remove sealing washer from vent line.
▶ Increase pressure.
✓ SBV must open, before SAV responds.
4. Check zero shut off
▶ Open isolating valve and wait, until the output pressure of the regulator is constant.
The pressure difference between input and output pressure of the regulator must
remain constant.
83263502 • 2/2014-12 • La 44-110

7 Commissioning
7.1.5 Check high pressure regulator type 5/1-25/50 …

9/1-100/150
The setting and function of the safety valves of the pressure regulating device must
be checked.
1. Check function of safety shut off valve (SAV)
To be able to check the SAV, the vent pressure of the safety vent valve (SBV) must
be higher than the release pressure of the SAV.
▶ Energise spring on safety vent valve.
▶ Connect test equipment.
▶ Increase pressure to 350 mbar.
✓ SAV must respond.
If the SAV does not respond:
▶ De-energise spring until the SAV responds.
2. Set safety vent valve (SBV)
▶ De-energise spring on SBV to 300 mbar vent pressure.
3. Check soundness of safety shut off valve (SAV)
The SAV has responded.
▶ Open and close isolating valve.
▶ Open test point between high pressure regulator and double gas valve.
The pressure enclosed between the gas isolating valve and the high pressure regu-
lator must not decrease.
▶ Close test point.
▶ Reset SAV.
4. Check zero shut off
▶ Open isolating valve and wait, until the output pressure of the regulator is constant.
The pressure difference between input and output pressure of the regulator must
remain constant.
83263502 • 2/2014-12 • La 45-110

7 Commissioning
7.1.6 Venting the gas valve train

The test burner must not be used to vent the gas valve train.
▶ If necessary, fit test nipple in front of valve 1 (see Ch. 7.1.3).

▶ Open test nipple and connect an approved vent hose.
▶ Vent hose must lead to atmosphere.
▶ Open gas isolating valve.
✓ The gas/air mixture in the valve train vents via the hose to safe atmosphere.
▶ Remove vent hose and immediately close test point.
▶ Use a test burner to ensure no air is present in the valve train.
✓ The line must be completely vented.
83263502 • 2/2014-12 • La 46-110

7 Commissioning
7.1.7 Preset pressure regulator
Determine setting pressure
Add the combustion chamber pressure in mbar to the setting pressure into double
gas valve.
▶ Determine setting pressure from the table and note down.

The details given for calorific value Hi relate to 0 °C and 1013 mbar.
The table values have been calculated under ideal conditions. The values are therefore
guide values for basic settings.
Full load in kW Min. connection pressure into isolat- Setting pressure into double gas valve
ing valve in mbar (low pressure supply) in mbar
Nominal diameter valve 1” 1½” 2” DN DN DN DN 1” 1½” 2” DN DN DN DN
train 65 80 100 125 65 80 100 125
Natural Gas E (N); Hi = 37.26 MJ/m3 (10.35 kWh/m3); d = 0.606
1700 - 110 42 24 17 14 13 84 59 21 14 11 10 9
2000 - 151 56 32 22 17 16 115 80 29 18 15 13 12
2300 - 198 72 40 28 21 19 - 105 37 23 19 16 15
2600 - 251 90 49 34 25 22 - 134 46 28 23 19 18
3000 - - 117 63 42 30 27 - - 60 36 28 23 22
3400 - - 147 77 50 35 30 - - 73 42 33 27 25
3800 - - 180 92 58 40 34 - - 88 50 38 30 28
4100 - - 207 105 66 44 37 - - 101 56 42 33 31
Natural Gas LL (N); Hi = 31.79 MJ/m3 (8.83 kWh/m3); d = 0.641
1700 - 158 58 32 22 17 15 120 84 29 18 15 12 12
2000 - 216 78 43 29 22 19 - 115 39 24 19 16 15
2300 - 284 101 54 36 26 23 - - 51 30 24 20 19
2600 - - 126 67 44 31 27 - - 63 37 29 24 22
3000 - - 164 85 55 38 33 - - 81 47 36 29 27
3400 - - 207 105 66 45 38 - - 101 56 43 34 31
3800 - - 255 128 79 52 44 - - 123 67 50 39 36
4100 - - 294 146 89 58 48 - - - 76 56 43 39
Liquid Petroleum Gas(1; Hi = 25.89 kWh/m3; d = 1.555
1700 129 50 21 14 12 10 10 37 27 12 9 8 7 7
2000 178 67 28 18 14 12 12 51 37 16 11 10 9 9
2300 233 87 36 23 17 15 14 67 48 20 14 12 11 11
2600 296 110 44 27 21 17 16 84 60 24 17 15 13 13
3000 - 144 56 34 25 20 19 110 79 31 21 18 16 16
3400 - 182 69 41 30 24 22 140 99 38 25 21 19 18
3800 - 225 84 48 34 27 24 - 121 45 29 24 21 20
4100 - 260 96 54 38 29 26 - 140 51 32 27 23 22
(1
The selection for Liquid Petroleum Gas is calculated for Propane, it can however, also be used for Butane.
83263502 • 2/2014-12 • La 47-110

7 Commissioning
Preset setting pressure

▶ Check setting pressure range of spring fitted.
▶ If necessary replace spring (see Ch. 9.19).
▶ Close isolating valve 2.
▶ Remove end cap 1 and de-energise pressure regulator.
▶ Open test point into valve 1 and connect test gauge 4.
▶ Slowly open isolating valve and using the test burner 3 vent back pressure into
valve 1.
▶ Energise regulator and pre-set setting pressure determined:
▪ Clockwise rotation (+) = increase pressure
▪ Anticlockwise rotation (-) = decrease pressure
▶ Refit end cap.
7.1.8 Preset gas and air pressure switch

The presetting of the pressure switches is only valid during commissioning. Once
commissioning has been completed the pressure switches must be set correctly
(see Ch. 7.3).
Air pressure switch
without speed control approx. 15 mbar
with speed control approx. 3 mbar
Low gas pressure switch approx. ½ control pressure
High gas pressure switch approx. twice control pressure
Valve proving gas pressure switch approx. ½ control pressure(1
(1
The value must be greater than the maximum mixing pressure present during pre-
purge and less than the static pressure present.
83263502 • 2/2014-12 • La 48-110

7 Commissioning
7.2 Adjusting the burner

In addition to this chapter, the installation and operating manual Combustion Manager
W-FM 100/200 should be observed. This document contains detailed information
about:
▪ menu structure and navigation,
▪ parameter settings,
▪ editing of load points,
▪ function, etc.
Prerequisite
▶ Switch on voltage supply.
1. Switch off burner
The ABE is in Operating display in the sub menu Normal operation and
displays current values.
▶ Exit level using the [esc] key.
▶ Select Manual operation.
▶ Select Auto/Manual/Off.
▶ Set Burner Off.
✓ The burner switches off.
2. Enter password
▶ Select Param & Display.
▶ Select Access with HE (password for heating engineer).
▶ Enter HE password using dial knob and confirm with [ENTER] key.
3. Select fuel
Fuel can be selected via:
▪ external fuel selection switch,
▪ via ABE,
▪ via BMS system.
The external selection switch takes precedence. Only the fuel selected with the switch
can be used for commissioning.
Select fuel via ABE:

▶ Select Operation.
▶ Select Fuel.
▶ Select Fuel selection.
▶ Select fuel using dial knob and confirm with [ENTER] key.
83263502 • 2/2014-12 • La 49-110

7 Commissioning
7.2.1 Adjusting gas side
Prerequisite
✓ Gas pressure in gas valve train increases.
▶ Close isolating valve.
▶ Select Compound.
▶ Select Setting Gas.
▶ Select LoadLimits.
▶ Select MinLoad_Gas and set 0.0%.
▶ Select MaxLoad_Gas and set 100%.
▶ Use [esc] key to return to the display Load limits.
▶ Select Special positions.
▶ Select Ignition position.
▶ Select IgnPosGas (gas butterfly valve setting in ignition position).
▶ Check IgnPosGas (approx. 8.0° … 13.0° ).
▶ Use [esc] key to return to the display Ignition position.
▶ Select Program stop.
▶ Select 36 IgnPos.
▶ Use [esc] key to return to the display with Setting gas.
▶ Select Burner ON.
▶ Check rotation direction of burner motor.
✓ The burner starts and stops in ignition position without flame formation.
The mixing pressure in ignition position must be between 0.5 … 2 mbar above the
combustion chamber pressure.
▶ If necessary, adjust mixing pressure via air damper setting (IgnPosAir):
▪ Select Setting Gas.
▪ Select Special positions,
▪ Select Ignition position.
▪ Select IgnPosAir and adjust.
4. Check gas valves
▶ Set Program stop to 44 Interv 1.
▶ Ensure that the valves open and close correctly.
✓ The burner tries to ignite.
The low gas pressure switch is activated.
5. Ignition
✓ The burner restarts the function sequence.
It ignites and the stepping motors stop in the ignition position.
▶ Preset setting pressure on pressure regulator taking the expected combustion
chamber pressure into consideration (see Ch. 7.1.7).
▶ Determine combustion values at ignition position.
▶ Set O2 content of approx. 4 … 5 % via gas butterfly valve setting (IgnPosGas).
83263502 • 2/2014-12 • La 50-110

7 Commissioning

▶ Set Program stop to deactivated.
▶ Use [esc] key to return to the display Special positions.
▶ Select CurveParam.
▶ Press [ENTER] key.
✓ Point 1 is displayed.
▶ Check combustion values
▶ Adjust air damper setting (Air) and gas butterfly valve setting (Burn):
▪ Press [ENTER] key.
▪ Select Change point?.
▪ Select Stepping motor positions with start.
▪ Call up and change values with dial knob and [ENTER] key.
▪ Exit point 1 using [esc] key and save with [ENTER] key.
▶ Press [esc] key.
The menu displays Point, Manual and the current values of the burner.
▪ In menu Point all load points can be adjusted.
▪ In menu point Manual the current burner rating can be adjusted manually.
▶ Select Manual.
▶ Increase burner rating using dial knob whilst observing combustion values (excess
air) and flame stability.
▶ Set new intermediate load point using [ENTER] key if either:
▪ the CO content increases,
▪ or the flame reaches the limit of stability.
✓ The new intermediate load point is saved as point 2. The display automatically
changes to menu Point.
▶ Correct combustion values via gas butterfly valve position (Burn).
▶ Exit intermediate load point using the [esc] key and save with [ENTER] key.
▶ Repeat steps until full load (Load: 100) has been reached.
7. Adjust full load
When adjusting full load, the ratings data given by the boiler manufacturer and the
capacity graph of the burner should be observed (see Ch. 3.4.6).
▶ Calculate gas throughput (operating volume VB) to be set (see Ch. 7.6).
▶ In the full load point, set the position of the gas butterfly (Burn) to approx. 60.0
… 70.0°.
▶ Adjust setting pressure at the pressure regulator until gas throughput (VB) is ach-
ieved.
▶ Check combustion values.
▶ Determine combustion limit and set excess air (see Ch. 7.5).
▶ Re-determine gas throughput.
▶ 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.
▶ Drive to point 1 in menu Point, whilst observing the combustion values.
▶ Check combustion values and correct if necessary.
▶ Carry out ratings apportionment (see Ch. 7.7).
the required partial load. However, it must lie within the capacity graph of the burner.
83263502 • 2/2014-12 • La 51-110

7 Commissioning

▶ Delete all load points except for point 1 and full load (Load: 100).

Increase the burner rating starting at point 1 to set new intermediate load points up
to full load.

▶ Increase burner rating in menu Manual, whilst observing combustion values.

▶ Set new intermediate load point using [ENTER] key.
▶ Optimise combustion at intermediate load point.
▶ Repeat step for each load point.

▶ Restart burner in Manual operation.
▶ Check start behaviour and if necessary correct air damper setting in ignition posi-
tion (IgnPosAir).
If the ignition load setting has been changed:
▶ Re-check start behaviour.
12. Define partial load
▶ Select MinLoad.
▶ Define and set partial load whilst:
▪ observing instructions given by the boiler manufacturer,
▪ observing the capacity graph of the burner (see Ch. 3.4.6).
13. Set burner to Automatic Operation
▶ Set Automatic.
▶ If necessary parameterise load controller.
14. Data backup

▶ Select Updating.
▶ Select Param backup.
▶ Select LMV → AZL.
▶ Start data backup by pressing [ENTER] key.
✓ The values have been backed up from the combustion manager to the ABE.
83263502 • 2/2014-12 • La 52-110

7 Commissioning
7.2.2 Adjusting oil side
Prerequisite
▶ Open oil shut off devices.
▶ Select Compound.
▶ Select Setting oil.
▶ Select MinLoad_Oil and set 0.0%.
▶ Select MaxLoad_Oil and set 100%.
▶ Use [esc] key to return to the display Load limits.
The setting of the oil quantity regulator in ignition position is pre-set when supplied
(see burner data sheet).
▶ Select Special positions.
▶ Select Ignition position.
▶ Select IgnPosOil (setting oil quantity regulator in ignition position).
▶ Check IgnPosOil (approx. 31.0 … 47.0°).
▶ Use [esc] key to return to the display Ignition position.

▶ Select Program stop.
▶ Set 36 IgnPos.
▶ Use [esc] key to return to the display with Setting oil.
▶ Set Burner On.
▶ Check rotation direction of fan wheel.
✓ The burner starts and stops in ignition position without flame formation.
The mixing pressure in ignition position must be between 2 … 4 mbar above the
combustion chamber pressure.
▶ If necessary, adjust mixing pressure via air damper setting (IgnPosAir):
▪ Select Setting oil,
▪ Select Special positions,
▪ Select Ignition position.
▪ Select IgnPosAir and adjust.
In oil operation, the ignition speed should be 100 %.
83263502 • 2/2014-12 • La 53-110

7 Commissioning

The pressure in ignition position must be 28 … 30 bar, adjust if required.
▶ Check pressure at the pressure gauge.
▶ Remove end cap 1.
▶ Undo locknut 2.
▶ Set pressure using pressure regulating screw.
▪ Clockwise rotation = increase pressure
▪ Anticlockwise rotation = decrease pressure
5. Ignition
▶ Set Program stop to 44 Interv 1.
✓ The burner ignites and the stepping motors stop in the ignition position.
▶ Determine combustion values in ignition position.
▶ Set O2 content of approx. 5 % by positioning oil quantity regulator (IgnPosOil)
whilst observing return pressure and maintaining 8 bar.
83263502 • 2/2014-12 • La 54-110

7 Commissioning

▶ Set Program stop to deactivated.
▶ Use [esc] key to return to the display Special positions.
▶ Select CurveParam and CurveSet.
▶ Press [ENTER] key.
✓ Point 1 is displayed.
Point 1 has been factory preset to a specific oil throughput (see burner data sheet).
▶ Check combustion values
▶ If necessary adjust air damper setting (Air):
▪ Press [ENTER] key.
▪ Select Change point?.
▪ Select Stepping motor positions with start.
▪ Call up and change values with dial knob and [ENTER] key.
▪ Exit point 1 using [esc] key and save with [ENTER] key.
▶ Press [esc] key.
The menu displays Point, Manual and the current values of the burner.
▪ In menu Point all load points can be adjusted.
▪ In menu point Manual the current burner rating can be adjusted manually.
▶ Select Manual.
▶ Increase burner rating using dial knob whilst observing combustion values (excess
air) and flame stability.
▶ Set new intermediate load point using [ENTER] key if either:
▪ The soot limit has been reached
▪ or the flame reaches the limit of stability.
✓ The new intermediate load point is saved as point 2. The display automatically
changes to menu Point.
▶ Correct combustion values via oil quantity regulator position (Burn).
▶ Exit intermediate load point using the [esc] key and save with [ENTER] key.
▶ Repeat steps until full load (Load: 100) has been reached.
7. Adjust full load
When adjusting full load, the ratings data given by the boiler manufacturer and the
capacity graph of the burner should be observed (see Ch. 3.4.6).
The burner has been factory pre-sized for a specific oil throughput (see burner data
sheet).
▶ 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
(Burn) until the oil throughput required is achieved.
▶ Check combustion values.
▶ Determine combustion limit and set excess air (see Ch. 7.5).
83263502 • 2/2014-12 • La 55-110

7 Commissioning
▶ Drive to point 1 in menu Point, whilst observing the combustion values.
▶ Check combustion values and correct if necessary.
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 %.

the required partial load. However, it must lie within the capacity graph of the burner.

▶ Delete all load points except for point 1 and full load (Load: 100).

Increase the burner rating starting at point 1 to set new intermediate load points up
to full load.

▶ Increase burner rating in menu Manual, whilst observing combustion values.

▶ Set new intermediate load point using [ENTER] key.
▶ Optimise combustion at intermediate load point.
▶ Repeat step for each load point.
83263502 • 2/2014-12 • La 56-110

7 Commissioning

▶ Restart burner in Manual operation.
▶ Check start behaviour and if necessary correct air damper setting in ignition posi-
tion (IgnPosAir).
If the ignition load setting has been changed:
▶ Re-check start behaviour.
12. Define partial load
▶ Select MinLoad.
▶ Define and set partial load whilst:
▪ observing instructions given by the boiler manufacturer,
▪ Maintain return pressure of 8 bar.
▪ observing the capacity graph of the burner (see Ch. 3.4.6).
13. Set burner to Automatic Operation
▶ Set Automatic.
▶ If necessary parameterise load controller.
14. Data backup

▶ Select Updating.
▶ Select Param backup.
▶ Select LMV → AZL.
▶ Start data backup by pressing [ENTER] key.
✓ The values have been backed up from the combustion manager to the ABE.
83263502 • 2/2014-12 • La 57-110

7 Commissioning
7.3 Set pressure switches
7.3.1 Set oil pressure switch
Minimum oil pressure switch in supply (optional)

▶ Remove end cap.
▶ Set minimum oil pressure switch in the supply to 5 bar below the minimum pump
pressure.
▶ Refit end cap.
Maximum oil pressure switch in the return
▶ Remove end cap.
▶ Set max. oil pressure switch in the return to 5 bar, or for ring main operation set to
5 bar above the ring main pressure.
▶ Refit end cap.
83263502 • 2/2014-12 • La 58-110

7 Commissioning
7.3.2 Set gas pressure switch
Set low gas pressure switch

The switch point must be checked and if necessary adjusted during commissioning.
▶ Connect pressure measuring device to test point 1 of the low gas pressure switch.
▶ Start burner and drive to full load.
▶ Slowly close gas isolating valve until either:
▪ the O2 content in the flue gas increases to above 7 %,
▪ the flame stability considerably worsens,
▪ the flame signal falls to below 65 %,
▪ or the gas pressure drops to 70 %.
▶ Determine gas pressure.
▶ Set the gas pressure determined as switch point at the setting cam 2.
Check switch point
▶ Drive burner to 40 … 50 % of the rating.
✓ The gas pressure drops.
If the combustion manager switches off the burner, the low gas pressure switch has
been set correctly.
If the combustion manager initiates a controlled shutdown, the low gas pressure
switch operates too late. In this case:
▶ Increase switch point at setting cam 2.
▶ Re-check switch point.
20
30
150
50
130
70
11
0
90
83263502 • 2/2014-12 • La 59-110

7 Commissioning
Set valve proving gas pressure switch

▶ Use test burner 2 to reduce static pressure.
▶ Determine static pressure (PR) into valve 1 1.
▶ Switch on burner.
▶ Determine maximum pressure during pre-purge (PV) after valve 2 4.
▶ Calculate setting pressure for the valve proving gas pressure switch using the
following formula.
Setting pressure
▶ Set setting pressure at valve proving gas pressure switch 3.

✓ The burner must carry out the valve proving without going to lockout.
Set high gas pressure switch (optional)

▶ Set high gas pressure switch to 1.3 × PF (flow pressure at full load).
83263502 • 2/2014-12 • La 60-110

7 Commissioning
7.3.3 Set air pressure switches

The switch point must be checked and if necessary adjusted during commissioning.
▶ Remove closing cap 4 from air pressure switch.
▶ Connect pressure inlet of pressure measuring device 2 to the air pressure switch.
▶ Connect low pressure hose 1 to pressure measuring device using a T piece.
▶ Start the burner.
▶ Carry out differential pressure measurement across the whole ratings range and
determine the lowest differential pressure.
▶ Set 80 % of the determined differential pressure at the setting cam 3.
Example Lowest differential pressure 32 mbar
Switch point air pressure switch (80 %) 32 mbar × 0.8 = 25.6 mbar
Site specific influences on the air pressure (e.g. by the flue gas system, heat ex-
changer, installation location or air supply), may make it necessary to vary the setting
of the air pressure switch.
83263502 • 2/2014-12 • La 61-110

7 Commissioning
7.4 Concluding work

through leakage.
▶ Check and adjust the function of all regulating, control and safety devices of the
installation during operation.
▶ Remove gas pressure measuring devices and close all test points.
▶ Conclude valve proving of gas valve train (third test phase) (see Ch. 7.1.3).
▶ Check tightness of oil carrying components.
▶ Enter combustion values and settings in the commissioning record and/or test
sheet.
▶ Inform the operator about the use of the equipment.
▶ Hand the installation and operating manual to the operator and inform him that this
should be kept with the appliance.
▶ Point out to operator that the installation should be serviced annually.
83263502 • 2/2014-12 • La 62-110

7 Commissioning
7.5 Check combustion

Carry out flue gas measurements to ensure environmentally friendly, economical and
reliable operation of the installation.
Determine excess air

▶ Slowly close the air damper in the relevant operating point, until combustion limit
is reached (CO content approx. 100 ppm or soot 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 intake air,
- fluctuating intake temperature,
- fluctuating chimney draught.
Example
▶ Set air number (λ*), do not exceed CO content of 50 ppm.

▶ Measure and document O2 content.
▶ Check flue gas temperature
▶ Ensure that the flue gas temperature complies with the data supplied by the boiler
manufacturer.
▶ If necessary adjust flue gas temperature, e g.:
▪ Increase burner rating in partial load to avoid condensation in the flue gas ducts
(except on condensing units).
▪ Reduce burner rating in full load to improve efficiency.
▪ Adjust heat exchanger to the data supplied 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:
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
83263502 • 2/2014-12 • La 63-110

7 Commissioning
7.6 Calculate gas throughput

Formula symbol Explanation Example values
VB Operating volume [m3/h]. -
Volume measured at gas meter at current pressure and tempera-
ture (gas throughput)
VN Standard volume [m3/h] -
Volume gained by gas at 1013 mbar and 0 °C
f Conversion factor -
QN Heat rating [kW] 560 kW
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 Gas pressure at gas meter [mbar] 30 mbar
PBaro Barometric air pressure [mbar] (see table) 500 m ≙ 955 mbar
VG Gas throughput determined at gas meter 2 m3
TM Time measured during gas throughput (VG) 117 seconds
Determine the normal volume

▶ Calculate the normal volume (VN) using the following formula.
.
. .
Calculate conversion factor

▶ Determine gas temperature (tGas) and gas pressure (PGas) at gas meter.
▶ Determine air pressure (PBaro) from the 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.
Determine operating volume (gas throughput) required
.
.
.
Measure 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.
83263502 • 2/2014-12 • La 64-110

7 Commissioning
7.7 Ratings apportionment

▶ Assign rating [%] for load point to the following formula.
▶ Enter the calculated rating for load point in Load.
83263502 • 2/2014-12 • La 65-110

8 Shutdown
8 Shutdown
For breaks in operation:
83263502 • 2/2014-12 • La 66-110

9 Servicing
9 Servicing

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 system com-
ponents.
▶ Tightly close the screws on the test points ensuring the tests points are sealed.

Danger of getting burned on hot components

Hot components can lead to burns.
▶ Allow components to cool.
WARNING
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 (see Ch.
9.2).
Weishaupt recommends a service contract is entered into to ensure regular inspec-

tions.
The following components must only be replaced and must not be repaired in any
way:
▪ combustion manager
▪ flame sensor
▪ actuators (stepping motors)
▪ oil solenoid valves
▪ gas valves
▪ pressure regulator
▪ pressure switch.
83263502 • 2/2014-12 • La 67-110

9 Servicing
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.
Following servicing
▶ Check tightness of oil and gas carrying components.
▶ Check function of:
▪ ignition,
▪ flame monitoring,
▪ oil pump (pump pressure and suction resistance),
▪ gas carrying components (gas inlet and outlet pressure),
▪ pressure switch
▪ safety interlock circuit.
▶ Check combustion values, if necessary re-adjust the burner.
▶ Enter combustion values and settings in the commissioning record and/or test
sheet.
83263502 • 2/2014-12 • La 68-110

9 Servicing
9.2 Service plan

Components Criteria Service procedure
Fan wheel Soiling ▶ Clean
Damage ▶ Replace
Coupling cross on coupling Wear ▶ Replace
centre piece Recommendation: at least every 2 years
Air duct Soiling ▶ Clean
Air dampers Soiling ▶ Clean
Distance to housing 0.5 mm ±0.1 ▶ Adjust air dampers
Sleeve bearing air damper shaft Has play > 0.2 mm ▶ Replace
Foam parts of air regulator Damage/brittleness/soiling ▶ Replace
View port cover Air escaping ▶ Replace
Ignition cable Damage ▶ Replace
Ignition electrodes Soiling ▶ Clean
Damage/wear ▶ Replace
Combustion Manager 250 000 start-ups reached ▶ Recommendation: replace
(equal to approx. 10 years)
Flame sensor Soiling ▶ Clean
Damage ▶ Replace
Pressure switch Switch point ▶ Check
Flame tube/diffuser Soiling ▶ Clean
Damage ▶ Replace
Oil nozzle Soiling/wear ▶ Replace
Recommendation: at least every 5 years
Oil hoses Damage/oil escaping ▶ Replace
Pressure hoses nozzle assembly Damage/oil escaping ▶ Replace
Oil regulator Excess air due to wear ▶ Adjust burner
Hysteresis behaviour/damage/oil escap- ▶ Replace
ing
Oil solenoid valves Soundness ▶ Replace
Recommendation: at least every 10
years
Double gas valve/multifunction Damage/soundness ▶ Replace
assembly
Gas pressure regulator Control pressure ▶ Check
Damage/soundness ▶ Replace
Filter insert multifunction as- Soiling ▶ Replace
sembly/gas filter
83263502 • 2/2014-12 • La 69-110

9 Servicing
9.3 Hinge open the burner

Observe notes on servicing (see Ch. 9.1).
Damage to oil hoses due to mechanical strain

If oil hoses are leaking, oil can escape and lead to environmental damage.
▶ Avoid mechanical strain on the oil hoses when hinging open the burner.
WARNING
▶ Check hinge pin 1 on burner flange is fitted correctly.

▶ Remove view port cover.
▶ Unplug ignition cables 2.
▶ Remove plug from solenoid coil 3.
▶ Remove dome nut.
▶ Carefully hinge open the burner.
83263502 • 2/2014-12 • La 70-110

9 Servicing
9.4 Removing and refitting nozzle assembly

Removing
▶ Hinge open the burner.
▶ Undo screw 1, until it is flush with the mixing tube 2.
▶ Pull out nozzle assembly.
If the hinge range of the burner is limited:
▶ Place nozzle assembly into burner housing prior to hinging open.
Refitting
▶ Refit nozzle assembly in reverse order ensuring that the retainer 2 is horizontally
flush with the end of the mixing head.
▶ Set nozzle distance (see Ch. 9.5).
83263502 • 2/2014-12 • La 71-110

9 Servicing
9.5 Set nozzle distance

▶ Hinge open the burner (see Ch. 9.3).
The nozzle distance dimension A is set using the auxiliary dimension 1 between
mixing head and/or retainer and nozzle head solenoid coil.
Nozzle distance (dimen- Auxiliary dimension 1
sion A)
5 mm 65 mm
10 mm 70 mm Factory setting
▶ Undo locknut 2.
▶ Adjust nozzle head 3, until auxiliary dimension 1 has been reached.
▶ Re-tighten locknut.
9.6 Removing the mixing head

▶ Remove nozzle assembly.
▶ Remove locknut 1.
▶ Lift mixing head 2 and pull out.
83263502 • 2/2014-12 • La 72-110

9 Servicing
9.7 Set ignition electrodes

9.7.1 Set ignition electrodes nozzle assembly

The distance between the ignition electrodes and other components must be greater
than the spark gap between the electrodes.
The ignition electrodes must not touch the nozzle's atomising spray cone.
▶ Undo screw 1 on the ignition electrode holder.
▶ Set ignition electrodes.
▶ Tighten screw.
mm
.. 6 3 ... 4 mm
4.
9.7.2 Set ignition electrode diffuser

▶ Remove mixing head.
▶ Undo screw 1.
▶ Set ignition electrode.
▶ Tighten screw.
2 mm
83263502 • 2/2014-12 • La 73-110

9 Servicing
9.8 Set nozzle tubes

▶ Remove mixing head.
▶ Undo screw 1 and set nozzle tube.
▶ Tighten screw.
2 mm
9.9 Replacing the nozzle

Do not clean nozzle, always fit new nozzle.

▶ Remove ignition electrodes.
▶ Counter-hold on the nozzle assembly using a spanner and remove nozzle.
▶ Fit new nozzle ensuring it is seated tightly.
▶ Fit and adjust ignition electrodes.
1 Nozzle
2 Nozzle assembly
83263502 • 2/2014-12 • La 74-110

9 Servicing
9.10 Removing and refitting air damper stepping motor

Removing
▶ Remove stepping motor cover.
▶ Undo cable connections and remove cable entry 4.
▶ Undo locknut 1 on the coupling.
▶ Remove screws 3.
▶ Remove stepping motor from the coupling.
Refitting
▶ Refit stepping motor in reverse order, ensuring correct alignment of spring washer
2.
▶ Check address and Bus termination (see installation and operating manual Com-
bustion Manager W-FM 100/200).
83263502 • 2/2014-12 • La 75-110

9 Servicing
9.11 Removing air regulator

▶ Remove air damper stepping motor.
▶ Remove inlet mesh 2.
▶ Remove air regulator 1.
83263502 • 2/2014-12 • La 76-110

9 Servicing
9.12 Set air regulator

▶ Remove inlet mesh (see Ch. 9.11).
▶ If necessary remove air regulator (see Ch. 9.11).
Set air dampers
Only tamper proof screws should be used in the air regulator section.
If the distance of the air dampers to the housing on the stepping motor side is less
than the dimension of 0.3 mm ± 0.1:
▶ Undo screws 1.
▶ Align air dampers.
▶ Re-tighten screws.
▶ Check if air dampers have freedom of movement.
Check sleeve bearing
It must not be possible to axially move the air dampers without using force
(0 mm play).
If axial play 2 is present at the air dampers:
▶ Replace sleeve bearing.
0.3 mm ±0.1
83263502 • 2/2014-12 • La 77-110

9 Servicing
9.13 Removing and refitting gas butterfly stepping motor

Removing
▶ Remove stepping motor cover 3.
▶ Remove view port 1 - or - if stepping motor not at 0°, remove plug 2.
▶ Undo locknut 6.
▶ Remove bolts 5.
If the intermediate housing or the coupling need to be replaced:

▶ Undo second locknut of coupling 2.
▶ Carefully pull coupling from drive shaft.
▶ Remove shaft keys 1.
▶ Undo fixing screws and remove intermediate housing 3.
Refitting
▶ Refit stepping motor in reverse order, ensuring correct alignment of shaft key.
▶ Push coupling carefully and without pressure onto shaft.
83263502 • 2/2014-12 • La 78-110

9 Servicing
9.14 Removing and refitting oil quantity regulator stepping motor

Removing
▶ Remove stepping motor cover 3.
▶ Remove view port 1 - or - if stepping motor not at 0°, remove plug 2.
▶ Undo locknut 6.
▶ Remove bolts 5.
If the intermediate housing or the coupling need to be replaced:

▶ Undo second locknut of coupling 2.
▶ Carefully pull coupling from drive shaft.
▶ Remove shaft keys 1.
▶ Undo fixing screws and remove intermediate housing 3.
Refitting
▶ Refit stepping motor in reverse order, ensuring correct alignment of shaft key.
▶ Push coupling carefully and without pressure onto shaft.
83263502 • 2/2014-12 • La 79-110

9 Servicing
9.15 Set pump coupling

A flexible pump coupling is fitted between fan wheel and oil pump.
▶ Remove air regulator cover.
▶ Undo Allen screw 2 on the pump coupling.
▶ Align pump coupling to ensure that no axial tension is applied to the drive shaft of
the magnetic coupling and that the coupling centre piece 1 has an axial play of
1.5 mm.
▶ Tighten Allen screw.
9.16 Set magnetic coupling

In the neutral position, the clearance of the coupling discs must be 0.4 … 0.6 mm.
▶ Undo hexagonal screws 2 on the magnetic coupling.
▶ Adjust clearance 1 by axial movement.
▶ Re-tighten hexagonal screws.
83263502 • 2/2014-12 • La 80-110

9 Servicing
9.17 Removing fan wheel

The fan wheel is connected to the motor shaft with a left hand thread screw
M8 x 30 DIN 912.
▶ Undo screw 1.
▶ Remove fan wheel with fan wheel puller from motor shaft.
9.18 Check position of inlet nozzle

▶ Open view port cover 1.
▶ Carry out a visual inspection through the view port once its cover has been opened.
✓ The arrow on the inlet nozzle 2 must point upwards.
83263502 • 2/2014-12 • La 81-110

9 Servicing
9.19 Replace spring on pressure regulator

If the setting range of the spring used in the pressure regulator is insufficient, a dif-
ferent type of spring can be selected.
Low pressure regulator

▶ Remove closing cap 2.
▶ Turn adjusting screw 1 anticlockwise.
✓ The spring 3 is de-energised.
▶ Remove complete setting mechanism 4.
▶ Change spring.
▶ Stick label for new spring to name plate.
Type of spring/colour Setting pressure range

orange 5 … 20 mbar
blue 10 … 30 mbar
red 25 … 55 mbar
yellow 30 … 70 mbar
black 60 … 110 mbar
pink 100 … 150 mbar
grey 140 … 200 mbar
High pressure regulator

83263502 • 2/2014-12 • La 82-110

10 Troubleshooting
10 Troubleshooting
10.1 Procedures for fault conditions
Burner out of operation

If the burner does not start despite heat demand:
▶ Check voltage supply
▶ Check function and setting of all regulating, control and safety devices.
▶ Check all burner related functions.
Fault
If a fault occurs, the combustion manager initiates a controlled shutdown.
The ABE displays the fault.
▶ Read the error code and proceed according to the error message (see installation
and operating manual combustion manager).
The burner restarts automatically as soon as the fault condition has been rectified.
Lockout
If a lockout condition occurs, the combustion manager initiates a fault shutdown and
burner lockout.
The ABE displays the lockout.
▶ Read the error code and proceed according to the error message (see installation
and operating manual combustion manager).
Once the error has been rectified, the combustion manager has to be reset for restart.
Resetting
Damage resulting from incorrect servicing

The combustion plant could be damaged.
▶ Do not carry out more than 2 lockout resets successively.
CAUTION ▶ Faults must be rectified by qualified personnel.
If the ABE displays a fault:
▶ Press [esc] key once.
▶ Reset burner using the [ENTER] key.
If the [esc] key has been pressed twice, reset can only be carried out via the menu.
▶ Select Operating display.
▶ Select Status/Reset.
✓ Current lockout is displayed.
▶ Exit display using the [esc] key.
▶ Reset burner using the [ENTER] key.
Exchanging the unit
▶ Select and check fault history and lockout history before replacing the combustion
manager or ABE and include when returning the unit for exchange.
83263502 • 2/2014-12 • La 83-110

10 Troubleshooting
10.2 Rectifying faults

Fault Cause Rectification
Burner motor does not run No voltage ▶ Check voltage supply
Overload relay or motor protection ▶ Check setting
switch has tripped
Contactor defective ▶ Replace contactor
Burner motor defective ▶ Replace burner motor
No ignition Ignition electrodes too far apart or short ▶ Set ignition electrodes (see Ch. 9.7)
circuit
Ignition electrodes dirty or wet ▶ Clean and set ignition electrodes
(see Ch. 9.7)
Ceramic insulator defective ▶ Replace ignition electrodes
Ignition cable defective ▶ Replace ignition cable
Ignition unit defective ▶ Replace ignition unit
Solenoid valve does not open No voltage ▶ Check voltage supply
Coil defective ▶ Replace coil
Oil pump supplies no oil Shut off valve closed ▶ Open shut off valve
Oil supply leaking ▶ Check oil supply
Anti siphon valve does not open ▶ Check valve, if necessary replace
Oil filter of oil supply soiled ▶ Clean filter insert or replace
Oil pump defective ▶ Replace oil pump
No oil throughput at the nozzle Nozzle blocked ▶ Replace nozzle (see Ch. 9.9)
No voltage at the nozzle head solenoid ▶ Check voltage supply
coil
Nozzle head solenoid coil defective ▶ Replace coil
No flame formation despite igni- Ignition electrodes set incorrectly ▶ Set ignition electrodes (see Ch. 9.7)
tion and fuel Pressure into the mixing head too high ▶ Correct mixing pressure in ignition
load setting, if necessary adjust mixing
head (see Ch. 4.3)
No ignitable fuel/air mixture in the mixing ▶ Reduce distance between double gas
head valve and gas butterfly valve
(see Ch. 5.1)
Poor start behaviour of burner Pressure into the mixing head too high ▶ Correct mixing pressure in ignition
load setting, if necessary adjust mixing
head (see Ch. 4.3)
Ignition electrodes set incorrectly ▶ Set ignition electrodes (see Ch. 9.7)
Too much or too little fuel ▶ Correct fuel quantity in ignition posi-
tion via fuel actuator
Combustion manager does not Flame sensor soiled ▶ Clean flame sensor
detect a flame signal Flame signal insufficient ▶ Check flame signal
▶ Check flame sensor
▶ Check burner setting
Flame sensor defective ▶ Replace flame sensor
Combustion pulsating and/or Incorrect combustion air quantity ▶ Check combustion values
burner booming Mixing head set incorrectly ▶ Set mixing head (see Ch. 4.3)
Back pressure from the system ▶ Check flue gas system
(see Ch. 13.2)
Burner rating required is not Mixing head not opened far enough ▶ Set mixing head (see Ch. 4.3)
achieved Inlet nozzle fitted incorrectly ▶ Check position inlet nozzle
(see Ch. 9.18)
83263502 • 2/2014-12 • La 84-110

10 Troubleshooting
Fault Cause Rectification

Flame failure during operation Oil supply leaking/suction resistance too ▶ Check oil supply (see Ch. 13.1)
high
Oil nozzle soiled ▶ Replace nozzle (see Ch. 9.9)
Flame signal insufficient ▶ Check flame signal
▶ Check flame sensor
▶ Check burner setting
Oil pump makes severe me- Oil pump sucks air ▶ Check oil supply is not leaking
chanical noise Suction resistance in oil line too high ▶ Clean filter
▶ Check oil supply (see Ch. 13.1)
Oil nozzle atomisation uneven Nozzle soiled/worn ▶ Replace nozzle (see Ch. 9.9)
Combustion head is contamina- Oil nozzle defective ▶ Replace nozzle (see Ch. 9.9)
ted with oil or has heavy carbon Mixing head set incorrectly ▶ Set mixing head (see Ch. 4.3)
deposits
Incorrect combustion air quantity ▶ Adjust burner
Boiler room ventilated insufficient ▶ Ensure sufficient boiler room ventila-
tion
Oil supply system at nozzle head leaking ▶ Check oil supply system
Solenoid does not close tightly Dirt particles in the solenoid valve ▶ Replace solenoid valve
83263502 • 2/2014-12 • La 85-110

11 Spares
11 Spares
1.01
(1
1.06
(1
1.03 (1 1.05
1.07
1.10
1.04
(1
1.02
1.09
1.08
1.21
1.11
1.12
1.15
1.17
1.15
1.16
1.20
1.22
1.19
1.16
1.18
1.14
1.13
83263502 • 2/2014-12 • La 86-110

11 Spares
Pos. Description Order No.

1.01 View port cover complete 211 314 01 02 2
1.02 View port 211 104 01 19 2
1.03 View port closing cover 211 104 01 13 2
– Spring nut 4 x 9 412 509
1.04 Hinge pin 16 x 275 211 314 01 05 7
1.05 Circlip 12 431 611
1.06 Hinge flange 217 314 01 01 7
Stud screw M12 x 55 421 028
– Washer B13 430 801
– Hexagonal nut M12 411 600
1.07 Stud screw M12 x 55 421 028
1.08 Dome nut M12 DIN 1587 412 401
1.09 Washer B 13 430 801
1.10 Flange gasket 380 x 302.5 111 974 00 07 7
1.11 Cable entry W-FM complete 211 104 01 05 2
1.12 Air regulator housing 211 314 02 10 7
1.13 Foam cladding rear 211 314 02 04 7
1.14 Foam cladding front 211 314 02 03 7
1.15 Screw M8 x 245 402 529
1.16 Screw M8 x 43 / 304 211 314 02 13 7
1.17 Clamping ring Ø 8 mm 490 500
1.18 Air regulator cover 211 314 02 16 7
1.19 Foam cladding air air regulator cover 211 314 02 05 7
1.20 Spring nut 6 x 20 412 506
1.21 Name plate 211 314 01 03 7
1.22 Cable entry set 211 104 01 50 2
83263502 • 2/2014-12 • La 87-110

11 Spares
2.05
2.03
2.04
2.01
2.09
2.06 2.30
2.10
2.08
2.07 2.29 2.31
2.32
2.02
2.33
2.11 2.32
2.16
2.17
2.18
2.20
2.20 2.19
2.20
2.20
2.20
2.20
2.14 2.28
2.27
2.21
2.20 2.26
2.22 2.20
2.23
2.24 2.13
2.22
2.25
2.25 2.15
2.23
2.15
2.12
83263502 • 2/2014-12 • La 88-110

11 Spares

2.01 Motor WM-D132/210-2/10K0 380-415V 50Hz 215 315 07 01 0
with star delta switching
2.02 Star delta switching YDRT2025-M 217 313 07 38 2
– contactor 3RT2025 230V 50/60Hz 703 110
– auxiliary switch block 1S+1OE 703 215
– electronic timer relay 703 283
2.03 Motor WM-D132/210-2/10K0 380-415V 50Hz
– with terminal board 215 315 07 02 0
– for external frequency converter 215 315 07 03 0
2.04 Motor for inbuilt frequency converter 215 315 07 06 0
Motor WM-D132/210-2/10K0 380-415V 50Hz
2.05 Frequency configured 215 315 07 04 7
Motor WM-D132/210-2/10K0 380-415V 50Hz for
W-FM 200
2.06 Cable gland set 211 104 01 50 2
2.07 Fan wheel TS-S 348 x 104.5 R 50Hz black 211 314 08 02 1
2.08 Screw M8 x 30 LH DIN 912 8.8 402 560
2.09 Serrated washer J 8.4 DIN 6797 431 501
2.10 Washer 8.5 x 22 x 5 211 404 08 06 7
2.11 Inlet nozzle 50Hz 211 314 02 06 7
2.12 Air inlet mesh 211 314 02 19 2
– Screws M5 x 16 Duo Taptite 409 312
2.13 Air regulator complete 211 314 02 03 2
2.14 Air regulator 211 314 02 11 7
2.15 Air damper 211 314 02 12 7
2.16 Stepping motor SQM 45.291 A9 WH 3Nm 651 470
– Cable entry complete with 2 W-FM plugs 217 605 12 05 2
2.17 Shaft key 3 x 3.7 DIN 6888 490 157
2.18 Air damper shaft with coupling 211 314 02 08 2
2.19 Air damper shaft with spring pin 211 314 02 09 2
2.20 Sleeve bearing set air regulator 211 104 02 50 2
2.21 Air regulator scale 211 314 02 17 7
2.22 Adjusting lever 211 104 02 04 7
2.23 Screw M5 x 12 with Precote 211 104 02 18 7
2.24 Ball joint rod 211 104 02 19 2
2.25 Screw M6 x 16 with Tuflock 402 268
2.26 Screw M6 x120 DIN 7500 409 371
2.27 Washer A 6.4 DIN 125 430 400
2.28 Washer 5.1 x 11 x 0.6 430 015
2.29 Threaded socket 217 104 24 01 7
2.30 Air pressure switch
– LGW 50 A2P 2.5 - 50 mbar 691 373
– LGW 10 A2P 1.0 - 10 mbar 691 385
2.31 Plug for LGW 446 011
2.32 Threaded socket R1/8 453 003
2.33 Hose 4.0 x 1.75 300 mm 232 400 24 01 7
83263502 • 2/2014-12 • La 89-110

11 Spares
3.01
3.01
3.06
3.02
3.02
3.03
3.05
3.03
3.04
3.26
3.25 3.08 3.08

3.29
3.24 3.07
3.23 3.09 3.11
3.28
3.22 3.10 3.09
3.21 3.13
3.09
3.15 3.10
3.20
3.09
3.19 3.16 3.10
3.10 3.12
3.17
3.08 3.13
3.30
3.60 3.14
3.27
3.09 3.18
3.49
3.61 3.10
3.09
3.52 3.10
3.10
3.60 3.31
3.37 3.09 3.10
3.59 3.54
3.36
3.51
3.58
3.55 3.53
3.56 3.48
3.50
3.32
3.57 3.33
3.53 3.34
3.50
3.52
3.35
3.39 3.34
3.38
3.45
3.47
3.40
3.44 3.46
3.43
3.42
3.41
3.62
3.40
3.63
83263502 • 2/2014-12 • La 90-110

11 Spares

3.01 Pressure hose DN 6 210 301 10 02 2
3.02 Hexagonal nut M16 x 1.5 210 104 10 08 7
3.03 Bulkhead connector 218 324 06 01 7
3.04 Screwed union EVT 12LOMD 452 502
3.05 Bypass plug BUZ 12-L with nut 211 404 13 01 2
3.06 Pressure gauge 0 to 40 bar with ball valve 121 364 85 02 0
3.07 Oil line 12 x 1.5 bulkhead conn.-oil reg. 215 324 06 03 8
3.08 Screwed union EVW 12LOMD 452 452
3.09 Screwed union XGE 12-PLR G3/8-A 452 254
3.10 Sealing ring A 17 x 21 x 1.5 DIN 7603 Cu 440 003
3.11 Oil line 12 x 1.5 SV - bulkhead conn. supply 215 324 06 02 8
3.12 Oil quantity regulator Series S3 211 704 15 20 2
3.13 Shaft key 3 x 3.7 DIN 6888 490 157
3.14 Intermediate housing for oil regulator series B 211 704 15 27 2
3.15 View port 33 x 33 x 6 211 404 17 02 7
3.16 Oblong plug GPN 270 R 3015 446 115
3.17 Spring coupling bar series 2 217 704 15 10 7
3.18 Stepping motor SQM 45,291 A9 3 Nm 651 470
3.19 Screwed union EVL 12-PL 452 552
3.20 Olive DPR12LX 452 773
3.21 Union nut M12 LX 452 836
3.22 Threaded socket 12 x G1/4 x 42 121 464 85 02 7
3.23 Sealing ring A 13.5 x 17 x 1.5 DIN 7603 Cu 440 010
3.24 Threaded socket G1/4I x G1/2I x 40 290 504 13 03 7
3.25 Sealing ring C 6.2 x 17.5 x 2 DIN 16258 Cu 440 007
3.26 Pressure switch type DSA46 F001 1 - 10 bar 640 096
3.27 Oil line 12 x 1.5 pressure switch - SV ret. 215 324 06 04 8
3.28 Solenoid valve 5406 NC DN 13 110-120V 50Hz 604 820
3.29 Solenoid coil 110-120V 50Hz 20W 604 692
3.30 Oil line 12x1.5 strainer - SV supply 218 324 06 04 8
3.31 Strainer G 3/8 PN50 499 042
3.32 Treaded socket 12 x G3/8 x 46 prem. 121 464 85 04 2
3.33 Screwed union XGE 12-LR G1/2-A CF 452 259
3.34 Sealing ring A 21 x 26 x 1.5 DIN 7603 Cu 440 020
3.35 Pump TA4C 4010-7W 601 052
3.36 Pressure gauge -1 to +9 bar with ball valve 121 364 85 03 0
3.37 Pressure gauge 0 to 40 bar with ball valve 110 002 82 02 2
3.38 Threaded socket DN 25 M38 x 1.5 x G1/2 181 174 06 01 7
3.39 Pipe elbow DN25 M38 x38 x M38 x 38 x G 1/8 453 252
3.40 Oil hose DN 25 1300 mm long 491 029
83263502 • 2/2014-12 • La 91-110

11 Spares
3.01
3.01
3.06
3.02
3.02
3.03
3.05
3.03
3.04
3.26
3.25 3.08 3.08

3.29
3.24 3.07
3.23 3.09 3.11
3.28
3.22 3.10 3.09
3.21 3.13
3.09
3.15 3.10
3.20
3.09
3.19 3.16 3.10
3.10 3.12
3.17
3.08 3.13
3.30
3.60 3.14
3.27
3.09 3.18
3.49
3.61 3.10
3.09
3.52 3.10
3.10
3.60 3.31
3.37 3.09 3.10
3.59 3.54
3.36
3.51
3.58
3.55 3.53
3.56 3.48
3.50
3.32
3.57 3.33
3.53 3.34
3.50
3.52
3.35
3.39 3.34
3.38
3.45
3.47
3.40
3.44 3.46
3.43
3.42
3.41
3.62
3.40
3.63
83263502 • 2/2014-12 • La 92-110

11 Spares

3.41 Threaded socket DN25 M38 x 1.5 x M26 x 1.5 181 174 06 02 7
3.42 Sealing ring A 27 x 32 x 2 DIN 7603 Cu 440 039
3.43 Collar screw X BSCH G 1/2 A 450 651
3.44 Housing XDSVW18-LR 450 650
3.45 Sealing ring X DKAZ G 1/2 A 450 652
3.46 Screwed union KOR18-12-PL 452 152
3.47 Union nut M18LX 452 803
3.48 Oil line 12 x 1.5 SV - pump return 218 324 06 05 8
3.49 Solenoid valve 6027 NC DN 10 110-120V 50Hz 604 840
3.50 Stud screw M10Fo x 25 DIN 939 421 066
3.51 Pump flange 218 214 09 03 7
3.52 Remove closing plug 256 306 06 02 7
3.53 Screw M8 x 100 218 214 09 02 7
3.54 Clamping ring Ø 8 mm 490 500
3.55 Magnetic coupling WMK20/1 long vers. 230V 218 324 09 03 2
3.56 Retaining washer 155 101 09 03 7
3.57 Screw M5 x 16 DIN 963 404 013
3.58 Bearing flange 218 404 09 01 2
3.59 Pump coupling 54,3 x D35 drilling 12 218 324 09 01 2
3.60 Universal joint 111 151 09 01 7
3.61 Coupling centre piece 301.4 mm 218 324 09 02 2
3.62 Threaded socket DN25 M38 x 1.5 x G 1 122 362 00 07 7
3.63 Sealing ring A 33 x 39 x 2 DIN 7603 Cu 440 032
83263502 • 2/2014-12 • La 93-110

11 Spares
4.01
4.03 4.02*
4.12
4.04
4.06
4.08
4.05
4.09
4.06
4.07
4.10
4.11
4.13
4.17
4.15
4.18
4.14
4.19
4.20
4.32
4.16
4.21
4.31
4.31
4.33
4.22
4.34
4.24
4.23
4.27
4.26 4.30
4.29
4.25
4.27
4.28
83263502 • 2/2014-12 • La 94-110

11 Spares

4.01 Flame tube WM-G(L)30/2 217 314 14 01 2
4.02 Extension pipe
– extended by 150 mm* 217 314 14 11 2
– extended by 300 mm* 217 314 14 12 2
4.03 Lock nut M12 x 109 151 907 01 10 7
4.04 Gasket 92 x 200 x 2 rubber cork 151 907 00 01 7
4.05 Gas butterfly DN80 w. intermediate housing cpl. 217 505 25 02 2
4.06 Shaft key 3 x 3.7 DIN 6888 490 157
4.07 Intermediate housing for gas butterfly series B 217 704 25 02 2
4.08 View port 33 x 33 x 6 211 404 17 02 7
4.09 Rectangular plug 446 115
4.10 Spring coupling bar series 2 217 704 15 10 7
4.11 Stepping motor SQM 45.291 A9 WH 3Nm 651 470
4.12 Mixing head cpl. 230V
– Standard 218 324 14 01 2
– extended by 150 mm* 218 324 14 08 2
– extended by 300 mm* 218 324 14 09 2
4.13 Diffuser cpl. 222K x 45 217 314 14 04 2
4.14 Nozzle tube 30 x 1.5 x 79 217 314 14 06 7
4.15 Central gas tube 8 x 1.5 217 315 14 05 7
4.16 Distributor ring 217 314 14 03 7
4.17 Clamp for electrodes 218 204 14 08 7
4.18 Ignition electrode 217 204 14 24 7
4.19 Ignition cable 11/6.4
– 800 mm (Standard) 217 204 11 08 2
– 1000mm (for 150 mm extension)* 217 204 11 10 2
4.20 Mixing tube internal
– Standard (99 x 420) 217 405 14 25 7
– extended by 150 mm* 290 405 14 05 7
– extended by 300 mm* 290 405 14 06 7
4.21 Mixing tube external
– Standard (140 x 231.5) 217 314 14 04 7
– extended by 150 mm* 217 314 14 09 7
– extended by 300 mm* 217 314 14 10 7
4.22 Mixing head 217 314 14 02 7
* Only in conjunction with combustion head extension.
83263502 • 2/2014-12 • La 95-110

11 Spares
4.01
4.03 4.02*
4.12
4.04
4.06
4.08
4.05
4.09
4.06
4.07
4.10
4.11
4.13
4.17
4.15
4.18
4.14
4.19
4.20
4.32
4.16
4.21
4.31
4.31
4.33
4.22
4.34
4.24
4.23
4.27
4.26 4.30
4.29
4.25
4.27
4.28
83263502 • 2/2014-12 • La 96-110

11 Spares

4.23 Nozzle head MDK60 250W 230V 50-60Hz
with solenoid coil
– Standard 211 404 10 03 2
– extended by 150 mm* 211 404 10 09 2
– extended by 300 mm* 211 404 10 07 2
4.24 Oil line 8 x 1 supply
– Standard 218 324 06 02 8
– extended by 150 mm* 218 324 06 06 8
– extended by 300 mm* 218 324 06 08 8
4.25 Oil line 8 x 1 return
– Standard 218 324 06 03 8
– extended by 150 mm* 218 324 06 07 8
– extended by 300 mm* 218 324 06 09 8
4.26 Retainer 218 324 14 03 7
4.27 Screw M6 x 18 DIN 933 401 360
4.28 Solenoid coil MDK60 230V 50-60Hz ZM 280-1 605 928
4.29 Plug socket with cable 850 mm 716 535
4.30 Electrode holder 218 324 14 02 7
4.31 Ignition electrode 218 324 11 01 7
4.32 Washer 40 x 6.6 x 2.5 177 205 14 46 7
4.33 Ignition cable 11/4.1
– 800 mm (Standard) 218 204 11 08 2
4.34 Spill type nozzle
– W 160 kg S4 50 ° 612 977
– W 180 kg S4 50 ° 612 978
– W 200 kg S4 50 ° 612 979
– W 225 kg S4 50 ° 612 980
– W 250 kg S4 50 ° 612 981
– W 275 kg S4 50 ° 612 982
– W 300 kg S4 50 ° 612 983
– W 330 kg S4 50 ° 612 984
– W 360 kg S4 50 ° 612 985
– W 390 kg S4 50 ° 612 990
– W 160 kg S5 50 ° V 612 813
– W 180 kg S5 50 ° V 612 814
– W 200 kg S5 50 ° V 612 815
– W 225 kg S5 50 ° V 612 816
– W 250 kg S5 50 ° V 612 817
– W 275 kg S5 50 ° V 612 818
– W 300 kg S5 50 ° V 612 819
– W 330 kg S5 50 ° V 612 820
– W 360 kg S5 50 ° V 612 821
– W 390 kg S5 50 ° V 612 822
* Only in conjunction with combustion head extension.
83263502 • 2/2014-12 • La 97-110

11 Spares
5.09
5.08
5.07
5.06 5.10
5.05
5.17
5.11
5.16
5.03 5.24
5.01 5.04 5.19
5.13
5.12
5.02 5.18
5.20
5.23
5.14
5.21
5.22
5.15
83263502 • 2/2014-12 • La 98-110

11 Spares

5.01 ABE for W-FM 100/200
– Western Europe 1 (GB, D, F, I, E, P) 600 439
– Western Europe 2 (GB, NL, DK, S, N, FIN) 600 440
– Eastern Europe 1 (GB, PL, H, CZ, HR, SLO) 600 441
– Eastern Europe 2 (GB, RUS, D, TR, R, BG) 600 442
5.02 Plug cable W-FM…ABE
– ABE fitted to housing 217 706 12 10 2
– ABE fitted external 4000 mm 217 706 12 19 2
5.03 Cover complete
– ABE inbuilt 211 314 12 01 2
– ABE external 211 314 12 02 2
5.04 Combustion manager 230 V 50/60 Hz
– W-FM 100 without load controller 600 460
– W-FM 100 with load controller 600 461
– W-FM 200 600 463
5.05 Stay bolt cover W-FM 211 104 12 03 7
5.06 Mounting plate for W-FM100/200 211 314 12 05 7
5.07 Flame sensor QRI B2.B180B 600 651
5.08 Flange for flame sensor QRI 217 706 12 09 7
5.09 Seal for flange flame sensor QRI 217 104 12 01 7
5.10 Limit switch 211 104 01 06 2
5.11 Transf. for W-FM 100/200 AGG 5.220 230V 600 331
5.12 Plug cable W-FM transf. 230V/12V 217 706 12 01 2
5.13 Plug cable W-FM transf. 12-0-12V 217 104 12 01 2
5.14 Plug cable W-FM - air stepping motor 217 605 12 21 2
5.15 Plug cable
– SQM to SQM 600 mm 217 605 12 07 2
– SQM to SQM 900 mm 217 605 12 08 2
5.16 Ignition unit type W-ZG03 230V with W-FM plug 218 204 11 05 2
5.17 Seal for ignition unit 3 pole 218 204 11 01 7
5.18 Plug cable W-FM air pressure switch X3-02 217 706 12 03 2
5.19 Plug cable W-FM solenoid valve X8-03 217 706 12 07 2
5.20 Plug cable W-FM DSA46 3 x 0.75 1700mm 211 706 12 03 2
5.21 DMV plug 4 pole 250V 217 304 26 01 2
5.22 GW plug 4 pole 250V 217 304 26 02 2
5.23 Plug cable with rectifier and plug X6-02 218 114 12 01 2
83263502 • 2/2014-12 • La 99-110

11 Spares
5.09
5.08
5.07
5.06 5.10
5.05
5.17
5.11
5.16
5.03 5.24
5.01 5.04 5.19
5.13
5.12
5.02 5.18
5.20
5.23
5.14
5.21
5.22
5.15
83263502 • 2/2014-12 • La 100-110

11 Spares

5.24 W-FM plug
– X3-01 Motor On 716 300
– X3-02 Air pressure switch 716 301
– X3-03 Limit switch burner flange 716 302
– X3-04 Mains and safety circuit 716 303
– X4-01 Oil/Gas change-over 716 304
– X4-02 Ignition unit 716 305
– X4-03 Solenoid valve venting APS 716 306
– X5-01 min. oil press. DSA58 716 307
– X5-02 max. oil press. DSA46 716 308
– X5-03 Control circuit 716 309
– X6-01 Start release 716 310
– X6-02 Magnetic coupling - oil pump 716 311
– X6-03 Oil safety valve 716 312
– X7-01 Oil valve stage 2 716 313
– X7-02 Oil valve stage 3 716 314
– X7-03 Start release Gas 716 315
– X8-01 Oil - Gas- display 716 316
– X8-02 Oil valve additional 716 317
– X8-03 Oil valve 1; 2 x 110V 716 318
– X9-01 Gas, PV, V1, V2, SV 716 319
– X9-02 N, PE 716 320
– X9-03 Gas max./min. 716 321
– X10-01 Transformer 230/12V 716 322
– X10.02.1 Flame sensor QRB 716 323
– X10-02.2 Flame sensor QRI 716 332
– X50 CAN-Bus ABE 716 325
– X51 CAN-Bus stepping motor 716 326
– X52 Transformer 2 x 12V 716 327
– X60 Temperature sensor 716 328
– X61 Actual value U/I 716 329
– X62 Set value U/I 716 330
– X63 Output 4-20mA 716 331
– X70 Proximity switch motor 716 333
– X71 Gas meter 716 334
– X72 Oil meter 716 335
– X73 Frequency converter 716 336
83263502 • 2/2014-12 • La 101-110

12.1 Appliance categories
Labelling of gas and dual fuel burners to EN 676

EN 676, "Automatic forced draught burner for gaseous fuels", is used for the imple-
mentation of the basic requirements of the Gas Appliance Directive 2009/142/EC.
EN 676 from November 2003 stipulates the following appliance categories for forced
draught gas burners under point 4.4.9:
I2R for Natural Gas
I3R for Liquid Petroleum Gas
II2R/3R for Natural Gas / Liquid Petroleum Gas
The test gases listed under point 5.5.1, table 4 (EN 676) and the minimum test pres-
sures determined and listed under point 5.1.2, table 5 (EN 676) are used to provide
the evidence of service performance for the burner during type testing.
As -weishaupt- gas and dual fuel burners fulfil this requirement completely, the ap-
pliance category, as well as the test gases used with the permissible connection
pressure range, are listed on the name plate when labelling the burner to
point 6.2 (EN676). This clearly defines the suitability of the burner for use with second
and/or third family gases.
On the basis of a type test report to EN 45001/ISO 17025 from an accredited test
centre, the EU Type Testing Certificate to Gas Appliance Directive 2009/142/EC
also quotes the appliance category, the supply pressure and the country of destina-
tion.
EN 437, "Test gases, test pressures, appliance categories", describes the interrela-
tionships and the special national characteristics relating to this subject in detail.
The following tables give an overview of the interrelationships between the R Cate-
gories and the nationally used appliance categories with their types of gas and
connection pressures.
83263502 • 2/2014-12 • La 102-110

Alternative appliance category to I2R

Country of destination Appliance category Test gas Connection pressure
mbar
AL (Albania) I2H G 20 20
AT (Austria) I2H G 20 20
BA (Bosnia) I2H G 20 20
BE (Belgium) I2E+, I2N, I2E(R)B G 20 + G 25 Pressures
20 / 25
BG (Bulgaria) I2H G 20 20
BY (Belarus)
CH (Switzerland) I2H G 20 20
CY (Cyprus) I2H G 20 20
CZ (Czech Republic) I2H G 20 20
DE (Germany) I2ELL, I2E, I2L G 20 / G 25 20
DK (Denmark) I2H G 20 20
EE (Estonia) I2H G 20
ES (Spain) I2H G 20 20
FI (Finland) I2H G 20 20
FR (France) I2Esi, I2E+, I2L G 20 + G 25 Pressures
20 / 25
GB (United Kingdom) I2H G 20 20
GR (Greece) I2H G 20 20
HR (Croatia) I2H G 20 20
HU (Hungary) I2H G 20 20
IE (Ireland) I2H G 20 20
IS (Iceland) I2H G 20 20
IT (Italy) I2H G 20 20
LT (Lithuania)
LU (Luxembourg) I2E G 20 20
LV (Latvia)
MD (Moldova) I2H G 20 20
MK (Macedonia) I2H G 20 20
MT (Malta) I2H G 20 20
NL (The Netherlands) I2L G 25 25
NO (Norway) I2H G 20 20
PL (Poland) I2E G 20 / GZ 410 20
PT (Portugal) I2H G 20 20
RO (Romania) I2H G 20 20
SE (Sweden) I2H G 20 20
SI (Slovenia) I2H G 20 20
SK (Slovakia) I2H G 20 20
SRB (Serbia) I2H G 20 20
TR (Turkey) I2H G 20 25
UA (Ukraine) I2H G 20 20
83263502 • 2/2014-12 • La 103-110

Alternative appliance category to I3R

Country of destination Appliance category Test gas Connection pressure
mbar
AL (Albania) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
AT (Austria) I3B/P, I3P G 30 + G 31 50
BA (Bosnia) I3B/P G 30 30 (28-30)
BE (Belgium) I3+, I3P, I3B, I3B/P G 30 + G 31 Pressures
28 - 30 / 37
BG (Bulgaria) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
BY (Belarus)
CH (Switzerland) I3B/P, I3+, I3P G 30 + G 31 Pressures
28 - 30 / 37
CY (Cyprus) I3B/P, I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
CZ (Czech Republic) I3B/P, I3+, I3P G 30 + G 31 Pressures
28 - 30 / 37
DE (Germany) I3B/P, I3P G 30 + G 31 50
DK (Denmark) I3B/P G 30 + G 31 30 (28 - 30)
EE (Estonia) I3B/P G 30
ES (Spain) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
FI (Finland) I3B/P G 30 + G 31 30 (28 - 30)
FR (France) I3+, I3P, I3B G 30 Pressures
28 - 30 / 37
G 31 Pressures
112 / 148
GB (United Kingdom) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
GR (Greece) I3B/P, I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
HR (Croatia) I3B/P, I3P G 30 + G31 50
HU (Hungary) I3B/P G 30 + G31 50
IE (Ireland) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
IS (Iceland) I3B/P
IT (Italy) I3B/P, I3+, I3P G 30 + G 31 Pressures
28 - 30 / 37
LT (Lithuania)
LU (Luxembourg) I3B/P G 30
LV (Latvia)
MD (Moldova) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
MK (Macedonia) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
MT (Malta) I3+, I3P, I3B G 30 + G 31 Pressures
28 - 30 / 37
NL (The Netherlands) I3B/P, I3P G 30 + G 31 30 (28 - 30)
NO (Norway) I3B/P G 30 + G 31 30 (28 - 30)
PL (Poland) I3B/P G 30
PT (Portugal) I3+, I3P, I3B G 30 Pressures
28 - 30 / 37
G 31 Pressures
50 / 67
RO (Romania) I3B/P G 30
SE (Sweden) I3B/P G 30 + G 31 30 (28 - 30)
SI (Slovenia) I3B/P G 30 30
SK (Slovakia) I3B/P G 30 30
SRB (Serbia) I3B/P, I3P G 30 + G 31 20
TR (Turkey) I3B/P G 30 + G 31 30
UA (Ukraine) I3B/P, I3P G 30 + G 31 50
83263502 • 2/2014-12 • La 104-110

Alternative appliance category to II2R/3R

Country of destination Appliance category Test gas Connection pressure Test gas Connection pressure
mbar mbar
AL (Albania) II2H3+, II2H3P G 20 20 G 31 30
AT (Austria) II2H3B/P, II2H3P G 20 20 G 30 + G 31 50
BA (Bosnia) II2H3B/P G 20 20 G 30
BE (Belgium) II2E+3P, II2H3B/P G 20, G 25 Pressures G 30 + G 31 Pressures
20 / 25 28 - 30 / 37
BG (Bulgaria) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
28 - 30 / 37
BY (Belarus)
CH (Switzerland) II1a2H, II2H3B/P, G 20 20 G 30 + G 31 Pressures
II2H3+, II2H3P 28 - 30 / 37
CY (Cyprus) II2H3B/P, II2H3+, G20 20 G 30 + G 31 Pressures
II2H3P 28 - 30 / 37
CZ (Czech Republic) II2H3B/P, II2H3+, G 20 20 G 30 + G 31 Pressures
II2H3P 28 - 30 / 37
DE (Germany) II2ELL3B/P, II2E3B/P G 20 20 G 30 + G 31 50
DK (Denmark) II1a2H, II2H3B/P G 20 G 20 G 30 + G 31 30
EE (Estonia) II2H3B/P G 20 20 G 30 30
ES (Spain) II2H3P, II2H3+ G 20 20 G 30 + G 31 Pressures
28 - 30 / 37
FI (Finland) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
FR (France) II2E+3+, II2E+3P, G 20 20 G 30 Pressures
II2Esi3B/P 28 - 30 / 37
G 31 Pressures
112 /148
GB (United Kingdom) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
28 - 30 / 37
GR (Greece) II2H3B/P, II2H3+, G 20 20 G 30 + G 31 Pressures
II2H3P 28 - 30 / 37
HR (Croatia) II2H3B/P G 20 20 G 30 + G 31 30 (28-30)
HU (Hungary) II2H3B/P G 20 20 G 30 + G 31
IE (Ireland) II2H3+, II2H3P G 20 20
IS (Iceland) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
IT (Italy) II1a2H, II2H3B/P, G 20 20 G 30 + G 31 Pressures
II2H3+, II2H3P 28 - 30 / 37
LT (Lithuania)
LU (Luxembourg) II2E3B/P G 20 20 G 30 + G 31
LV (Latvia)
MD (Moldova) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
30 / 37
MK (Macedonia) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
30 / 37
MT (Malta) II2H3+, II2H3P G 20 20 G 30 + G 31 Pressures
30 / 37
NL (The Netherlands) II2L3B/P, II2L3P G 25 25 G 30 + G 31 30
NO (Norway) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
PL (Poland) II2E3B/P G 20 20 G 30 + G 31 30 (28 - 30)
PT (Portugal) II2H3+, II2H3P G 20 20 G 30 Pressures
28 - 30 / 37
G 31 Pressures
50 / 67
RO (Romania) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
SE (Sweden) II1a2H, II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
SI (Slovenia) II2H3B/P G 20 20 G 30 30
SK (Slovakia) II2H3B/P G 20 20 G 30 30
SRB (Serbia) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
TR (Turkey) II2H3B/P G 20 25 G 30 + G 31 30 + 37
UA (Ukraine) II2H3B/P G 20 20 G 30 + G 31 30 (28 - 30)
83263502 • 2/2014-12 • La 105-110

13 Project planning
13 Project planning
13.1 Oil supply

The operational safety of oil fired plant is only guaranteed when the installation of the
oil supply is carried out carefully. The installation must comply with country specific
and local regulations (e. g. DIN 4755, EN 12514, TRÖI).
General information relating to the oil supply

▪ The oil supply should be installed in such a way that it is possible to hinge open
the burner.
▪ Do not use cathode protection system with steel tanks.
▪ Fit oil filter in front of pump, mesh aperture maximum 100 μm.
▪ With oil temperatures < 5 °C the separation of paraffin can cause oil lines, oil filters
and nozzles to become blocked. Avoid placing oil tanks and pipelines in areas
subject to frost.
Suction resistance
Pump damage due to excessive suction resistance

A suction resistance greater than 0.4 bar can damage the pump.
▶ Reduce suction resistance – or – install oil supply pump or suction unit, whilst
CAUTION observing the maximum supply pressure at the oil filter.
The suction resistance depends on:

▪ length and diameter of suction line,
▪ pressure loss of oil filter and/or other components,
▪ lowest oil level in the oil storage tank (max 3.5 m below the oil pump).
Shut off devices at the burner
Damage caused by the shut off device closing too fast

Pressure surges and cavitation can damage the components of the oil supply.
▶ When testing the operation of the limit switches the shut off device must only be
CAUTION closed until the safety shut off responds.
▶ The shut off device can only be closed completely when the burner pump has shut
off.
▪ The isolating valves operate mechanically in compound and are fitted with a limit
switch, which inhibits burner operation when the isolating valves are closed.
▪ Protect shut off devices in the return line from accidental closure.
The installation of non return valves is not permitted.
83263502 • 2/2014-12 • La 106-110

13 Project planning
13.1.1 Single pipe oil supply

If the oil supply is via a pressurised single pipe system, a Weishaupt oil circulation
tank or technically similar, which complies with the relevant regulations, must be in-
stalled.
Recommended pump supply pressure 1 … 1.5 bar.
13.1.2 Ring main operation

Oil supply via ring main system is recommended for:
▪ large installations (industrial and district heating), which are run almost continually,
▪ larger distances,
▪ several burners.
For installation and function drawing for ring main operation see Technical work
sheets.
▪ The installation of a duplex oil pump station as ring main pump is recommended.
Cleaning and service work on the pump or oil filter is then possible during burner
operation.
▪ The supply quantity must be a minimum of one and a half to twice the total firing
rates of all burners supplied by the ring main.
▪ The burners are connected to the ring main via a two pipe system.
▪ Set ring main pressure for fuel oil EL via pressure regulating valve to 1 … 1.5 bar.
▪ The oil filter must be suitable for the ring main pressure.
▪ An oil circulation device or Weishaupt gas/air separator should be fitted at each
oil outlet point. Observe information label on separator.
13.1.3 Oil circulation unit

The ring main supply can be fitted with an oil circulation unit.
The unit consists of:
▪ oil meter,
▪ edge plate filter,
▪ circulation tank,
▪ limit switch for burner lockout,
▪ safety valve.
Smallest size to be considered is 2 (from 100 l/h). For installation instructions see the
installation and operating manual Weishaupt oil circulation unit (Print No. 434).
13.2 Flue gas system

When designing the flue gas system observe BDH Info sheet No. 32 "Requirements
on flue gas systems (see www.bdh-koeln.de).
83263502 • 2/2014-12 • La 107-110

14 Key word index
A Factory presetting ...............................................................23

Adjustment ...........................................................................49 Fan pressure ........................................................................39
Air damper ...................................................... 11, 24, 75, 77 Fan wheel ..................................................................... 11, 81
Air number ............................................................................63 Fault .......................................................................................83
Air pressure ..........................................................................64 Filter .................................................................................... 106
Air pressure switch ..................................................... 11, 61 Flame signal .........................................................................16
Air regulator .................................................................. 76, 77 Flame tube .................................................................... 22, 26
Ambient conditions .............................................................17 Flame tube setting ...................................................... 24, 25
Aperture ........................................................................ 22, 26 Flange gasket ......................................................................26
Appliance category ......................................................... 102 Flow pressure ......................................................................34
Approval data .......................................................................17 Flow temperature ................................................................34
Flue gas losses ....................................................................63
Flue gas measurement ......................................................63
B Flue gas system ............................................................... 107
Breaks in operation ............................................................66 Flue gas temperature .........................................................63
Burner motor ........................................................................16 Fuel ........................................................................................17
Fuel oil ...................................................................................17
C Fusing ....................................................................................17
Calorific value ......................................................................47
Capacity graph ....................................................................19 G
CE Pin ...................................................................................17 Gas butterfly valve ..............................................................13
CO content ..........................................................................63 Gas connection pressure .................................. 28, 41, 47
Combustion air ...................................................................... 8 Gas family .......................................................................... 102
Combustion chamber pressure .......................................19 Gas filter ...............................................................................12
Combustion head ...............................................................19 Gas setting pressure .........................................................47
Combustion head extension ..................................... 22, 25 Gas supply ...........................................................................28
Combustion heat rating ............................................. 19, 24 Gas throughput ...................................................................64
Combustion Manager ................................................ 16, 36 Gas tube ...............................................................................74
Combustion test ..................................................................63 Gas valve train ............................................................. 28, 30
Commissioning ............................................................ 39, 49 Gas/air separator ............................................................. 107
Connection pressure .......................................... 28, 41, 47 Guarantee ............................................................................... 7
Consumption .......................................................................17
Coupling ....................................................................... 78, 79 H
Heat exchanger ...................................................................22
D High gas pressure switch ........................... 12, 29, 31, 60
Data backup ................................................................. 52, 57 High pressure regulator ..................................... 44, 45, 82
Delivery status .....................................................................23 Hinge flange .........................................................................26
Design lifespan ............................................................... 8, 67 Humidity ................................................................................17
Dimension E ................................................................. 24, 25
Dimensions ...........................................................................20 I
Dimensions S1 ....................................................................24
Display ...................................................................................38 Ignition electrode ................................................................73
Display and operating unit (ABE) ............................ 16, 38 Ignition position ........................................................... 50, 53
Disposal .................................................................................. 9 Ignition unit ...........................................................................16
Double gas valve ........................................... 12, 28, 29, 31 Inlet nozzle ............................................................................81
Drilling diagram ...................................................................22 Installation .............................................................................22
Ducted air intake ............................................................ 8, 19 Installation elevation ...........................................................19
Installation location .............................................................22
Isolating valve ......................................................................12
E
Electrical connection ..........................................................36 L
Electrical data ......................................................................17
Electrode ..............................................................................73 Liability ..................................................................................... 7
Emission ................................................................................18 Limit switch ..........................................................................16
Excess air ..............................................................................63 Lockout .................................................................................83
Exchanging the unit ............................................................83 Low gas pressure switch ................................... 12, 32, 59
Extension ..............................................................................25 Low gas pressure switch .......................................... 29, 31
Low pressure regulator .....................................................82
F
Fabrication number .............................................................10
83263502 • 2/2014-12 • La 108-110

14 Key word index
M Return pressure ........................................................... 40, 54

Magnetic coupling ..............................................................80 Ring main operation ........................................................ 107
Max. oil pressure switch ............................................ 14, 58 Ring main pump ............................................................... 107
Measuring device ................................................................39
Metering slot ........................................................................14 S
Min. oil pressure switch ............................................. 14, 58 Safety measures ................................................................... 8
Mixing head .................................................................. 11, 24 Safety shut off valve ................................................... 44, 45
Mixing pressure ...................................................................39 Safety vent valve ......................................................... 44, 45
Motor ...................................................................... 16, 17, 37 Safety vent valve .................................................................45
SAV ................................................................................ 44, 45
N SBV ................................................................................ 44, 45
Name plate ...........................................................................10 Sequence of operation ......................................................15
Noise emission value .........................................................18 Serial number .......................................................................10
Normal volume .....................................................................64 Service ..................................................................................67
Nozzle ............................................................................ 23, 74 Service interval ....................................................................67
Nozzle assembly .......................................................... 14, 71 Setting diagram ...................................................................24
Nozzle distance ...................................................................72 Setting pressure ..................................................................47
Nozzle selection table ........................................................23 Setting pressure range ......................................................82
Nozzle shut off .....................................................................14 Shutdown .............................................................................66
Nozzle tube ...........................................................................74 Shutdown time ....................................................................66
Single pipe operation ...................................................... 107
Sleeve bearing .....................................................................77
O Smell of gas ........................................................................... 8
Oil circulation unit ............................................................ 107 Solenoid valve .....................................................................14
Oil filter ............................................................................... 106 Sound power level ..............................................................18
Oil hose .................................................................................34 Sound pressure level .........................................................18
Oil meter ............................................................................ 107 Soundness test ...................................................................42
Oil nozzle ...................................................................... 23, 74 Spare part .............................................................................87
Oil pump ................................................................ 14, 34, 40 Speed ............................................................................ 53, 56
Oil quantity regulator ..........................................................14 Spring ....................................................................................82
Oil ressure measuring device ..........................................40 Spring coupling bar .................................................... 78, 79
Oil supply .................................................................... 34, 106 Stability problems ...............................................................84
Oil temperatures .............................................................. 106 Standards .............................................................................17
Oil throughput ............................................................. 14, 23 Start problems .....................................................................84
Operating panel ..................................................................38 Stepping motor .................................................... 75, 78, 79
Operating problems ...........................................................84 Storage .................................................................................17
Operating unit ......................................................................38 Suction resistance ........................................................... 106
Operating volume ...............................................................64 Supply ........................................................................... 27, 34
Supply pressure ................................................... 34, 40, 54
P Supply temperature ............................................................34
Supply voltage .....................................................................17
Partial load .................................................................... 52, 57
Pre-filter ............................................................................. 106
Pressure gauge ...................................................................40 T
Pressure measuring device ...................................... 39, 40 Temperature .........................................................................17
Pressure regulating screw ................................................54 Test points ............................................................................43
Pressure regulator .................................12, 28, 44, 45, 82 Test pressure .......................................................................42
Pressure switch ......................................11, 14, 58, 59, 61 Throughput ...........................................................................23
Pressure switches ..............................................................48 Transport ...............................................................................17
Pulsating ...............................................................................84 Type key ................................................................................10
Pump ...................................................................... 14, 34, 40 Type of Gas ..........................................................................17
Pump coupling ....................................................................80 Type of gas ........................................................................ 102
Pump pressure ..................................................... 23, 40, 54
V
R Vacuum .............................................................................. 106
Rating ....................................................................................19 Vacuum gauge ....................................................................40
Ratings apportionment ......................................................65 Valve proving .......................................................................13
Refractory .............................................................................22 Valve proving gas pressure switch
Reset .....................................................................................83 .....................................................................13, 29, 31, 32, 60
Return ............................................................................ 27, 34 Valve train ..................................................................... 30, 47
83263502 • 2/2014-12 • La 109-110

14 Key word index
Voltage supply .....................................................................17
W
Weight ...................................................................................21
Z
Zero shut off ................................................................. 44, 45
83263502 • 2/2014-12 • La 110-110

83263502 • 2/2014-12 • La

at www.weishaupt.de


almost any roof.

from Neuberger
flexible.
collectors.
83263502 • 2/2014-12 • La
Additional sheet
Position change high gas pressure switch 83513602 • 1/2013-04

Additional sheet
Position change high gas pressure switch
1 User instructions
1 User instructions
This additional manual forms part of the appliance and must be kept on site.
This additional sheet replaces the installation examples for gas valve trains in the
installation and operating manual of the burner. It applies to the following burner types:
▪ Monarch burners 1 - 11
▪ WM - burners 10 - 30
▪ Industrial burners 30 - 70
▪ WK - burners 40 - 80
The installation position of the high gas pressure switch has changed. All other in-
formation and safety notes given in the installation and operating instructions remain
applicable and must be adhered to.
83513602 • 1/2013-04 • La 2-7

Additional sheet
2 Installation examples
2.1 Screwed gas valve train for high pressure supply

Installation position of high gas pressure switch has changed.
1 Double gas valve

3 Gas filter
5 Pressure regulator
6 Terminal box (for W-FM 100/200)
9 Ignition gas valve (depending on burner type)
83513602 • 1/2013-04 • La 3-7

Additional sheet
2.2 Screwed valve train for low pressure supply

1 Double gas valve

3 Gas filter
83513602 • 1/2013-04 • La 4-7

Additional sheet
2.3 Flanged valve train for high pressure supply

1 Double gas valve

3 Gas filter
83513602 • 1/2013-04 • La 5-7

Additional sheet
2.4 Flanged valve train for low pressure supply

Installation position of high gas pressure switch remains unchanged.
1 Double gas valve

3 Gas filter
83513602 • 1/2013-04 • La 6-7

Additional sheet
3 Installation
3 Installation
3.1 Installation example high gas pressure switch

If the connection cable to the high gas pressure switch is insufficient in length, fit new
cable (max. length 10 m). For W-FM 100/200, use the enclosed screw terminals for
the terminal box.
Installation example high gas pressure switch fitted to pressure gauge

▶ Remove closing plug 2.
▶ Screw threaded socket 1 into high gas pressure switch 4, ensuring correct
alignment of seal 3.
Installation example of high gas pressure switch with T piece mounting

When installing, use only tested and approved sealing materials whilst observing all
process information.
▶ Screw double nipples 3 and 5 into T piece 1 (use reducer 2 on valve train
sizes R1½” and R2”).
▶ Screw double nipple 5 with T piece 1 into pressure regulator.
▶ Screw high gas pressure switch 4 to double nipple 3.
83513602 • 1/2013-04 • La 7-7

www.weishaupt.de Max Weishaupt GmbH, D-88475 Schwendi
Weishaupt (UK) Limited Neachells Lane, Willenhall, WV13 3RG

www.weishaupt.co.uk
Printed in Germany. All rights reserved.
Product Description Performance
W-Burners The compact series, proven millions of times over: Up to 570 kW

Economical, reliable, fully automatic. Gas, oil and
dual fuel burners for domestic and commercial appli-
cations. The purflam burner gives almost soot-free
combustion of oil with greatly reduced NOx emissions.
Monarch and The legendary industrial burner: Up to

industrial burners Tried and tested, long lived, clear construction. 11,700 kW
Gas, oil and dual fuel burners for district heat
provision.
multiflam® burners Innovative Weishaupt technology for large burners: Up to

Minimal emission values particularly at ratings over 17,000 kW
one megawatt. Oil, gas and dual fuel burners with
patented fuel distribution system.
WK Modular powerhouses: Up to
industrial burners Adaptable, robust, powerful. 22,000 kW
Oil, gas and dual fuel burners for industrial plant.
Thermo Unit The Thermo Unit heating systems from cast iron or Up to 55 kW
steel: Modern, economic, reliable.
For environmentally friendly heating.
Fuel: Gas or oil as desired.
Thermo Condens The innovative condensing boilers with the SCOT Up to

system: Efficient, low in emissions, versatile. Ideal for 1,200 kW
domestic heating. Floor standing gas condensing
boiler with ratings of up to 1200 kW (cascade), for
higher heat demands.
Heat pumps The heat pump programme offers solutions for Up to 130 kW
utilisation of heat from air, soil and ground water.
The systems are suitable for refurbishment or new
builds. It is possible to use several heat pumps in
cascade operation.
Solar systems Free energy from the sun:

Perfectly coordinated components, innovative, proven.
Pleasantly shaped flat roof collectors to support
heating and of domestic water
Water heater / The attractive domestic water heating range

energy reservoir includes classic water heaters which are supplied
through a heating system and energy reservoirs
which can be fed through solar systems.
Control technology / From control panels to complete building management

building systems – at Weishaupt you can find the entire
management spectrum of modern control technology.
Future oriented, economical and flexible.
83513602 • 1/2013-04 • La
Additional sheet
Supplement service plan dual fuel burners WM 10 ... 50 83540102 1/2016-06

Additional sheet
Supplement service plan dual fuel burners WM 10 ... 50
1 User instructions
1 User instructions
This manual forms part of the equipment and must be kept on site.
Carefully read the manual prior to working on the unit.
This instruction supplements the following chapters in the installation and operating
manual of the burner:
Notes on servicing
Service plan
All other information and safety instructions given in the installation and operating
manual remain valid and must be observed.
83540102 1/2016-06 La 2-6

Additional sheet
2 Servicing
2 Servicing

should be serviced annually. Depending on site conditions more frequent checks
may be required.
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. 2.2].
83540102 1/2016-06 La 3-6

Additional sheet
2 Servicing
2.2 Service plan
Supplement to the service plan

The supplement to the service plan contains only the safety-relevant components
including their design lifespan.
All other instructions relative to service given in the installation and operating
manual of the burner remain valid and must be observed.
Components Criteria / design lifespan(1 Service procedure
Air pressure switch Switch point Check
250 000 burner starts or 10 years(2 Replace
Combustion Manager
^^
Flame sensor Soiling Clean
Damage Replace
QRI:
250 000 burner starts or 10 years(2
QRA:
^^
10 000 operating hours
Nozzle head
^^
Oil hose Damage/oil escaping Replace
^^
5 years
Oil quantity regulator Excess air due to wear Replace
Hysteresis behaviour/damage/oil escap-
ing
^^
Oil solenoid valve Soundness Replace
(2
^^
250 000 burner starts or 10 years
Oil pressure switch Switch point Check
^^
Double gas valve Fault identified Replace
With valve testing system (valve
proving)
^^
Double gas valve Function/soundness Replace

Without valve testing system less than DN 25:
(valve proving) 200 000 burner starts or 10 years(2
DN 25 to DN 65:
DN 80 to DN 150:
^^
Actuator SKP for Function Replace
double gas valve VGD 45 000 operating hours
^^
Gas pressure regulator Setting pressure Check

Function/soundness Replace
15 years
Gas pressure switch Switch point Check
(2
50 000 burner starts or 10 years Replace
€€
(1
The specified design lifespan applies for typical use in heating, hot water and steam systems as well as for thermal
process systems to EN 746.
(2
If a criterion is reached, carry out maintenance measures.
83540102 1/2016-06 La 4-6

83540102 1/2016-06 La

at www.weishaupt.de


almost any roof.

from Neuberger
flexible.
collectors.
83540102 1/2016-06 La
EU conformity certification
Language 02
Product description Dual fuel burner

Type WM-GL 30/2-A
(W-FM 100/200)
Manufacturer Max Weishaupt GmbH
Address Max-Weishaupt-Straße 14, DE-88475 Schwendi
The sole responsibility for issuing this conformity declaration lies with the manufacturer.
The content of the statement described above complies with the relevant harmonisation legislation of the European
Union:
EMC 2014/30/EU
Standards applied: EN 61000-6-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007
LVD 2014/35/EU
Standards applied: EN 60335-1:2010, EN 60335-2-102:2010
MD 2006/42/EC
Standards applied: EN 267 Appendix J, EN 676 Appendix J
GAD 2009/142/EC
Standard applied: EN 676:2008
PED (1 97/23/EC to 18.07.2016
2014/68/EU from 19.07.2016
Standards applied: EN 267 Appendix K, EN 676 Appendix K
Conformity assessment procedures: Module B
Notified Body: TÜV SÜD IS, Ridlerstraße 65, DE-80339 Munich, ID-No. 0036
(1
With the appropriate choice of equipment.
Signed for and on behalf of:
MAX WEISHAUPT GMBH
ppa. ppa.

Manager research and Development Manager Production and Quality Management
%& '

$ (

! )*
" +,) (- ./
# +, ) ( 01234% 55267
!$ % $ &$ $
!$ $ % %' &$ $ ' $ $ (
)*
894 :12;<7;%&
+ * (, -.
+4/- :=;2:;%$
+ * (,
/-
0 $ % ' $ $ $ % $
"1 22(
%4/ :12;=5;%&
+ * (,
/
0 $ % ' $ $ $ % $
(1 -232()
+$& 4 ---
+ % $ *
"#5 6(+7#) ! 8"97

1 +$ 1 :
" $ 1 ' " ; "
Industrieregler KS 40-1 für
Weishaupt-Brenner
Bedienungsanleitung
9499-040-63201
Deutsch w English w Francais
Gültig ab: 01/2012

© PMA Prozeß- und Maschinen-Automation GmbH 2012 Printed in Germany (0112)
Alle Rechte vorbehalten. Ohne vorhergehende schriftliche Genehmigung
ist der Nachdruck oder die auszugsweise fotomechanische oder
anderweitige Wiedergabe diese Dokumentes nicht gestattet.
Dies ist eine Publikation von PMA Prozeß- und Maschinen Automation
Postfach 310229
D-34058 Kassel
Germany
Inhaltsverzeichnis
1 Montage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Elektrischer Anschluß . . . . . . . . . . . . . . . . . . . . . . . 6
3 Bedienung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Konfigurier-Ebene . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Parameter-Ebene . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Kalibrier-Ebene . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Programmgeber. . . . . . . . . . . . . . . . . . . . . . . . . . 29
8 Technische Daten . . . . . . . . . . . . . . . . . . . . . . . . 31
9 Sicherheitshinweise . . . . . . . . . . . . . . . . . . . . . . . . 34
10 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11 Electrical connections . . . . . . . . . . . . . . . . . . . . . . 39
12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
13 Configuration level . . . . . . . . . . . . . . . . . . . . . . . . 46
14 Parameter setting level . . . . . . . . . . . . . . . . . . . . . . 56
15 Calibration level . . . . . . . . . . . . . . . . . . . . . . . . . 59
16 Programmer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
17 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18 Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
19 Montage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
20 Raccordement électrique . . . . . . . . . . . . . . . . . . . . . 72
21 Utilisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
22 Niveau de configuration . . . . . . . . . . . . . . . . . . . . . 80
23 Niveau de paramétrage . . . . . . . . . . . . . . . . . . . . . . 90
24 Niveau d’étalonnage . . . . . . . . . . . . . . . . . . . . . . . 93
25 Programmateur . . . . . . . . . . . . . . . . . . . . . . . . . 96
26 Caractéristiques techniques . . . . . . . . . . . . . . . . . . . 98
27 Consignes de sécurité . . . . . . . . . . . . . . . . . . . . . . 102
Montage
1 Montage
min.48 (1.89")
max. 60°C
4 ")
0. ")
(3.62" +0. 03)

( 65 min. 0°C
10
4. 0
.
+0, 8
")
(4
.0 .1
.4
18
(0 1.
.0
92
1
max.
-weishaupt-
95% rel. %
126
96 (3.78")
+0,6
SP.X SG 45
125 Ada
+0.02
Err
(1.77" )
48 (1.89")
Loc 10V i mA/Pt 10V 10V
Loc Loc mA/Pt
mA/Pt
Loc 10V mA/Pt

Sicherheitsschalter
Ü oder:
Ü
*
*
Sicherheitsschalter:
Zum Zugriff auf die Drahthakenschalter muß der Regler unter leichtem Drücken
oben und unten mit kräftigem Zug an den Aussparungen des Frontrahmens aus
dem Gehäuse gezogen werden
INP1 Volt mA/Pt 1 Thermoelement, Widerstandsthermometer oder

Ferngeber an INP1
10V Druckaufnehmer (0..10V) an INP1
Loc offen Zugang zu den Ebenen wie mittels Engineeringtool
eingestellt 2
geschlossen 1 alle Ebenen uneingeschränkt zugänglich
1 Auslieferungszustand 2 Default-Einstellung: alle Ebenen

ausgeblendet, Passzahl = OFF
a Drahthakenschalter INP1 Volt immer in Stellung links oder rechts. Offen

lassen des Drahthakenschalters kann zu Fehlfunktionen führen!
l Achtung! Das Gerät enthält ESD-gefährdete Bauteile.
9499-040-63201 5 KS40-1 -weishaupt-

Elektrischer Anschluß
2 Elektrischer Anschluß
Option
P
A
9
26 L
di2 (-)
90...250V
10 27 N
11 -
di3 10
20
5 19 OUT1
Ut(+) 21
22
OUT2
23
24b OUT3
24 g h
g b c
7 + INP2
100%
8
0%
6
3
+ +
0% 10V * 1 2 20mA **
2 - 3 -
1 + 100% 2 1
INP1
a b c d e f g
* Drahthakenschalter INP1 Volt muß in Stellung 10V sein
** Drahthakenschalter INP1 Volt muß in Stellung mA/Pt sein
Anschluß des Eingangs INP1

Eingang für die Regelgröße x1 (Istwert).
a Thermoelement
b Widerstandsthermometer (Pt 100/Pt1000/KTY)
c Ferngeber 50-30-50 [
d Spannung 0..10V (* : siehe Anschlußbild)
e Druckaufnehmer (3-Leiter-Anschluß)
f Druckaufnehmer (2-Leiter-Anschluß)
g Strom 0..20mA (** : siehe Anschlußbild)
Anschluß des Eingangs INP2

Siehe Eingang INP1.
Anschluß der Eingänge di2/di3

Digitaler Eingang di2 zur externen Umschaltung zwischen SP und SP.2
(SP/SP.2).
Digitaler Eingang di3, ext. Umschaltung 3-Punkt-Schrittregler/Signalgerät
(DPS/SG).
KS40-1 -weishaupt- 6 9499-040-63201

Bedienung
3 Bedienung
3.1 Frontansicht
1 1 Zustände der Schalt-

ausgänge OUT1..3
2 Leuchtet, wenn
Grenzwert 1 nicht über-
2
1 2 3 OK
schritten ist
3 Istwertanzeige
4 Regler arbeitet als
3 Signalgerät
0 SP.x
126. SG
&
4
5
6
7
8
Selbstoptimierung aktiv
Eintrag in der Errorliste
Sollwert, Stellgröße
125
Ruft erweiterte Bedien-
! Ada
5 ebene / Errorliste auf
9
" Err
6
Veränderung des Soll-
wertes im Automatik-
oder des Stellwertes im
7 Hand-Betrieb
0 Sollwert SP.2 ist wirksam
! Sollwertgradient wirksam
§
è
" Handbetrieb
8 § Funktionstaste
$ $ Hand-Automatik-
Umschaltung ( " )
% PC-Anschluß für
% 9 BlueControl
(Engineering-Tool)
& Signalisierung
PArA-Ebene (leuchtet)
ConF-Ebene (blinkt)
g In der oberen Anzeige wird immer der Istwert angezeigt. In der Parameter- und
Konfigurier-Ebene sowie der Error-Liste wechselt die untere Anzeige zyklisch
zwischen dem einzustellenden Parameter und dem Parameter-Wert.
9499-040-63201 7 KS40-1 -weishaupt-

Bedienung
3.2 Bedienebene
Der Inhalt der erweiterten Bedienebene wird mit Hilfe des Engineering Tools
festgelegt. Es können Parameter in die erweiterte Bedienebene kopiert werden,
die oft benutzt werden oder deren Anzeige wichtig ist.
Automatik Hand
126 iÒ i 126
125 y 21
È È
Ì Ì
time
out Ù Ò Ù time
out
126 126
y 21 125
nur È
Anzeige Ì
Ù Ù
erweiterte Bedienebene
time
out
Errorliste (wenn Fehler vorhanden)
126 Anzeige
126
FbF.1 Err
wechselt
2 Err
Die Err-LED zeigt einen Fehler oder Warnung an
Die Errorliste ist nur dann sichtbar, wenn ein

Fehler-Eintrag vorliegt. Ein aktueller Eintrag in der
Errorliste (Alarm, Fehler) wird durch die Err-LED im SP.X
126 SG
Display angezeigt. 125 Ada

Err
Err-LED- Status Bedeutung weiteres Vorgehen

blinkt Alarm steht an, Fehler vorhanden - in Errorliste über Fehler-Nummer die
Fehler-Art bestimmen
- Fehler beseitigen
leuchtet Fehler beseitigt, - in Errorliste Alarm durch drücken der
Alarm nicht quittiert È - oder Ì -Taste quittieren
- Alarmeintrag ist damit gelöscht
aus kein Fehler,
alle Alarmeinträge gelöscht
KS40-1 -weishaupt- 8 9499-040-63201

Bedienung
Error-Liste:
Name Beschreibung Ursache Mögliche Abhilfe
E.1 Interner Fehler, z.B defektes EEPROM -PMA Service kontaktieren
nicht behebbar -Gerät einschicken
E.2 Interner Fehler, z.B. EMV - Störung -Gerät kurzzeitig vom Netz trennen
rücksetzbar -Meß- u. Netzleitungen getrennt führen
- Schütze entstören
FBF.1 / 2 Fühlerbruch Eingang 1 / 2 Fühler defekt INP1 / 2 Fühler austauschen,
Verdrahtungsfehler INP1 / 2 Anschluß überprüfen
Sht.1 / 2 Kurzschluß Eingang 1 / 2 Fühler defekt INP1 / 2 Fühler austauschen,
Verdrahtungsfehler INP1 / 2 Anschluß überprüfen
POL.1 Verpolung Eingang 1 Verdrahtungfehler Verdrahtung INP1 vertauschen
LooP Regelkreis-Alarm (LOOP) -Eingangssignal defekt -Heiz- bzw. Kühlstromkreis überprüfen
od. nicht korrekt -Fühler überprüfen eventuell ersetzen
angeschlossen -Regler und Schaltvorrichtung
-Ausgang nicht korrekt überprüfen
angeschlossen
AdA.H Adaptions-Alarm Heizen siehe Error-Status siehe Error-Status Adaption Heizen
(ADAH) Adaption Heizen
Lim.1 / 2 gespeicherter eingestellter Grenzwert eventuell Einstellgrenzen oder Prozeß
/3 Grenzwertalarm 1 / 2 / 3 1 / 2 / 3 verletzt überprüfen
Inf.1 Zeitgrenzwert-Meldung eingestellte Anwendungsspezifisch
Betriebsstunden
erreicht
Inf.2 Schaltspielzahl-Meldung eingestellte Anwendungsspezifisch
Schaltspielzahl erreicht
Error-Status ( nur Error AdA.H / AdA.C haben Error-Status 3 - 9 ):

Error-Status Beschreibung Verhalten
0 kein Fehler
1 gespeicherter Fehler nach Quittierung in Errorliste Wechsel zu Error-Status 0
2 anstehender Fehler nach Fehlerbeseitigung Wechsel zu Error-Status 1
3 falsche Wirkungsrichtung Regler umkonfigurieren (invers i direkt)
4 keine Reaktion der Regelgröße eventuell Regelkreis nicht geschlossen: Fühler, Anschlüsse
und Prozeß überprüfen
5 tiefliegender Wendepunkt Prozeß abkühlen lassen und erneut Adaptionsversuch
starten
6 Sollwertüberschreitungsgefahr eventuell Sollwert vergrößern (invers), verkleinern
(Parameter ermittelt) (direkt)
7 Stellgrößensprung zu klein Prozeß abkühlen lassen und erneut Adaptionsversuch
starten
8 Sollwertreserve zu klein Sollwert vergrößern (invers), verkleinern (direkt)
9 Impulsversuch fehlgeschlagen eventuell Regelkreis nicht geschlossen: Fühler, Anschlüsse
und Prozeß überprüfen
9499-040-63201 9 KS40-1 -weishaupt-

Bedienung
3.3 Selbstoptimierung (automatische Adaption der Regelparameter)
Nach dem Start durch den Bediener führt der Regler einen Adaptionsversuch
durch. Er errechnet dabei aus den Kennwerten der Regelstrecke die Parameter für
ein schnelles, überschwingfreies Ausregeln auf den Sollwert.
g ti und td werden bei der Adaption nur berücksichtigt, wenn sie vorher
nicht auf OFF sind.
Start der Adaption:

Der Bediener kann die Selbstoptimierung jederzeit starten. Dazu sind die Tasten
Ù und È gleichzeitig zu drücken. Die AdA-LED fängt an zu blinken.
Der Regler gibt 0% Stellgröße aus, wartet, bis der Prozeß zur Ruhe gekommen ist
und beginnt die Adaption (AdA-LED Dauerleuchten).
Der Adaptionsversuch selbst wird vom Regler gestartet, wenn folgende
Voraussetzungen erfüllt sind:
w Der Abstand Istwert i Sollwert muß ? 10% des Sollwertbereiches
( SP.Hi - SP.LO) sein (bei inversem Betrieb: Istwert unterhalb Sollwert, bei
direktem Betrieb: Istwert oberhalb Sollwert).
War die Adaption erfolgreich, erlischt die AdA-LED und der Regler arbeitet mit
den neu ermittelten Regelparametern weiter.
Abbruch der Adaption durch den Bediener:

Der Bediener kann die Selbstoptimierung jederzeit abbrechen. Dazu sind die
Tasten Ù und È gleichzeitig zu drücken. Der Regler arbeitet daraufhin im
Automatik-Betrieb mit den alten Parameterwerten weiter.
Abbruch der Adaption durch den Regler:

Fängt während der laufenden Adaption die Err-LED an zu blinken, liegen
regeltechnische Gegebenheiten vor, die eine erfolgreiche Adaption verhindern.
Der Regler hat in diesem Fall die Adaption abgebrochen. Er schaltet seine
Ausgänge ab (Stellwert 0%), um Sollwertüberschreitungen zu verhindern.
Der Anwender hat 2 Möglichkeiten die fehlgeschlagene Adaption zu quittieren:
1. Gleichzeitiges Drücken der Ù und È Tasten:

Regler regelt mit den alten Parametern im Automatik-Betrieb weiter.
Err-LED blinkt weiter bis Adaptionsfehler in Error-Liste quittiert wird
2. Drücken der Ù Taste:
Anzeige der Error-Liste in der erweiterten Bedienebene. Nach Quittierung der
Fehlermeldung regelt der Regler im Automatik-Betrieb mit den alten
Parametern weiter
Abbruchursachen: r siehe Seite 9 "Error-Status"
KS40-1 -weishaupt- 10 9499-040-63201

Bedienung
Beispiele für Adaptionsversuch 3-Punkt-Schrittregler
Nach dem Start (1) fährt der Regler W

das Stellglied zu (2 Out.3). Hat sich X
der Istwert genügend weit vom
Sollwert entfernt (3), so wird die
Änderung des Istwertes während 1 t
min. gemessen (4). Danach wird das
Stellglied aufgefahren (5 Out.1). Ist
der Wendepunkt erreicht (6) oder 1 min
sind genügend Messungen t
durchgeführt, so werden die Parameter 1 2 3 4 5 6
ermittelt und übernommen.
3.4 Optimierungshilfe für manuelle Optimierung
Die Optimierungshilfe sollte bei Geräten benutzt werden, bei denen die
Regelparameter ohne Selbstoptimierung eingestellt werden sollen.
Dazu kann der zeitliche Verlauf der Regelgröße x nach einer sprungartigen
Änderung der Stellgröße y herangezogen werden. Es ist in der Praxis oft nicht
möglich, die Sprungantwort vollständig (0 auf 100%) aufzunehmen, da die
Regelgröße bestimmte Werte nicht überschreiten darf. Mit den Werten Tg und
xmax (Sprung von 0 auf 100 %) bzw. Δt und Δx (Teil der Sprungantwort) kann die
maximale Anstiegsgeschwindigkeit vmax errechnet werden.
y
100% y = Stellgröße
Yh Yh = Stellbereich
0%
Tu = Verzugszeit (s)
t
Tg = Ausgleichszeit (s)
x
Tg Xmax = Maximalwert der Regelstrecke
Xmax
Xmax { x
{X
Vmax = = = max. Anstiegs-
Tg {t
{t
geschwindigkeit der Regelgröße
Tu t
Aus den ermittelten Werten der Verzugszeit Tu , der maximalen

Anstiegsgeschwindigkeit vmax und dem Kennwert K können nach den
Faustformeln die erforderlichen Regelparameter bestimmt werden. Bei
schwingendem Einlauf auf den Sollwert ist Pb1 zu vergrößern.
9499-040-63201 11 KS40-1 -weishaupt-

Bedienung
Einstellhilfen
Kennwert Regel vorgang Störung Anfahrvorgang
Pb1 größer stärker gedämpft langsameres Ausregeln langsamere Energierücknahme
kleiner schwächer gedämpft schnelleres Ausregeln schnellere Energierücknahme
td1 größer schwächer gedämpft stärkere Reaktion frühere Energierücknahme
kleiner stärker gedämpft schwächere Reaktion spätere Energierücknahme
ti1 größer stärker gedämpft langsameres Ausregeln langsamere Energierücknahme
kleiner schwächer gedämpft schnelleres Ausregeln schnellere Energierücknahme
Faustformeln
K = Vmax * Tu Regelverhalten Pb1 [phy.Einheiten] td1 [s] ti1 [s]
PID 1,7 * K 2 * Tu 2 * Tu
Bei 2-Punkt- und PD 0,5 * K Tu OFF
3-Punkt-Reglern ist die
Schaltperiodendauer auf PI 2,6 * K OFF 6 * Tu
t1 / t2 ≤ 0,25 * Tu P K OFF OFF
einzustellen. 3-Punkt-Schrittregler 1,7 * K Tu 2 * Tu
3.5 Bedienstruktur
Nach Einschalten der Hilfsenergie startet das Gerät mit der Bedien-Ebene.
Es wird der Betriebszustand angenommen der vor dem Neustart aktiv war.
126 Ù 126 Ù
125 3 Sek
PArA
126 Ù
Ì ConF
126 Ù
Ì End
a Zum Zugriff auf die Parameter- und Konfigurier-Ebene muß der Drahthaken-
schalter Loc geschlossen sein (Auslieferzustand).
KS40-1 -weishaupt- 12 9499-040-63201

Konfigurier-Ebene
4 Konfigurier-Ebene
4.1 Konfiguration mit qUIC
In der Konfigurier-Ebene wird die Funktion des Reglers durch Veränderung des
Konfiguration-Wortes Con1 festgelegt. In der unteren Anzeige wechselt
Con1 mit dem für Con1 eingestellten Code.
r
SP.X
126 r Ù r
SG PArA
125 Ada
Err
3 sec.
Ì
r Ù r qUIC r Ù r È
ConF Con1 Ì rÙ
123.8 123.8
Con1 1520
A B C D
Bedeutung des Codes:

A 0 Reaktion bei Fühlerbruch wie Istwert größer Sollwert
1 Reaktion bei Fühlerbruch wie Istwert kleiner Sollwert
2 Nur P30/W-Anschluß, immer Istwert kleiner Sollwert *
B 0 Ferngeber 50-30-50 [ / Druckaufnehmer 0..10V, Anzeigebereich 0,0...100,0 (%)
1 Ferngeber 50-30-50 [ / Druckaufnehmer 0..10V, Anzeigebereich 0,00...1,00 (bar)
4 Widerstandsthermometer Pt 100 [ , Bereich 0...200°C
5 Widerstandsthermometer Pt 100 [ , Bereich 0...400°C
6 Thermoelement Typ L, Bereich 0...900°C
7 Thermoelement Typ K, Bereich 0...1350°C
C 0 Funktion Signalgerät mit Umschalter
1 3-Punkt-Signalgerät
2 Umschaltbar: 3-Punkt-Schrittregler (DPS) i Signalgerät mit Umschalter (SG)
3 Umschaltbar: 3-Punkt-Schrittregler (DPS) i 3-Punkt-Signalgerät (SG)
D 0 nicht änderbar
* Bei A = 2 nur B = 0 … 3 möglich
9499-040-63201 13 KS40-1 -weishaupt-

Konfigurier-Ebene
Nach dem Ausstieg aus der Konfigurier-Ebene (siehe Seite 12) durchläuft der
Regler automatisch eine Neu-Initialisierung (alle Elemente der Anzeige leuchten)
und geht dann in den normalen Betrieb über (Bedienebene).
g Führende Nullen werden nicht angezeigt (Bsp.: Bei Code 0400 Anzeige 400)
Konfigurationsbeispiel 1 (Code 0400):

KS40-1 als Signalgerät mit Umschalter für
2-stufigen Brenner: 123.8 123.8
Meßbereich 0...200°C,
Widerstandsthermometer Pt 100,
Con1 400
Reaktion bei Fühlerbruch wie Istwert größer
Sollwert.
Konfigurationsbeispiel 2 (Code 2120):

KS40-1 als 3-Punkt-Schrittregler:
Anschluß an Druck-Meßumformer P30/W, 123.8 123.8
Meßbereich 0,00...1,00 bar,
Reaktion bei Fühlerbruch wie Istwert kleiner
Con1 2120
Sollwert.
Funktion: Signalgerät mit Umschalter

ACHTUNG: Die beiden W
Relais 1 und 2 sind so ON
gekoppelt, daß die OUT1
Kontakte die Funktion OFF
Sd1 = Sd2
eines Umschalters erfüllen. ON
Dabei muß sichergestellt OUT2
werden, daß beide Relais -X W OFF XW
nicht gleichzeitig anziehen H.1
oder abfallen. Ausnahme: ON
stromloser Zustand. Grenzwert OUT3
OFF
HYS.1
Einstellungen:
Schaltdifferenzen: Sd1 / Sd2: in physikalische Werten

Grenzwert OUT3: Bei Überschreitung des Grenzwertes fällt das Relais ab.
Oberer Grenzwert H.1 : in physikalischen Werten
Schaltdifferenz HYS.1 : in physikalischen Werten
Signal-LEDs: LED1: leuchtet, wenn OUT1 angezogen ist
LED2: leuchtet, wenn OUT2 angezogen ist
OK-LED: leuchtet, wenn Grenzwert nicht erreicht
Parameter: siehe Kapitel 5 “Parameter-Ebene”
KS40-1 -weishaupt- 14 9499-040-63201

Konfigurier-Ebene
Funktion: 3-Punkt-Signalgerät
Sd1
ON
OUT1
OFF
Sd2
ON d.SP
OUT2 W
-X W OFF XW
H.1
ON
Grenzwert OUT3
OFF
HYS.1
Einstellungen:
OUT1: Einschaltpunkt ist mit dem Sollwert gekoppelt.

Schaltdifferenz Sd1: in physikalischen Werten.
OUT2: Ausschaltpunkt liegt immer vor dem Sollwert!

Einstellbereich d.SP : in physikalischen Werten.
Schaltdifferenz Sd2: in physikalischen Werten.
Oberer Grenzwert H.1: in physikalischen Werten.
Schaltdifferenz HYS.1: in physikalischen Werten.

9499-040-63201 15 KS40-1 -weishaupt-

Konfigurier-Ebene
Funktion: 3-Punkt-Schrittregler
W ON
OUT2
-X W OFF XW
OUT1 XSd
ON -A A
SH
H.1
ON
Grenzwert OUT3
OFF
HYS.1
Einstellungen:
Regler: SH: in physikalischen Werten

Ansprechschwelle A: 0,5 w SH
Schaltdifferenz XSd : 0,06 w SH + 0,08
Laufzeit des Stellantriebes zw. Brennerkleinlast und
-großlast tt: 3...9999 s
Mindest-Einschaltdauer: fest, TEmin = 100 ms
Regelparameter: Pb1 = 0,01...9999 : in physikalischen Werten °C oder °F

(Anzahl Nachkommastellen wird durch CON1 festgelegt)
Ti = 1...9999 s ( OFF = kein I-Anteil)
td = 1...9999 s ( OFF = kein D-Anteil)
Oberer Grenzwert H.1 : in physikalischen Werten.
Schaltdifferenz HYS.1 : in physikalischen Werten.

Stromloser Zustand: alle Relais abgefallen, Kontakte offen
KS40-1 -weishaupt- 16 9499-040-63201

Konfigurier-Ebene
4.2 Konfiguration ohne qUIC ( qUIC= OFF)
Wird während Netz-Ein des Reglers die Ù - Taste gedrückt gehalten, wird die
Konfiguration mit qUIC abgeschaltet.
Jetzt stehen dem Benutzer alle Konfigurations-Einstellungen zur Verfügung.
Soll wieder zur Konfiguration mit qUIC gewechselt werden, müssen während
Netz-Ein des Reglers, die beiden Tasten Ì È gedrückt gehalten werden.
a Hierbei wird der Regler auf die werksseitig eingestellten Default-Werte

zurückgesetzt!
Übersicht der Konfiguration:
Con1
Eigene
Name Wertebereich Beschreibung Default
Einstellung
Con1 0000...2330 qUIC - Konfiguration 0000
Drahthakenschalter (auf Platine)

Eigene
Name Stellung Beschreibung Default
Einstellung
Loc offen oder Drahthakenschalter zur Verriegelung der ConF- und geschlossen
geschlossen PArA-Ebene (wenn in BlueControl freigegeben)
InP.1 mA/Pt oder 10V Drahthakenschalter zur Wahl der Eingangsgröße InP.1 mA/Pt
Cntr
Eigene
Einstellung
SP.Fn Grundkonfiguration der Sollwertverarbeitung 0
0 Festwertregler umschaltbar auf externen Sollwert
(→ LOGI/ SP.E)
1 Programmregler
8 Festwertregler mit externer Verschiebung (SP.E)
9 Programmregler mit externer Verschiebung (SP.E)
C.Fnc Regelverhalten (Algorithmus) 0
0 2-Punkt-Signalgerät
1 PID-Regler (2-Punkt und stetig)
2 D/ Y/Aus, bzw. 2-Punktregler mit Teil-/Volllastumschaltung
3 2 x PID (3-Punkt und stetig)
4 3-Punkt-Schrittregler
7 3-Punkt Signalgerät
8 3-Punkt-Schrittregler umschaltbar auf Signalgerät
9 3-Punkt-Schrittregler umschaltbar auf 3-Punkt-Signalgerät
9499-040-63201 17 KS40-1 -weishaupt-

Konfigurier-Ebene
Eigene
Einstellung
mAn Handverstellung zugelassen 1
0 nein
1 ja (siehe auch LOGI/ mAn)
C.Act Wirkungsrichtung des Reglers 0
0 Invers, z.B. Heizen
1 Direkt, z.B. Kühlen
FAIL Verhalten bei Fühlerbruch 1
0 Reglerausgänge abgeschaltet
1 y = Y2
2 y = mittlerer Stellgrad. Der maximal zulässige Stellgrad
kann mit dem Parameter Ym.H eingestellt werden. Damit
keine unzulässigen Werte ermittelt werden, erfolgt die
Mittelwertbildung nur wenn die Regelabweichung kleiner als
der Parameter L.Ym ist (nur bei C.Fnc = 1, 2, 3 )
rnG.L -1999...9999 X0 (untere Regelbereichsgrenze) 1 0
rnG.H -1999...9999 X100 (obere Regelbereichsgrenze) 1 100
InP.1
Eigene
Einstellung
S.tYP Sensortyp 50
0 Thermoelement Typ L (-100...900°C) , Fe-CuNi DIN
1 Thermoelement Typ J (-100...1200°C) , Fe-CuNi
2 Thermoelement Typ K (-100...1350°C), NiCr-Ni
3 Thermoelement Typ N (-100...1300°C), Nicrosil-Nisil
4 Thermoelement Typ S (0...1760°C), PtRh-Pt10%
5 Thermoelement Typ R (0...1760°C), PtRh-Pt13%
18 Sonderthermoelement
20 Pt100 (-200,0 ... 100,0 °C)
21 Pt100 (-200,0 ... 850,0 °C)
22 Pt1000 (-200,0...200,0 °C)
23 KTY 11-6 (Spezial 0...4500 Ohm)
30 0...20mA / 4...20mA 2
40 0...10V / 2...10V 2
50 Potentiometer 0...160 Ohm 2
1 rnG.L und rnG.H geben den Regelbereich an, auf den sich u.a. die
Selbstoptimierung bezieht
2 Bei Strom-, Spannungs- oder Potentiometer-Eingangssignalen muß eine
Skalierung vorgenommen werden (siehe Kapitel 5.1)
KS40-1 -weishaupt- 18 9499-040-63201

Konfigurier-Ebene
Eigene
Einstellung
S.Lin Linearisierung (nur bei S.tYP = 30 (0..20mA) und 40 0
(0..10V) einstellbar)
0 Keine
1 Sonderlinearisierung. Erstellen der Linearisierungstabelle
mit BlueControl (Engineering-Tool) möglich. Voreingestellt
ist die Kennlinie für KTY 11-6 Temperatursensoren.
Corr Meßwertkorrektur / Skalierung 2
0 Ohne Skalierung
1 Offset-Korrektur (in CAL-Ebene)
2 2-Punkt-Korrektur (in CAL-Ebene)
3 Skalierung (in PArA-Ebene)
InP.2
Eigene
Einstellung
I.Fnc Funktionsauswahl von INP2 0
0 keine Funktion (nachfolgende Inp.-Daten werden
übersprungen)
2 Externer Sollwert SP.E (Umschaltung -> LOGI/ SP.E)
S.tYP Sensortyp 30
20 Pt100 (-200,0 ... 100,0 °C)
21 Pt100 (-200,0 ... 850,0 °C)
22 Pt1000 (-200,0...200,0 °C)
23 KTY11-6 (Spezial 0...4500 Ohm)
30 0...20mA / 4...20mA 1
50 Potentiometer ( 0...160 Ohm) 1
Corr Meßwertkorrektur / Skalierung 0
0 Ohne Skalierung
1 Offset-Korrektur (in CAL-Ebene)
2 2-Punkt-Korrektur (in CAL-Ebene)
3 Skalierung (in PArA-Ebene)
In.F -1999...9999 Ersatzwert von INP2 off
1 Bei Strom- und Potentiometersignalen muß eine Skalierung vorgenommen

werden (siehe Kapitel 5.1)
9499-040-63201 19 KS40-1 -weishaupt-

Konfigurier-Ebene
Lim
Eigene
Einstellung
Fnc.1 Funktion des Grenzwertes 1 / 2 /3 1/0/0
Fnc.2 0 abgeschaltet
Fnc.3 1 Messwertüberwachung
2 Messwertüberwachung + Speicherung des Alarmzustands.
Ein gespeicherter Grenzwert kann über die Error Liste oder
einen digitalen Eingang bzw. die Ò -Taste zurückgesetzt
werden (-> LOGI/ Err.r)
Src.1 Quelle für Grenzwert 1 /2 / 3 1/0/0
Src.2 0 Istwert = Absolutalarm
Src.3 1 Regelabweichung Xw (Istwert - Sollwert) = Relativalarm
2 Regelabweichung Xw (=Relativalarm) mit Unterdrückung
beim Anfahren und bei Sollwertänderung
6 wirksamer Sollwert Weff
7 Stellgröße y (Reglerausgang)
LP.AL Überwachung auf Regelkreis-Unterbrechung (nur bei 0
PID-Reglern - C.Fnc 1,2,3,...)
0 kein LOOP Alarm
1 LOOP Alarm aktiv. Eine Unterbrechung des Regelkreises
wird erkannt, wenn bei Y=100% nach Ablauf von 2 x ti keine
entsprechende Reaktion des Istwertes erfolgt.
Out.1 / 2 / 3
Eigene
Einstellung
O.Act Wirkungsrichtung von Ausgang OUT1 Out.1: 0
0 Direkt / Arbeitsstromprinzip Out.2: 0
Out.3: 1
1 Invers / Ruhestromprinzip
Y.1 Reglerausgang Y1 / Y2 Out.1: 1 / 0
Y.2 0 nicht aktiv Out.2: 0 / 1
Out.3: 0 / 0
1 aktiv
Lim.1 Meldung Grenzwert 1 / 2 / 3 Out.1: 0 / 0 / 0
Lim.2 0 nicht aktiv Out.2: 0 / 0 / 0
Out.3: 1 / 0 / 0
Lim.3 1 aktiv
LP.AL Meldung Unterbrechungsalarm Out.1: 0
0 nicht aktiv Out.2: 0
Out.3: 0
1 aktiv
FAi.1 Meldung INP1-Fehler / INP2-Fehler Out.1: 0 / 0
FAi.2 0 nicht aktiv Out.2: 0 / 0
Out.3: 1 / 0
1 aktiv
KS40-1 -weishaupt- 20 9499-040-63201

Konfigurier-Ebene
LOGI
Eigene
Einstellung
L_r Local / Remote Umschaltung (Remote: Verstellung von 0
allen Werten über Front ist blockiert)
0 keine Funktion
1 immer aktiv
3 DI2 schaltet *
4 DI3 schaltet *
5 è -Taste schaltet *
SP.2 Umschaltung auf zweiten Sollwert SP.2 3
0 keine Funktion *
3 DI2 schaltet *
4 DI3 schaltet *
SP.E Umschaltung auf externen Sollwert SP.E 0
0 keine Funktion
1 immer aktiv
3 DI2 schaltet *
4 DI3 schaltet *
Y2 Y/Y2 Umschaltung 0
0 keine Funktion
3 DI2 schaltet *
4 DI3 schaltet *
6 Ò -Taste schaltet *
mAn Automatik/Hand Umschaltung 6
0 keine Funktion
1 immer aktiv
3 DI2 schaltet *
4 DI3 schaltet *
6 Ò -Taste schaltet *
C.oFF Ausschalten des Reglers 0
0 keine Funktion
3 DI2 schaltet *
4 DI3 schaltet *
6 Ò -Taste schaltet
9499-040-63201 21 KS40-1 -weishaupt-

Konfigurier-Ebene
Eigene
Einstellung
m.Loc Blockierung der Ò -Taste 0
0 keine Funktion
3 DI2 schaltet *
4 DI3 schaltet *
Err.r Rücksetzen aller gespeicherten Einträge der Errorliste 0
0 keine Funktion
3 DI2 schaltet *
4 DI3 schaltet *
6 Ò -Taste schaltet
P.run Programmgeber-Run/Stop 5
0 keine Funktion
3 DI2 schaltet *
4 DI3 schaltet *
SG Umschaltung der Regelfunktionalität zwischen 4
Motorschritt und Signalgerät
0 keine Funktion
3 DI2 schaltet *
4 DI3 schaltet *
5 è -Taste schaltet
di.Fn Funktion der digitalen Eingänge (gilt für alle Eingänge) 0
0 direkt
1 invers
2 Tasterfunktion
* Mehrfachnennungen und damit Verknüpfung der Signale ist möglich und
muß, wenn verlangt, vom Anwender ausgeschlossen werden.
othr
Unit Einheit 1
0 ohne Einheit
1 °C
2 °F
dP Dezimalpunkt (max. Nachkommastellen) 0
0 keine Dezimalstelle
1 1 Dezimalstelle
2 2 Dezimalstellen
3 3 Dezimalstellen
C.dEL 0...200 Modem delay [ms] 0
9499-040-63201 22 KS40-1 -weishaupt-

Parameter-Ebene
5 Parameter-Ebene
Cntr
Bei
qUIC Eigene
Einstellung
sichtbar
f Pb1 1...9999 Proportionalbereich 1 (Heizen) in phys. Einheit 10
(z.B. °C)
Pb2 1...9999 Proportionalbereich 2 (Kühlen) in phys. Einheit 10
(z.B. °C)
f ti1 1...9999 Nachstellzeit 1 (Heizen) [s] 10
ti2 1...9999 Nachstellzeit 2 (Kühlen) [s] 10
f td1 1...9999 Vorhaltezeit 1 (Heizen) [s] 10
td2 1...9999 Vorhaltezeit 2 (Kühlen) [s] 10
t1 0,4...9999 Minimale Periodendauer 1 (Heizen) [s]. Beim 10
Standard ED-Wandler ist die kleinste Impulslänge
1/4 x t1
t2 0,4...9999 Minimale Periodendauer 2 (Kühlen) [s]. Beim 10
Standard ED-Wandler ist die kleinste Impulslänge
1/4 x t2
f SH 0...9999 Neutrale Zone, bzw. Schaltdifferenz Signalgerät 1
[phys. Einheit]
f Sd1 0,0...9999 Schaltdifferenz Relais 1 für Signalgerät mit 0,1
Umschalter
f Sd2 0,0...9999 Schaltdifferenz Relais 2 für 3-Punkt-Signalgerät 0,1
f d.SP -1999...9999 Schaltpunktabstand Vorkontakt D / Y / Aus [phys. 0
Einheit]
f tP 0,1...9999 Mindest Impulslänge [s] OFF
f tt 3...9999 Motorlaufzeit des Stellmotors [s] 60
Y.Lo -105...105 Untere Stellgrößenbegrenzung [%] 0
Y.Hi -105...105 Obere Stellgrößenbegrenzung [%] 100
Y2 -100...100 Zweiter Stellwert [%] 0
Y.0 -105...105 Arbeitspunkt für die Stellgröße [%] 0
Ym.H -105...105 Begrenzung des Mittelwertes Ym [%] 5
L.Ym 1...9999 Max. Abweichung xw, zum Start der 8
Mittelwertermittlung [phys. Einheit]
SEtP
Bei
qUIC Eigene
Einstellung
sichtbar
SP.LO -1999...9999 Untere Sollwertgrenze für Weff 0
SP.Hi -1999...9999 Obere Sollwertgrenze für Weff 100
f SP.2 -1999...9999 Zweiter Sollwert 10
r.SP 0...9999 Sollwertgradient [/min] OFF
KS40-1 -weishaupt- 23 9499-040-63201

Parameter-Ebene
ProG
Bei
qUIC Eigene
Einstellung
sichtbar
SP.01 -1999...9999 Segmentendsollwert 1 100
Pt.01 0...9999 Segmentzeit 1 [min] 10
InP.1
Bei
qUIC Eigene
Einstellung
sichtbar
InL.1 -1999...9999 Eingangswert des unteren Skalierungspunktes 38,5
OuL.1 -1999...9999 Anzeigewert des unteren Skalierungspunktes 0
InH.1 -1999...9999 Eingangswert des oberen Skalierungspunktes 61,5
OuH.1 -1999...9999 Anzeigewert des oberen Skalierungspunktes 100
t.F1 0,0...100,0 Filterzeitkonstante [s] 0,5
InP.2
Bei
qUIC Eigene
Einstellung
sichtbar
InL.2 -1999...9999 Eingangswert des unteren Skalierungspunktes 0
OuL.2 -1999...9999 Anzeigewert des unteren Skalierungspunktes 0
InH.2 -1999...9999 Eingangswert des oberen Skalierungspunktes 100
OuH.2 -1999...9999 Anzeigewert des oberen Skalierungspunktes 100
t.F2 0,0...100,0 Filterzeitkonstante [s] 0,5
Lim
Bei
qUIC Eigene
Einstellung
sichtbar
L.1 -1999...9999 Unterer Grenzwert 1 OFF
f H.1 -1999...9999 Oberer Grenzwert 1 20
f HYS.1 0...9999 Hysterese von Grenzwert 1 0,1
L.2/3 -1999...9999 Unterer Grenzwert 2 / 3 OFF
H.2/3 -1999...9999 Oberer Grenzwert 2 / 3 OFF
HYS.2/3 0...9999 Hysterese von Grenzwert 2 / 3 1
KS40-1 -weishaupt- 24 9499-040-63201

Parameter-Ebene
5.1 Eingangs-Skalierung (nur sichtbar bei qUIC= OFF)
Werden Strom- oder Spannungssignale als Eingangsgrößen für InP.1 oder

InP.2 verwendet, muß in der Parameter-Ebene eine Skalierung der Eingangs-
und Anzeigewerte erfolgen. Die Angabe des Eingangswertes des unteren und
oberen Skalierpunktes erfolgt in der jeweiligen elektrischen Größe (mA/ V).
phys.
Größe
OuH.x
mA / V phys. Größe
OuL.x
InL.x InH.x mA/V
5.1.1 Eingang Inp.1
g Parameter InL.1 , OuL.1, InH.1 und OuH.1 sind nur sichtbar, wenn
ConF / InP.1 / Corr = 3 gewählt wurde.
S.tYP Eingangssignal InL.1 OuL.1 InH.1 OuH.1
30 0 … 20 mA 0 beliebig 20 beliebig
(0...20mA) 4 … 20 mA 4 beliebig 20 beliebig
40 0 … 10 V 0 beliebig 10 beliebig
(0...10V) 2 … 10 V 2 beliebig 10 beliebig
Über diese Einstellungen hinaus können InL.1 und InH.1 in dem durch die
Wahl von S.tYP vorgegebenen Bereich (0...20mA / 0...10V) eingestellt werden.
a Soll bei dem Einsatz von Thermoelementen und Widerstandsthermometern
(Pt100) die genormte Skalierung benutzt werden, müssen die Einstellungen von
InL.1 und OuL.1 sowie von InH.1 und OuH.1 übereinstimmen.
g Sind Veränderungen der Eingangs-Skalierung in der Kalibrier-Ebene (r Seite
26) vorgenommen worden, werden diese in der Eingangs-Skalierung in der
Parameter-Ebene dargestellt. Wird die Kalibrierung wieder zurückgesetzt (OFF),
sind die Skalierungsparameter wieder auf die Default-Einstellung zurückgesetzt.
5.1.2 Eingang InP.2
Wie Eingang InP.1, aber nur S.Typ = 30 wählbar!
9499-040-63201 25 KS40-1 -weishaupt-

Kalibrier-Ebene
6 Kalibrier-Ebene
g Meßwertkorrektur ( CAL) nur sichtbar, wenn ConF / InP.1 / Corr = 1 od. 2

und qUIC= OFF gewählt wurde.
Im Kalibrier-Menü ( CAL) kann eine Anpassung des Meßwertes durchgeführt

werden. Es stehen zwei Methoden zur Verfügung :
Offset-Korrektur
( ConF/ InP.1 / Corr =1 ): Anzeige Standardeinstellung
Offset-Korrektur
w kann online am Prozeß
erfolgen
OuL.1neu
OuL.1alt
InL.1 X
2-Punkt-Korrektur
( ConF/ InP.1 / Corr = 2 ): Anzeige Standardeinstellung
2-Punkt-Korrektur
w mit Istwertgeber offline
durchführbar oder
w online in 2 Schritten
zunächst den einen Wert OuH.1alt
korrigieren und später, z.B. OuH.1neu

nach dem Aufheizen des
Ofens, den zweiten Wert
korrigieren.
OuL.1neu
OuL.1alt
InL.1 InH.1 X
KS40-1 -weishaupt- 26 9499-040-63201

Kalibrier-Ebene
Offset-Korrektur ( ConF/ InP.1 / Corr =1):
r
SP.X
126 SG r Ù r PArA
125 Ada
Err 3 sec.
Ì
:
CAL r Ù r InP.1 r Ù r InL.1 r Ù
r OuL.1 È r Ù
Ì
r End r Ù
InL.1: Hier wird der Eingangswert des Skalierungspunktes angezeigt.

Der Bediener muß warten, bis der Prozeß zur Ruhe gekommen ist.
Danach bestätigt er den Eingangswert mit der Ù - Taste.
OuL.1: Hier wird der Anzeigewert des Skalierungspunktes angezeigt.
Vor der Kalibrierung ist OuL.1 gleich InL.1.
Der Bediener kann mit den ÈÌ - Tasten den Anzeigewert korrigieren.
Danach bestätigt er den Anzeigewert mit der Ù - Taste.
9499-040-63201 27 KS40-1 -weishaupt-

Kalibrier-Ebene
2-Punkt-Korrektur ( ConF/ InP.1 / Corr = 2):
SP.X
126 r Ù r
run PArA
125 Ada
Err
3 sec.
Ì
:
r

È
InL.1
Ù
È
OuL.1
Ì
rÙ
InH.1 rÙ
È
InH.1
Ù
È
OuH.1
Ì
rÙ
r End r Ù
InL.1: Hier wird der Eingangswert des unteren Skalierungspunktes angezeigt.

Der Bediener muß mit einem Istwertgeber den unteren Eingangswert
einstellen. Danach bestätigt er den Eingangswert mit der Ù - Taste.
OuL.1: Hier wird der Anzeigewert des unteren Skalierungspunktes angezeigt.
Vor der Kalibrierung ist OuL.1 gleich InL.1.
Der Bediener kann mit den ÈÌ - Tasten den unteren Anzeigewert
korrigieren. Danach bestätigt er den Anzeigewert mit der Ù - Taste.
InH.1: Hier wird der Eingangswert des oberen Skalierungspunktes angezeigt.
Der Bediener muß mit dem Istwertgeber den oberen Eingangswert
einstellen. Danach bestätigt er den Eingangswert mit der Ù - Taste.
OuH.1: Hier wird der Anzeigewert des oberen Skalierungspunktes angezeigt.
Vor der Kalibrierung ist OuH.1 gleich InH.1.
Der Bediener kann mit den ÈÌ - Tasten den oberen Anzeigewert
korrigieren. Danach bestätigt er den Anzeigewert mit der Ù - Taste.
g Die in der CAL - Ebene abgeänderten Parameter ( OuL.1, OuH.1) können
wieder zurückgesetzt werden indem die Parameter mit der Dekrement-Taste Ì
unter den untersten Einstellwert gestellt werden ( OFF).
KS40-1 -weishaupt- 28 9499-040-63201

Programmgeber
7 Programmgeber
W,X SP.01 SP.02

SP.03
SP.04
W,X W
Pt.01 Pt.02 Pt.03 Pt.04 t
Einrichten des Programmgebers:

Zum Verwenden des Reglers als Programmgeber muß im ConF-Menü der
Parameter SP.Fn = 1 gewählt werden. Gestartet wird der Programmgeber über
einen der digitalen Eingänge di2..3 oder è -Taste. Welcher Eingang zum Starten
des Programmgebers genutzt werden soll, wird durch entsprechende Wahl des
Parameters P.run = 3 / 4 / 5 im ConF-Menü festgelegt.
Soll das Programmende als digitales Signal einem der Relaisausgänge
zugewiesen werden, muß bei dem entsprechenden Ausgang OUT.1...OUT.3 im
ConF-Menü der Parameter P.End = 1 gewählt werden.
Parametrierung des Programmgebers:

Dem Anwender steht ein Programmgeber mit 4 Segmenten zur Verfügung. Im
PArA -Menü muß für jedes Segment eine Segmentdauer Pt.01 .. Pt.04 (in
Minuten) und ein Segment-Zielsollwert SP.01 .. SP.04 festgelegt werden.
Starten/Stoppen des Programmgebers:

Gestartet wird der Programmgeber durch ein digitales Signal an dem durch den
Parameter P.run gewählten Eingang di2..3 oder durch die è -Taste.
Der Programmgeber errechnet sich aus Segmentendsollwert und Segmentzeit den
Sollwertgradienten, mit dem der Segmentendsollwert erreicht werden soll. Dieser
Gradient ist immer wirksam. Da der Programmgeber das erste Segment beim
aktuellen Istwert startet, kann sich die effektive Laufzeit des ersten Segmentes
verändern (Istwert ≠ Sollwert).
Nach Ablauf des Programms regelt der Regler mit dem letzten eingestellten
Zielsollwert weiter.
Wird das Programm in seinem Verlauf gestoppt (Rücksetzen des digitalen
Signales an di2..3 oder der è -Taste), kehrt der Programmgeber an den Anfang
des Programms zurück und wartet auf ein erneutes Startsignal.
9499-040-63201 29 KS40-1 -weishaupt-

Programmgeber
+ Programmparameter können bei laufendem Programm geändert werden.

Änderung der Segmentzeit:
Veränderung der Segmentzeit führt zur Neuberechnung des erforderlichen
Gradienten. Ist die Segmentzeit bereits abgelaufen, so wird direkt mit dem neuen
Segment begonnen. Der Sollwert ändert sich dabei sprungförmig.
Änderung des Segment-Endsollwertes:

Veränderung des Sollwertes führt zur Neuberechnung des erforderlichen
Gradienten um den neuen Sollwert in der Restzeit des Segmentes zu erreichen.
Dabei kann der erforderliche Gradient auch das Vorzeichen wechseln.
KS40-1 -weishaupt- 30 9499-040-63201

8 Technische Daten
EINGÄNGE ZUSATZEINGANG INP2

Auflösung: > 14 Bit
ISTWERTEINGANG INP1 Abtastzyklus: 100 ms
Auflösung: > 14 Bit (20.000 Schritte) Strommeßbereich
Dezimalpunkt: 0 bis 3 Nachkommastellen
Technische Daten wie INP1
Grenzfrequenz: 2 Hz (analog)
dig. Eingangsfilter: einstellbar 0,0...100,0 s Potentiometer
Abtastzyklus: 100 ms r Tabelle 2 (Seite 33)
Meßwertkorrektur: 2-Punkt- oder Offsetkorrektur
Anschlußtechnik: 3-Leiter
Thermoelemente Leitungswiderstand: max. 30 Ohm
r Tabelle 1 (Seite 33 ) Meßkreisüberwachung: Bruch
Eingangswiderstand: ≥ 1 MΩ
Einfluß des Quellenwiderstands: 1 μV/Ω STEUEREINGÄNGE DI2,DI3
Temperaturkompensation: intern Konfigurierbar als Schalter oder Taster!
Anschluß eines potentialfreien Kontaktes der
Bruchüberwachung
zum Schalten “trockener” Stromkreise
Strom durch den Fühler: ≤ 1 μA geeignet ist.
Wirkungsweise konfigurierbar
Geschaltete Spannung: 5V
Widerstandsthermometer Strom: 160 μA
r Tabelle 2 (Seite 33 )
TRANSMITTERSPEISUNG UT
Anschlußtechnik: 2- oder 3-Leiter
Leitungswiderstand: max. 30 Ohm Leistung: 22 mA / ≥ 18 V
Meßkreisüberwachung: Bruch und Kurzschluß
GALVANISCHE TRENNUNGEN
Ferngeber 50-30-50 [ Sicherheitstrennung
Strom- und Spannungsmeßbereiche Funktionstrennung
r Tabelle 3 (Seite 33 )
Meßanfang, Meßende: beliebig innerhalb des Netzanschlüsse Istwerteingang INP1
Zusatzeingang INP2
Meßbereichs
Skalierung: beliebig -1999...9999 Digitaleingänge di2,3
Linearisierung: 16 Segmente, anpaßbar mit Transmitterspeisung UT
BlueControl Relaisausgänge OUT1,2
Dezimalpunkt: einstellbar Relaisausgang OUT3
Meßkreisüberwachung: 12,5% unter Meßanfang
(2mA, 1V)
9499-040-63201 31 KS40-1 -weishaupt-

AUSGÄNGE UMGEBUNGSBEDINGUNGEN
RELAISAUSGÄNGE OUT1, OUT2 Schutzart

Gerätefront: IP 65 (NEMA 4X)
Kontaktart: 2 Schließer mit
gemeinsamen Gehäuse: IP 20
Kontaktanschluß Anschlüsse: IP 00
Schaltleistung maximal: 500 VA, 250 V, 2A bei
48...62 Hz, Zulässige Temperaturen
ohmsche Last Betrieb: 0...60°C
Schaltleistung minimal: 6V, 1 mA DC Anlaufzeit: ≥ 15 Minuten
Lebensdauer elektrisch: 800.000 Schaltspiele bei Grenzbetrieb: -20...65°C
max. Schaltleistung Lagerung: -40...70°C
RELAISAUSGANG OUT3 Feuchte

75% im Jahresmittel, keine Betauung
Kontaktart: Potentialfreier Wechsel
Schaltleistung maximal: 500 VA, 250 V, 2A bei Erschütterung und Stoß
48...62 Hz,
ohmsche Last Schwingung Fc (DIN 68-2-6)
Schaltleistung minimal: 5V, 10 mA AC/DC Frequenz: 10...150 Hz
Lebensdauer elektrisch: 600.000 Schaltspiele bei im Betrieb: 1g bzw. 0,075 mm
max. Schaltleistung außer Betrieb: 2g bzw. 0,15 mm
Hinweis: Schockprüfung Ea (DIN IEC 68-2-27)
Bei Anschluß eines Steuerschützes an
OUT1...OUT3 ist eine RC-Schutzbeschaltung Schock: 15g
nach Angaben des Schützherstellers am Schütz Dauer: 11ms
erforderlich, um hohe Spannungsspitzen zu
vermeiden. Elektromagnetische Verträglichkeit
Erfüllt EN 61 326-1
(für kontinuierlichen, nicht-überwachten
HILFSENERGIE Betrieb)
WECHSELSPANNUNG
ALLGEMEINES
Spannung: 90...260 V AC
Frequenz: 48...62 Hz Gehäuse
Leistungsaufnahme ca. 4,0 VA Werkstoff: Makrolon 9415 schwer
entflammbar
Brennbarkeitsklasse: UL 94 VO, selbstverlöschend
VERHALTEN BEI NETZAUSFALL
Einschub, von vorne steckbar
Konfiguration, Parameter und eingestellte
Sollwerte, Betriebsart: Sicherheit
Dauerhafte EEPROM-Speicherung Entspricht EN 61010-1 (VDE 0411-1):
Überspannungskategorie II
Verschmutzungsgrad 2
Arbeitsspannungsbereich 300 V
Schutzklasse II
KS40-1 -weishaupt- 32 9499-040-63201

Dicht an Dicht-Montage möglich
Elektrische Anschlüsse
Gebrauchslage: beliebig
Flachsteckmesser 1 x 6,3 mm oder 2 x 2,8 mm
Gewicht: 0,27kg
nach DIN 46 244
Mitgeliefertes Zubehör
Montage
Bedienungsanleitung
Tafeleinbau mit je zwei Befestigungs-
Befestigungselemente
elementen oben/unten oder rechts/links,
Tabelle 1 Thermoelementmeßbereiche
Thermoelementtyp Meßbereich Genauigkeit Auflösung (Ô)
L Fe-CuNi (DIN) -100...900°C -148...1652°F ß 2K 0,1 K
J Fe-CuNi -100...1200°C -148...2192°F ß 2K 0,1 K
K NiCr-Ni -100...1350°C -148...2462°F ß 2K 0,2 K
N Nicrosil/Nisil -100...1300°C -148...2372°F ß 2K 0,2 K
S PtRh-Pt 10% 0...1760°C 32...3200°F ß 2K 0,2 K
R PtRh-Pt 13% 0...1760°C 32...3200°F ß 2K 0,2 K
T Cu-CuNi -200...400°C -328...752°F ß 2K 0,05 K
C W5%Re-W26%Re 0...2315°C 32...4199°F ß 2K 0,4 K
D W3%Re-W25%Re 0...2315°C 32...4199°F ß 2K 0,4 K
E NiCr-CuNi -100...1000°C -148...1832°F ß 2K 0,1 K
B * PtRh-Pt6% 0(100)...1820°C 32(212)...3308°F ß 2K 0,3 K
* Angaben gelten ab 100°C

Tabelle 2 Widerstandsgebermeßbereiche
Art Meßstrom Meßbereich Genauigkeit Auflösung (Ô)
Pt100 -200...100°C -140...212°F ß 1K 0,1K
Pt100 -200...850°C -140...1562°F ß 1K 0,1K
Pt1000 -200...200°C -140...392°F ß 2K 0,1K
KTY 11-6 * -50...150°C -58...302°F ß 2K 0,05K
Spezial 0,2mA 0...4500
Spezial 0...450
Poti 0...160 ß 0,1 % 0,01 %
Poti 0...450
Poti 0...1600
* Oder Spezial
Tabelle 3 Strom- und Spannungmeßbereiche

Meßbereich Eingangswiderstand Genauigkeit Auflösung (Ô)
0-10 Volt ~ 110 kΩ ß 0,1 % 0,6 mV
0-20 mA 49 Ω (Spannungsbedarf ß 2,5 V) ß 0,1 % 1,5 μA
9499-040-63201 33 KS40-1 -weishaupt-

Sicherheitshinweise
9 Sicherheitshinweise
Dieses Gerät ist gemäß VDE 0411-1 / EN 61010-1 gebaut und geprüft und hat
das Werk in sicherheitstechnisch einwandfreiem Zustand verlassen.
Das Gerät stimmt mit der Europäischen Richtlinie 89/336/EWG (EMV) überein
und wird mit dem CE-Kennzeichen versehen.
Das Gerät wurde vor Auslieferung geprüft und hat die im Prüfplan
vorgeschriebenen Prüfungen bestanden. Um diesen Zustand zu erhalten und
einen gefahrlosen Betrieb sicherzustellen, muß der Anwender die Hinweise und
Warnvermerke beachten, die in dieser Bedienungsanleitung enthalten sind.
Das Gerät ist ausschließlich bestimmt zum Gebrauch als Meß- und Regelgerät in
technischen Anlagen.
a Weist
Warnung
das Gerät Schäden auf, die vermuten lassen, daß ein gefahrloser Betrieb
nicht möglich ist, so darf das Gerät nicht in Betrieb genommen werden.
ELEKTRISCHER ANSCHLUSS
Die elektrischen Leitungen sind nach den jeweiligen Landesvorschriften zu
verlegen (in Deutschland VDE 0100). Die Meßleitungen sind getrennt von den
Signal- und Netzleitungen zu verlegen.
INBETRIEBNAHME
Vor dem Einschalten des Gerätes ist sicherzustellen, daß die folgenden Punkte
beachtet worden sind:
w Es ist sicherzustellen, daß die Versorgungsspannung mit der Angabe auf dem
Typenschild übereinstimmt.
w Alle für den Berührungsschutz erforderlichen Abdeckungen müssen
angebracht sein.
w Ist das Gerät mit anderen Geräten und / oder Einrichtungen
zusammengeschaltet, so sind vor dem Einschalten die Auswirkungen zu
bedenken und entsprechende Vorkehrungen zu treffen.
w Das Gerät darf nur in eingebautem Zustand betrieben werden.
w Die für den Reglereinsatz angegebenen Temperatureinschränkungen müssen
vor und während des Betriebes eingehalten werden.
AUSSERBETRIEBNAHME
Soll das Gerät außer Betrieb gesetzt werden, so ist die Hilfsenergie allpolig
abzuschalten. Das Gerät ist gegen unbeabsichtigten Betrieb zu sichern.
Ist das Gerät mit anderen Geräten und / oder Einrichtungen zusammen-geschaltet,
so sind vor dem Abschalten die Auswirkungen zu bedenken und entsprechende
Vorkehrungen zu treffen.
KS40-1 -weishaupt- 34 9499-040-63201

Sicherheitshinweise
WARTUNG, INSTANDSETZUNG UND UMRÜSTUNG

Die Geräte bedürfen keiner besonderen Wartung.
a Beim
Warnung
Öffnen der Geräte oder Entfernen von Abdeckungen und Teilen können
spannungsführende Teile freigelegt werden. Auch können Anschlußstellen
spannungsführend sein.
Vor dem Ausführen dieser Arbeiten muß das Gerät von allen
Spannungsquellen getrennt sein.
Nach Abschluß dieser Arbeiten ist das Gerät wieder zu schließen, und alle
entfernten Abdeckungen und Teile sind wieder anzubringen. Es ist zu prüfen, ob
Angaben auf dem Typenschild geändert werden müssen. Die Angaben sind
gegebenenfalls zu korrigieren.
l Achtung
Beim Öffnen der Geräte können Bauelemente freigelegt werden, die gegen
elektrostatische Entladung (ESD) empfindlich sind. Die nachfolgenden Arbeiten
dürfen nur an Arbeitsplätzen durchgeführt werden, die gegen ESD geschützt sind.
Umrüstungen, Wartungs- und Instandsetzungsarbeiten dürfen nur von geschulten
fach- und sachkundigen Personen durchgeführt werden. Dem Anwender steht
hierfür der PMA-Service zur Verfügung.
9499-040-63201 35 KS40-1 -weishaupt-

Sicherheitshinweise
9.1 Rücksetzen auf Werkseinstellung

Für den Fall, dass es zu einer Fehlkonfiguration gekommen ist, kann das Gerät
auf seine Hersteller-Werkseinstellung zurückgesetzt werden.
Um das Rücksetzen einzuleiten, muss der Bediener während des

Netzeinschaltens die Inkrement- und die Dekrement-Taste gleichzeitig gedrückt
halten.
dann muss über die Inkrement-Taste YES angewählt werden.

Mit der Bestätigungstaste Enter wird der Factory-Reset bestätigt und der
Kopiervorgang ausgelöst (Anzeige COPY).
Danach startet das Gerät erneut.
1 2 3 4
ÌÈ + Power on È Ù
SP.x
FAC run SP.x
FAC run SP.x
FAC run SP.x
FAC run
8.8.8.8.
SP.x run
torY Ada
Err no Ada
Err YES Ada
Err
COPY Ada
Err
8.8.8.8. Ada
Err
1. 2.
In allen anderen Fällen wird keine Rücksetzung durchgeführt

(Abbruch über Timeout).
g Ist eine der Bedienebenen blockiert worden (über BlueControl®) und der
Sicherheitsschalter Loc offen, so ist kein Rücksetzen auf die Werkseinstellung
möglich.
g Wurde eine Pass-Zahl (über BlueControl®) definiert und ist der Sicherheits-
schalter Loc offen, aber keine Bedienebene blockiert, so wird der Bediener nach
der Bestätigung in 3 mit dem Text PASS aufgefordert, die korrekte Pass-Zahl
einzugeben. Bei fehlerhafter Pass-Zahl wird keine Rücksetzung durchgeführt.
g Der Kopiervorgang COPY kann mehrere Sekunden dauern.

Danach geht das Gerät in den normalen Betrieb über.
KS40-1 -weishaupt- 36 9499-040-63201

Sicherheitshinweise
9499-040-63201 37 KS40-1 -weishaupt-

Mounting
10 Mounting
min.48 (1.89")
max. 60°C
)
. 4" )
(0 5"
(3.62" +0. 03)

.6 min. 0°C
10
+0, 8
")
(4
.1
.4
18
1.
..0
92
1
04
.
(0
max.
-weishaupt-
95% rel. %
126
96 (3.78")
+0,6
SP.X SG 45
125 Ada
Err
(1.77" +0.02)
48 (1.89")
Loc Loc mA/Pt
mA/Pt
Loc 10V mA/Pt

Safety switch
Ü or:
Ü
*
*
Safety switch:
For access to the safety switches, the controller must be withdrawn from the
housing. Squeeze the top and bottom of the front bezel between thumb and
forefinger and pull the controller firmly from the housing..
10V i mA/Pt mA/Pt 1 Thermocouple / Pt100 or transducer at InP.1

10V Pressure transmitter (0..10V) at InP.1
Loc open Access to the levels is as adjusted by means of
BlueControl (engineering tool) 2
closed 1 all levels accessible wihout restriction
1 Factory setting 2 Default setting: display of all levels

suppressed, password PASS = OFF
a safety
Safety switch 10V i mA/Pt always in position left or right. Leaving the
switch open may lead to faulty functions!
l Caution! The unit contains ESD-sensitive components.
9499-040-63201 39 KS40-1 -weishaupt-

Electrical connections
11 Electrical connections
Option
P
A
9
26 L
di2 (-)
90...250V
10 27 N
11 -
di3 10
20
5 19 OUT1
Ut(+) 21
22
OUT2
23
24b OUT3
24 g h
g b c
7 + INP2
100%
8
0%
6
3
+ +
0% 10V * 1 2 20mA **
2 - 3 -
1 + 100% 2 1
INP1
a b c d e f g
* Safety switch INP1 (mA i 10V) in position 10V

** Safety switch INP1 (mA i 10V) in position mA/Pt
Connection of input INP1

Input for variable x1 (process value)
a thermocouple
b resistance thermometer (Pt100/ Pt1000/ KTY/ ...)
c Transducer 50-30-50 Ω
d voltage (0/2...10V)
e pressure transmitter (3-wire connection)
f pressure transmitter (2-wire connection)
g current (0/4...20mA)
Connection of input INP2

See input INP1.
Connection of inputs di2/di3

Digital input di2 for external switching between SP and SP.2 (SP/SP2).
Digital input di3 for external switching between 3-point-stepping controller and
on/off controller (DPS/SG).
KS40-1 -weishaupt- 40 9499-040-63201

Operation
12 Operation
12.1 Front view
1 Status of switching outputs

1 OuT.1... 3
2 Lit with limit value 1 not
exceeded
3 Process value display
2
1 2 3 OK
4 Controller works as on/off
controller
5 Self-tuning active
3 6 Entry in error list
0 SP.x
126. SG
&
4
7 Set-point, controller output
8 Enter key:
calls up extended operating
!
"
125 Ada
Err
5
6
level / error list
9 Up/down keys:
changing the set-point or the
controller output value
0 Set-point SP.2 or SP.E is
7 effective
! Set-point gradient effective
è
" Manual mode
§ 8 § Function key
$ Manual-automatic-mode
$ switching ( " )
% PC connection for BlueControl
% 9 (engineering tool)
& Signalization
PArA level (burns)
ConF level (blinks)
g In the upper display line, the process value is always displayed. At parameter,
configuration, calibration as well as extended operating level, the bottom display
line changes cyclically between parameter name and parameter value.
9499-040-63201 41 KS40-1 -weishaupt-

Operation
12.2 Operating level
The content of the extended operating level is determined by means of

BlueControl (engineering tool). Parameters which are used frequently or the
display of which is important can be copied to the extended operating level.
Automatic Manual
126 iÒ i 126
125 y 21
È È
Ì Ì
time
out Ù Ò Ù time
out
126 126
y 21 125
only È
display Ì
Ù Ù
Extended operating level

time
out
Errorliste (if error exists)
126 display
126
FbF.1 Err
switching
2 Err
Maintenance manager / Error list
With one or several errors, the extended operating level

always starts with the error list. Signalling an actual
entry in the error list (alarm, error) is done by the Err SP.X
126 SG
LED in the display. To reach the error list press Ù

twice.
125 Ada
Err
Err LED status Signification Proceed as follows

blinks Alarm due to existing error - Determine the error type in the error list
via the error number
- Remove the error
lit Error removed, - Acknowledge the alarm in the error list
Alarm not acknowledged pressing key È or Ì
- The alarm entry was deleted.
off No error,
all alarm entries deleted
KS40-1 -weishaupt- 42 9499-040-63201

Operation
Error list:
Name Description Cause Possible remedial action
E.1 Internal error, - E.g. defective EEPROM - Contact PMA service
cannot be removed - Return unit to our factory
E.2 Internal error, can be - e.g. EMC trouble - Keep measurement and power supply
reset cables in separate runs
- Ensure that interference suppression of
contactors is provided
FbF.1/ Sensor break INP1 / - Sensor defective - Replace INP1 / 2 sensor
2 2 - Faulty cabling - Check INP1 / 2 connection
Sht.1/ Short circuit INP1 / 2 - Sensor defective - Replace INP1/ 2 sensor
2 - Faulty cabling - Check INP1 / 2 connection
POL.1 INP1 polarity error - Faulty cabling - Reverse INP1 polarity
LooP Control loop alarm - Input signal defective or not - Check heating or cooling circuit
(LOOP) connected correctly - Check sensor and replace it, if necessary
- Output not connected correctly - Check controller and switching device
AdA.H Self-tuning heating - See Self-tuning heating error - see Self-tuning heating error status
alarm (ADAH) status
LiM.1/ stored limit alarm 1 / 2 - adjusted limit value 1 / 2 / 3 - check process
2/3 /3 exceeded
Inf.1 time limit value - adjusted number of operating - application-specific
message hours reached
Inf.2 duty cycle message - adjusted number of duty cycles - application-specific
(digital ouputs) reached
Error status (error status 3 - 9 only with error AdA.H / AdA.C ):
Error status Signification

0 No error/message not visible, except with acknowledgement
1 Stored error Change to error status 0 after acknowledgement in error list
2 Existing error Change to error status 1 after error removal
3 Faulty control action Re-configure controller (inverse i direct)
4 No response of process The control loop is perhaps not closed: check sensor, connections
variable and process
5 Low reversal point Increase ( ADA.H) max. output limiting Y.Hi or decrease
( ADA.C) min. output limiting Y.Lo
6 Danger of exceeded set-point If necessary, increase (inverse) or reduce (direct) set-point
(parameter determined)
7 Output step change too Increase ( ADA.H) max. output limiting Y.Hi or reduce
small (dy > 5%) ( ADA.C) min. output limiting Y.Lo
8 Set-point reserve too small Increase set-point (invers), reduce set-point (direct) or increase
set-point range (r PArA / SEtp / SP.LO and SP.Hi )
9 Impulse tuning failed The control loop is perhaps not closed: check sensor, connections
and process
9499-040-63201 43 KS40-1 -weishaupt-

Operation
12.3 Self-tuning
After starting by the operator, the controller makes a self-tuning attempt. The
controller uses the process characteristics for quick line-out to the set-point
without overshoot.
g ti and td are taken into account only, if they were not set to
OFFpreviously.
Self-tuning start
The operator can start self-tuning at any time. For this, keys Ù and È must be
pressed simultaneously. The AdA LED starts blinking.
The controller outputs 0% or Y.Lo, waits until the process is at rest and starts
self-tuning (AdA LED lit permanently).
The self-tuning attempt is started when the following prerequisite is met:

w The difference between process value i set-point must be ≥ 10% of the
set-point range ( SP.Hi - SP.LO) (with inverse action: process value smaller
than set-point, with direct action: process value higher than set-point).
After successful self-tuning, the AdA-LED is off and the controller continues
operating with the new control parameters.
Self-tuning cancellation by the operator:

Self-tuning can always be cancelled by the operator. For this, press Ù and È
key simultaneously. The controller continues operating with the old parameters in
automatic mode in the first case and in manual mode in the second case.
Self-tuning cancellation by the controller:

If the Err LED starts blinking while self-tuning is running, successful self-tuning
is prevented due to the control conditions. In this case, self-tuning was cancelled
by the controller. The controller switches off its outputs (controller output 0%).
Acknowledgement procedures in case of unsuccessful self-tuning:
1. Press keys Ù and È simultaneously:

The controller continues controlling using the old parameters in automatic
mode. The Err LED continues blinking, until the self-tuning error was
acknowledged in the error list.
2. Press key Ù :
Display of error list at extended operating level. After acknowledgement of
the error message, the controller continues control in automatic mode
using the old parameters.
Cancellation causes:
r page 43: "Error status self-tuning heating ( ADA.H) and cooling ( ADA.C)"
KS40-1 -weishaupt- 44 9499-040-63201

Operation
Examples for self-tuning attempt 3-point-stepping controller
After the start (1) the controller W

closes the actuator (2 Out.3). When X
the difference between process value
and set-point is big enough (3), the
changing of the process value is t
monitored for 1 min. (4). Afterwards
the actuator is opened (5 Out.1). If
the reversal point is reached (6) or
1 min
there are made enough measurements,
the parameters are detected and are t
adopted. 1 2 3 4 5 6
12.4 Manual tuning
The optimization aid should be used with units on which the control parameters
shall be set without self-tuning.
For this, the response of process variable x after a step change of correcting
variable y can be used. Frequently, plotting the complete response curve (0 to
100%) is not possible, because the process must be kept within defined limits.
Values Tg and xmax (step change from 0 to 100 %) or Δt and Δx (partial step
response) can be used to determine the maximum rate of increase vmax.
y
100%
Yh
y = correcting variable
Yh = control range
0%
Tu = delay time (s)
t
x
Tg
Tg = recovery time (s)
Xmax
Xmax = maximum process value
{X Xmax { x
Vmax = = = max. rate of
{t Tg {t
Tu t increase of process value
The control parameters can be determined from the values calculated for delay
time Tu , maximum rate of increase vmax, control range Xh and characteristic K
according to the formulas given below. Increase Xp, if line-out to the set-point
oscillates.
9499-040-63201 45 KS40-1 -weishaupt-

Operation
Parameter adjustment effects

Parameter Control Line-out of disturbances Start-up behaviour
Pb1 higher increased damping slower line-out slower reduction of duty cycle
lower reduced damping faster line-out faster reduction of duty cycle
td1 higher reduced damping faster response to disturbances faster reduction of duty cycle
lower increased damping slower response to disturbances slower reduction of duty cycle
ti1 higher increased damping slower line-out slower reduction of duty cycle
Formulas
K = Vmax * Tu controller behavior Pb1 [phy. units] td1 [s] ti1 [s]
PID 1,7 * K 2 * Tu 2 * Tu
With 2-point and PD 0,5 * K Tu OFF
3-point controllers,
the cycle time must be PI 2,6 * K OFF 6 * Tu
adjusted to P K OFF OFF
t1 / t2 ≤ 0,25 * Tu 3-point-stepping 1,7 * K Tu 2 * Tu
12.5 Operating structure
After supply voltage switch-on, the controller starts with the operating levels.
The controller status is as before power off.
126 Ù 126 Ù PASS

125 3 sec.
PArA
126 Ù PASS
Ì ConF
126 Ù PASS
Ì CAL
126 Ù
Ì End
a To get access to the configuration and the parameters the saftey switch Loc must
be closed (factory setting).
KS40-1 -weishaupt- 46 9499-040-63201

Configuration level
13 Configuration level
13.1 Configuration with qUIC
At configuration level, the controller function is determined by changing

configuration word Con1 . Con1 and the code adjusted for Con1 are
displayed alternately on the lower display line.
r
SP.X
126 r Ù r
SG PArA
125 Ada
Err
3 sec.
Ì
ConF Con1 Ì rÙ
123.8 123.8
Con1 1520
A B C D
Code signification:
A 0 Reaction at sensor break as process value higher than set-point.
1 Reaction at sensor break as process value smaller than set-point
2 Only P30/W connection, always process value smaller than set-point *
B 0 Potentiometric transducer 50-30-50 [ / pressure sensor 0..10V, display range
0,0...100,0 (%)
1 Potentiometric transducer 50-30-50 [ / pressure sensor 0..10V, display range
0,00...1,00 (bar)
0,0...16,0 (bar)
0,0...40,0 (bar)
4 Resistance thermometer Pt 100 [ , range 0...200°C
5 Resistance thermometer Pt 100 [ , range 0...400°C
6 Thermocouple type L, range 0...900°C
7 Thermocouple type K, range 0...1350°C
C 0 Signaller with switching
1 3-point signaller
2 3-point stepping controller (DPS) switchable to signaller (SG)
3 3-point stepping controller (DPS) switchable to 3-point signaller (SG)
D 0 Not changeable
* Only possible with A = 2 and B = 0 … 3
9499-040-63201 47 KS40-1 -weishaupt-

Configuration level
After exit from the configuration level (see page 43, the controller is
re-initialized (all display elements are lit) and changes over to normal operation
(operating level).
g Leading zeros are not displayed (ex.: display 400 with code 0400)
Configuration example 1 (code 0400):

KS40-1 as a signaller with
switch-over contact for 2-stage burner: 123.8 123.8
Measuring range 0...200°C,
Resistance thermometer Pt 100,
Con1 400
Reaction at sensor break
as process value higher than set-point.
Configuration example 2 (code 2120):

KS40-1 as 3-point stepping controller:
Connection to pressure transmitter P30/W, 123.8 123.8
Measuring range 0,00...1,00 bar,
Reaction at sensor break as process value
Con1 2120
smaller than set-point.
Function: Signaller with switch-over contact

CAUTION: The two relays W
1 and 2 are coupled, i.e. ON
the contacts have OUT1
switch-over function. OFF
Sd1 = Sd2
Ensure that the two relays ON
are not energized or OUT2
de-energized -X W OFF XW
simultaneously. Exception: H.1
de-energized condition. ON
Limit OUT3
OFF
Settings: HYS.1
Switching differences: Sd1 / Sd2: in physical values

Limit value OUT3: The relay is de-energized when exceeding the limit.
Upper limit value H.1 : in units of phys. quantity.
Switching difference HYS.1 : in units of phys.quantity
Signalling LEDs: LED1: lit when OUT1 is energized
LED2: lit when OUT2 is energized
OK-LED: lit, unless the limit value is reached
Parameter: see chapter 13 “Parameter level”
KS40-1 -weishaupt- 48 9499-040-63201

Configuration level
Function: 3-point signaller
Sd1
ON
OUT1
OFF
Sd2
ON d.SP
OUT2 W
-X W OFF XW
H.1
ON
Limit OUT3
OFF
HYS.1
Settings:
OUT1: Switch-on point is coupled with the set-point.

Switching difference Sd1: in units of phys. quantity.
OUT2: Switch-off point is always below the set-point!

Adjustment range d.SP : in units of phys. quantity
Switching difference Sd2: in units of phys. quantity.
Limit value OUT3: With the limit value exceeded, the relay is de-energized.
High limit value H.1: in units of phys. quantity.
Switching difference HYS.1: in units of phys.quantity.
Signal LEDs: LED1: lit, when OUT1 is energized

LED2: lit, when OUT2 is energized
OK LED: lit, when limit value not reached
Parameters: see chapter 13 “Parameter level”
9499-040-63201 49 KS40-1 -weishaupt-

Configuration level
Function: 3-point stepping controller
W ON
OUT2
-X W OFF XW
OUT1 XSd
ON -A A
SH
H.1
ON
Limit OUT3
OFF
HYS.1
Settings:
Controller: SH: in units of phys. quantity

Response threshold A: 0,5 w SH
Switching difference XSd : 0,06 w SH + 0,08
Actuator travel time tt: 3...9999 s
Min.duty cycle: fixed, TEmin = 100 ms
Control parameters: Pb1 = 0,01...9999 : in unit of phys. quantity °C or °F

(number of digits behind the decimal point is determined
by CON1)
Ti = 1...9999 s ( OFF = no I-action)
td = 1...9999 s ( OFF = no D-action)
Limit value OUT3: With exceeded limit value, the relay is de-energized.
High limit value H.1 : in units of phys. quantity
Switching difference HYS.1 : in units of phys. quantity
Signalling LEDs: LED1: lit when OUT1 is energized

LED2: lit when OUT2 is energized
OK LED: lit, unless limit value is reached
De-energized condition: all relays de-energized, contacts open
Parameters: see chapter 13 “Parameter level”
KS40-1 -weishaupt- 50 9499-040-63201

Configuration level
13.2 Configuration without qUIC ( qUIC= OFF)
When key Ù is kept pressed during controller supply voltage switch-on, the
configuration is switched off with qUIC.
Now, all configuration settings are available to the user.
For changing back to configuration with qUIC , the two keys Ì È must be
kept pressed during controller supply voltage switch-on.
a Hereby, the controller is reset to the factory-set default values !

Configuration survey:
Con1
Name Value range Description Default Own setting
Con1 0000...2330 qUIC - Configuration 0000
Wire hook switches (on electronic card)

Loc open or closed Wire hook switch for locking the ConF- and PArA- closed
level (if enabled with BlueControl)
InP.1 mA/Pt or 10V Wire hook switch for chosing InP.1 signal type mA/Pt
Cntr
SP.Fn Basic configuration of setpoint processing 0
0 set-point controller can be switched over to external set-point
(-> LOGI/ SP.E)
1 programmer
8 standard controller with external offset (SP.E)
9 programmer with external offset (SP.E)
C.Fnc Control behavior (algorithm) 0
0 2-point signaller
1 PID controller (2-point and continuous)
2 Δ/ Y/Off, or 2-point controller with partial/full load
switch-over
3 2 x PID (3-point and continuous)
4 3-point stepping controller
7 3-point signaller
8 3-point stepping controller switchable to signaller
9 3-point stepping controller switchable to 3-point signaller
KS40-1 -weishaupt- 51 9499-040-63201

Configuration level

mAn Manual operating permitted 1
0 no
1 yes (see also LOGI/ mAn)
C.Act Method of controller operation 0
0 Inverse, e.g. heating
1 Direct, e.g. cooling
FAIL Behavior at sensor break 1
0 Controller outputs switched of
1 y = Y2
2 y = mean output. The maximum permissible output can be
adjusted with parameter Ym.H. To prevent determination of
inadmissible values, mean value formation is only if the
control deviation is lower than parameter L.Ym.
rnG.L -1999...9999 X0 (low limit range of control) 1 0
rnG.H -1999...9999 X100 (high limit range of control) 1 100
InP.1
S.tYP Sensor type selection 50
0 Thermocouple type L (-100...900°C) , Fe-CuNi DIN
1 Thermocouple type J (-100...1200°C) , Fe-CuNi
2 Thermocouple type K (-100...1350°C), NiCr-Ni
3 Thermocouple type N (-100...1300°C), Nicrosil-Nisil
4 Thermocouple type S (0...1760°C), PtRh-Pt10%
5 Thermocouple type R (0...1760°C), PtRh-Pt13%
20 Special thermocouple
20 Pt100 (-200,0 ... 100,0 °C)
21 Pt100 (-200,0 ... 850,0 °C)
22 Pt1000 (-200,0...200,0 °C)
23 KTY 11-6 (special 0...4500 Ohm)
30 0...20mA / 4...20mA 2
40 0...10V / 2...10V 2
1 rnG.L and rnG.H indicate the control range to which e.g. self-tuning is
related.
2 With current , voltage or potentiometer input signals, scaling is required
(see section 13.1).
9499-040-63201 52 KS40-1 -weishaupt-

Configuration level

S.Lin Linearization (only at S.tYP = 30 (0..20mA) and 40 0
(0..10V) adjustable)
0 None
1 Linearization to specification. Creation of linearization table
with BlueControl (engineering tool) possible. The
characteristic for KTY 11-6 temperature sensors is preset.
Corr Measured value correction ( scaling 2
0 Without scaling
1 Offset correction (at CALlevel)
2 2- point correction (at CALlevel)
3 Scaling (at PArA level)
InP.2
I.Fnc Function selection of INP2 0
0 No function
2 External set-point SP.E (switching -> LOGI/ SP.E)
S.tYP Sensor type selection 30
20 Pt100 (-200,0 ... 100,0 °C)
21 Pt100 (-200,0 ... 850,0 °C)
22 Pt1000 (-200,0...200,0 °C)
22 KTY11-6 (special 0...4500 Ohm)
30 0...20mA / 4...20mA 1
Corr Measured value correction / scaling 0
0 Without scaling
1 Offset correction (at CALlevel)
2 2-point correction (at CALlevel)
3 Scaling (at PArA level)
In.F -1999...9999 alternative value Inp2 off
Lim
Fnc.1 Function of limit 1 / 2 / 3 1/0/0
Fnc.2 0 Switched off
Fnc.3 1 Measured value monitoring
2 Measured value monitoring + alarm status storage. A stored
limit value can be reset via error list, Ò-key or a digital
input ( -> LOGI/ Err.r)
1 With current or potentiometer input signals, scaling is required

(see section 13.1).
9499-040-63201 53 KS40-1 -weishaupt-

Configuration level

Src.1 Source of limit 1 / 2 / 3 1/0/0
Src.2 0 Process value = absolut alarm
Src.3 1 Control deviation Xw (process value - set-point) relativ
alarm
2 Control deviation Xw (relativ alarm) with suppression after
start-up and set-point change
6 Effective set-point Weff
7 Correcting variable (controller output)
LP.AL Monitoríng of control loop interruption 0
0 Switched off
1 LOOP alarm active
Out.1 / 2 / 3
O.Act Method of operation of output OUT1 Out.1: 0
0 Direct / normally open Out.2: 0
Out.3: 1
1 Inverse / normaly closed
Y.1 Controller output Y1 / Y2 Out.1: 1 / 0
Y.2 0 Not active Out.2: 0 / 1
Out.3: 0 / 0
1 Active
Lim.1 Limit 1 / 2 / 3 signal Out.1: 0 / 0 / 0
Lim.2 0 Not active Out.2: 0 / 0 / 0
Out.3: 1 / 0 / 0
Lim.3 1 Active
LP.AL Interruption alarm signal (LOOP) Out.1: 0
0 Not active Out.2: 0
Out.3: 0
1 Active
FAi.1 INP1 / INP2 error signal Out.1: 0 / 0
FAi.2 0 Not active Out.2: 0 / 0
Out.3: 1 / 0
1 Active
LOGI
L_r Local / Remote switching (Remote: adjusting of all values 0
by front keys is blocked)
0 No function
1 Always active
3 DI2 switches *
4 DI3 switches *
5 è key switches *
KS40-1 -weishaupt- 54 9499-040-63201

Configuration level

SP.2 Switching to second set-point SP.2 3
0 No function
3 DI2 switches *
4 DI3 switches *
5 è key switches *
SP.E Switching to external set-point SP.E 0
0 No function
1 Always active
3 DI2 switches *
4 DI3 switches *
5 è key switches *
Y2 Y/Y2 switching 0
0 No function
3 DI2 switches *
4 DI3 switches *
5 è key switches *
6 Ò key switches *
mAn Automatic/manual switching 6
0 No function
1 Always active
3 DI2 switches *
4 DI3 switches *
5 è key switches *
6 Ò key switches *
C.oFF Switch of the controller 0
0 No function
3 DI2 switches *
4 DI3 switches *
5 è key switches *
6 Ò key switches *
m.Loc Blocage of the Ò key 0
0 No function
3 DI2 switches *
4 DI3 switches *
5 è key switches *
9499-040-63201 55 KS40-1 -weishaupt-

Configuration level

Err.r Reset of all error list entries 0
0 No function
3 DI2 switches *
4 DI3 switches *
5 è key switches *
6 Ò key switches *
SG Switching of the controller behavior between 4
3-point-stepping controller and signaller
0 No function
3 DI2 switches *
4 DI3 switches *
5 è key switches *
P.run Programmer Run/Stop 5
0 No function
3 DI2 switches *
4 DI3 switches *
5 è key switches *
di.Fn Function of digital inputs (valid for all inputs) 0
0 Direct
1 Inverse
2 Toggle key function
* Multiple switching is possible and should be excluded on demand.
othr
Unit Unit 1
0 Without unit
1 °C
2 °F
dP Decimal point (max. number of digits behind the decimal 0
point)
0 No digit behind decimal point
1 1 digit behind decimal point
2 2 digits behind decimal point
3 3 digits behind decimal point
C.dEl 0...200 Modem delay [ms] 0
KS40-1 -weishaupt- 56 9499-040-63201

Parameter setting level
14 Parameter setting level
Cntr
Visible
with Name Value range Description Default Own setting
qUIC
f Pb1 1...9999 Proportional band 1 (heating) in phys. dimensions 10
(e.g. °C)
Pb2 1...9999 Proportional band 2 (cooling) in phys. dimensions 10
(e.g. °C)
f ti1 1...9999 Integral action time 1 (heating) [s] 10
ti2 1...9999 Integral action time 2 (cooling) [s] 10
f td1 1...9999 Derivative action time 1 (heating) [s] 10
td2 1...9999 Derivative action time 2 (cooling) [s] 10
t1 0,4...9999 Minimal cycle duration 1 (heating) [s]. The 10
minimum impulse is 1/4 x t1
t2 0,4...9999 Minimal cycle duration 2 (heating) [s]. The 10
minimum impulse is 1/4 x t2
f SH 0...9999 Dead zone or switching differential for on-off 1
control [phys. dimensions)
f Sd1 0,0...9999 Switching differntial relais 1 for signaller with 0,1
partial/full load switch-over
f Sd2 0,0...9999 Switching differntial relais 2 for 3-point signaller 0,1
f d.SP -1999...9999 Trigger point speration for series contact Δ / Y / Off 0
[phys. dimensions]
f tP 0,1...9999 Minimum impulse [s] OFF
f tt 3...9999 Actuator response time for servo-motor [s] 60
Y.Lo -120...120 Lower output limit [%] 0
Y.Hi -120...120 Upper output limit [%] 100
Y2 -120...120 2. correcting variable 0
Y.0 -120...120 Working point for the correcting variable [%] 0
Ym.H -120...120 Limitation of the mean value Ym [%] 5
L.Ym 0...9999 Max. deviation xw at the start of mean value 8
calculation [phys. dimensions]
SETP
Visible
qUIC
SP.LO -1999...9999 Set-point limit low for Weff 0
SP.Hi -1999...9999 Set-point limit high for Weff 100
f SP.2 -1999...9999 Set-point 2. 20
r.SP 0...9999 Set-point gradient [/min] OFF
9499-040-63201 57 KS40-1 -weishaupt-

14 ProG
.1 Visible
qUIC
SP.01 -1999...9999 Segment end set-point 1 100
Pt.01 0...9999 Segment time 1 [min] 10
InP.1
Visible
qUIC
InL.1 -1999...9999 Input value for the lower scaling point 38,5
OuL.1 -1999...9999 Displayed value for the lower scaling point 0
InH.1 -1999...9999 Input value for the upper scaling point 61,5
OuH.1 -1999...9999 Displayed value for the lower scaling point 100
t.F1 0,0...100,0 Filter time constant [s] 0,5
InP.2
Visible
qUIC
InL.2 -1999...9999 Input value for the lower scaling point 0
OuL.2 -1999...9999 Displayed value for the lower scaling point 0
InH.2 -1999...9999 Input value for the upper scaling point 100
OuH.2 -1999...9999 Displayed value for the upper scaling point 100
t.F2 0,0...100,0 Filter time constant [s] 0,5
Lim
Visible
qUIC
L.1 -1999...9999 Lower limit 1 OFF
f H.1 -1999...9999 Upper limit 1 20
f HYS.1 0...9999 Hysteresis limit 1 0,1
L.2/3 -1999...9999 Lower limit 2 / 3 OFF
H.2/3 -1999...9999 Upper limit 2 / 3 OFF
HYS.2/3 0,0...9999 Hysteresis limit 2 / 3 0,1
KS40-1 -weishaupt- 58 9499-040-63201

Input scaling (only visible with qUIC = OFF)
When using current or voltage signals as input variables for InP.1 or InP.2,
scaling of input and display values at parameter setting level is required.
Specification of the input value for lower and higher scaling point is in the
relevant electrical unit (mA/ V).
phys.
quantity
OuH.x
mA / V phys. quantity
OuL.x
InL.x InH.x mA/V
14.1.1 Input Inp.1
g Parameters InL.1 , OuL.1, InH.1 and OuH.1 are only visible if

ConF / InP.1 / Corr = 3 is chosen.
S.tYP Input signal InL.1 OuL.1 InH.1 OuH.1

30 0 … 20 mA 0 any 20 any
(0...20mA) 4 … 20 mA 4 any 20 any
40 0 … 10 V 0 any 10 any
(0...10V) 2 … 10 V 2 any 10 any
In addition to these settings, InL.1 and InH.1 can be adjusted in the range
(0...20mA / 0...10V) determined by selection of S.tYP .
a For using the predetermined scaling with thermocouple and resistance
thermometer (Pt100), the settings for InL.1 and OuL.1 and for InH.1 and
OuH.1 must have the same value.
g Input scaling changes at calibration level (r page 26) are displayed by input
scaling at parameter setting level. After calibration reset (OFF), the scaling
parameters are reset to default.
14.1.2 Input InP.2

As input InP.1, but only S.Typ = 30 adjustable!
9499-040-63201 59 KS40-1 -weishaupt-

Calibration level
15 Calibration level
g Measured value correction ( CAL) is only visible if ConF / InP.1 / Corr = 1

or 2 and qUIC = OFF is chosen.
The measured value can be matched in the calibration menu ( CAL). Two
methods are available:
Offset correction
( ConF/ InP.1 / Corr =1 ): display standard setting
offset correction
w possible on-line at the
process
OuL.1new
OuL.1old
InL.1 X
2-point correction
( ConF/ InP.1 / Corr = 2 ): display standard setting
2-point correction
w is possible off-line with
process value simulator
w Correct the first value at
first and the second value OuH.1old
subsequently, e.g. after OuH.1new

heating up the oven, on-line
in two steps.
OuL.1new
OuL.1old
InL.1 InH.1 X
KS40-1 -weishaupt- 60 9499-040-63201

Calibration level
Offset correction ( ConF/ InP.1 / Corr =1 ):
SP.X
126 run r Ù r PArA
125 Ada
Err 3 sec.
Ì
:
r OuL.1 È r Ù
Ì
r End r Ù
InL.1: The input value of the scaling point is displayed.

The operator must wait, until the process is at rest.
Subsequently, the operator acknowledges the input value by pressing
key Ù.
OuL.1: The display value of the scaling point is displayed.
Before calibration, OuL.1 is equal to InL.1.
The operator can correct the display value by pressing keys ÈÌ .
Subsequently, he confirms the display value by pressing key Ù.
9499-040-63201 61 KS40-1 -weishaupt-

Calibration level
2-point correction ( ConF/ InP.1 / Corr =1 ):
SP.X
126 r Ù r
run PArA
125 Ada
Err
3 sec.
Ì
r :
È
InL.1
Ù
È
OuL.1
Ì
rÙ
InH.1 rÙ
È
InH.1
Ù
È
OuH.1
Ì
rÙ
r End r Ù
InL.1: The input value of the lower scaling point is displayed.

The operator must adjust the lower input value by means of a
process value simulator and confirm the input value by pressing key Ù.
OuL.1: The display value of the lower scaling point is displayed.
Before calibration, OuL.1 equals InL.1.
The operator can correct the lower display value by pressing the ÈÌ
keys. Subsequently, he confirms the display value by pressing key Ù.
InH.1: The input value of the upper scaling point is displayed.
The operator must adjust the upper input value by means of the
OuH.1: The display value of the upper scaling point is displayed.
Before calibration OuH.1 equals InH.1.
The operator can correct the upper display value by pressing keys ÈÌ
g The parameters (OuL.1, OuH.1) changed at CAL level can be reset by adjusting
the parameters below the lowest adjustment value (OFF) by means of decrement
key Ì .
KS40-1 -weishaupt- 62 9499-040-63201

Programmer
16 Programmer
W,X SP.01 SP.02

SP.03
SP.04
W,X W
Pt.01 Pt.02 Pt.03 Pt.04 t
Programmer set-up:
For using the controller as a programmer, select parameter SP.Fn = 1 in the
ConF menu. The programmer is started via one of digital inputs di2..3 or the è
key. Which input shall be used for starting the programmer is determined by
selecting parameter P.run = 3 / 4 / 5 in the ConF menu accordingly.
For assigning the program end as a digital signal to one of the relay outputs,
parameter P.End = 1 must be selected for the relevant output OUT.1...OUT.3 in
the ConF menu.
Programmer parameter setting:

A programmer with 4 segments is available to the user. Determine a segment
duration Pt.01 .. Pt.04 (in minutes) and a segment target set-point SP.01 ..
SP.04 for each segment in the PArA menu.
Starting/stopping the programmer:

Starting the programmer is done by a digital signal at input di2..3 or the è key
selected by parameter P.run .
The programmer calculates a gradient from segment end setpoint and segment
time. This gradient is always valid. Normaly, the programmer starts the first
segment at process value. Because of this the effective run-time of the first
segment may differ from the at PArA level setted segment time (process value ≠
setpoint).
After program end, the controller continues controlling with the target set-point
set last.
If the program is stopped during execution (signal at digital input di2..3 or the è
key is taken away), the programmer returns to program start and waits for a new
start signal.
9499-040-63201 63 KS40-1 -weishaupt-

Programmer
+ Program parameter changing while the program is running is possible.

Changing the segment time:
Changing the segment time leads to re-calculation of the required gradient. When
the segment time has already elapsed, starting with the new segment is done
directly, where the set-point changes with a step.
Changing the segment end setpoint:

Changing the set-point leads to re-calculation of the required gradient, in order to
reach the new set-point during the segment rest time, whereby the required
gradient polarity sign can change.
KS40-1 -weishaupt- 64 9499-040-63201

17 Technical data
INPUTS
SUPPLEMENTARY INPUT INP2
PROCESS VALUE INPUT INP1 Resolution: > 14 bits
Scanning cycle: 100 ms
Resolution: > 14 bits
Accuracy: < 0,5 %
Decimal point: 0 to 3 digits behind the
decimal point Current measuring range
Dig. input filter: adjustable 0,0...100,0 s
Technical data as for INP1
Scanning cycle: 100 ms
Measured value 2-point or offset correction Potentiometer
correction: r Table 2 (page 58 )
Thermocouples Connection: 3-wire
r Table 2 (page 58 ) Lead resistance: max. 30 Ohm
Input circuit monitor: break
Input resistance: ≥ 1 MΩ
Effect of source resistance: 1 μV/Ω
CONTROL INPUT DI2/DI3
Cold-junction compensation Configurable as switch or push-button!
Maximal additional error: ± 0,5 K Connection of a potential-free contact suitable
for switching “dry” circuits.
Sensor break monitoring
Switched voltage: 5V
Sensor current: ≤ 1 μA Current: 160 μA
Configurable output action
TRANSMITTER SUPPLY UT (OPTION)
Resistance thermometer
r Table 2 (page 58 ) Power: 22 mA / ≥ 18 V
Connection: 2 or 3-wire
Lead resistance: max. 30 Ohm
GALVANIC ISOLATION
Input circuit monitor: break and short circuit Safety isolation
Potentiometric transducer 50-30-50 Power supply Process value input INP1

connections Supplementary input INP2
Current and voltage signals Digital inputs di2, 3
r Table 3 (page 58 ) Transmitter supply UT
Span start, end of span: anywhere within Relay outputs OUT 1,2
measuring range Relay output OUT3
Scaling: selectable -1999...9999

Function isolation
Linearization: 16 segments, adaptable
with BlueControl
Decimal point: adjustable
Input circuit monitor: 12,5% below span start
(2mA, 1V)
9499-040-63201 65 KS40-1 -weishaupt-

ENVIRONMENTAL CONDITIONS
RELAY OUTPUTS OUT1, OUT2
Protection modes
Contact type: 2 NO contacts with
common connection Front panel: IP 65 (NEMA 4X)
Max. contact rating: 500 VA, 250 V, 2A at Housing: IP 20
48...62 Hz, Terminals: IP 00
resistive load
Min. contact rating: 6V, 1 mA DC Permissible temperatures
Operating life (electr.): 800.000 duty cycles with For specified 0...60°C
max. rating accuracy:
Warm-up time: ≥ 15 minutes
RELAY OUTPUT OUT3 For operation: -20...65°C
Contact type: potential-free changeover For storage: -40...70°C
contact
Humidity
Max.contact rating: 500 VA, 250 V, 2A at 48...62
Hz, 75% yearly average, no condensation
resistive load
Shock and vibration
Min. contact rating: 5V, 10 mA AC/DC
Operating life (electr.): 600.000 duty cycles with Vibration test Fc (DIN 68-2-6)
max. contact rating Frequency: 10...150 Hz
Note: Unit in operation: 1g or 0,075 mm
If the relays OUT1...OUT3 operate external Unit not in operation: 2g or 0,15 mm
contactors, these must be fitted with RC
snubber circuits to manufacturer specifications Shock test Ea (DIN IEC 68-2-27)
to prevent excessive switch-off voltage peaks. Shock: 15g
Duration: 11ms
POWER SUPPLY
Electromagnetic compatibility
AC SUPPLY Complies with EN 61 326-1
(for continuous, non-attended operation)
Voltage: 90...260 V AC
Frequency: 48...62 Hz
GENERAL
Power consumption approx. 7,0 VA
Housing
BEHAVIOUR WITH POWER FAILURE Material: Makrolon 9415
Configuration, parameters and adjusted flame-retardant
set-points, control mode: Flammability class: UL 94 VO, self-extinguishing
Non-volatile storage in EEPROM Plug-in module, inserted from the front
Safety test
Complies with EN 61010-1 (VDE 0411-1):
Overvoltage category II
Contamination class 2
Working voltage range 300 V
Protection class II
KS40-1 -weishaupt- 66 9499-040-63201

Electrical connections High-density mounting possible
Flat-pin connectors 1 x 6,3 mm or 2 x 2,8 mm
Mounting position: uncritical
to DIN 46 244
Weight: 0,27kg
Mounting
Accessories delivered with the unit
Panel mounting with two fixing clamps at
Operating manual
top/bottom or right/left,
Fixing clamps
Table 1 Thermocouples measuring ranges

Thermoelementtyp Meßbereich Genauigkeit Auflösung (Ô)
J Fe-CuNi -100...1200°C -148...2192°F ß 2K 0,1 K
K NiCr-Ni -100...1350°C -148...2462°F ß 2K 0,2 K
S PtRh-Pt 10% 0...1760°C 32...3200°F ß 2K 0,2 K
R PtRh-Pt 13% 0...1760°C 32...3200°F ß 2K 0,2 K
T Cu-CuNi -200...400°C -328...752°F ß 2K 0,05 K
C W5%Re-W26%Re 0...2315°C 32...4199°F ß 2K 0,4 K
D W3%Re-W25%Re 0...2315°C 32...4199°F ß 2K 0,4 K
E NiCr-CuNi -100...1000°C -148...1832°F ß 2K 0,1 K
B * PtRh-Pt6% 0(100)...1820°C 32(212)...3308°F ß 2K 0,3 K
* Specifications valid for 100°C
Table 2 Resistance transducer measuring ranges

Art Meßstrom Meßbereich Genauigkeit Auflösung (Ô)
Pt100 -200...100°C -140...212°F ß 1K 0,1K
Pt100 -200...850°C -140...1562°F ß 1K 0,1K
Pt1000 -200...200°C -140...392°F ß 2K 0,1K
KTY 11-6 * -50...150°C -58...302°F ß 2K 0,05K
Spezial 0...450
Poti 0...160 ß 0,1 % 0,01 %
Poti 0...450
Poti 0...1600
* Or special
Table 3 Current and voltage measuring ranges

Range Input resistance Accuracy Resolution (Ô)
0-10 Volt ~ 110 kΩ ß 0,1 % ß 0,6 mV
0-20 mA 49 Ω (voltage requirement ß 2,5 V) ß 0,1 % ß 1,5 μA
9499-040-63201 67 KS40-1 -weishaupt-

Safety hints
18 Safety hints
This unit was built and tested in compliance with VDE 0411-1 / EN 61010-1 and
was delivered in safe condition.
The unit complies with European guideline 89/336/EWG (EMC) and is provided
with CE marking.
The unit was tested before delivery and has passed the tests required by the test
schedule. To maintain this condition and to ensure safe operation, the user must
follow the hints and warnings given in this operating manual.
The unit is intended exclusively for use as a measurement and control instrument
in technical installations.
a IfWarning
the unit is damaged to an extent that safe operation seems impossible, the unit
must not be taken into operation.
ELECTRICAL CONNECTIONS
The electrical wiring must conform to local standards (e.g. VDE 0100). The input
measurement and control leads must be kept separate from signal and power
supply leads.
COMMISSIONING
Before instrument switch-on, check that the following information is taken into
account:
w Ensure that the supply voltage corresponds to the specifications on the type
label.
w All covers required for contact protection must be fitted.
w If the controller is connected with other units in the same signal loop, check
that the equipment in the output circuit is not affected before switch-on. If
necessary, suitable protective measures must be taken.
w The unit may be operated only in installed condition.
w Before and during operation, the temperature restrictions specified for
controller operation must be met.
SHUT-DOWN
For taking the unit out of operation, disconnect it from all voltage sources and
protect it against accidental operation.
If the controller is connected with other equipment in the same signal loop, check
that other equipment in the output circuit is not affected before switch-off. If
KS40-1 -weishaupt- 68 9499-040-63201

Safety hints
MAINTENANCE, REPAIR AND MODIFICATION

The units do not need particular maintenance.
a When
Warning
opening the units, or when removing covers or components, live parts and
terminals may be exposed.
Before starting this work, the unit must be disconnected completely.
After completing this work, re-shut the unit and re-fit all covers and components.
Check if specifications on the type label must be changed and correct them, if
necessary.
l Caution
When opening the units, components which are sensitive to electrostatic
discharge (ESD) can be exposed. The following work may be done only at
workstations with suitable ESD protection.
Modification, maintenance and repair work may be done only by trained and
authorized personnel. For this purpose, the PMA service should be contacted.
9499-040-63201 69 KS40-1 -weishaupt-

Safety hints
18.1 Resetting to factory setting
In case of faultyconfiguration, KS4x-1 can be reset to the default condition.
For this, the operator must keep the keys increment and decrement pressed during
power-on.
Then, press key increment to select YES.
Confirm factory resetting with Enter and the copy procedure is started
(display COPY).
Afterwards the device restarts.
1 2 3 4
SP.x
FAC run SP.x
FAC run SP.x
FAC run SP.x
FAC run
8.8.8.8.
SP.x run
torY Ada
Err no Ada
Err YES Ada
Err
COPY Ada
Err
8.8.8.8. Ada
Err
1. 2.
In all other cases, no reset will occur (timeout abortion).
g If one of the operating levels was blocked and the safety lock is open, reset to
factory setting is not possible.
g If a pass number was defined (via BlueControl® ) and the safety lock is open, but
no operating level was blocked, enter the correct pass number when prompted in
3. A wrong pass number aborts the reset action.
g The copy procedure ( COPY) can take some seconds.

Now, the transmitter is in normal operation.
KS40-1 -weishaupt- 70 9499-040-63201

Safety hints
9499-040-63201 71 KS40-1 -weishaupt-

Montage
19 Montage
min.48 (1.89")
max. 60°C
)
. 4" )
(0 5"
(3.62" +0. 03)

.6 min. 0°C
10
+0, 8
")
(4
.1
.4
18
1.
..0
92
1
04
.
(0
max.
-weishaupt-
95% rel. %
126
96 (3.78")
+0,6
SP.X SG 45
125 Ada
Err
(1.77" +0.02)
48 (1.89")
Loc Loc mA/Pt
mA/Pt
Loc 10V mA/Pt

Actionneur de protection
Ü ou:
Ü
*
*
Commutateurs de sécurité:
Pour l’accès aux commutateurs de sécurité, saisir le régulateur aux découpes du
cadre frontal et le retirer de son boîtier sous une pression légère en haut et en bas.
10V imA/Pt mA/Pt 1 Signal courant / Pt100 / thermocouple à l’entrée

InP.1
10V Signal tension à l’entrée InP.1
Loc ouvert Accès aux niveaux réglés au moyen du BlueControl
(outil d’ingénierie) 2
fermée 1 Accès possible à tous les nivaux
1 Réglage après livraison 2 Par défaut: affichage tous niveaux

supprimés, mot de passe PASS = OFF
a position
Le commutateur de sécurité 10V i mA/Pt doit toujours être mis dans la
gauche ou droite. Un commutateur de sécurité ouvert risque de
perturber le bon fonctionnement de l’appareil!
l Attention! L’appareil contient des pièces sensibles aux décharges

électrostatiques.
9499-040-63201 73 KS40-1 -weishaupt-

Raccordement électrique
20 Raccordement électrique
Option
P
A
9
26 L
di2 (-)
90...250V
10 27 N
11 -
di3 10
20
5 19 OUT1
Ut(+) 21
22
OUT2
23
24b OUT3
24 g h
g b c
7 + INP2
100%
8
0%
6
3
+ +
0% 10V * 1 2 20mA **
2 - 3 -
1 + 100% 2 1
INP1
a b c d e f g
* Commutateur de sécurité mA i 10V dans la position 10V
** Commutateur de sécurité mA i 10V dans la position mA/Pt
Raccordement de l’entrée INP1 2

Entrée pour la variable x1 (mesure).
a thermocouple
b sonde à résistance (Pt100/ Pt1000/ KTY/ ...)
c transmetteur à résistance 50-3-50 Ω
d tension (0/2...10V)
e gamme d'affichage (connexion à 3 fils)
f gamme d'affichage (connexion à 2 fils)
g courant (0/4...20mA)
Raccordement de l’entrée INP2 3

Vue l'entrée INP1.
Raccordement des entrées di2/3 7

Entrée numérique di2 pour commutation externe de SP et SP.2 (SP/SP.2).
Entrée numérique di3 pour commutation externe de régulateur pas-à-pas 3 plages
et de régulateur tout ou rien (DPS/SG).
KS40-1 -weishaupt- 74 9499-040-63201

Utilisation
21 Utilisation
21.1 Vue de la face avant
1 Etats des sorties sur contacts

1 OuT.1... 3
2 Allumé lorsque la limite 1
n’a pas été dépassée
3 Affichage de la mesure
2
1 2 3 OK
4 Régulateur tout ou rien actif
5 Autoréglage actif
6 Entrée dans la liste des erreurs
3 7 Consigne, signal de sortie
0 SP.x
126. SG
&
4
8 Touche d’entrée: appel du
niveau d’utilisation élargi / de la
liste d’erreurs
9 Touches à flèche (haut/bas):
!
"
125 Ada
Err
5
6
changement de la consigne
ou de la sortie réponse
0 La consigne SP.2 ou SP.E est
7 effective
! Gradient de consigne effectiv
" Operation manuel
è
§ Touches à function
§ 8 $ Service manuel/ autre
$ fonction (→ ConF/ LOGI )
% Connexion à l'ordinateur pour
le programme BlueControl
% 9 (Engineering Tool)
& Signalisation
niveau PArA (allumé)
niveau ConF (alterneé)
g Sur l’affichage supérieur, la mesure est toujours affichée. En paramétrage,

configuration, étalonnage et utilisation élargie, l’affichage inférieur change
cycliquement entre le nom et la valeur du paramètre.
9499-040-63201 75 KS40-1 -weishaupt-

Utilisation
21.2 Niveau d’utilisation
Le contenu du niveau d’utilisation élargi est déterminé au moyen du BlueControl

(outil d’ingénierie). Il est possible de copier des paramètres souvent utilisés ou
dont l’affichage est important en niveau d’utilisation élargi.
Automatique Manuel
126 iÒ i 126
125 y 21
È È
Ì Ì
time
out Ù Ò Ù time
out
126 126
y 21 125
seulement È
indication Ì
Ù Ù
Niveau d’utilisation élargi

time
out
Liste des erreurs (En cas d’une erreur)
126 Indication
126
FbF.1 Err
alternée
2 Err
Gestionnaire d’entretien / liste des erreurs
En cas d’une ou de plusieurs erreurs, le niveau

d’utilisation élargi commence toujours par la liste des
erreurs. Une entrée actuelle dans la liste des erreurs SP.x
126 run
(alarme, erreur) est affichée par le témoin LED Err.

Afficher la liste des erreurs en appuyant 2 fois sur Ù .
125 Ada
Err
LED Err Signification Mesure

Clignotant Alarme, erreur - Déterminer type d' erreur au moyen du
numéro d’erreur dans la liste
- Corriger l’erreur
Allumé Erreur éliminée, sans avoir acquitté - Acquitter l’alarme dans la liste en tapant
l’alarme sur È ou Ì
- L’entrée d’alarme a été effacée.
Eteinte sans erreur, toutes les entrées
d'alarmes effacées
KS40-1 -weishaupt- 76 9499-040-63201

Utilisation
Liste des erreurs:

Nom Description Cause Mesure de dépannage
E.1 Erreur interne, le - par ex., EEPROM défectueuse - Contacter le Service PMA
dépannage n’est pas - Retourner appareil au fournisseur.
possible
E.2 Erreur interne, peut être - par ex., problème compatibilité - Séparer les lignes de mesure des
effacé électromagnétique câbles d’alimentation
- Antiparasitage des contacteurs
FbF.1 Rupture du capteur - capteur défectueux - Remplacer le capteur INP1 / 2
/ 2 INP1 / 2 - erreur câblage - Vérifier le raccordement de l’entrée
INP1 / 2
Sht.1 Court-circuit INP1 / 2 - capteur défectueux - Remplacer le capteur INP1 / 2
/2 - erreur câblage - Vérifier le raccordement INP1 / 2
POL.1 Erreur de polarité - erreur câblage - Corriger la polarité INP1
INP1
LooP Alarme boucle de - Signal d’entrée défectueux ou - Vérifier le circuit de chauffage et de
régulation (LOOP) raccordé incorrect. refroidissement.
- Sortie racordeé incorrectement - Vérifier le capteur et le remplacer
- Vérifier le régulateur et le
dispositif de commutation
AdA.H Alarme d’adaptation - voir l'état d'erreur autoréglage - voir l'état d'erreur d'adaptation
chauffage (ADAH) chauffage chauffage
LiM.1 Mémorisation alarme - dépassement seuil 1 / 2 / 3 - vérifier le processus
limite 1 / 2 / 3
Inf.1 Message limite de temps - nombre des heures de - selon l'utilisation
fonctionnement réglées atteint
9499-040-63201 77 KS40-1 -weishaupt-

Utilisation
Etat d’erreur (seulement l'error ADA.H / ADA.C a l'etat d'erreur 3 - 9):

Etat d’erreur Description Comportement
0 Sans erreur
1 erreur mémorisée changement en état d’erreur 0après acquittement dans la
liste des erreurs
2 erreur présente changement en état d’erreur 1 après correction de l’erreur
3 Faux sens d’action Reconfigurer le régulateur (inverse i direct)
4 Pas de réaction de la variable La boucle de régulation n’est peut-être pas fermée: vérifier le
réglée capteur, les connexions et le processus
5 Point de renvoi faible Augmenter la limitation du signal de sortie max. Y.Hi
(ADA.H) ou réduire la limitation min. du signal de sortie
Y.Lo (ADA.C)
6 Risque dépassement consigne Le cas échéant, augmenter ou réduire (direct) la consigne
(paramètre déterminé) (inverse)
7 Changement variable de Augmenter la limitation supérieure de la variable de
correction trop faible (Dy > correction Y.Hi (ADA.H) ou réduire la limitation inférieure
5%) de la variable de sortie Y.Lo (ADA.C)
8 Réserve de consigne trop faible Augmenter (inverse), réduire (direct) la consigne
ou augmenter la plage de réglage de la consigne
(r PArA/ SEtp/ SP.LO et SP.Hi )
9 Tentative d’impulsion échouée Eventuellement, la boucle de régulation n’est pas fermée:
vérifier le capteur, les connexions et le processus
21.3 Autoréglage
Après la mise en route par l’opérateur, le régulateur fait une tentative

d’optimisation en calculant les paramètres pour un équilibrage rapide et sans
dépassement à la consigne à partir des caractéristiques du processus.
g Pendant l’autoréglage, le régulateur tient compte des valeurs ti et td à la
condition qu’elles n’étaient pas OFF auparavant.
Mise en route de l’autoréglage

L’opérateur peut toujours mettre en route l’autoréglage. A cet effet, appuyer
simultanément sur les touches Ù et È .
Le témoin LED AdA se met à clignoter.
Le régulateur sort une variable de correction de 0% ou Y.Lo, attend la
stabilisation du processus et met en route l’autoréglage (la LED AdA est allumée
continuellement).
La tentative d’autoréglage proprement dite est mise en route par le régulateur, si
la condition suivante est satisfaite:
w L’ecart mesure i consigne doit être de 10% de la plage de consigne
( SP.Hi - SP.LO) (fonctionnement inverse: mesure inférieure à la consigne,
fonctionnement direct: mesure supérieure à la consigne).
KS40-1 -weishaupt- 78 9499-040-63201

Utilisation
Si l’autoréglage a réussi, la LED Ada s’éteind et le régulateur poursuit son

fonctionnement avec les paramètres nouveaux.
Abandon de l’autoréglage par l’opérateur:

L’opérateur peut toujours abandonner l’autoréglage. A cet effet, appuyer
simultanément sur les touches Ù et È . Le régulateur poursuit son
fonctionnement au moyen des anciens paramètres en mode automatique.
Abandon de l’autoréglage par le régulateur:

Si la LED Err se met à clignoter pendant l’autoréglage, les conditions de
régulation empêchent la réussite de l’autoréglage. Dans ce cas, la régulation a été
abandonnée par le régulateur. Le régulateur fermé l’organe de réglage
(sortie 0%).
Acquittement de l’autoréglage échoué
1. Appuyer simultanément sur les touches Ù et È:
Le régulateur poursuit son fonctionnement en automatique au moyen des
anciens paramètres.
La LED Err clignote jusqu’à ce que l’erreur d’autoréglage soit acquittée dans
la liste des erreurs.
2. Appuyer sur la touche Ù:
La liste des erreurs est affichée au niveau d’utilisation élargie. Après
l’acquittement du message d’erreur, le régulateur poursuit le fonctionnement
en mode automatique avec les anciens paramètres.
Causes de l’abandon:
→ Page 78: "Etat d’erreur autoréglage chauffage (ADA.H) et refroidissement
(ADA.C)"
9499-040-63201 79 KS40-1 -weishaupt-

Utilisation
Exemple de tentatives d’autoréglage (régulateur pas-à-pas à 3 plages)
Après la mise en marché (1) le W

régulateur ferme le capteur (2 X
Out.3). Lorsque la différence entre la
valeur de mesure et la valeur de
consigne est suffisament importante, t
(3), le changement de la valeur de
mesure est mesuré pendant 1 min.
(4). Ensuite le capteur est ouvert (5 1 min
Out.1). Lorsque le point de retour est t
atteint (6) ou lorsque suffisament de 1 2 3 4 5 6
mesures ont été effectuées, les
paramètres sont alors détéctés et retenus.
21.4 Optimisation manuelle
L’aide d’optimisation doit être utilisée pour les appareils sur lesquels les
paramètres de régulation doivent être réglés sans autoréglage. A cette fin, on peut
utiliser la réponse de la variable x après un changement brusque de la variable de
correction y. Normalement, il n’est pas possible de tracer la courbe complète de
la réponse (0 à 100%), car le processus doit rester à l’intérieur de certaines
limites. Les valeurs Tg et xmax (échelon de 0 à 100 %) ou Δt et d Δx (réponse à un
échelon partiel du processus) peuvent être utilisées pour déterminer la vitesse
d’accroissement vmax.
y
100%
Yh
y = variable de correction
Yh = étendue de l’action correctrice
0%
t
Tu = temps mort (s)
x
Xmax
Tg Tg = temps de restitution (s)
Xmax = valeur max. du processus
Xmax { x
{X Vmax = = = vitesse max.
{t Tg {t
d’accroissement var. processus
Tu t
Les paramètres de régulation peuvent être déterminés à partir des valeurs

calculées temps mort Tu , vitesse maximum d’accroissement vmax et de la
caractéristique K suivant les formules indiquées.Augmenter Pb1 si l’équilibrage
à la consigne oscille.
KS40-1 -weishaupt- 80 9499-040-63201

Utilisation
Effet du réglage des paramètres

Paramètre Régulation Perturbations Comportement de démarrage
Pb1 élargir Atténuation accrue Equilibrage plus lent Réduction plus lente du cycle d’action
réduire Atténuation réduite Equilibrage plus rapide Réduction plus rapide du cycle d’action
td1 élargir Atténuation réduite Réponse plus rapide aux Réduction plus rapide du cycle d’action
perturbations
réduire Atténuation accrue Réponse plus lente aux Réduction plus lente du cycle d’action
perturbations
ti1 élargir Atténuation accrue Equilibrage plus lent Réduction plus lente du cycle d’action
réduire Atténuation réduite Equilibrage plus rapide Réduction plus rapide du cycle d’action
Formules
K = Vmax * Tu Comportement de régulation Pb1 [unités td1 [s] ti1 [s]
d’ingénierie]
PID 1,7 * K 2 * Tu 2 * Tu
Avec des régulateurs à 2 PD 0,5 * K Tu OFF
ou à 3 plages le temps
de cycle est mis à t1 / PI 2,6 * K OFF 6 * Tu
t2 ≤ 0,25 * Tu
P K OFF OFF
Régulateur pas-à-pas à 3 plages 1,7 * K Tu 2 * Tu
21.5 Structure d’utilisation
Après la mise sous tension, l’appareil est en utilisation.

Le mode de fonctionnement est celui d’avant la coupure du secteur.
126 Ù 126 Ù PASS

125 3 sec.
PArA
126 Ù PASS
Ì ConF
126 Ù PASS
Ì CAL
126 Ù
Ì End
a Pour l'accès au niveau de configuration et au niveau de paramétrage le

commutateur de sécurité Loc doit être mis fermée.
9499-040-63201 81 KS40-1 -weishaupt-

Niveau de configuration
22 Niveau de configuration
22.1 Configuration avec qUIC
Au niveau de configuration, la fonction du régulateur est déterminée en

changeant le mot de configuration Con1 . Con1 et le code réglé pour Con1
sont affichés alternativement sur la ligne d’affichage inférieure.
r
SP.X
126 r Ù r
SG PArA
125 Ada
Err
3 sec.
Ì
ConF Con1 Ì rÙ
123.8 123.8
Con1 1520
A B C D
Signification du code:
A 0 Réaction en cas de rupture capteur: comme mesure supérieure à la consigne
1 Réaction en cas de rupture capteur: comme mesure inférieure à la consigne
2 Seulement raccordement P30/W, toujours mesure inférieure à la consigne
B 0 Transmetteur à résistance 50-30-50 [ / capteur de pression 0..10V, gamme
d’affichage 0,0...100,0 (%)
1 Transmetteur à résistance 50-30-50 [ / capteur de pression 0..10V, plage d’affichage
0,00...1,00 (bar)
2 Transmetteur à résistance 50-30-50 [ / capteur de pression 0..10V, gamme
d’affichage 0,0...16,0 (bars)
3 Transmetteur à résistance 50-30-50 [ / capteur de pression 0..10V, gamme
d’affichage 0,0...40,0 (bars)
4 Transmetteur à résistance Pt 100 [ , gamme 0...200°C
5 Transmetteur à résistance Pt 100 [ , gamme 0...400°C
6 Thermocouple type L, gamme 0...900°C
7 Thermocouple type K, gamme 0...1350°C
C 0 Régulateur tout ou rien 2 plages
1 Règulateur tout ou rien 3 plages
2 Régulateur pas-à-pas 3 plages avec commutation à régulateur tout ou rien
3 Régulateur pas-à-pas 3 plages avec commutation à régulateur tout ou rien 3 plages
D 0 -
* Seulement possible avec A = 2 et B = 0 … 3
KS40-1 -weishaupt- 82 9499-040-63201

Après la sortie du niveau de configuration (voir la page 73, le régulateur est

réinitialisé automatiquement (tous les éléments d’affichage sont allumés) et passe
en fonctionnement normal (niveau d’utilisation).
g Des zéros au début ne sont pas affichés (p.e.: affichage 400 avec le code 0400).
Exemple de configuration 1 (code 0400):

KS40-1 comme alarme avec contact
inverseur pour brûleur à 2 étages: 123.8 123.8
Gamme de mesure 0...200°C,
Sonde à résistance Pt 100,
Con1 400
Réaction en cas de rupture du capteur
Comme mesure supérieure à la consigne.
Exemple de configuration 2 (code 2120):

KS40-1 comme régulateur pas-à-pas à 3
plages: raccordement au transmetteur de 123.8 123.8
pression P30/W, Gamme de mesure
0,00...1,00 bars, Réaction en cas de rupture
Con1 2120
du capteur comme mesure inférieure à la
consigne.
Fonction: alarme avec contact inverseur

ATTENTION: Les deux W
relais 1 et 2 sont reliés, ON
c.à.d. la fonction des OUT1
OFF
contacts est celle d’un Sd1 = Sd2
inverseur. Attention à ce ON
OUT2
que les deux relais ne -X W OFF XW
soient pas excités H.1
simultanément. Exception: ON
état désexcité. Seuil OUT3
OFF
HYS.1
Réglage:
Différence de commutation: Sd1 / Sd2: en unités de la quantité physique

Seuil OUT3: Le relais est tombé au repos lorsque le seuil est dépassé.
Seuil supérieur H.1 : en unités de la quantité phys.
Différ. commut. HYS.1 : en unités de la quantité phys.
Témoins LED: LED1: allumé lorsqu’ OUT1 est excité
LED2: allumé lorsqu’ OUT2 est tombé au repos
LED OK: allumé lorsque le seuil n’est pas atteint
Paramètre: voir le paragraphe 21 “Niveau de paramétrage”
9499-040-63201 83 KS40-1 -weishaupt-

Fonction: alarme à 3 plages
Sd1
ON
OUT1
OFF
Sd2
ON d.SP
OUT2 W
-X W OFF XW
H.1
ON
Seuil OUT3
OFF
HYS.1
Réglages:
OUT1: Point de mise en circuit relié à la consigne.

Différ. de commut. Sd1: en unités de la quantité phys.
OUT2: Point de mise hors circuit toujours inf. à la consigne!

Plage de reglage d.SP : en unités de la quantité phys.
Différ. de commut. Sd2: en unités de la quantité phys.
Seuil OUT3: Lorsque le seuil est dépassé, le relais est tombé au

repos.
Seuil sup., H.1: en unités de la quantité phys.
Différ. de commut. HYS.1: en unités de la quantité phys.
Témoins LEDs: LED1: allumé lorsqu’ OUT1 est au repos

LED2: allumé lorsqu’ OUT2 est au repos
LED OK: allumé lorsque le seuil n’a pas été atteint
Paramètres: voir le paragraphe 21 “Niveau de paramétrage”
KS40-1 -weishaupt- 84 9499-040-63201

Fonction: régulateur pas-à-pas à 3 plages
W ON
OUT2
-X W OFF XW
OUT1 XSd
ON -A A
SH
H.1
ON
Seuil OUT3
OFF
HYS.1
Réglages:
Régulateur: SH: en unités de la quantité phys.

Seuil de réponse A: 0,5 w SH
Différence de commutation XSd : 0,06 w SH + 0,08
Temps de réponse de l’organe de réglage tt: 3...9999 s
Cycle d’action min.: fixe, TEmin = 100 ms
Paramètres: Pb1 = 0,01...9999 : en unités de la quantité physique °C

ou °F (le nombre des chiffres
derrière le point décimal est
déterminé par CON1)
Ti = 1...9999 s ( OFF = sans action I)
td = 1...9999 s ( OFF = sans action D)
Seuil OUT3: Lorsque le seuil est dépassé, le relais tombe au repos.

Seuil supérieur H.1 : en unités de la quantité phys.
Différ. de commut HYS.1 : en unités de la quantité phys.
Témoin LEDs: LED1: allumé lorsqu’ OUT1 est excité

LED2: allumé lorque’ OUT2 est excité
LED OK: allumé lorsque le seuil n’est pas atteint
Etat désexcité: tous les relais tombés au repos, contacts ouverts
Paramètres: voir le paragraphe 21 “Niveau de paramétrage”
9499-040-63201 85 KS40-1 -weishaupt-

22.2 Configuration sans qUIC ( qUIC= OFF)

Si l’on maintient la touche Ù enfoncée lors de la mise en circuit du régulateur, la
configuration est mise hors circuit avec qUIC.
Toutes les configurations sont alors disponibles.
Pour retourner à la configuration avec qUIC , maintenir les deux touches Ì È
enfoncées pendant la mise en circuit du régulateur.
a Le régulateur est alors remis aux valeurs par défaut!
Vue d’ensemble de la configuration:
Con1
Ajustage
Nom Plage Description Dèfaut
individuel
Con1 0000...2330 Configuration avec qUIC 0000
Contact à crouchet (sur card électronique)

Ajustage
individuel
Loc ouvert ou fermé Contact à crouchet pour verrouillagé la niveau ConF fermé
et PArA (si permettré avec BlueControl)
InP.1 mA/Pt ou 10V Contact à crouchet pour choisi le signal à InP.1 mA/Pt
Cntr
Ajustage
individuel
SP.Fn Configuration de base du traitement de consigne 0
0 Régulateur à consigne interne pouvant être commuté sur
consigne externe (→ LOGI/ SP.E)
1 Programmateur
8 Régulateur à consigne interne + consigne externe ( SP.E)
9 Programmateur + consigne externe (SP.E) OFF
C.Fnc Comportement de régulation (algorithme) 0
0 Régulateur tout ou rien 2 plages
1 Régulateur PID (2 plages et continu)
2 Δ/êtoile/arrêt ou régulateur 2 plages avec commutation de
charge partielle/complète
3 2 x PID (3 plages et continu)
4 Régulateur pas-à-pas 3 plages
7 Régulateur tout ou rien 3 plages
8 Régulateur pas-à-pas 3 plages avec commutation à régulateur
tout ou rien
9 Régulateur pas-à-pas 3 plages avec commutation à régulateur
tout ou rien 3 plages
KS40-1 -weishaupt- 86 9499-040-63201
Ajustage
individuel
mAn Réglage manuel permis 1
0 Non
1 Oui (voir également LOGI/ mAn)
C.Act Sens d'action du régulateur 0
0 Inverse, p.ex. chauffage
1 Direct, p.ex. refroidissement
FAIL Comportement en cas de rupture du capteur 1
0 Mis hors circuit des sorties du régulateur
1 y = Y2
2 y = sortie moyenne. La sortie maximum admissible est
réglable au moyen du paramètre Ym.H. Afin d’éviter la
détermination de valeurs inadmissibles, la formation de la
valeur moyenne n’a lieu que lorsque l’écart de réglage est
inférieur au paramètre L.Ym .
rnG.L -1999...9999 X0 (limite intérieure de la plage de régulation) 1 0
rnG.H -1999...9999 X100 (limite supérieure de la plage de régulation) 1 100
InP.1
Ajustage
Nom Plage Description Défaut
individuel
S.tYP Type de capteur 50
0 Thermocouple type L (-100...900°C) , Fe-CuNi DIN
1 Thermocouple type J (-100...1200°C) , Fe-CuNi
18 Selon spécifiction thermocouple
20 Pt100 (-200,0 ... 100,0 °C)
21 Pt100 (-200,0 ... 850,0 °C)
22 Pt1000 (-200,0...200,0 °C)
23 KTY 11-6 (selon spécifiction 0...4500 Ohm)
30 0...20mA / 4...20mA 2
40 0...10V / 2...10V 2
50 Potentiométre 0...160 Ohm 2
1 rnG.L et rnG.H indiquent la plage de réglage à laquelle l’autoréglage

se rapporte.
2 Pour des signaux d’entrée courant, tension ou potentiométre, une mise à
l'échelle est requise (voir le paragraphe 21.1)
9499-040-63201 87 KS40-1 -weishaupt-

Ajustage
individuel
S.Lin Linéarisation (réglable seulement avec S.tYP = 30 0
(0..20mA) et 40 (0..10V) )
0 Néante
1 Linéarisation selon spécification. La création de la table de
linéarisation est possible au moyen de la fonction
BlueControl (outil d’ingénierie). La caractéristique pour les
capteurs de température KTY 11-6 a été préréglée.
Corr Correction de la valeur mesurée / mise à l'èchelle 2
0 Sans mise à l'èchelle
1 Correction du déclage (au niveau CAL)
2 Correction 2 points (au niveau CAL)
3 Mise à l'èchelle (au niveau PArA)
InP.2
Ajustage
individuel
I.Fnc Sélection de la fonction d' INP2 0
0 Sans fonction
2 Consigne externe SP.E (commutation -> LOGI/ SP.E)
S.tYP Type de capteur 30
20 Pt100 (-200,0 ... 100,0 °C)
21 Pt100 (-200,0 ... 850,0 °C)
22 Pt1000 (-200,0...200,0 °C)
23 KTY 11-6 (selon spécifiction 0...4500 Ohm)
30 0...20mA / 4...20mA 1
50 Potentiomètre ( 0...160 Ohm) 1
Corr Correction de la valeur mesurée / mise à l'èchelle 0
0 Sans mise à l'èchelle
1 Correction du déclage (au niveau CAL)
2 Correction 2 points (au niveau CAL)
3 Mise à l'èchelle (au niveau PArA)
In.F -1999...9999 replacement en échange de Inp2 OFF
Lim
Ajustage
Name Value range Description Default
individuel
Fnc.1 Fonction de seuil 1 / 2 / 3 1/0/0
Fnc.2 0 Mis hors circuit
Fnc.3 1 Surveillance de la valeur mesuré
1 Pour des signaux d’entrée courant ou potentiométre, une mise à l’échelle
est requise (voir le paragraphe 21.1)
KS40-1 -weishaupt- 88 9499-040-63201

Ajustage
Name Value range Description Default
individuel
2 Surveillance de la valeur mesurée +mémorisation de l’état
d’alarme. Un seuil mémorisé peut être effacé par
l’intermédiaire de la liste des erreurs ou par une entrée
numériue ou au moyen de la touche Ò (→ LOGI/Err.r)
Src.1 Source de seuil 1 / 2 / 3 1/0/0
Src.2 0 Mesure = alarme absolue
Src.3 1 Ecart de réglage Xw (mesure - consigne) = alarme relative
2 Ecart de réglage Xw (alarme relative) avec supression lors du
démarrage et en cas de changement de la consigne
6 Consigne effective Weff
7 Variable de correction (sortie régulateur)
LP.AL Surveillance de coupure de la boucle de régulation 0
0 Sans alarme LOOP
1 Alarme LOOP actif
Out.1 / 2 / 3
Ajustage
individuel
O.Act Sens d'action de la sortie OUT 1 Out.1: 0
0 Direct / normalement ouvert Out.2: 0
Out.3: 1
1 Inverse / normalement fermé
Y.1 Sortie régulateur Y1 / Y2 Out.1: 1 / 0
Y.2 0 Inactive Out.2: 0 / 1
Out.3: 0 / 0
1 Active
Lim.1 Alarme seuil 1 / 2 / 3 Out.1: 0 / 0 / 0
Lim.2 0 Inactive Out.2: 0 / 0 / 0
Out.3: 0 / 0 / 1
Lim.3 1 Active
LP.AL Alarme interruption (LOOP) Out.1: 0
0 Inactive Out.2: 0
Out.3: 0
1 Active
FAi.1 Alarme erreur INP1 / INP2 Out.1: 0 / 0
FAi.2 0 Inactive Out.2: 0 / 0
Out.3: 1 / 0
1 Active
LOGI
Ajustage
individuel
L_r Commutation local / à distance 0
0 Sans fonction
1 Toujours active
3 DI2 *
4 DI3 *
5 Touche è *
9499-040-63201 89 KS40-1 -weishaupt-

Ajustage
individuel
SP.2 Commutation à la seconde consigne SP.2 3
0 Sans fonction
3 DI2 *
4 DI3 *
5 Touche è *
SP.E Commutation à la consigne externe SP.E 0
0 Sans fonction
1 Toujours active
3 DI2 *
4 DI3 *
5 Touche è *
Y2 Commutation Y/Y2 0
0 Sans fonction
3 DI2 *
4 DI3 *
5 Touche è *
6 Touche Ò *
mAn Commutation automatique/manuel 6
0 Sans fonction
1 Toujours active
3 DI2 *
4 DI3 *
5 Touche è *
6 Touche Ò *
C.oFF Mise hors circuit du régulateur 0
0 Sans fonction
3 DI2 *
4 DI3 *
5 Touche è *
6 Touche Ò *
m.Loc Interdiction de la touche Ò 0
0 Sans fonction
3 DI2 *
4 DI3 *
5 Touche è *
KS40-1 -weishaupt- 90 9499-040-63201

Ajustage
individuel
Err.r Effacement de toutes les entrées mémorisée de la liste des 0
erreurs
0 Sans fonction
3 DI2 *
4 DI3 *
5 Touche è *
6 Touche Ò *
P.run Programmateur Marche/Arrêt 5
0 Sans fonction
3 DI2 *
4 DI3 *
5 Touche è *
SG Commutation de régulateur pas-à-pas 3 plages et 4
régulateur tout ou rien
0 Sans fonction
3 DI2 *
4 DI3 *
5 Touche è *
di.Fn Fonction des entrées numériques (valable pour toutes les 0
entrées)
0 Direct
1 Inverse
2 Touche basculant entre 2 fonctions
* Accès multiple est possible.
othr
Ajustage
individuel
Unit Unité 1
0 Non unité
1 °C
2 °F
dP Virgule décimale 0
0 Non virgule décimale
1 1 décimale
2 2 décimale
3 3 décimale
C.dEl 0...200 Modem delay (ms) 0
9499-040-63201 91 KS40-1 -weishaupt-

Niveau de paramétrage
23 Niveau de paramétrage
Cntr
Visible
Ajustage
avec Nom Plage Description Défaut
individuel
qUIC
f Pb1 1...9999 Bande proportionnelle 1 (chauffage) en unités 10
d’ingénierie (par ex. °C)
Pb2 1...9999 Bande proportionnelle 2 (refroidissement) en unités 10
d’ingénierie (par ex. °C)
f ti1 1...9999 Temps intégral 1 (chauffage) [s] 10
ti2 1...9999 Temps intégral 2 (refroidissement) [s] 10
f td1 1...9999 Temps dérivé 1 (chauffage) [s] 10
td2 1...9999 Temps dérivé 2 (refroidissement) [s] 10
t1 0,4...9999 Temps de cycle min. 1 (chauffage) [s]. La longueur 10
d’impulsions min. est de 1/4 x t1
t2 0,4...9999 Temps de cycle min. 2 (refroidissement) [s]. La 10
longueur d’impulsion min. est de 1/4 x t2
f SH 0...9999 Zone neutre ou différence de commutation alarme 1
[unités d’ingénierie]
f Sd1 0,0...9999 Difference de commutation relais 1 pour régulateur 0,1
tout ou rien avec commutation
f Sd2 0,0...9999 Difference de commutation relais 2 pour régulateur 0,1
tout ou rien 3 plages
f d.SP -1999...9999 Séparation entre les seuils contact supplémentaire 0
Δ / Y / arrêt [unités d’ingénierie]
f tP 0,1...9999 Longueur d’impulsions min. [s] OFF
f tt 3...9999 Temps de réponse de l’organe de réglage [s] 60
Y.Lo -120...120 Limitation inférieure de la variable de correction 0
[%]
Y.Hi -120...120 Limitation supérieure de la variable de correction 100
[%]
Y2 -120...120 Seconde variable de correction [%] 0
Y.0 -120...120 Point de travail pour la variable de correction [%] 0
Ym.H -120...120 Limitation de la valeur moyenne Ym [%] 5
L.Ym 0...9999 Ecart max. xw, pour la mise en route du calcul de la 8
valeur moyenne [unités d’ingénierie]
SEtP
Visible
Ajustage
individuel
qUIC
SP.LO -1999...9999 Limite de consigne inférieure pour Weff 0
SP.Hi -1999...9999 Limite de consigne supérieure pour Weff 100
f SP.2 -1999...9999 Seconde consigne 0
r.SP 0...9999 Gradient de consigne [/min] OFF
KS40-1 -weishaupt- 92 9499-040-63201

ProG
Visible
Ajustage
individuel
qUIC
SP.01 -1999...9999 Consigne de fin de segment 1 100
Pt.01 0...9999 Temps du segment 1 [min] 10
InP.1
Visible
Ajustage
individuel
qUIC
InL.1 -1999...9999 Valeur d’entrée du point de mise à l’échelle inf. 38,5
OuL.1 -1999...9999 Valeur d’affichage du point de mise à l’échelle inf. 0
InH.1 -1999...9999 Valeur d’entrée du point de mise à l’échelle sup. 61,5
OuH.1 -1999...9999 Valeur d’affichage du point de mise à l’échelle sup. 100
t.F1 0,0...100,0 Constante de temps du filtre [s] 0,5
InP.2
Visible
Ajustage
individuel
qUIC
InL.2 -1999...9999 Valeur d'entrée du point de mise à l'échelle inférieur 0
OuL.2 -1999...9999 Valeur d'affichage du point de mise à l'échelle 0
inférieur
InH.2 -1999...9999 Valeur d'entrée du point de mise à l'échelle supérieur 100
OuH.2 -1999...9999 Valeur d'affichage du point de mise à l'échelle 100
supérieur
t.F2 0,0...100,0 Constante de temps du filtre [s] 0,5
Lim
Visible
Ajustage
individuel
qUIC
L.1 -1999...9999 Seuil inférieur 1 OFF
f H.1 -1999...9999 Seuil supérieur 1 20
f HYS.1 0...9999 Hystérésis du seuil 1 0,1
L.2/3 -1999...9999 Seuil inférieur 2 / 3 OFF
H.2/3 -1999...9999 Seuil supérieur 2 / 3 OFF
HYS.2/3 0...9999 Hystérésis du seuil 2 / 3 0,1
9499-040-63201 93 KS40-1 -weishaupt-

23.1 Mise à l’échelle des entrées (seulement visible con qUIC = OFF)
Si l’on utilise des signaux de courant ou de tension comme variables d’entrée

pour InP.1 ou InP.2, la mise à l’échelle des valeurs d’entrée et d’affichage
doit s’effectuer au niveau de réglage des paramètres. Spécifier la valeur d’entrée
du point de mise à l’échelle inférieur et supérieur en unités de la quantité
électrique correspondante (mA/ V).
grandeur
physique
OuH.x
mA / V grandeur physique
OuL.x
InL.x InH.x mA/V
23.1.1 Entrée Inp.1
g Les paramètres InL.1 , OuL.1, InH.1 et OuH.1 sont visibles seulement

lorsque ConF / InP.1 / Corr = 3 a été choisi.
S.tYP Signal d’entrée InL.1 OuL.1 InH.1 OuH.1

30 0 … 20 mA 0 quelconque 20 quelconque
(0...20mA) 4 … 20 mA 4 quelonque 20 quelconque
40 0 … 10 V 0 quelonque 10 quelonque
(0...10V) 2 … 10 V 2 quelonque 10 quelonque
Outre ces réglages, InL.1 et InH.1 peuvent être réglés à l’intérieur de la plage
déterminée par le choix de S.tYP (0...20mA / 0...10V).
a Afin d’utiliser la mise à l’échelle prédéterminée avec thermocouple et sonde à
résistance (Pt100), les réglages de InL.1 et OuL.1 et les réglages de InH.1
et OuH.1 doivent correspondre.
g Des changements de la mise à l’échelle des entrées réalisés au niveau
d’étalonnage (r page 26) sont affichés dans la mise à l’échelle des entrées au
niveau de réglage des paramètres. Lorsque l’étalonnage est effacé, les paramètres
de mise à l’échelle sont remis aux valeurs par défaut.
23.1.2 Entrée InP.2
Comme entrée InP.1, mais seulement S.Typ = 20.
KS40-1 -weishaupt- 94 9499-040-63201

Niveau d’étalonnage
24 Niveau d’étalonnage
g La correction de la valeur mesurée ( CAL) est visible seulement lorsque

ConF / InP.1 / Corr = 1 ou 2 et qUIC= OFF ont été choisis.
L’adaptation de la valeur mesurée est possible au menu d’étalonnage (CAL).

Deux méthodes sont disponibles :
Correction du décalage
( ConF/ InP.1 / Corr =1 ): Indication Réglage standard
Correction du décalage
w peut se fait «en ligne»
pendant le processus
OuL.1neuf
OuL.1vieille
InL.1 X
Correction 2 points
( ConF/ InP.1 / Corr = 2 ): Indication Réglage standard
Correction 2 points
w possible «hors ligne» au
moyen d’un simulateur
w Corriger d’abord la
première valeur et ensuite la OuH.1vieille
deuxième, par exemple, OuH.1neuf

après la mise à température
du four, en ligne en deux
étapes.
OuL.1neuf
OuL.1vieille
InL.1 InH.1 X
9499-040-63201 95 KS40-1 -weishaupt-

Correction du décalage ( ConF/ InP.1 / Corr =1):
SP.X
126 run r Ù r PArA
125 Ada
Err 3 sec.
Ì
:
r OuL.1 È r Ù
Ì
r End r Ù
InL.1: La valeur d'entrée du point de mise à l'échelle est affichée.

l'opérateur doit attendre jusqu'à ce que le processus soit au repos.
Ensuite, il confirme la valeur d'entrée par appui sur la touche Ù.
OuL.1: La valeur d'affichage du point de mise à l'échelle est affichée.
Avant l'étalonnage, OuL.1 est égal à InL.1.
L'opérateur peut corriger la valeur d'affichage par appui sur les touches
ÈÌ.
Ensuite, il confirme la valeur d'affichage en tapant sur la touche Ù.
KS40-1 -weishaupt- 96 9499-040-63201

Correction 2 points ( ConF/ InP.1 / Corr = 2):
SP.X
126 r Ù r
run PArA
125 Ada
Err
3 sec.
Ì
:
r
È
InL.1
Ù
È
OuL.1
Ì
rÙ
InH.1 rÙ
È
InH.1
Ù
È
OuH.1
Ì
rÙ
r End r Ù
InL.1: La valeur d'entrée du point de mise à l'échelle inférieur est affichée.

L'opérateur doit régler la valeur d'entrée inférieure au moyen d'un
simulateur. Ensuite, il confirme la valeur d'entrée en tapant sur la touche Ù.
OuL.1: La valeur d'affichage du point de mise à l'échelle inférieur est affichée.
Avant l'étalonnage, OuL.1 est égal à InL.1.
L'opérateur peut corriger la valeur d'affichage inférieur au moyen des
touches ÈÌ . Ensuite, il confirme la valeur d'affichage en tapant sur la
touche Ù.
InH.1: La valeur d'entrée du point de mise à l'échelle supérieur est affiché.
L'opérateur doit régler la valeur d'entrée supérieure au moyen du
simulateur. Ensuite, il confirme la valeur d'entrée au moyen de la touche Ù.
OuH.1: La valeur d'affichage du point de mise à l'échelle supérieur est affichée.
Avant l'étalonnage, OuH.1 est égale à InH.1.
L'opérateur peut corriger la valeur d'affichage supérieure au moyen des
touches ÈÌ . Ensuite, il confirme la valeur d'affichage en tapant sur la
touche Ù.
g Les paramètres modifiés au niveau CAL ( OuL.1, OuH.1) peuvent être remis à
l'état préalable en les mettant à une valeur inférieure à la valeur de réglage
inférieure au moyen de la touche de diminution Ì ( OFF).
Les paramètres modifiés par cette fonction sont mémorisés et affichés au niveau
PArA .
9499-040-63201 97 KS40-1 -weishaupt-

Programmateur
25 Programmateur
W,X SP.01 SP.02

SP.03
SP.04
W,X W
Pt.01 Pt.02 Pt.03 Pt.04 t
Configuration du programmateur:
Pour utiliser le régulateur comme programmateur, le paramètre SP.Fn = 1 doit
être choisi dans le menu ConF. La mise en route du programmateur s'effectue
par l'intermédiaire d'une des entrées numériques di2..3 ou la touche è. Quelle
entrée doit être utilisée pour la mise en route du programmateur est déterminée en
choisissant le paramètre P.run = 3 / 4 / 5 dans le menu ConF.
Afin d'attribuer la fin de programme à l'une des sorties relais sous la forme d'un
signal logique, choisir le paramètre P.End = 1 pour la sortie correspondante
OUT.1...OUT.3 dans le menu ConF.
Paramétrage du programmateur:
Un programmateur à 4 segments est disponible. Déterminer une durée de
segment de Pt.01 .. Pt.04 (en minutes) et une consigne cible du segment
SP.01 .. SP.04 dans le menu PArA .
Mise en route/arrêt du programmateur:

Le programmateur est mis en route par un un signal logique appliqué à l'entrée
di2..3 ou la touche è choisie dans le paramètre P.run.
Le programmateur calcule le gradient de segment pour atteindre la consigne de
fin de segment à partir de celle-ci et le temps de segment. Ce gradient est toujours
effectif. Comme le programmateur met en route le premier segment à la mesure
actuelle, le temps effectif du premier segment peut être différent du temps de
segment réglé au niveau de paramétrage (mesure ≠ consigne).
Après la fin du programme, le régulateur poursuit le réglage avec la dernière
consigne cible réglée auparavant.
Si le programme est arrêté pendant l'exécution (suppression du signal logique à
l'entrée di2..3 ou la touche è), le programmateur retourne au début du
programme et attend un nouveau signal de mise en route.
KS40-1 -weishaupt- 98 9499-040-63201

Programmateur
+ Le changement des paramètres du programme pendant l'exécution du

programme est possible.
Changement du temps de segment:

Le changement du temps de segment provoque le recalcul du gradient requis. Si
le temps de segment a déjà expiré, le programme est mis en route directement
avec le nouveau segment et la consigne change par échelons.
Changement de la consigne de fin de segment:

Le changement de la consigne provoque le recalcul du gradient requis pour
attendre la nouvelle consigne pendant la durée résiduelle du segment. Le gradient
peut changer de signe de polarité.
9499-040-63201 99 KS40-1 -weishaupt-

26 Caractéristiques techniques
Début, fin de gamme: quelconque à l'intérieur de
la gamme de mesure
ENTREES Mise à l'échelle: quelconque -1999...9999
Linéarisation: 16 segments adaptables au
ENTREE DE CONSIGNE INP1 moyen de BlueControl
Résolution: > 14 bits Point décimal: réglable
Point décimal: 0 à 3 chiffres derrière le Surveillance du circuit 12,5% inférieur au début de
point décimal d'entrée: gamme (2mA, 1V)
Filtre d'entrée réglable 0,0...100 s
numérique: ENTREE SUPPLEMENTAIRE INP2
Cycle 100 ms Résolution: > 14 bits
d'échantillonnage: Cycle 100 ms
Correction de la valeur 2 points ou correction du d'échantillonnage:
mesurée: décalage Justesse: < 0,5 %
Thermocouples Potentiométre
r table 1 (page 33 )
Raccordement: 3 fils
Résistance d'entrée: ≥ 1 MΩ
Résistance en ligne: max. 30 Ohm
Effet de la résistance de source: 1 μV/Ω
Surveillance du circuit break
Compensation de soudure froide d'entrée:
Erreur supplémentaire max.: ± 0,5 K Signaux de courant
Surveillance de rupture du capteur Caractéristiques techniques comme INP1
Courant dans le capteur: ≤ 1 μA

ENTREE DE COMMANDE DI2,DI3
Sens d'action configurable
Configurable comme commutateur ou comme
Transmetteur à résistance 50-30-50 bouton-poussoir!Raccordement d'un contact
libre de potentiel approprié pour la
Sonde à résistance commutation de circuits «secs».
Raccordement: 2 ou 3 fils Tension commutée: 5V
Résistance en ligne: max. 30 Ohm Courant: 160 μA
Surveillance du circuit rupture ou court-circuit
d'entrée: ALIMENTATION TRANSMETTEUR UT
Gamme de me sure selon spécification Puissance: 22 mA / ≥ 18 V
La caractéristique mémorisée pour la sonde
KTY 11-6 peut être adaptée au moyens de outil
d'ingénierie (BlueControl).
Gamme de mesure physique: 0...4500 Ohm
Nombre des segments de 16
linéarisation
Signaux de courant et de tension

r table 3 (page 33 )
KS40-1 -weishaupt- 100 9499-040-63201

fabricant sont exigés afin d'éviter l'usure des
ISOLEMENTS GALVANIQUE contacts à cause des pics de tension à la
coupure.
isolement de sécurité
isolement des fonctions
ALIMENTATION
Entrée de mesure INP1 TENSION ALTERNATIVE
Raccords du secteur Entrée suppl. INP2
Tension: 90...260 V c.a.
Entrée numérique di2/3
Fréquence: 48...62 Hz
Alimentation Consommation de environ 7,0 VA
transmetteur UT
puissance
Sorties relais OUT 1,2
Sortie relais OUT3
COMPORTEMENT EN CAS DE
DEFAILLANCE DU SECTEUR
SORTIES
Configuration, paramètres et consignes
réglées, mode de fonctionnement:
SORTIES RELAIS OUT1, OUT2
Mémorisation non volatile en EEPROM
Type de contact: 2 contacts normalement
ouverts avec connexion
commune
CONDITIONS AMBIANTES
Puissance de coupure 500 VA, 250 V, 2A bei
maximale: 48...62 Hz, Mode de protection
charge ohmique
Puissance de coupure 6V, 1 mA c.c. Face avant: IP 65 (NEMA 4X)
minimale: Boîtier: IP 20
Durée de vie électrique: 800.000 cycles de Bornes: IP 00
commutation à la
puissance de coupure max. Température admissibles
Fonctionnement: 0...60°C
SORTIE RELAIS OUT3 Temps de chauffe: ≥ 15 minutes
Pour la précision -20...65°C
Type de contact: inverseur libre de potentiel spécifiée:
Puissance de coupure 500 VA, 250 V, 2A à Stockage: -40...70°C
maximale: 48...62 Hz,
charge ohmique Humidité
Puissance de coupure 5V, 10 mA c.a./c.c.
75% moyenne annuelle, sans condensation
minimale:
Durée de vie électrique: 600.000 cycles de EChocs et vibration
commutation à la
puissance de coupure Test de vibration Fc (DIN 68-2-6)
maximale Fréquence: 10...150 Hz
Nota: En fonctionnement: 1g ou 0,075 mm
Si les relais OUT1...OUT3 commandent des Hors 2g ou 0,15 mm
contacteurs externes, des circuits de fonctionnement:
protection RC selon les spécifications du
9499-040-63201 101 KS40-1 -weishaupt-

Testc de choc Ea (DIN IEC 68-2-27)
Choc: 15g
Durée: 11ms
Compatibilité électromagnétique
Répond à EN 61 326-1
(pour le fonctionnement en continu non
surveillé)
EN GÈNERAL
Boîtier
Matière: Makrolon 9415 peu
inflammable
Classe UL 94 VO, à extinction
d'inflammabilité: spontanée
Le module enfichable est inséré de la face avant.
Sécurité
Répond à EN 61010-1 (VDE 0411-1):
Catégorie de surtension II
Degré de contamination 2
Plage dela tension de travail 300 V
Classe de protection II
Raccordements électriques
Connecteurs plats 1 x 6,3 mm ou 2 x 2,8 mm
selon DIN 46 244
Montage
Montage en tableau au moyen de deux pièces
de fixation sur le haut et le bas ou sur la
droite/gauche.
Le montage haut densité est possible.
Position de non critique
montage:
Poids: 0,27kg
Accessoires livrés avec l'appareil

Notices d'utilisation
Pièces de fixation
KS40-1 -weishaupt- 102 9499-040-63201

Table 1 Gammes de mesure pour des thermocouples
Art Gamme de mesure Précision Résolution (Ô)
J Fe-CuNi -100...1200°C -148...2192°F ß 2K 0,1 K
K NiCr-Ni -100...1350°C -148...2462°F ß 2K 0,2 K
S PtRh-Pt 10% 0...1760°C 32...3200°F ß 2K 0,2 K
R PtRh-Pt 13% 0...1760°C 32...3200°F ß 2K 0,2 K
T Cu-CuNi -200...400°C -328...752°F ß 2K 0,05 K
C W5%Re-W26%Re 0...2315°C 32...4199°F ß 2K 0,4 K
D W3%Re-W25%Re 0...2315°C 32...4199°F ß 2K 0,4 K
E NiCr-CuNi -100...1000°C -148...1832°F ß 2K 0,1 K
B* PtRh-Pt6% 0(100)...1820°C 32(212)...3308°F ß 2K 0,3 K
* Spécifications s'appliques à 100°C
Table 2 Gammes de mesures pour des sondes à résistance

Art Courant de Gamme de mesure Précision Résolution (Ô)
mesure
Pt100 -200...100°C -140...212°F ß 1K 0,1K
Pt100 -200...850°C -140...1562°F ß 1K 0,1K
Pt1000 -200...200°C -140...392°F ß 2K 0,1K
KTY 11-6 * -50...150°C -58...302°F ß 2K 0,05K
Spezial 0...450
Poti 0...160 ß 0,1 % 0,01 %
Poti 0...450
Poti 0...1600
* Ou Spezial
Table 3 Gammes de mesure pour courant et tension

Gamme de Résistance d'entrée Précision Résolution (∅)
mesure
0-10 Volt ~ 110 kΩ ß 0,1 % ß 0,6 mV
0-20 mA 49 Ω (tension exigée ß 2,5 V) ß 0,1 % ß 1,5 μA
9499-040-63201 103 KS40-1 -weishaupt-

Consignes de sécurité
27 Consignes de sécurité
L'appareil a été construit et testé conformément avec VDE 0411-1 / EN 61010-1.
A la livraison, son état de sécurité est parfait.
L'appareil répond à la directive européenne 89/336/CEE (CEM). Il est muni du
marquage CE.
Avant la livraison, l'appareil a passé les essais exigés par les plans de test. Afin
de maintenir l'appareil en bon état et pour garantir le fonctionnement sûr,
l'utilisateur doit tenir compte des consignes de sécurité et de mises en garde des
présentes notices d'utilisation.
L'appareil est destiné exclusivement à l'utilisation pour des fin de mesure et de
régulation dans des installations techniques.
a SiMise en garde
l'appareil présente des endommagements donnant lieu à soupHonner que le
fonctionnement sûr n'est pas garanti, il ne doit pas être mis en service.
RACCORDEMENT ELECTRIQUE
Le câblage électrique sera fait en conformité avec les standards locaux (par ex.
VDE 0100). Les lignes de mesure doivent être maintenues séparées des lignes du
signal et du secteur.
MISE EN SERVICE
Avant la mise sous tension de l'appareil, tenir compte des renseignements
suivants:
w S'assurer que la tension d'alimentation soit bien celle spécifiée sur l'étiquette
de l'appareil.
w Tous les couvercles requis pour la protection contre le contact doivent être en
position.
w Si l'appareil est connecté avec d'autres unités dans la même boucle de signal,
vérifier que l'enclenchement de l'appareil ne risque pas d'affecter les
équipements dans le circuit de sortie. Si nécessaire, prendre des mesure de
protection appropriées.
w L'appareil doit être utilisé seulement à l'état installé.
w Avant et pendant le fonctionnement, tenir compte des limites de température
spécifiées pour l'utilisation du régulateur.
MISE HORS SERVICE

Pour mettre l'appareil hors service, il faut le débrancher complètement du secteur.
Protéger l'appareil contre le fonctionnement accidentel.
Avant de débrancher le régulateur, vérifier si cela ne risque pas d'affecter le
fonctionnement d'un autre appareil connecté sur le même signal, et prendre, si
nécessaire, des mesures appropriées.
KS40-1 -weishaupt- 104 9499-040-63201

ENTRETIEN, REPARATIONS ET MODIFICATIONS

Les appareils n'exigent pas d'entretien particulier.
a Attention
Mise en garde
à certaines bornes ou parties sensibles en démontant le couvercle ou
d'autres parties.
Avant de réaliser ces travaux, l'appareil doit être débranché de toute source
de tension.
Après la réalisation de ces travaus, refermer l'appareil et remettre en place tous

les couvercles et les composants. Vérifier si les spécifications sur l'étiquette de
l'appareils doivent être changées et les corriger, si nécessaire.
l Attention
Lors du démontage des appareils, des composants sensibles à la décharge
électrostatique (DES) risquent d'être mis à nus. De ce fait, des réparations doivent
être réalisées seulement à des postes de travail protégés contre la décharge
électrostatique.
Les modifications, l'entretien et les réparations doivent être faits seulement par un
personnel qualifié. A cette fin, le service PMA est à la disposition de l'utilisateur.
9499-040-63201 105 KS40-1 -weishaupt-

27.1 Remise au réglage réalisé à l'usine
Dans le cas d’une mauvaise configuration, KS4x-1 remis aux valeurs usine
Pour cela, l’operateur doit appuyer sur les boutons monte et descente ?? durant la
mise sous tension.
Après, appuyez sur la flèche du haut ? afin de sélectionner YES.
Confirmez a l’aide du bouton Entrée et la procédure COPY commence (affiche
COPY)
Après cela, l’unité se réinitialise.

1 2 3 4
SP.x
FAC run SP.x
FAC run SP.x
FAC run SP.x
FAC run
8.8.8.8.
SP.x run
torY Ada
Err no Ada
Err YES Ada
Err
COPY Ada
Err
8.8.8.8. Ada
Err
1. 2.
Dans tous les autres cas, aucune remise à zéro se produira (avortement timeout).
g Dans tout autres cas, la remise aux valeurs par défaut ne s’effectuera pas
(temporisation sortie des menus)
g Si un code d’accès a été défini (via Blue Control) and que le verrouillage de
sécurité est ouvert, mais que aucun niveaux soit verrouiller, Entrez le bon code
d’accès lorsqu’il vous sera demander 3. Un code erroné annulera l’action de
remise à zéro.
g La procédure copy (COPY) peut prendre quelques secondes.

Maintenant, le transmetteur est en opération normal
KS40-1 -weishaupt- 106 9499-040-63201

9499-040-63201 107 KS40-1 -weishaupt-

9499- 040- 63201
Subject to alterations without notice © PMA Prozeß- und Maschinen-Automation GmbH

Änderungen vorbehalten P.O.B. 310 229, D-34058 Kassel, Germany A6
Sours réserve de toutes modifications Printed in Germany 9499-040-63201
PMA Prozeß- und Maschinen-Automation GmbH
Digital 280-1
digital indicator
Digital 280-1
Digital 280-1
Operating manual
English
9499-040-67311
Valid from: 8495
û BlueControl
More efficiency in engineering,
more overview in operating:
The projecting environment for the BluePort controllers
o n
e N!
O dat e
s
I
T p d
N U e .
T E and nlin D
ATrsion ma-o A-C
Ve .p PM
ini ww r on
M w o
Description of symbols
in the text: on the device:
g General information a Follow the operating instructions

a General warning
l Attention: ESD-sensitive devices
© PMA Prozeß- und Maschinen-Automation GmbH • Printed in Germany

All rights reserved.
No part of this document may be reproduced or published in any form or by any means
without prior written permission from the copyright owner.
A publication of PMA Prozeß- und Maschinen Automation

P.O.Box 310229
D-34058 Kassel
Germany
Inhaltsverzeichnis
1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Connecting diagram. . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Terminal connection . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Behaviour after power-on . . . . . . . . . . . . . . . . . . . . . 10
3.3 Operating level . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.1 Min/max function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.2 Tare function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.3 Sample&hold amplifier . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.4 O2 measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.5 Extended operating level . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.6 Alarm handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Maintenance manager / Error list . . . . . . . . . . . . . . . . 16
4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Control parameters. . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Self-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3.1 Self-tuning start ( Ù + È ) . . . . . . . . . . . . . . . . . . . . . . 18
4.3.2 Self-tuning cancellation . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3.3 Acknowledgement procedures in case of unsuccessful self-tuning . 19
4.3.4 Examples for self-tuning attempts . . . . . . . . . . . . . . . . . . 19
4.3.5 (controller inverse, heating or heating/cooling) . . . . . . . . . . . 19
4.4 Manual tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Operating structure . . . . . . . . . . . . . . . . . . . . . . . . 22
5 Configuration level . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Configuration survey . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3 Configuration examples . . . . . . . . . . . . . . . . . . . . . . 30
5.3.1 On-Off controller / Signaller (inverse) . . . . . . . . . . . . . . . . . 30
Digital 280-1 3
5.3.2 2-point controller (inverse) . . . . . . . . . . . . . . . . . . . . . . . 31
5.3.3 Continuous controller (inverse) . . . . . . . . . . . . . . . . . . . . . 32
5.3.4 Digital 280-1 with measured value output . . . . . . . . . . . . . . . 33
6 Parameter setting level . . . . . . . . . . . . . . . . . . . . . . 34
6.1 Parameter survey . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3 Input scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.1 Input Inp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7 Calibration level . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Offset correction . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8 BlueControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11 Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.1 Resetting to factory setting . . . . . . . . . . . . . . . . . . . . 47
4 Digital 280-1
Mounting
1 Mounting
)
. 4" max. 60°C
(0 " )
10 (4 .65
8 min. 0°C
11
min.48
(1.89")
max.
%
(1.77" +0.02)
Digital 280-1
95% rel.
48 (1.89")
45 +0,6
1. 4..0
OUT1
(0
OUT2
.1 .4"
.0
OUT3
ADA
0 )
FUNC
ERR
F
min max
92 +0,8
(3.62"
+0.03
) 96 (3.78")
Loc 10V i mA/Pt
security switch
or
Ü Ü
*
* Loc 10V mA/Pt
Safety switch:
For access to the safety switches, the indicator must be withdrawn from the hou-
sing. Squeeze the top and bottom of the front bezel between thumb and forefinger
and pull the controller firmly from the housing..
10V i mA/Pt right 1 Current signal / Pt100 / thermocouple/mV at InP

left Voltage signal (V) at InP
Loc open Access to the levels is as adjusted by means of BlueControl
(engineering tool) 2
closed 1 all levels accessible wihout restriction
1 Factory setting 2 Default setting: display of all levels

suppressed, password PASS = OFF
a Safety switch 10V i mA/Pt always in position left or right. Leaving the
safety switch open may lead to faulty functions!
l Caution! The unit contains ESD-sensitive components.
Digital 280-1 5
2 Electrical connections
2.1 Connecting diagram

Option
1
6 di2 (2)
1 L 90...250V
1
3
2 N 24V AC/DC
3
4
6 di3 5
4
6 OUT1
7 UT 5 4
7
6 OUT2
g h i
8
Logic
9 7 7
10 8 U 8 OUT3
Modbus RTU 11 9 9 5
12
RGND RXD-B
10
13
GND
11 3
8 RXD-A
14 di1
12
TXD-B
15 di1
DATA B 13 + +
16
0 mA V*
17
14 - - - INP1
DATA A TXD-A mV
15
+ 100% + 2
RS485 RS422 a b c d e f
* Safety switch mA i V in position left
g The indicator is provided with screw terminals from 0,5 to 2,5mm².
2.2 Terminal connection
Power supply connection 1

See chapter 10 "Technical data"
Connection of input INP1 2
Input for variable x1 (process value)
a thermocouple
b resistance thermometer (Pt100/ Pt1000/ KTY/ ...)
c potentiometer
d current (0/4...20mA)
e voltage (-2,5...115/-25...1150/-25...90/ -500...500mV)
f voltage (0/2...10V/ -5...5V)
6 Connecting diagram Digital 280-1

Connection of input di1 3

Digital input, configurable as switch or push-button
Connection of outputs OUT1/2 4

Relay outputs 250V/2A normally open with common contact connection
Connection of output OUT3 5
g logic (0..20mA / 0..12V)

h voltage (0/2...10V)
i current (0/4...20mA)
i transmitter power supply
Connection of inputs di2/3 6 (option)

Digital inputs (24VDC external), galvanically isolated, configurable as switch or
push-button
Connection of output UT 7 (option)

Supply voltage connection for external energization
Connection of bus interface 8 (option)

RS422/485 interface with Modbus RTU protocol
6 7 di2/3, UT 2-wire transmitter supply 6 OUT3 transmitter supply

Option
+24VDC 5mA
1
(2) 1
5 7
-
3
5mA 4 3
8
0V 5 +
+ 6
4
9 13V
5
17,5V 7 22mA
6
22mA - 8
10
9 7
10 8 OUT3 11
11 9
12
12
+ 10 +
1 13
11
13
3
14 J
15
12
14
K 16
13 + -
2
17
14 15 2
- 15 -
3
J K
1
x
a Ifconnection
U and the universal output OUT3 is used there may be no external galvanic
T
between measuring and output circuits!
Digital 280-1 Terminal connection 7

6 OUT 3 als Logikausgang mit Solid-State-Relais (Reihen- und Parallel-Schaltung)
serial installation parallel installation
4
Imax=22mA SSR
5 _
4V
6 +
Logic SSR Imax=22mA SSR

_ _
7 7
12V 4V 12V
8 + 8 +
9 SSR 9 SSR
_ _
4V
10 + +
9 RS485 interface (with RS232-RS485 interface converter) *
12
12 12
12 12
12
RGND 10
10 RGND 10
10 RGND 10
13
13 13
13 13
13
11 11
11 11
11
14
14 14
14 14
14
DATA B
15
15
12
13
DATA B
15
15
12
12 DATA B
15
15
12
12 PC
13
13 13
13
RT DATA A
16
(16)
14 DATA A
16
(16) 16
(16)
14
14 DATA A 14
14
17
17 17
17 17
17
15 15
15 15
15
interface
converter
max. 1000m RS485-RS232
RGND optional connection twisted pair RT
J RT = line resistance
* Interface description Modbus RTU in seperate manual: see page 41.
8 Terminal connection Digital 280-1

Connecting exampleDigital 280-1:

L1
L2
fuse fuse fuse

TB 40-1 1
Digital 280-1 temperature limiter
1 1
22 2
33 contactor 33
4 4
5 5
6 6
SSR
Logic _
7 7
8 8
+
9 9
10
10 10
11
11 11
12
12 12
13
13 13
14
14 14 reset-
15
15 15 switch
+ +
heating
N1
N2
1 TB 40-1 temperature limiter

standard-version (3 relay)
TB40-100-0000D-000
r further versions on demand
a CAUTION:
Using a temperature limiter is recommendable in systems where
overtemperature implies a fire hazard or other risks.
Digital 280-1 Terminal connection 9

Operation
3 Operation
3.1 Front view
Digital 280-1
OUT1
2 OUT2
OUT3 1
3 ADA
4 FUNC
5 ERR
6 F 0
min max
7 8 9
1 measured value display

2 statuses of switching outputs OuT.1... 3 (or alarm statuses)
3 lit with self-tuning activated
4 lit with tare or sample & hold function activated
5 lit with entry in the error list
6 function-key
7 down-key
8 up-key
9 enter-key: calls up extended operating level/ errorlist
0 pc connection for BlueControl (engineering-tool)
g The measured value is displayed as standard. At parameter setting, configuration,

calibration level and at the extended operating level, the display changes
cyclically between parameter name and parameter value.
3.2 Behaviour after power-on

After supply voltage switch-on, the unit starts with the operating level.
The unit is in the condition which was active before power-off.
10 Front view Digital 280-1

Operation
3.3 Operating level
3.3.1 Min/max function

The minimum and maximum values are stored.
Digital 280-1 Digital 280-1

OUT1 OUT1
OUT2 OUT2
OUT3 OUT3
ADA ADA
FUNC FUNC
ERR ERR
Ì Ì
min max
OUT1 OUT1
OUT2 OUT2
OUT3 OUT3
ADA ADA
FUNC FUNC
ERR ERR
As long as the Ì key is pressed, the minimum As long as the È key is pressed, the maximum
value is displayed. value is displayed.
Deleting the minimum value

Keeping the Ì key pressed whilst actuating key È deletes the minimum value.
Additionally, determination whether a digital input or key è should delete the mi-
nimum value is possible during configuration (rES.L).
Deleting the minimum and maximum values can be done also via interface.
Deleting the maximum value

Keeping the È key pressed whilst actuating key Ì deletes the maximum value.
Additionally, determination whether a digital input or key è should delete the ma-
ximum value is possible during configuration (rES.H).
Deleting the minimum and maximum values can be done also via interface.
g When switching off Digital 280-1, minimum and maximum values are deleted.
Digital 280-1 Operating level 11

Operation
3.3.2 Tare function

When switching on the tare function, the instantaneous measured value is set to
zero. In this case, measurement is continued with this offset. By switching off the
tare function, the actual measured value is displayed again.
measured value
effective value
t
è è è
ADA ADA ADA
FUNC FUNC FUNC
ERR ERR ERR
Tare can be activated during configuration (Func r Fnc.1 = 1).

Dependent of configuration, tare can be made effective via one of the digital in-
puts di1, di2, di3, the è key or interface (LOGI r tArA).
3.3.3 Sample&hold amplifier

With the sample & hold function activated, the measured value is held on the dis-
play. By switching off the sample & hold function, the actual measured value is
displayed again.
measured value
effective value
t
è è è è è
ADA ADA ADA ADA ADA
FUNC FUNC FUNC FUNC FUNC
ERR ERR ERR ERR ERR
Sample & hold can be activated during configuration (Func r Fnc.1 = 2).
Dependent of configuration, sample & hold can be made effective via one of the
digital inputs di1, di2, di3,the è -key or via interface (LOGI r HOLd).

Operation
3.3.4 O2 measurement
For measurement, lambda probes (l probes) are used.
The electromotive force (in Volt) supplied by the l probes is dependent of the
instantaneous oxygen content and of the temperature. Therefore, Digital 280-1
can display accurate measurement results only, provided that the probe tempera-
ture is known to the indicator.
Enter the temperature in °C in parameter tEmP. When using heated l probes, the
probe temperature can be entered directly. When using non-heated l probes, ho-
wever, the displayed values can be accurate only for a narrow temperature band.
g Unless the probe temperature is known, we recommend using our KS90-1
Oxygen (temperature measurement via a second input).
Configuration:
Adjust O2 measurement in function 1:
Func r Fnc.1 3 O2 measurement
Display: The displayed value is always a % value.

As it is mostly necessary to cover a wide measuring range, we recommend adju-
sting a high number of digits behind the decimal point during configuration, whe-
reby loss of high values is prevented due to floating decimal point display
(0,0001 (1 ppm) to 99999 is possible) .
Specify the number of digits behind the decimal point below othr :
0 0 digits behind the decimal point
1 1 digit behind the decimal point
othrr dP 2 2 digits behind the decimal point
Adjust the sensor type to one of the high-impedance voltage inputs in InP:
Specification in BlueControl Effective measuring range
41 Special ( 0...100 mV) -2,5...115 mV
Inp.1r 42 Special ( 0...1000 mV) -25...1150 mV
S.tYP 43 Special ( -25...90 mV)
44 Special ( -500...500 mV)
These high-impedance inputs are not provided with break monitoring. If necessa-
ry, measurement input protection is possible via limit value processing.

Operation
3.3.5 Extended operating level

The content of the extended operating level is determined by means of BlueCon-
trol (engineering tool). Parameters which are important or which are used fre-
quently can be copied into the extended operating level.
Actuating key Ù switches to the first value
Digital 280-1
of the extended operating level (may be
OUT1
OUT2
OUT3
preceded by error list or set-point).
ADA
FUNC
ERR
The selected parameters can be changed
by pressing keys Ì and È.
Ù
OUT1 OUT1
OUT2 OUT2
OUT3 OUT3
ADA ADA
FUNC FUNC
ERR ERR
Press Ù to go to the next parameter.

Ù
OUT1 OUT1
OUT2 OUT2
OUT3 OUT3
ADA ADA
FUNC FUNC
ERR ERR
Ù Press Ù to return to the normal display

after the last parameter .
14 Operating level Digital 280-1

Operation
3.3.6 Alarm handling

Max. three alarms can be configured and assigned to the individual outputs. Ge-
nerally, outputs OuT.1... OuT.3 can be used each for alarm signalling. If more
than one signal is linked to one output the signals are OR linked. Each of the 3 li-
mit values Lim.1 … Lim.3 has 2 trigger points H.x (Max) and L.x (Min), which
can be switched off individually (parameter = “OFF”). Switching difference
HYS.x of each limit value is adjustable.
Operaing principle absolut alarm Operating principle relative alarm

L.1 = OFF L.1 = OFFF
InL.1 InH.1
SP
InL.1 InH.1
H.1
H.1
HYS.1
HYS.1
LED LED
H.1 = OFF H.1 = OFF

InL.1 InH.1 SP
InL.1 InH.1
L.1 L.1
HYS.1 HYS.1
LED LED
SP
InL.1 InH.1
InL.1 InH.1
H.1
L.1 H.1
L.1 HYS.1 HYS.1
HYS.1 HYS.1
LED LED
LED LED
normally closed ( ConF / Out.x / O.Act = 0 )

normally open ( ConF / Out.x / O.Act = 1 )

Operation
g The variable to be monitored can be selected seperately for each alarm via
configuration
The following variables can be monitored:
w process value
w control deviation xw (process value - set-point)
w control deviation xw + suppression after start-up or set-point change
As there is automatically a control deviation after starting up and after
set-point changes, however, the alarm is suppressed, until the signal was
within the limits once.
w Set-point
w Correcting variable y (controller output signal)
g If measured value monitoring + alarm status storage is chosen ( ConF / Lim /
Fnc.x = 2), the alarm relay remains switched on until the alarm is resetted in the
error list ( Lim 1..3 = 1) or via interface.
3.4 Maintenance manager / Error list Digital 280-1

OUT1
In case of one or several errors, the extended operating OUT2
level always starts with the error list. A current entry OUT3
ADA
into the error list (alarm or error) is displayed by the FUNC
Err LED in the display. ERR
For displaying the error list, pressing 1x Ù is necessary.

(with configuration as a controller, press 2x Ù).
Err LED status Signification Proceed as follows

blinks Alarm due to - Determine the error type in the error list via the error number
existing error - Remove the error
lit Error removed, - Acknowledge the alarm in the error list pressing key È or Ì
Alarm not - The alarm entry was deleted.
acknowledged
off No error, all alarm entries deleted
g Saved alarms (Err-LED is lit) can be acknowledged and deleted with the digital
input di1/2/3 or the Ò-key.
Configuration, see page 31: ConF / LOGI / Err.r
g If an alarm is still valid that means the cause of the alarm is not removed so far
(Err-LED blinks), then other saved alarms can not be acknowledged and deleted.
Error status Signification
2 Existing error Change to error status 1 after error removal
1 Stored error Change to error status 0 after acknowledgement in error list
0 No error/message not visible, except with acknowledgement
16 Maintenance manager / Error list Digital 280-1

Controller
4 Controller
In addition to the simple indicator function, Digital 280-1 can be used also as a
signaller or an on/off controller, as a two point or a continuous controller.
Prerequisite: Digital 280-1 is fitted with option “with outputs” and is configured
for the controller function.
Configuration:
Function 2 provides selection between indicator and controller:
Func r Fnc.2 Controller
4.1 Operation
Adjusting the set-point
Digital 280-1
OUT1
OUT2
OUT3
Press key Ù to switch over to the
ADA
FUNC
ERR
set-point. The set-point can be changed
by pressing keys Ì und È .
Ù
OUT1 OUT1
OUT2 OUT2
OUT3 OUT3
ADA ADA
FUNC FUNC
ERR ERR
Ù
error list, if errors pending
Ù
extended operating level, if configured
Ù
4.2 Control parameters

The range of different processes to be controlled is very wide, from very fast
pressure control to very slow thermal processes such as control of a blast furnace.
As the controller behaviour has to be different with each of these processes, the
control parameters must be adjusted for the relevant process individually. Adjust-
ment can be done either manually or by the controller itself.
Digital 280-1 Operation 17

Controller
4.3 Self-tuning
After starting by the operator, the controller makes a self-tuning attempt. The
controller uses the process characteristics for quick line-out to the set-point wit-
hout overshoot.
g Self-tuning start can be locked via BlueControl (engineering tool) ( P.Loc).
g ti and td are taken into account only, if they were ¹ OFF previously.
4.3.1 Self-tuning start ( Ù + È ) Digital 280-1

OUT1
The operator can start self-tuning at any time. For OUT2
this, keys Ù and È must be pressed simultane- OUT3
ously. The AdA LED starts blinking. ADA
FUNC
The controller outputs 0% or Y.Lo, waits until the ERR
process is at rest and starts self-tuning (AdA LED
lit permanently).
The self-tuning attempt is started when the following prerequisite is met:

w The difference between process value i set-point must be ³ 10% of the
set-point range ( SP.Hi - SP.LO) (with inverse action: process value smaller
than set-point, with direct action: process value higher than set-point).
After successful self-tuning, the AdA-LED is off and the controller continues
operating with the new control parameters.
4.3.2 Self-tuning cancellation

By the operator:
Self-tuning can always be cancelled by the operator. For this, press Ù and È
key simultaneously. The controller continues operating with the old parameters.
By the controller:
If the Err LED starts blinking whilst self-tuning is running, successful self-tuning
is prevented due to the control conditions. In this case, self-tuning was cancelled
by the controller.
Dependent of control type, the output status is:
w 3-pnt. stepping controller:
actuator is closed (0% output)
w 2-pnt./ 3-pnt./ continuous controller:
If self-tuning was started from the automatic mode, the controller output is
0%. With self-tuning started from manual mode, the controller output is Y2.
18 Self-tuning Digital 280-1

Controller
Error-Status Selfoptimization
Error status Description Behaviour
0 No error
3 Faulty control action Re-configure controller (inverse i direct)
4 No response of process variable The control loop is perhaps not closed: check
sensor, connections and process
5 Low reversal point Increase ( ADA.H) max. output limiting Y.Hi or
decrease ( ADA.C) min. output limiting Y.Lo
6 Danger of exceeded set-point If necessary, increase (inverse) or reduce (direct)
(parameter determined) set-point
7 Output step change too small Increase ( ADA.H) max. output limiting Y.Hi or
(dy > 5%) reduce ( ADA.C) min. output limiting Y.Lo
8 Set-point reserve too small Increase set-point (inverse), reduce set-point
(direct) or increase set-point range(r PArA / SEtp
/ SP.LO and SP.Hi )
4.3.3 Acknowledgement procedures in case of unsuccessful self-tuning

1. Press keys Ù and È simultaneously:
The controller continues controlling using the old parameters
The Err LED continues blinking, until the self-tuning error was
acknowledged in the error list.
2. Press key Ù :
Display of error list at extended operating level. After acknowledgement
of the error message, the controller continues control using the old
parameters.
4.3.4 Examples for self-tuning attempts

4.3.5 (controller inverse, heating or heating/cooling)
X
Start: heating power switched on W
2
Heating power Y is switched off (1).
When the change of process value X
t
was constant during one minute (2), 100%
Y
the power is switched on (3). 0%
start r 1 3 t turning point
At the reversal point, the self-tuning at-
tempt is finished and the new parameter blinks lit off
are used for controlling to set-point W.
Digital 280-1 Self-tuning 19

Controller
Start: heating power switched off

X
The controller waits 1,5 minutes (1). W
Heating power Y is switched on (2).
At the reversal point, the self-tuning at-
tempt is finished and control to the 100%
t
Y
set-point is using the new parameters. 0%
start r 1 2 t turning point
blinks lit off

Start: at set-point
X
Heating power Y is switched off (1). W
If the change of process value X was 2
constant during one minute and the con-
trol deviation is > 10% of SP.Hi - 100%
t
Y
SP.LO (2), the power is switched on 0%
(3). At the reversal point, the self-tu- start r 1 3 t turning point
ning attempt is finished, and control to

blinks lit off
set-point W is using the
new parameters.
4.4 Manual tuning
The optimization aid should be used with units on which the control parameters
shall be set without self-tuning.
For this, the response of process variable x after a step change of correcting va-
riable y can be used. Frequently, plotting the complete response curve (0 to
100%) is not possible, because the process must be kept within defined limits.
Values Tg and xmax (step change from 0 to 100 %) or Dt and Dx (partial step re-
sponse) can be used to determine the maximum rate of increase vmax.
y
100% y = correcting variable
Yh Yh = control range
0%
Tu = delay time (s)
t
Tg = recovery time (s)
x
Tg Xmax = maximum process value
Xmax
Xmax { x
{X Vmax = = = max. rate of
Tg {t
{t
increase of process value
Tu t
Digital 280-1 Manual tuning 20

Controller
The control parameters can be determined from the values calculated for delay
time Tu , maximum rate of increase vmax, control range Xh and characteristic K ac-
cording to the formulas given below. Increase Xp, if line-out to the set-point os-
cillates.
Parameter adjustment effects

Parameter Control Line-out of disturbances Start-up behaviour
Pb1 higher increased damping slower line-out slower reduction of duty cycle
td1 higher reduced damping faster response to disturbances faster reduction of duty cycle
lower increased damping slower response to disturbances slower reduction of duty cycle
ti1 higher increased damping slower line-out slower reduction of duty cycle
Formulas
K = Vmax * Tu controller behavior Pb1 [phy. units] td1 [s] ti1 [s]
PID 1,7 * K 2 * Tu 2 * Tu
With 2-point and PD 0,5 * K Tu OFF
3-point controllers,
the cycle time must PI 2,6 * K OFF 6 * Tu
be adjusted to P K OFF OFF
t1 / t2 £ 0,25 * Tu
3-point-stepping 1,7 * K Tu 2 * Tu
Digital 280-1 Manual tuning 21

Controller

After supply voltage switch-on, the controller starts with the operating levels.

OUT1 3s OUT1
Ù
OUT2 OUT2
OUT3
ADA
FUNC Ù
OUT3
ADA
FUNC
PASS
ERR ERR
Digital 280-1
OUT1
Ù PASS
OUT2
Ì OUT3
ADA
FUNC
ERR
Digital 280-1
OUT1
Ù PASS
OUT2
Ì OUT3
ADA
FUNC
ERR
Digital 280-1
OUT1
Ù
OUT2
Ì OUT3
ADA
FUNC
ERR
g PArA - level:
At PArA - level, the right decimal point of the upper display line is lit
continuously.
g ConF - level:
At ConF - level, the right decimal point of the upper display line blinks
When safety switch Loc is open, only the levels enabled by means
of BlueControl (engineering tool) are visible and accessible by entry
PASS of the password adjusted by means of BlueControl (engineering
tool). Individual parameters accessible without password must be
copied to the extended operating level.
Factory setting: Safety switch Loc closed: all levels accessible without
restriction, password PASS = OFF.
Safety switch Password entered with Function disabled or enabled Access via the instrument
Loc BluePort® with BluePort® front panel:
closed OFF / password disabled / enabled enabled
open OFF / password disabled disabled
open OFF enabled enabled
open Password enabled enabled after password
entry
Digital 280-1 Operating structure 22

Configuration level
5.1 Configuration survey
ConF Configuration level
Display, operation,
digital Inputs
Functions
Output 1
Output 2
Output 3
interface
OUt.1
OUt.2
OUt.3
LOGI
Othr
Func
Limits
InP
Lim
End
Input
È Fnc.1 StYP Fnc.1 O.Act O.tYP L_r bAud

Ì Fnc.2 S.Lin Src.1 Y.1 O.Act Err.r Addr
C.Fnc Corr Fnc.2 Lim.1 Y.1 tArA PrtY
C.Act Src.2 Lim.2 Lim.1 HOLd dELY
See output 1
rnG.L Fnc.3 Lim.3 Lim.2 rES.L Unit

rnG.H Src.3 FAi.1 Lim.3 rES.H dP
FAi.1 di.Fn DISP
OuT.0 C.dEl
Out.1
O.Src
Adjustment:
w The configuratiuons can be adjusted by means of keys ÈÌ .

w Transition to the next configuration is by pressing key Ù .
w After the last configuration of a group, donE is displayed and followed by
automatic change to the next group
g Return to the beginning of a group by pressing the Ù key for 3 sec.
Digital 280-1 Configuration survey 23

Configuration level
5.2 Configuration
Dependent of instrument version and configuration, spare parameters are not dis-
played.
Func
name value range description default
Fnc.1 function 1 0
0 no function
1 tare - function
2 sample & hold
3 O2 - measuring
Fnc.2 function 2 0
0 indicator
1 controller
C.Fnc controller behavior (algorithm) 1
0 on/off controller e.g. signaller with one output
1 PID-controller (2-point and continuous)
C.Act operating principle of the controller 0
0 inverse, e.g. heating
1 direct, e.g. cooling
rnG.L -19999...99999 X0 (lower controlrange limit) 1 -100
rnG.H -19999...99999 X100 (upper controlrange limit) 1 1200
1 rnG.L and rnG.H indicate the control range to which self-tuning refers.
InP
S.tYP sensortype 1
0 thermocouple type L (-100...900°C), Fe-CuNi DIN
1 thermocouple type J (-100...1200°C), Fe-CuNi
2 thermocouple type K (-100...1350°C), NiCr-Ni
3 thermocouple type N (-100...1300°C), Nicrosil-Nisil
4 thermocouple type S (0...1760°C), PtRh-Pt10%
5 thermocouple type R (0...1760°C), PtRh-Pt13%
6 thermocouple type T (-200...400°C), Cu-CuNi
7 thermocouple type C (0...2315°C), W5%Re-W26%Re
8 thermocouple type D (0...2315°C), W3%Re-W25%Re
9 thermocouple type E (-100...1000°C), NiCr-CuNi
10 thermocouple type B (0/100...1820°C), PtRh-Pt6%
18 thermocouple Sonder (linearization necessary)
20 pt100 (-200.0 ... 100,0 °C)
21 pt100 (-200.0 ... 850,0 °C)
22 pt1000 (-200.0...8500.0 °C)
23 special 0...4500 Ohm (preset to KTY11-6)
24 special 0...450 Ohm (scaling necessary)
30 0...20mA / 4...20 mA (scaling necessary r page 36)
40 0...10V / 2...10 V (scaling necessary r page36)
Digital 280-1 Configuration 24

Configuration level

41 special (-2,5...115 mV scaling necessary r page36)
42 special (-25...1150 mV scaling necessary r page 36)
45 special (-5...5 V scaling necessary r page 36)
50 potentiometer 0...160 Ohm
S.Lin linearization only adjustable with S.tYP: 18, 23, 24, 30, 40 ... 45 0
0 none
1 Special linearization
Editing the linearization table with BlueControl (engineering tool) is
possible. The characteristic for KTY 11-6 temperature sensors is factory-set.
Corr measurement value correction / scaling 0
0 no correction
1 offset-correction (in CAL - level)
2 2-point-correction (in CAL - level)
3 scaling (in PArA - level)
fAI1 forcing INP (only visible with BlueControl!) 0
0 no forcing
1 forcing via interface
Lim
name value range
description default
Fnc.1 function of limit 1 (2, 3) 1
Fnc.2 0 switched off
1 measured value monitoring
Fnc.3 2 measured value monitoring + storing of alarm status.
A stored limit value can be set back via error list or digital input or
è -key (® LOGI/ Err.r).
3 signal change
4 signal change + storing of alarm status.
A stored limit value can be set back via error list or digital input or
è -key (® LOGI/ Err.r).
Src.1 source for limit value 1 (2, 3) 0
Src.2 0 process value = absolut alarm
1 control deviation Xw (processvalue - set-point) = relative alarm
Src.3
2 control deviation Xw (=relative alarm) with suppression at start
and with set-point change
3 measured value INP
6 set-point
7 y (controller output)
Hour OFF..999999 operating hours (only visible with BlueControl!) OFF
Swit OFF..999999 operation cycle number (only visible with BlueControl!) OFF
25 Configuration Digital 280-1

Configuration level
Out.1 und Out.2

O.Act circuit direction of output OUT1 0
0 direct / open circuit principle
1 inverse / closed circuit priciple
Y.1 controller output Y1 0
0 not active
1 active
Lim.1 message limit value 1/2/3
Lim.2 0 not active
Lim.3 1 active Out.1/2/3
FAi.1 message INP error 0
0 not active
1 active
fOut forcing OUT1 (2) (only visible with BlueControl!) 0
0 no forcing
Out.3
O.tYP signaltype OUT3 0
0 relay / logic
1 0 ... 20 mA continuous
2 4 ... 20 mA continuous
3 0...10V continuous
4 2...10V continuous
5 transmitter supply
O.Act circuit direction of output OUT3 (only visible with O.TYP=0 ) 1
0 direct / open circuit principle
1 inverse / closed circuit priciple
Y.1 controller output Y1 (only visible with O.TYP=0) 0
0 not active
1 active
Lim.1 message limit value 1 (only visible with O.TYP=0) 1
0 not active
1 active
Lim.2 message limit value 2/3 (only visible with O.TYP=0) 0
Lim.3 0 not active
1 active
FAi.1 message INP-error (only visible with O.TYP=0) 1
0 not active
1 active
Out.0 -19999... scaling of analog output for 0% (0/4mA e.g. 0/2V, only visible 0
99999 with O.TYP=1..5)
Out.1 -19999... scaling of analog output for 100% (20mA bzw. 10V, only 100
99999 visible with O.TYP=1..5)

Configuration level

O.Src signalsource for analog output OUT3 (only visible with O.TYP=1..5) 1
0 not active
1 controller output y1 (continuous)
3 process value
4 effective set-point Weff
5 control deviation xw (process value - set-point )
fOut forcing OUT3 (only visible with BlueControl!) 0
0 no forcing
LOGI
L_r local / remote swith-over (remote: adjustment of all values via 0
front is blocked)
0 no function (switch-over via interface is possible)
1 always active
2 di1 switches
3 di2 switches(only visible with OPTION)
4 di3 switches(only visible with OPTION)
5 è -key switches
Err.r reset of all stored messages of the errorlist 0
2 di1 switches
3 di2 switches (only visible with OPTION)
5 è -key switches
tArA 0
2 di1 switches
5 è -key switches
HoLd 0
2 di1 switches
5 è -key switches
rES.L 0
2 di1 switches
5 è -key switches

Configuration level

rES.H 0
2 di1 switches
5 è -key switches
di.Fn function of digital inputs (valid for all inputs) 0
0 direct
1 inverse
2 keyfunction (adjustable for 2-point-operation with interface and
di1/2/3 or front-key)
fDI1 forcing di1/di2/di3 (only visible with BlueControl!) 0
0 no forcing
fDI2
fDI3
othr
bAud baudrate of interface (only visible with OPTION) 2
0 2400 baud
1 4800 baud
2 9600 baud
3 19200 baud
Addr 1...247 adresse of Schnittstelle (only visible with OPTION) 1
PrtY parity of data on interface (only visible with OPTION) 1
0 no parity (2 stopbits)
1 even parity
2 odd parity
3 no parity with 1 stopbit
dELY 0...200 response delay [ms] (only visible with OPTION) 0
Unit unit 1
0 no unit
1 °C
2 °F
dP dezimalpoint (max. dezimalpoint ) 0
0 no decimalplace
1 1 decimalplace
2 2 decimalplaces
3 3 decimalplaces
4 4 decimalplaces
dIsp measuring value display 1
1 full display resolution
2 display resolution= 2 digits

Configuration level
name value range

description default
C.dEl 0..200modem delay [ms] 0
FrEq switch-over 50/60 Hz (only visible with BlueControl!) 0
0 netfrequency 50 Hz
1 netfrequency 60 Hz
IAdA blocked selfoptimization (only visible with BlueControl!) 0
0 free
1 blocked
IExo extended operation level blocked (only visible with BlueControl!) 0
0 free
1 blocked
ILat suppression error memory
0 free
1 blocked
Pass OFF...99999 password -19999 ...99999 OFF
IPar parameterlevel blocked (only visible with BlueControl!) 1
0 free
1 blocked
ICnf configurationlevel blocked (only visible with BlueControl!) 1
0 free
1 blocked
ICal calibrationlevel blocked (only visible with BlueControl!) 1
0 free
1 blocked
g Resetting the controller configuration to factory setting (Default)

r chapter 11.1 (page 47)
â
+ BlueControl - the engineering tool for the BluePort controller series
Three engineering tools with different functionality facilitating Dig 280-1 confi-
guration and parameter setting are available (see chapter 8 : Accessory equipment
with ordering information). In addition to configuration and parameter setting,
the engineering tools are used for data acquisition and offer long-term storage
and print functions. The engineering tools are connected to Dig 280-1 via the
front-panel interface "BluePortâ" by means of PC (Windows 95 / 98 / NT) and a
PC adaptor.
Description BlueControl: see chapter 8: BlueControl (page 40)

Configuration level
5.3 Configuration examples
5.3.1 On-Off controller / Signaller (inverse)
InL.1 SP.LO SP SP.Hi InH.1

InP.1Ê
100%
Out.1Â SH
0%
ConF / Cntr: SP.Fn = 0 set-point controller

C.Fnc = 0 signaller with one output
C.Act = 0 inverse action
(e.g. heating applications)
ConF / Out.1: O.Act = 0 action Out.1 direct
Y.1 = 1 control output Y1 active
PArA / Cntr: SH = 0...9999 switching difference (symmetrical
to the trigger point)
PArA / SEtP: SP.LO = -1999...9999 set-point limit low for Weff
SP.Hi = -1999...9999 set-point limit high for Weff
For direct signaller action, the controller action must be changed
(ConF / Cntr / C.Act = 1 )
process-value
SH
Set-point
Output
30 Configuration examples Digital 280-1

Configuration level
5.3.2 2-point controller (inverse)

InP.1Ê
100% PB1
Out.1Â
0%
ConF / Cntr: SP.Fn=0 set-point controller

C.Fnc = 1 2-point controller (PID)
ConF / Out.1: O.Act = 0 action Out.1 direct
Y.1 = 1 control output Y1 active
PArA / Cntr: Pb1 = 0,1...9999 proportional band 1 (heating)
in units of phys. quantity (e.g. °C)
ti1 = 1...9999 integral time 1 (heating) in sec.
td1 = 1...9999 derivative time 1 (heating) in sec.
t1 = 0,4...9999 min. cycle time 1 (heating)
g For direct action, the controller action must be changed

(ConF / Cntr / C.Act = 1 ).
Set-point
Process-value
Output
Digital 280-1 Configuration examples 31

Configuration level
5.3.3 Continuous controller (inverse)

InP.1Ê
20 mA PB1
Out.3Â
0/4 mA
ConF / Cntr: SP.Fn=0 set-point controller

C.Fnc = 1 continuous controller (PID)
ConF / Out.3: O.tYP = 1/2 Out.3 type ( 0/4 … 20mA )
Out.0 = -1999...9999 scaling analog output 0/4mA
Out.1 = -1999...9999 scaling analog output 20mA
PArA / Cntr: Pb1 = 0,1...9999 proportional band 1 (heating)
in units of phys. quantity (e.g. °C)
ti1 = 1...9999 integral time 1 (heating) in sec.
td1 = 1...9999 derivative time 1 (heating) in sec.
t1 = 0,4...9999 min. cycle time 1 (heating)
g For direct action of the continuous controller, the controller action must be
changed ( ConF / Cntr / C.Act = 1 ).
g To prevent control outputs Out.1 and Out.2 of the continuous controller from
switching simultaneously, the control function of outputs Out.1 and Out.2
must be switched off ( ConF / Out.1 and Out.2 / Y.1 and Y.2 = 0 ).
32 Configuration examples Digital 280-1

Configuration level
5.3.4 Digital 280-1 with measured value output
phys.
unit
Out.1
phys. unit mA / V
Out.0
0/4mA 20mA
0/2V 10V
Logic
7
U 8 OUT3
9
ConF / Out.3: O.tYP = 1 Out.3 0...20mA continuous

= 2 Out.3 4...20mA continuous
= 3 Out.3 0...10V continuous
Out.0 = -1999...9999 scaling Out.3
for 0/4mA or 0/2V
Out.1 = -1999...9999 scaling Out.3
for 20mA or 10V
O.Src=3 signal source for Out.3 is
the process value
Digital 280-1 Configuration examples 33

6 Parameter setting level

6.1 Parameter survey
Depending on unit version and configuration spare parameters are not shown.
PArA Parameter-Level
Func Functions
Lim Limits
InP Input
È End
tEmP InL L.1

Ì
Pb1 OuL H.1
ti1 InH HYS.1
td1 OuH dEL.1
t1 tF L2
SH b.F H.2
Y2 E.tc HYS.2
Y.Lo dEL.2
Y.Hi L.3H.3
Y0 HYS.3
SP.LO HYS.3
SP.Hi dEL.3
Adjustment:
w The parameters can be adjusted by means of keys ÈÌ

w Transition to the next parameter is by pressing key Ù
w After the last parameter of a group, donE is displayed, followed by
automatic change to the next group.
g Return to the beginning of a group is by pressing the Ù key for 3 sec.
If for 30 sec. no keypress is excecuted the controler returns to the process va-
lue and setpoint display ( Time Out = 30 sec. )
Digital 280-1 Parameter survey 34

6.2 Parameter
Func
tEmP 1...99999 1 probetemperature for O2 measuring 650
Pb1 1...99999 1 proportional band in phys. unit (z.B. °C) 100
ti1 1...99999 reset time 1 [s] (ti1=0 = off = switched off) 180
td1 1...99999 derivative time1 (heating) [s] (td1=0 = off = switched off) 180
t1 0,4...99999 min. cycle duration1 (heating) [s]. 10
The smallest pulse duration is 1/4 x t1
SH 0...9999 neutral zone, e.g. switching difference signalunit [phys. unit] 2
Y2 -120...120 2nd control value [%] becomes effective with recognized process 0
value error -FAIL
Y.Lo -120...120 lower controller value limit [%] 0
Y.Hi -120...120 upper controller value limit [%] 100
Y.0 -120...120 working point for controller value [%] 0
Sp.LO -99999...99999 lower set-point limit [phys. unit] 0
SP.Hi -99999...99999 upper set-point limit [phys. unit] 100
1 Valid for ConF/ othr/ DP = 0. At DP = 1/ 2/ 3/4 so 0,1 / 0,01 / 0,001, 0,0001.
InP
InL -19999...99999 input value of lower scaling point 0
OuL -19999...99999 display value of lower scaling point 0
InH -19999...99999 input value of upper scaling point 20
OuH -19999...99999 display value of upper scaling point 20
t.F 0,1...999,9 filtertime constant [s] 0,5
b.F 0...99999 filterbandwidth 5
E.tc 0...100 external temperaturecompensation OFF
Lim
L.1 -19999...99999 lower limit value 1 (L.1< -19999 = off) -10
H.1 -19999...99999 upper limit value 1 (H.1< -19999 = off) 10
HYS.1 0...99999 hysteresis of limit value 1 1
dEL.1 0...99999 alarm 1 delay 0
L.2 -19999...99999 lower limit value 2 (L.2< -19999 = off) OFF
H.2 -19999...99999 upper limit value 2 (H.2< -19999 = off) OFF
L.3 -19999...99999 lower limit value 3 (L.3< -19999 = off) OFF
H.3 -19999...99999 upper limit value 3 (H.3< -19999 = off) OFF
g Resetting the controller configuration to factory setting (Default)

r chapter 11.1 (page 47)
Digital 280-1 Parameter 35

6.3 Input scaling

When using current or voltage signals as input variables for InP.1 or InP.2,
scaling of input and display values at parameter setting level is required. Specifi-
cation of the input value for lower and higher scaling point is in the relevant elec-
trical unit (mA / V).
phys.
unit
OuH.x
mA / V phys. unit
OuL.x
InL.x InH.x mA/V
6.3.1 Input Inp
g Parameters InL.1 , OuL.1, InH.1 and OuH.1 are only visible if

ConF / InP.1 / Corr = 3 is chosen.
The parameters InL and InH determine the input range
Example mA:
InL= 4 and InH 0 20 means, the measurement is from 4 to 20 mA.
a For using the predetermined scaling with thermocouple and resistance
thermometer (Pt100), the settings for InL.1 and OuL.1 and for InH.1 and
OuH.1 must have the same value.
36 Input scaling Digital 280-1

Calibration level
7 Calibration level
g Measured value correction ( CAL) is only visible if ConF / InP.1 / Corr = 1

or 2 is chosen.
The measured value can be matched in the calibration menu ( CAL). Two me-
thods are available:
7.1 Offset correction

( ConF/ InP.1 / Corr =1 ): display standard-setting
Offset-correction
possible on-line at the process
OuLnew
OuLold
InL X
Display Standardeinstellung
2-point correction 2-Punkt-Korrektur
( ConF/ InP.1 / Corr = 2 ):
w is possible off-line with process

value simulator OuHalt
w online in 2 Schritten zunächst OuHneu
den einen Wert korrigieren und
später, z.B. nach dem Aufheizen
des Ofens, den zweiten Wert
korrigieren.
OuLneu
OuLalt
InL InH X
Digital 280-1 Offset correction 37

Calibration level
Offset correction ( ConF/ InP.1 / Corr =1 ):
Digital 280-1
OUT1
OUT2
OUT3
ADA
FUNC
ERR
rÙ r PArA
3 sec. Ì
r
ConF
Ì
r
CAL r Ù r InPr Ùr InL rÙ
È
InL
Ù
r È
ÌÙ
OuL
r End rÙ
InL.1: The input value of the scaling point is displayed.

Subsequently, the operator acknowledges the input value by pressing
key Ù.
OuL.1: The display value of the scaling point is displayed.
Before calibration, OuL.1 is equal to InL.1.
The operator can correct the display value by pressing keys ÈÌ .
38 Offset correction Digital 280-1

Calibration level
2-point correction ( ConF/ InP.1 / Corr =1 ):

Digital 280-1
OUT1
OUT2
r Ù r PArA
OUT3
ADA
FUNC
3 sec.
r
Ì
ERR
ConF
r
Ì
CAL r Ù r InP r Ù r InL r Ù
È
InL
Ù
È
OuL
Ì
rÙ
InH rÙ
È
InH
Ù
È
OuH
Ì
rÙ
r End r Ù
InL.1: The input value of the lower scaling point is displayed.

The operator must adjust the lower input value by means of a
OuL.1: The display value of the lower scaling point is displayed.
Before calibration, OuL.1 equals InL.1.
The operator can correct the lower display value by pressing the ÈÌ
keys. Subsequently, he confirms the display value by pressing key Ù.
InH.1: The input value of the upper scaling point is displayed. .
The operator must adjust the upper input value by means of the
OuH.1: The display value of the upper scaling point is displayed.
Before calibration OuH.1 equals InH.1.
Digital 280-1 Offset correction 39

BlueControl
8 BlueControl
BlueControl is the projection environment for the BluePort â controller series of
PMA. The following 3 versions with graded functionality are available:
Functionality Mini Basic Expert
parameter and configuration setting yes yes yes
controller and control loop simulation yes yes yes
download: writes an engineering to the controller yes yes yes
online mode/ visualisation SIM only yes yes
creation of user defined linearizations yes yes yes
configuration of extended operating level yes yes yes
upload: reads an engineering from the controller SIM only yes yes
diagnosis function no no yes
file, save engineering data no yes yes
printer function no yes yes
online documentation, help system no yes yes
measurement correction (calibration procedure) no yes yes
program editor no no yes
data acquisition and trend function SIM only yes yes
network and multiuser licence no no yes
personal assistant function yes yes yes
extended simulation no no yes
extended diagnose and service no no yes
The mini version is - free of charge - at your disposal as download at PMA home-
page www.pma-online.de or on the PMA-CD (please ask for).
At the end of
the installati-
on the licence
number has to
be stated or
DEMO mode
must be cho-
sen. At
DEMO mode
the licence
number can
be stated sub-
sequently un-
der Help r
Licence r
Change.
40 Digital 280-1
Versions
9 Versions
Digital 280-1 D 2 8 0 1 00 00
Connection via screw-terminal 1

90..250V AC 0
24VAC / 18..30VDC 1
90..250V AC, 2 relay+ mA/V/logic 2
24VAC / 18..30VDC, 2 relay+ mA/V/logic 3
No option 0
Modbus RTU + transmitter supply
1
Digital inputs di2, di3 (optocoupler)
Standard configuration 0
Configuration to specification 9
no operation manual 0
operation manual german D
operation manual english E
operation manual french F
Standard (CE - certified 0
UL-certified U
Accessories delivered with the unit

Operating manual (if selected by the ordering code)
w 2 fixing clamps
Accessory equipment with ordering information

Description Order no.
Heating current transformer 50A AC 9404-407-50001
PC-adaptor for the front-panel interface 9407-998-00001
Standard rail adaptor 9407-998-00061
Operating manual German 9499-040-62718
Operating manual English 9499-040-62711
Operating manual French 9499-040-62732
Interface description Modbus RTU German 9499-040-63518
Interface description Modbus RTU English 9499-040-63511
BlueControl (engineering tool) Mini Download www.pma-online.de
BlueControl (engineering tool) Basic 9407-999-11001
BlueControl (engineering tool) Expert 9407-999-11011
Digital 280-1 41
Technical data
10 Technical data
Switched voltage: 2,5 V
INPUTS Current: 50 mA
PROCESS VALUE INPUT INP1 CONTROL INPUTS DI2, DI3 (OPTION)

Configurable as switch or push-button!
Resolution: > 15 bits
Optocoupler input for active triggering
Decimal point: 0 to 4 digits behind the decimal
point Nominal voltage 24 V DC external
Limiting frequency: 2 Hz (analog) Current sink (IEC 1131 type 1)
Dig. input filter: adjustable 0,1...100 s Logic “0” -3...5 V
Scanning cycle: 100 ms Logic “1” 15...30 V
Measured value 2-point or offfset correction Current requirement approx.. 5 mA
correction: Transmitter supply UT (Option)
Thermocouple ® Table 1 Power: 22 mA / ‡ 18 V
Input resistance: ‡ 1 MW
Source resistance effect: 1 mV/W If the universal output OUT3 is used there may
be no external galvanic connection between
Temperature compensation
Internal temperature compensation measuring and output circuits!
Maximum additional error ± 0,5 K
FILTER
External temperature compensation A first order mathematic filter which is adjustable for time
between 0 and 100 °C or adjustable 32 und 212 °F constant and bandwidth is built in.
The bandwidth is the adjustable tolerance around the process
Break monitoring value within which the filter is active. Measured value changes
Sensor current: £ 1 mA exceeding the adjusted bandwidth are output directly.
Resistance thermometer ® Table 2 OUTPUTS

Connection technique: 3-wire Survey of outputs
Lead resistance: max. 30 Ohm Output Used as
Input circuit monitoring: break and short circuit
OUT1 (relay)
Resistance measuring range OUT2 (relay) Limit contacts, alarms, control output
The BlueControl software can be used for adaptation of the OUT3 (logic)
characteristic stored for temperature sensor KTY 11-6.
OUT3 (continuous) Control output, process value, set-point,
Physical measuring range: 0...450 Ohm
0...4500 Ohm
control deviation,
Number of linearization segments 15 13V/22mA transmitter power supply
Current and voltage measuring ranges * All logic signals can be combined in an OR function!
® Table 3
RELAY OUTPUTS OUT1, OUT2
Span start, span end: anywhere within the measuring
range Contact type: 2 NO contacts with common
Scaling: selectable -19999...99999 connection
Linearization: 15 segments, adaptable via Max. contact rating: 500 VA, 250 V, 2A at 48...62 Hz,
BlueControl resistive load
Decimal point: adjustable Min. contact rating: 6V, 1 mA DC
Input circuit monitoring: with 4..20mA and 2..10V: Operating life (electr.): 800.000 duty cycles with max.
12,5% below span start (2mA, rating
1V) Note:
If the relays OUT1...OUT3 operate external contactors, these
CONTROL INPUT DI1 must be fitted with RC snubber circuits to manufacturer
Configurable as switch or push-button! specifications to prevent excessive switch-off voltage peaks..
Connection of a potential-free contact suitable
for switching “dry” circuits.
42 Digital 280-1
Technical data
OUT3 AS UNIVERSAL OUTPUT w Measured value change

Galvanically isolated from the inputs. w Measured value change and storage
Freely scalable Several limit values and alarms can be combined by a logic OR
Resolution: 11 Bit function and output e.g. as a common alarm.
Timeconstant of DA-transducer T90 50 ms
Limitfrequency of the whole continuous ALARM + MAINTENANCE MANAGER
controller > 2 Hz
Displayof error messages, warnings and stored limit signallings
Current output in the error list.
Messages are stored and can be reset manually.
0/4...20 mA configurable.
Signal range: 0...ca.21,5 mA
Max. load: £ 500 W Possible elements of the error list:
Load effect: 0,02 % / 100 W w Sensor break, short circuit, polarity error
Resolution: £ 22 mA (0,1%) w Self-tuning error
Accuracy £ 40 mA (0,2%) w Stored limit values
- E.g. recalibration warning
Voltage output (short-circuit proof)
(when exceeding an adjustable number of
0/2...10V configurable operating hours, a message is displayed)
Signal range: 0...ca.11 V - E.g. maintenance interval of switching element
Min. load: ³ 2 kW (when exceeding an adjustable number of
Load effect: kein Einfluß switching cycles, a message is displayed)
Resolution: £ 11 mV (0,1%) w Internal errors (RAM, EEPROM, ...)
Accuracy £ 20 mV (0,2%)
OUT3 used as transmitter supply DISPLAY
Output power: 22 mA / ³ 13 V Display
5-digit 19 mm LED
OUT3 used as logic output
Load £ 500 W 0/£ 20 mA POWER SUPPLY
Load > 500 W 0/> 13 V Dependent of order:
FUNCTIONS AC SUPPLY
Control behaviour Voltage: 90...250 V AC
w Signaller with adjustable siwtching Frequency: 48...62 Hz
difference (ON/OFF controller) Power consumption approx. 7.3 VA
w PID controller (2-point and continuous) UNIVERSAL SUPPLY 24 V UC
Control parameters self-adjusting or manually adjustable via
front panel keys or BlueControl software. AC voltage: 20,4...26,4 V AC
Limit value functions DC voltage: 18...31 V DC
Monitoring is provided for: exceeded max., min. or max. and Power consumption: approx.. 7.3 VA
min. limit value with adjustable hysteresis.
The following signals can be monitored:
BEHAVIOUR WITH POWER FAILURE
Configuration, parameters and adjusted
w Measured value set-points, control mode:
w Process value Non-volatile storage in EEPROM
w Control deviation
w Control deviation with suppression after BLUEPORT FRONT INTERFACE
start-up or set-point changes Connection of PC via PC adapter (see "Accessory equipment").
w Set-point The BlueControl software is used to configure, set parameters
w Correcting variable Y and operate the KS4x-1.
Functions BUS INTERFACE (OPTION)

w Measured value monitoring
Galvanically isolated
w Measured value monitoring with storage. Physical: RS 422/485
Reset via front panel keys or digital input
Digital 280-1 43
Technical data
Protocol: Modbus RTU Electrical connections

Transmission speed: 2400, 4800, 9600, 19.200 bits/sec
Address range: 1...247 Screw terminals for 0,5 to 2,5 mm²
Number of controllers per bus: 32 Mounting
Repeaters must be used to connect a higher number of Panel mounting with two fixing clamps at
controllers.
top/bottom or right/left,
ENVIRONMENTAL CONDITIONS High-density mounting possible
Protection modes Mounting position: uncritical
Weight: 0,27kg
Front panel: IP 65
Housing: IP 20 Accessories delivered with the unit
Terminals: IP 00 Operating manual
Permissible temperatures Fixing clamps
For specified accuracy: 0...60°C
Warm-up time: ³ 15 minutes
For operation: -20...65°C
For storage: -40...70°C
Humidity
75% yearly average, no condensation
Shock and vibration
Vibration test Fc (DIN 68-2-6)
Unit in operation: 1g or 0,075 mm
Unit not in operation: 2g or 0,15 mm
Shock test Ea (DIN IEC 68-2-27)
Shock: 15g
Duration: 11ms
Complies with EN 61 326-1
(for continuous, non-attended operation)
ALLGEMEINES
Housing
Material: Makrolon 9415 flame-retardant
Flammability class: UL 94 VO, self-extinguishing
Plug-in module, inserted from the front
Safety test
Complies with EN 61010-1 (VDE 0411-1):
Overvoltage category II
Contamination class 2
Working voltage range 300 V
Protection class II
cUL certification
(Type 1, indoor use)
File: E 208286
Digital 280-1 44
Technical data
Tabelle 1 thermocouple measuring range

thermocouple type measuring range accuracy resolution (Æ)
L Fe-CuNi (DIN) -100...900°C -148...1652°F £2K 0,05 K
J Fe-CuNi -100...1200°C -148...2192°F £2K 0,05 K
K NiCr-Ni -100...1350°C -148...2462°F £2K 0,1 K
N Nicrosil/Nisil -100...1300°C -148...2372°F £2K 0,1 K
S PtRh-Pt 10% 0...1760°C 32...3200°F £2K 0,1 K
R PtRh-Pt 13% 0...1760°C 32...3200°F £2K 0,1 K
T Cu-CuNi -200...400°C -328...752°F £2K 0,025 K
C W5%Re-W26%Re 0...2315°C 32...4199°F £2K 0,2 K
D W3%Re-W25%Re 0...2315°C 32...4199°F £2K 0,2 K
E NiCr-CuNi -100...1000°C -148...1832°F £2K 0,05 K
B(1) PtRh-Pt6% 0(100)...1820°C 32(212)...3308°F £3K 0,15 K
special -25....75 mV £ 0,1 % 0,005 %
(1)
Values for type B are valid from 100°C.
Table 2 Resistance transducer measuring ranges

Type Meas.curr. Measuring range Accuracy Resolution (Æ)
Pt100 -200...850°C -328...1562°F £1K
0,05 K
Pt1000 -200...850°C -328...1562°F £2K
Special* 0...4500 [**
Special 0,2 mA 0...450 [**
Pot. 0...160 [** £ 0,1 % 0,005 %
Pot. 0...450 [**
Pot. 0...1600 [**
* Characteristic KTY 11-6 (-50...150°C) is factory-set.
** inclusive of lead resistance
Table 3 Current and voltage measuring ranges

Measuring range Input resistance Accuracy Resolution (Æ)
0...20 mA 49 W (voltage requirement
£ 0,1 % 0,75 mA
£ 2,5 V)
0...10 Volt » 110 kW £ 0,1 % 0,4 mV
-2,5...115 mV* ? 1M[ £ 0,1 % 4 µV
-25...1150 mV* ? 1M[ £ 0,1 % 40 µV
-25...90 mV* ? 1M[ £ 0,1 % 4µV
-500...500 mV* ? 1M[ £ 0,1 % 40 µV
-5...5Volt » 110 kW £ 0,1 % 0,4 mV
* high-impedance voltage ranges without break monitoring
Digital 280-1 45
Safety hints
11 Safety hints
This unit was built and tested in compliance with VDE 0411-1 / EN 61010-1 and
was delivered in safe condition.
The unit complies with European guideline 89/336/EWG (EMC) and is provided
with CE marking.
The unit was tested before delivery and has passed the tests required by the test
schedule. To maintain this condition and to ensure safe operation, the user must
follow the hints and warnings given in this operating manual.
The unit is intended exclusively for use as a measurement and control instrument
in technical installations.
a Warning
If the unit is damaged to an extent that safe operation seems impossible, the unit
must not be taken into operation.
The electrical wiring must conform to local standards (e.g. VDE 0100). The input
measurement and control leads must be kept separate from signal and power
supply leads.
In the installation of the controller a switch or a circuit-breaker must be used and
signified. The switch or circuit-breaker must be installed near by the controller
and the user must have easy access to the controller.
COMMISSIONING
Before instrument switch-on, check that the following information is taken into
account:
w Ensure that the supply voltage corresponds to the specifications on the type
label.
w All covers required for contact protection must be fitted.
w If the controller is connected with other units in the same signal loop, check
that the equipment in the output circuit is not affected before switch-on. If
w The unit may be operated only in installed condition.
w Before and during operation, the temperature restrictions specified for
controller operation must be met.
SHUT-DOWN
For taking the unit out of operation, disconnect it from all voltage sources and
protect it against accidental operation.
If the controller is connected with other equipment in the same signal loop, check
that other equipment in the output circuit is not affected before switch-off. If ne-
cessary, suitable protective measures must be taken.
46 Digital 280-1
Safety hints
MAINTENANCE, REPAIR AND MODIFICATION

The units do not need particular maintenance.
a Warning
When opening the units, or when removing covers or components, live parts and
terminals may be exposed.
Before starting this work, the unit must be disconnected completely.
After completing this work, re-shut the unit and re-fit all covers and components.
Check if specifications on the type label must be changed and correct them, if ne-
cessary.
l Caution
When opening the units, components which are sensitive to electrostatic dischar-
ge (ESD) can be exposed. The following work may be done only at workstations
with suitable ESD protection.
Modification, maintenance and repair work may be done only by trained and aut-
horized personnel. For this purpose, the PMA service should be contacted.
a The cleaning of the front of the controller should be done with a dry or a wetted
(spirit, water) kerchief.
11.1 Resetting to factory setting
In case of faulty configuration, Digital 280-1 Digital 280-1

can be reset to the default condition. OUT1
OUT2
OUT3
ADA
FUNC
For this, keep the following two keys pressed ERR
during power-on :
È Ì
The digital indicator reset to default is signalled by displaying rEsEt shortly

in the display. Subsequently, the digital indicator returns to normal operation.
Digital 280-1 Resetting to factory setting 47

Index Input scaling . . . . . . . . . . . . . . 36
0-9 L
2-point correction. . . . . . . . . . . . 37 LED
A Ada - LED . . . . . . . . . . . . 10
Alarm handling . . . . . . . . . . . . . 15 Err - LED . . . . . . . . . . . . 10
ì - LED . . . . . . . . . . . . . 10
Anschlußbeispiele
SP.x - LED. . . . . . . . . . . . 10
OUT3 als Logikausgang . . . . . 8
M
B
Maintenance manager . . . . . . . . . 16
BlueControl. . . . . . . . . . . . . . . 40
measured value output . . . . . . . . . 33
Bus interface
Technical Data. . . . . . . . . . 43 Mounting. . . . . . . . . . . . . . . . . 5
C O
Calibration (CAL) . . . . . . . . . . . 37 Offset correction. . . . . . . . . . 37 - 39
Calibration level (CAL) . . . . . . 37 - 39 operating structure . . . . . . . . . . . 22
Configuration examples Output OUT1
2-point controller . . . . . . . . 31 Configuration . . . . . . . . . . 26
Signaller . . . . . . . . . . . . . 30 Technical data . . . . . . . . . . 42
Configuration level Output OUT2
Parameter survey . . . . . . . . 23 Configuration . . . . . . . . . . 26
Technical data . . . . . . . . . . 42
Configuration-level (ConF)
Configuration-Parameter . . 24 - 29 Output OUT3
Configuration . . . . . . . . . . 26
Connecting diagram . . . . . . . . . . . 6
Connecting examples P
di2/3, 2-wire transmitter supply . 7 Parameter setting level
OUT3 transmitter supply . . . . . 7 Parameter survey . . . . . . . . 34
RS485 interface . . . . . . . . . . 8 Parameter-Level (PArA)
continuous controller . . . . . . . . . . 32 Parameter . . . . . . . . . . . . 35
control inputs di1, di2, di3 R
Configuration . . . . . . . . . . 27 Resetting to factory setting . . . . . . . 47
D S
Digital inputs di1, di2, di3 Safety hints . . . . . . . . . . . . 46 - 47
Technical data . . . . . . . . . . 42 Safety switch. . . . . . . . . . . . . . . 5
E Safety test. . . . . . . . . . . . . . . . 44
Equipment . . . . . . . . . . . . . . . 41 Selbstoptimierung
F Start . . . . . . . . . . . . . . . 18
Factory setting . . . . . . . . . . . . . 22 Self-tuning
Front view . . . . . . . . . . . . . . . 10 Cancelation . . . . . . . . . . . 18
Start . . . . . . . . . . . . . . . 18
Frontansicht . . . . . . . . . . . . . . 10
V
I
Versions . . . . . . . . . . . . . . . . 41
Input INP1
configuration. . . . . . . . . . . 24
Parameter setting . . . . . . . . 35
Digital 280-1 48
A5 auf A6 gefaltet 2-fach geheftet, SW-Druck, Normalpapier 70g weiß
Subject to alterations without notice © PMA Prozeß- und Maschinen-Automation GmbH A6

Änderungen vorbehalten P.O.B. 310 229, D-34058 Kassel, Germany
Sous réserve de toutes modifications Printed in Germany 9499-040-67311 (08/2013)
Die technische Auswahl und zeichnerische Anordnung der Komponenten
ist nicht geprüft. Alle Maßangaben sind ca. Angaben.
The technical selection and graphical arrangement of the components
has not been tested. All dimensions are appr.
26.04.17 Gräser -weishaupt-

Max Weishaupt GmbH
88475 Schwendi
WM-GL30/2-A ZM-R R2
Pfeiffer AB210965471
Turbaco
JUMO safetyM STB/STW
Safety temperature limiter,
safety temperature monitor
according to DIN EN 14597
Operating Manual
(translation of the German
original manual)
70115000T90Z004K000
V1.01/EN /00564764
Operating overview
Operating overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Safety temperature monitor (STW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.2 Safety temperature limiter (STB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3 Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2 Identifying the device version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Changing of the factory set switching behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.3 Device software versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.4 Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.5 Service addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.2 Installation location, DIN rail installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.3 Close mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.5 Electrical isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.6 Use of the setup interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1 Installation notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5 Commissioning the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Inhalt
Inhalt
5.1 Display and operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.2 Setting the display after switch-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.3 Selecting and editing parameters (plausibility inquiry for input values) . . . . . . . . . . . . . . . . . . . . . . . . .31
5.4 Aborting edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5.5 Alarm acknowledgement using the Reset key (only for temperature limiters STB) . . . . . . . . . . . . . . . .32
5.6 Alarm acknowledgement via binary input (only for temperature limiters STB). . . . . . . . . . . . . . . . . . . .32
5.7 Lead sealing the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
6 Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
6.2 Safety temperature monitor (STW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
6.2.1 Safe operating status STW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
6.3 Safety temperature limiter (STB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
6.3.1 Safe operating status STB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
6.4 Relevant standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
6.5 Validity of the Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
6.6 Connection possibilities of the sensors (SIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
6.6.1 Achievable SIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
6.7 Standards and definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6.7.1 Terms and abbreviations acc. to DIN EN 14597 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6.7.2 Terms and abbreviations acc. to DIN EN 61 508 and DIN EN 61 511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.8 Safety instrumented parameters related to the temperature monitoring unit . . . . . . . . . . . . . . . . . . . .43
6.8.1 Failure rates and SFF for 701150...23 (AC 230 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6.8.2 Failure rates and SFF for 701150...25 (AC/DC 24 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.9 Determining the Safety Integrity Level (SIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.9.1 Safety integrity of the hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.9.2 Safety-relevant system properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.10 Determining the achieved Performance Level PL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
6.10.1 Terms and abbreviations acc. to DIN EN ISO 13849 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
6.11 Connection possibilities of the sensors (PL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
6.11.1 Calculations DIN EN ISO 13849-1 Performance Level - low voltage 230 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
6.11.2 Calculations DIN EN ISO 13849-1 Performance Level - extra low voltage (ELV) 24 V . . . . . . . . . . . . . . . . . . . . . . . . .55
6.11.3 Contribution to risk minimization through the control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
6.12 Evaluating the achieved Performance Level PL and the relationship to the SIL . . . . . . . . . . . . . . . . . .58
6.13 Other applicable device documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
6.14 Behavior during operation and in case of malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
6.15 Regular tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
6.15.1 Recommended tests for temperature probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
7 Configuration level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.1 Navigation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
7.2 Analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
7.2.1 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
7.2.2 Sensor type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
7.2.3 Offset 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
7.2.4 Lead wire resistance 1 (resistivity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
7.2.5 Filter time 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
7.2.6 Scaling start 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
7.2.7 Scaling end 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
7.2.8 Sensor type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Inhalt
Inhalt
7.2.9 Offset 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
7.2.10 Lead wire resistance 2 (resistivity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
7.2.11 Filter time 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7.2.12 Scaling start 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7.2.13 Scaling end 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7.3 Limiter/monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
7.3.1 Device function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
7.3.2 Switching behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
7.3.3 Limit value, hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
7.3.4 Pre-alarm function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
7.3.5 Pre-alarm, hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
7.3.6 Error Pre-alarm, Relay pre-alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
7.3.7 Limit value difference, hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
7.3.8 Setting range min. (formerly ALHI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
7.3.9 Setting range max. (formerly ALLO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
7.4 Binary input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
7.4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
7.5 Analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
7.5.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
7.5.2 Signal type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
7.5.3 Scaling start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
7.5.4 Scaling end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
7.5.5 Error cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
7.5.6 Error signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
7.5.7 Behavior when leaving the scaling range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
7.6 Display/operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
7.6.1 Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
7.6.2 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
7.6.3 Decimal place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
7.6.4 Normal display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
7.6.5 Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
7.6.6 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
7.6.7 Time-out light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
7.6.8 Time-out operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
7.6.9 Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
7.7 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
7.7.1 Limit switching cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
7.7.2 Current switching cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
7.7.3 Operating hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.1 Analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
8.2 Analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
8.3 Binary input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
8.4 Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
8.5 Measuring circuit monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
8.6 Voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
8.7 Test voltages according to EN 60730, part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8.8 Electrical safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8.9 Environmental influences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Inhalt
Inhalt
8.10 Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
8.11 Approvals/approval marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
8.12 Probes for the operating medium air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
8.13 Probes for the operating medium water and oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
8.14 Probes for the operating medium water, oil and air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
9 Setup program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.1 Minimum hardware and software prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
9.2 Displaying the device software version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
9.3 Forgotten the code? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
9.4 Special function: thermocouple reverse polarity protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
10 Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
11 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
12 What to do, if ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
13 Information for devices with extra code 062 GL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
13.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
13.2 Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
13.3 Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
14 Output behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
15 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
15.1 China RoHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
V1.01/EN 1 Brief description 10
1 Brief description
The safety temperature limiter (STB) and the safety temperature monitor (STW) are used to reliably detect and avert hazards
that could cause injuries, are harmful to the environment or cause destruction of production plants and produced goods, at an
early stage.
Its primary task is to reliably monitor thermal processes and switch the systems to an operationally safe status in the event of
malfunctions.
The measured value at the analog input can be recorded by various probes or standard signals.
The limit value overrange is indicated by the installed LEDs K1 and K2 (red) for each channel, and the installed relay "Alarm"
switches the system to an operationally safe status (alarm range).
The high standards of DIN EN 61 508 and DIN EN ISO 13849 are met by a device design, the 1oo2D structure of which ensures
reliable detection of errors and, thus, can also be used for applications according to the new Machinery Directive 2006/42/EC.
1.1 Safety temperature monitor (STW)

The STW is a safety component according to Machinery Directive, which, when activated, resets automatically if the probe
temperature has gone below / exceeded the limit value by an amount equal to the hysteresis. Possible settings: monitoring for
limit value overrange or underrange.
v Chapter 7.3.2 "Switching behavior"
1.2 Safety temperature limiter (STB)

The STB is a safety component according to Machinery Directive that is permanently locked after response. Manual reset using
the (RESET) key is only possible once the probe temperature has gone below / exceeded the limit value by an amount
equal to the hysteresis. Possible settings: monitoring for limit value overrange or underrange.
v Chapter 7.3.2 "Switching behavior"
The transparent cover can be lead sealed to prevent unauthorized operation.
However, the (RESET) key remains accessible.
1.3 Safety information
Symbol Meaning Explanation
H Note This symbol is used to draw your attention to important information.
A Caution This symbol is used when there is a risk of damage to equipment or data if the instructions are ig-
nored or not followed correctly.
Danger This symbol is used when there is a risk of injury to persons if the instructions are ignored or not
V followed correctly.
Read This text contains important information and must always be read before work is continued. Han-
dling the device in any way that is not described in the Operating Manual or that is expressly forbid-
den will jeopardize your warranty rights.
v Reference This symbol refers to further information in other manuals, chapters or sections.
abc1 Footnote Footnotes are remarks referring to specific points in the text marked with a superscript number.
* Instructions
for action
This symbol indicates that an action to be performed is described. The individual steps are marked
by an asterisk.
1.4 Safety
In the sense of "Network and system security" according the series of standards IEC 62443 no steps inside the device have
been taken .
This means, that only the aspects of "safety" are determined in the series of JUMO STB/STW.
V1.01/EN 1 Brief description 11

V1.01/EN 2 Identifying the device version 12
2 Identifying the device version

The type plate is affixed to the side of the device.
Switching behavior
Voltage supply AC 110 to 240 V: Voltage supply AC/DC20 to 30 V:
A The voltage supply must correspond to the voltage given on the type plate!
2.1 Changing of the factory set switching behavior
If the safety function according to EN 14597 is changed to Max-Alarm then that change should be corrected on the nameplate.
Example:
This change can be noted directly underneath the nameplate using a waterproof marker.

Basic type
701150 Safety temperature limiters (STB) / monitors (STW) according to DIN EN 14597
Version
8 Factory setting
9 Configured according to customer specifications
Language
01 German (factory setting)
02 English
03 French
Switching behavior
0251 Safety temperature monitor max. alarm (inverse, N/C contact)
0252 Safety temperature monitor min. alarm (direct, N/O contact)
0253 Safety temperature limiter max. alarm (inverse, N/C contact)
0254 Safety temperature limiter min. alarm (direct, N/O contact)
Measuring input1 (programmable)

1003 1x Pt100 in 2-wire circuit
2001 2x Pt100 in 3-wire circuit (ex-factory)
2036 2x W5Re-W26Re „C“
2037 2x W3Re-W25Re "D"
2039 2x Cu-CuNi "T"
2040 2x Fe-CuNi "J"
2041 2x Cu-CuNi "U"
2042 2x Fe-CuNi "L"
2043 2x NiCr-Ni "K"
2044 2x Pt10Rh-Pt "S"
2045 2x Pt13Rh-Pt "R"
2046 2x Pt30Rh-Pt6Rh "B"
2048 2x NiCrSi-NiSi "N"
1053 1x 4 to 20 mA
2053 2x 4 to 20 mA
Voltage supply
23 AC 110 to 240 V +10 % /-15 %, 48 to 63 Hz
25 20 to 30 V AC/DC, 48 to 63 Hz
Analog output (configurable)

001 0 to 20 mA
005 4 to 20 mA (ex-factory)
040 0 to 10 V
070 2 to 10 V
Extra code
058 SIL and PL approval
062 GL approval
701150 / 8- 01 - 0253 - 2001 - 23 / 005 , 062

1. The first number on the measuring input means single probe "1“ or double probe "2“
2.2 Scope of delivery

- JUMO safetyM STB/STW in the version ordered
- Operating Manual

2.3 Device software versions

Diagnosis module version: 257.02.01
Analog channel 1 version: 258.02.01
Analog channel 2 version: 258.02.01
2.4 Serial number

The serial number is indicated on the device.
h Press the + keys
Construction:
The first 8 digits specify the serial number: 0193 9251
Digit 9 and 10 the production plant in Fulda: 01
Digit 11 (second line) the hardware version: 0
Digit 12 and 13 the year: 2014
Digit 14 and 15 the calendar week: 16
Digit 16 to 19 consecutive numbers: 0045
2.5 Service addresses

v see last page
This operating manual is a translation of the German original manual.
It is valid for the following hardware and software versions:
Diagnosis module from version: 257.02.01
Analog channel 1 from version: 258.02.01
Analog channel 2 from version: 258.02.01
and replaces the following old software versions:

Diagnosis module from version: 257.01.XX
Analog channel 1 from version: 258.01.XX
Analog channel 2 from version: 258.01.XX
h Press the + keys
Keep the operating manual in a place accessible to all users at all times.
A All necessary settings are described in this Operating Manual.

Handling the device in any way that is not described in the Operating Manual or that is expressly forbidden will
jeopardize your warranty rights and may disable the safety function.
It is forbidden to access the inside of the device!
Repairs may only be performed by JUMO at the head office in Fulda.
Please contact the nearest subsidiary or the head office should you encounter any problems.

V1.01/EN 3 Installation 18
3 Installation
3.1 Dimensions
104.8 45
85
89.4
3.2 Installation location, DIN rail installation
V The device is hooked into a 35 mm DIN rail (EN 60715) from the front and
The device is not suitable for use in potentially explosive atmospheres.
pushed down to engage.
v The ambient conditions at the installation site must meet the requirements
specified in the technical data.
Chapter 8 "Technical data"
a As far as possible, the installation site should be vibration-free to prevent the screw-connections from working loose.
a The installation site should be free from aggressive media, e.g. acids and lyes, and, if possible, free from dust, flour or
other suspended matter in order to prevent the cooling slots from becoming clogged.
3.3 Close mounting
a Observe a minimum spacing of 20 mm from the top and bottom.

1. To allow the release slot to be accessed with a screwdriver from below.
2. To allow the device to be swiveled up and unhooked from the DIN rail for removal.
a Several devices may be mounted side by side without a gap.
3.4 Dismantling
h Insert a screwdriver into the release lug from below and lift up (1).
h Simultaneously swivel the screwdriver and case up out of the DIN rail (2).
3.5 Electrical isolation
(1) Analog inputs (2) Relay output "Alarm"
(3) Binary input
(5) Setup interface

(4) Relay output "Pre-alarm"
(6) Display
(7) Analog output
(8) Power supply
3.6 Use of the setup interface

- The setup interface USB is only designed for service use for a limited period, e.g. for transmitting setup data and during
commissioning.
- It is not suitable for operation in a fixed installation for an unlimited period as the monitoring function is switched off during
data transmission with the setup program.
V1.01/EN 4 Electrical connection 22
4.1 Installation notes
a Check that the safety temperature limiter is correctly installed for its application (temperature measurement) and is oper-
ated within the admissible system parameters.
a The device is designed for installation in switch cabinets, machines/plants or systems.
Ensure that the customer's fuse rating does not exceed 20 A.
a Isolate the device at all poles prior to starting service or repair work.
a All incoming and outgoing lines without a connection to the power supply network must be laid with shielded and
twisted lines. Connect the screen on the device side to ground.
a Do not run input and output lines close to current-carrying components or cables.
a Do not connect any additional consumers to the screw terminals for the device power supply.
a The choice of cable, the installation and the electrical connection of the device must conform to the requirements of VDE
0100 "Regulations on the Installation of Power Circuits with Nominal Voltages below 1000 V" or the appropriate local
regulations.
a Protect the relay circuit by suitable measures.
The maximum contact rating is 230 V/3 A (ohmic load).
a The electromagnetic compatibility conforms to the standards and regulations cited in the technical data.
v Chapter 8 "Technical data"
a During commissioning we recommend carrying out a trial run of the system until temperature switch-off at the set limit.
Only allow qualified electricians to carry out the electrical connection and the configuration settings until commis-
V sioning.
A
The approval according to DIN EN 14597 is only valid when the correct probe with DIN approval is set in the config-
uration level and also connected.
The limit value to be monitored must be within the admissible temperature range of the DIN probe.
v Chapter 8.12 "Probes for the operating medium air"
v Chapter 8.13 "Probes for the operating medium water and oil"
The monitoring function is deactivated during data transmission using the setup program.
v Chapter 12 "What to do, if ..."

4.2 Connection diagram
Connection is carried out via screw terminals. Lead Admissible cross sec-
tion
1 wire 2.5 mm2
fine-strand, 1.5 mm2
with core-end ferrule
Legend Remark Screw terminals Screw terminals
1, 2 Analog input1 (E1) Analog input2 (E2)
Thermocouple/ + – + –
double thermocouple
2 3 7 8
When connecting double thermocouples the measuring circuits (E1) and (E2) have to be installed so that
V they are electrically insulated. That means that both thermocouples do not have an electrical connection
to the protection fitting or each other. (insulated installation).
RTD temperature probe Pt100/Pt1000 in

J J
2-wire circuit
1 3 6 8
A Enter the lead resistance for RTD temperature probes in two-wire circuit when using greater line
lengths.
v Setup program: edit => analog inputs
RTD temperature probe Pt100/Pt1000

J J
in three-wire circuit
1 2 3 6 7 8


RTD temperature probe Pt100 in
V
two-wire circuit, individual probe for both analog J
inputs
1 3 6 8
Caution:
When only one probe (SIL2) is connected, the temperature limitation device
is reduced from SIL3 to SIL2. However, the internal 2-channel structure (1oo2D) in the device is still retained.
Both channels measure the same probe due to the simplified external circuit.
4 to 20 mA + – + –
Ix Ix
2 3 7 8
4 to 20 mA for both analog inputs + –
V 2
Ix
7
Caution:
When only one probe (SIL2) is connected, the temperature limitation device
is reduced from SIL3 to SIL2. However, the internal 2-channel structure (1oo2D) in the device is still retained.
Both channels measure the same current signal due to the simplified external circuit.
4 Binary input
Connection to a potential-free contact
Ground 4 5
5 Analog output: –
+
0 to 20 mA Ix,Ux
4 to 20 mA (ex-factory)
0(2) to 10V 9 10
Caution
V The analog output is not part of the safety func-

tion!
9 Voltage supply AC: DC:
according to rating plate L1 Line conductor N L1 (L+) L- L+
N Neutral (L-)
N L1 L- L+
10 Relay output "Alarm" (current-free state)
Relay (changeover contact element) with fuse cut-
out
Internal
circuitry


11 Relay output pre-alarm (KV) S
Changeover contact
P
Ö
11 12 13
Caution
V The pre-alarm relay output is not part of the

safety function!
5 Commissioning the device
5.1 Display and operating elements
h Connect the voltage supply - a test routine will start during which all LEDS will flash and the display with background light-
ing will indicate white pixels for 2 seconds and black pixels for 2 seconds.
Once the test routine has been completed, the device will indicate the main measured value (factory set).
v If an alarm or error message appears, refer to Chapter 10 "Alarm messages".
5.2 Setting the display after switch-on

v Chapter 7.6.4 "Normal display"
The screen is factory set to show the main measured value in German. The example shows the screen layout of a safety tem-
perature limiter monitoring a maximum value of 29.6°C with a pre-alarm set to 9.9°C.
H If the main measured value is within the hysteresis during "Power ON", the relay outputs "Pre-alarm" and "Alarm"
are deactivated.
1 Switching behavior 2 Device function

(1) (2) (3)
3 Binary input
7 Main measured value (7)
(4)
6 Pre-alarm 4 Temperature unit
(6)
5 Limit value (5)
V1.01/EN 5 Commissioning the device 29

Legend Remark
3 LCD display
Black and white with background lighting 96 x 64 pixels
6 LED KV (yellow)
Is lit if the relay output pre-alarm was triggered.
(Relay output pre-alarm is active)
7 LED KD (yellow)
Is lit if the diagnosis processor has switched off a compo-
nent.
8 Keys
(Can only be operated when the transparent hood is fold-
ed up)
Increase value / previous parameter
Reduce value / next parameter
Programming
RESET
12 Setup interface
13 LED K2 (red)
Is lit for all errors.
14 LED K1 (red)
Is lit for all errors.
15 LED OK
Green: OK range (no error)
OFF: Error occurred
5.3 Selecting and editing parameters (plausibility inquiry for input values)
The values are displayed in the standard display.
Carry out steps 1 to 4 to edit a value, e.g. in this case, the limit value
1 Press The first menu item "Analog inputs" has a black
background. The vertical line on the right shows
the current position.
2 Select limiter/monitor with
Use to change to the submenu
3 Press 2x until the limit value appears
Press (limit value flashes)
4 Use or to set the desired value

Limit value flashes in du-
Acknowledge with plicate on the display as a
(limit value is shown in duplicate) control.
5 Briefly press to confirm the value.

The value is applied and saved. Use + to return to the standard display
or menu topic "Back" or
return automatically after a timeout
H If no key is pressed, the device automatically returns to the standard display after 30 seconds (timeout) and the value
is not saved. The length of the timeout is configurable.
v see operating overview on the first inner page of this manual.

5.4 Aborting edit

+ are used to abort editing and retain the previous value.
5.5 Alarm acknowledgement using the Reset key (only for temperature limiters STB)
h Press (RESET) key and hold down
Ticks appear
after the errors The alarm is no longer pending and is acknowledged as soon as the time bar has fin-
ished (3 seconds).
A bell is
shown after
the error. The alarm condition is still pending and cannot be acknowledged.
5.6 Alarm acknowledgement via binary input (only for temperature limiters STB)
The binary input can be configured so that, for example, alarms can be unlocked via a potential-free contact.
The function only reacts to the switching flank from the "open" to the "closed" state.
The contact then behaves in the same way as the "Reset" button.
v Chapter 7.4.1 "Function"
5.7 Lead sealing the device
The device settings must not change under operating conditions.

A lead-sealed, transparent cover must therefore be placed over it to prevent uninten-
tional or unauthorized adjustment.
Two holes are provided to the left and right of the transparent cover through which wire
can be guided for lead sealing to connect the cover to the housing. The wire ends are
secured with the lead seal.

V1.01/EN 6 Safety Manual 34
6 Safety Manual
6.1 Brief description
The safety temperature limiter (STB) and safety temperature monitor (STW) enable early and reliable detection of risks which
could potentially result in personal injuries, environmental damage, or destruction of the production plant and production mate-
rials.
Its task is to reliably monitor process variables such as temperature or pressure and to switch the plants to an operationally
safe status in the event of malfunctions.
The measured value at the analog input can be recorded by various probes or standard signals.
Even when using double sensors (1oo2) only one physical measuring point is monitored at the measuring point.
Limit value exceedance is indicated by the installed LED K1 and K2 (red) for each channel. At the same time the integrated
safety tested Relay output "Alarm" (screw terminals 14 and 16) switches the system to safe operating status (alarm range).
The SIL3 requirements of DIN EN 61508 or PLe DIN EN ISO 13849 are met by a device concept that has a 1oo2D structure
which ensures reliable detection of errors.
6.2 Safety temperature monitor (STW)

The safety temperature monitor is a device that is automatically reset when activated once the sensor temperature has fallen
below or risen above the set limit value by an amount equal to the switching differential. Possible settings: monitoring for limit
value overrange or underrange.
Mode of operations:
- Minimum requirements: 2B, 2K, 2P
- Additional requirements: 2N, 2D
6.2.1 Safe operating status STW

The safe status is when the relay output alarm between terminals 14 and 16 is switched off (closed-circuit principle).
6.3 Safety temperature limiter (STB)
The safety temperature limiter is a device that is permanently locked after responding.
Manual reset using the (RESET) key is possible once the probe temperature has fallen below / has exceeded the limit value
by the amount of the switching differential. Possible settings: monitoring for overrange or underrange.
Mode of operations:
- Minimum requirements: 2B, 2J, 2V, 2K, 2P and adjustable with special tools
- Additional requirements: 2N, 2F, 2D
6.3.1 Safe operating status STB

The safe status is when the relay output alarm between terminals 14 and 16 is switched off (closed-circuit principle).
This status is maintained until manual unlocking is performed in the valid range of the device.
The transparent, sealable protective cover prevents unauthorized operation.
The (RESET) key for manual unlocking can be accessed with the aid of a tool.
6.4 Relevant standards

Failure of the devices could affect the safety of persons and/or the safety of the environment.
Certification to DIN EN 61508 is provided because of the worldwide use of these systems.
The temperature monitoring unit type 701150 with extra code "058" meets the requirements
- For safety function to SIL3 according to DIN EN 61508 parts 1 to 7:
Functional Safety - Safety Related Electrical /Electronic / Programmable Electronic Systems
- DIN EN 61 511 Parts 1 to 3:
Functional Safety - Safety-Related Systems for the Process Industry
- DIN EN 14 597
Temperature Regulation Equipment and Temperature Limiter for Heat-Generating Systems
- DIN EN 60 730-2-9:

Automatic Electrical Control and Regulating Devices for Household Use and Similar Applications Parts 2-9: Special Re-
quirements for Temperature-Dependent Control and Regulating Devices
- EN 61 326
- DIN EN ISO 13849-1 PLe
- UL 60730-2-9
- According to the Pressure Equipment Directive
6.5 Validity of the Safety Manual
H The evaluation described in this Safety Manual in terms of functional safety and display of certificates applies to
the specified versions of temperature monitoring units including sensor versions.
Specifications that do not take the sensor system into consideration is identified as such.
6.6 Connection possibilities of the sensors (SIL)

The JUMO safetyM STB/STW 701150 evaluation device structure is basically identical. Various possibilities to connect the
sensors are available. These possibilities are listed in the following table along with the achievable SIL level:
6.6.1 Achievable SIL
architecture Achievable SIL

Varia
Connected sensors
nt Sensor
Logic
system
1 1 × Pt100 in 2-wire cir- 1oo1 1oo2D 2
cuit, individual sensor
1a 2x Pt100/1000 2-wire 1oo2 1oo2D 3
circuit
2 2x Pt100/1000 3-wire 1oo2 1oo2D 3
circuit
3 2x thermocouple 1oo2 1oo2D 3
4 1x Pt100/1000 2-wire 1oo2 1oo2D 3
and 3-wire circuit
1x thermocouple
5 STB/STW 701150 Sensors 1oo2D SIL of the used systematic max. achievable max. achievable
without sensor system connected sensor (HW on- capability (SC) SIL of the sys- SIL of the sys-
1oo2D architecture. by the sys- ly) of the used tem with 1oo1 tem with 1oo2
No probe or use 4 to tem user sensor sensor system sensor system
20 mA Architecture architecture architecture
(means that the sen- acc. to con- 1 1 1 1
sor is not taken into nection 1oo1
account for the calcu- or 1oo2 1 2 1 2
lation). 2 2 2 2
2 3 2 3
3 3 3 3

Important information:
Variants 1 to 4 were evaluated with JUMO probes according to data sheets 901006 and 902006. For variant 5 no sensor sys-
tem was taken into account. In this case, the user selects the sensor system. For this reason, the user is responsible for evalu-
ating the achievable SIL.
If the used SIL-capable sensor consists of hardware and software (e.g. transmitter), the maximum SIL that can be achieved –
irrespective of the architecture – is the one according to which the sensor software was developed (so, for example, if the sen-
sor software has SIL2, the max. achievable SIL is 2).
The possibility to connect passive sensors such as double thermocouples, Pt100 sensors, or Pt1000 sensors means that the
sensors do not necessarily require a SIL qualification. In this case, the specification of the failure rates for the passive sensors
is sufficient for the SIL qualification of the overall system. The user of the system must always determine the PFDavg and/or
PFH value of the overall safety chain to evaluate the achieved SIL
Requirements regarding proof-check interval and lifetime apply only in terms of functional safety.
Requirements as specified by DIN EN 14 597 are defined in the Operating Manual B 701150 and are independent of the re-
quirements of this Safety Manual.
Temperature probe
Admissible measuring ranges must be observed for devices with approval according to DIN EN 14 597 and SIL certification. If
other temperature probes than those described by JUMO data sheets 901006 and 902006 are used, their registration and suit-
ability for use must be verified.
Use insulated connecting points for double thermocouples

For safety related reasons the measuring circuits of double thermocouples have to be installed so that they are electrically in-
sulated. That means that both thermocouples do not have an electrical connection to the protection fitting or each other. (insu-
lated installation).
6.7 Standards and definitions
6.7.1 Terms and abbreviations acc. to DIN EN 14597
Abbreviation Explanation
Type 2 Mode of operation for which the manufacturing variation and migration of the operating value, operat-
ing duration, or operating procedure has been checked.
Type B Micro disconnection in operation, corresponding contact disconnection at at least one pole to
provide functional reliability.
Type D A free trip mechanism that also cannot be closed temporarily for as long as the error persists.
Type F (STB) A mode of operation in which, after the RS has been installed, it can only be reset with the aid of a tool.
Type J (STB) A free trip mechanism with contacts that cannot be prevented from opening and which may not func-
tion as an automatically resetting RS if the means of resetting is held in the "Reset" or "On" position.
Type K A probe mode of operation in which a probe break or a disconnection between the probe head and the
switching head does not cause the operating value to increase.
Type N A mode of operation in which the operating value does not increase as a result of a leak in the probe or
in the parts that connect the probe and switching head. This mode is intended for use with electrical er-
ror models.
Type V (STB) A lockout that can only be reactivated through a manual reset.
Type P A mode of operation that is effective following a specified test through a change in temperature, as
specified in 17.101 of DIN EN 60730-2-9.

6.7.2 Terms and abbreviations acc. to DIN EN 61 508 and DIN EN 61 511.
Name Description
Actuator Part of a safety-related system that intervenes in the process to achieve a safe state.
EUC EUC (equipment under control)
Equipment, machine, apparatus, or system used for manufacturing, shaping materials,
for transport, medical purposes, or other activities.
E / E / PE Electrical/electronic/programmable electronic (E/E/EP):
based on electrical (E) and/or electronic (E) and/or programmable electronic (PE)
technology
Failure End of the ability of a functional unit to perform a required function.
Diagnostic coverage Partial reduction in the probability of dangerous hardware failures due to the use of
automatic diagnostic tests.
Errors A non-normal condition that can cause a reduction or the loss of the ability of a
functional unit to perform a required function.
Functional safety A part of overall safety related to the EUC and EUC control system that depends on the
correct function of the E/E/EP safety-relevant system, safety-relevant systems of other
technology, and external equipment for risk reduction.
Functional unit Unit consisting of hardware or software or both that is suitable for performing a
specified task.
Dangerous failure A failure with the potential of placing the safety-related system in a dangerous state or a
state without functional capability.
Safe failure A failure without the potential of placing the safety-related system in a dangerous state
or state without functional capability.
Hazard Potential source of damage
Security Absence of unjustifiable risks
Name Description
Safety function A function that is performed by an E / E / PE safety-related system, safety-related
system based on some other technology, or external equipment for reducing risk with
the goal of achieving or maintaining a safe state for the EUC taking into consideration a
specified dangerous event.
Safety integrity The probability that a safety-related system will perform the required safety function
under all specified conditions within a specified period of time according to
requirements.
Safety Integrity Level (SIL) One of four discrete levels for specifying the requirement for safety integrity of the
safety functions assigned to the E/E/PE safety related system. Safety Integrity Level 4
represents the highest level of safety integrity, while Safety Integrity Level 1 represents
the lowest.
Safety-related system A system that
- performs necessary safety functions that are required to reach or maintain a safe state
for the EUC and
- is designed by itself or with other E / E / PE safety-related systems of other
technology or external equipment for risk reduction to achieve the necessary safety
integrity for the required safety functions.
Safety Instrument System (SIS) Safety instrumented system to perform one or more safety-related functions. A SIS
consists of sensor(s), logic system, and actuator(s).
Lambda:  Failure rate per hour
Lambda dangerous: D Rate of dangerous failures per hour
Lambda angerous etect: DD Rate of detected dangerous failures per hour
Lambda angerous ndetect: DU Rate of undetected dangerous failures per hour
Lambda: S Rate of safe failures per hour
Lambda: SD Rate of detected safe failures per hour

Name Description
Lambda: SU Rate of undetected safe failures per hour
BPCS Basic Process Control System

DC Diagnostic Coverage
FIT Failures In Time (1x10-9 per h)
HFT Hardware Fault Tolerance
PFD Probability of Failure on Demand
PFDavg Average Probability of Failure on Demand
MooN Architecture with M from N channels
MTBF Mean Time Between Failures
MTTR Mean Time To Repair
SFF Safe Failure Fraction
SIL Safety Integrity Level
6.8 Safety instrumented parameters related to the temperature monitoring unit
The following parameters were calculated by means of an FMEDA component under the following conditions:
- Error models corresponding to requirements of DIN EN 61508 for conformity with SIL2 or SIL3
- Failure rate of components according to the RDF 2000 UTE C 80-810 standard and SN 29500
- Sensors were combined as a subsystem in the following five variants:
6.8.1 Failure rates and SFF for 701150...23 (AC 230 V)
Variant s dd dd SFF PFH (1/h) PFD avg

[Fit] [Fit] [Fit]
1 865.21 306.24 32.31 96 % 4.56 e-9 2.02 e-4
1a 865.21 306.24 32.31 96 % 1.05 e-9 4.57 e-5
2 868.17 303.28 32.31 96 % 1.05 e-9 4.57 e-5
-9
3 881.62 326.78 33.62 96 % 1.03 e 4.49 e-5
4 887.68 343.82 35.52 96 % 1.22 e-9 5.30 e-5
5 881.02 313.43 35.57 96 % 1.04 e-9 4.48 e-5
Variants 1 to 4 were evaluated with JUMO probes according to data sheets 901006 and 902006.
For variant 5 no sensor system was taken into account.
In this case, the user selects the sensor system.

6.8.2 Failure rates and SFF for 701150...25 (AC/DC 24 V)
Variant s dd dd SFF

PFH (1/h) PFD avg
[Fit] [Fit] [Fit]
1 799.3 306.32 33.61 96 % 6.59 e-9 2.91 e-4
1a 799.3 306.32 33.61 96 % 3.07 e-9 1.35 e-4
2 802.26 303.36 33.61 96 % 3.07 e-9 1.35 e-4
-9
3 827.25 324.71 37.91 96 % 3.13 e 1.37 e-4
4 833.31 341.75 39.81 96 % 3.23 e-9 1.41 e-4
5 818.96 323.07 36.26 96 % 3.05 e-9 1.33 e-4
Variants 1 to 4 were evaluated with JUMO probes according to data sheets 901006 and 902006.
For variant 5 no sensor system was taken into account.
In this case, the user selects the sensor system.
The PFH and PFDavg values were calculated with the assumption that the time to restore the system is 8 h (MTTR = 72 h). Fur-
thermore, the calculation was based on a lifetime of 10 years (T1 = 10 y). The Common Cause Factor was determined accord-
ing to the tables of DIN EN 61508 for sensor systems and logic.
6.9 Determining the Safety Integrity Level (SIL)
The achievable Safety Integrity Level is determined by the following safety-related parameters:
- Average probability of dangerous failures of a safety function on demand (PFDavg),
- Hardware Fault Tolerance (HFT) and
- Safe Failure Fraction (SFF).
The specific safety-related parameters for the 701150 measuring system may be found in the table of the "Safety-related pa-
rameters" chapter.
The following table shows how the "Safety Integrity Level" (SIL) depends on the "average probability of dangerous failures of a
safety function of the entire safety-related system" (PFDavg) according to DIN EN 61 508. The "low demand mode" is consid-
ered, i. e. the demand rate for the safety-related system averages once a year.
Table High Demand PFH
Safety Integrity Level Operating mode with high demand rate

(SIL) PFH (high demand mode)
4 10-9 to <10-8
3 10-8 to <10-7
2 10-7 to <10-6
1 10-6 to <10-5

Table Low Demand PFD

Safety Integrity Level Operating mode with low demand rate
(SIL) PFDavg (low demand mode)
4 10-5 to <10-4
3 10-4 to <10-3
2 10-3 to <10-2
1 10-2 to <10-1
The sensor, logic unit, and actuator together form a safety-related system that performs a safety function. The "average proba-
bility of dangerous failures of the entire safety-related system" (PFDavg) is usually divided up into the sensor, logic unit, and ac-
tuator subsystems according to the following diagram.
Typical subdivision of the "average probability of dangerous failures of a safety function on demand" (PFDavg) into subsystems
The specifications related to functional safety in this Safety Manual include sensor systems (resistance temperature sensors,
thermocouples), logic unit (701150), and (as signal contact) the relay output in the 701150 system.
The actuator (for example a power contactor) is system-related and must be taken into consideration separately according to
the standard for the safety loop.
6.9.1 Safety integrity of the hardware
According to DIN EN 61 508, a distinction must be made between systems of type A and systems of type B.
A subsystem can be considered to be type A if, for the components required to achieve the safety function,
- the failure behavior of all components used is sufficiently defined; and
- the behavior of the subsystem can be fully determined under failure conditions; and
- reliable failure data from experience in the field exists for the subsystem to show that the assumed failure rates for detected
and undetected dangerous failures are achieved.
A subsystem can be considered to be type B if, for the components required to achieve the safety function,
- the failure behavior of at least one of the components used is not sufficiently defined; or
- the behavior of the subsystem cannot be fully determined under failure conditions; or
- no sufficiently reliable failure data from experience in the field exists for the subsystem to support the utilized failure rates
for detected and undetected dangerous failures.
The 701150 temperature monitoring unit corresponds to a type B system.
The following table shows the achievable Safety Integrity Level (SIL) in dependency on the proportion of non-dangerous fail-
ures (SFF) and the hardware fault tolerance (HFT) for safety-related type B subsystems.
For 701150 the following table applies:
Safe Failure Fraction (SFF) Hardware fault tolerance (HFT) for type B
0 1 2
<60 % Not allowed SIL1 SIL2
60 to <90 % SIL1 SIL2 SIL3
90 to <99% SIL2 SIL3 SIL4
99 % SIL3 SIL4 SIL4

6.9.2 Safety-relevant system properties

Device versions differ in the following architectures:
The evaluation unit from 701150 in STW, STB versions is implemented as 1oo2D architecture.
The types with an individual sensor are executed in one-channel sensor systems (1oo1).
These are monitored:
- Probe break in the sensor system subsystem
- Probe short circuit in the sensor system subsystem
- Random hardware failure in one channel
The variants with two sensors are consistently structured with two channels.
The two subsystems have to be galvanically isolated from each other.
These are monitored:
- Probe break sensor system subsystem
- Probe short circuit in the sensor system subsystem
- Reverse polarity of the probes
- Random hardware failure in one channel
Systems have a lifetime of ten years.

The proof check for SIL2 and SIL3 certified systems is also ten years.
If the temperature is above/below the permissible limits, the system switches to the safe state without delay. Premature switch-
ing is admissible if a malfunction is detected.
Safety feature Requirement / comment
SIL SIL2 SIL3
The sensor system is included in the
SIL evaluation.
Operating mode concerning Operating mode with lower and higher demand rate possible on a customer-specific
safety function basis
Safety-critical inputs Temperature sensor inputs 4 to 20 mA current loop
Safety-relevant inputs Setup and parameterization
Safety-critical output Alarm contact limit value
Subsystem type Type B
Safety architecture (logic unit JUMO 1oo2D
STB/STW 701150)
Safety architecture (sensor system) SIL2 SIL3
1oo1 1oo2
Hardware error tolerance (logic unit HFT=1
JUMO STB/STW 70.1150)
Hardware error tolerance (sensor sys- SIL2: HFT=0 SIL3: HFT=1
tem)
Proportion of safe errors SIL2 sensor system HFT=0: 90 % to < 99 % SIL3 sensor system HFT=1:
90 % to <99 %
CCF Calculation according to DIN EN 61508 Part 7 Appendix D and/or DIN EN ISO 13849-
1 Table F.1 min. 65 %
Average failure probability of a safety SIL2: SIL3:
function on demand (overall system) Low demand: PFDavg < 10-2 Low demand: PFDavg < 10-3
High demand: PFH < 10-6 High demand: PFH < 10-7
Interval for repeat test No repeat test

Safety feature Requirement / comment

Planned operating duration 10 years
Architecture according to DIN EN ISO Sensor system, one-channel: Cat. 2 Sensor system, two-channel: Cat. 3
13849-1
MTTFd-DCavg according to DIN EN PL d:  62 years DCavg  60 % PL e: 62 years DCavg 90 %
ISO 13849-1 table K.1
Mode of operation and software JUMO STB/STW 701150 possesses the following mode of operations
class according to DIN EN 14597 2B, 2D, 2F, 2K, 2J, 2V, 2N, 2P software class C
6.10 Determining the achieved Performance Level PL

The following safety-related parameters are required to determine the Performance Level of components/devices:
As further parameters to be observed, operational aspects such as the demand rate and/or the test rate of the safety function
can also influence the resulting PL.
Excerpt from DIN EN ISO 13849-1
H This excerpt contains references to the complete standard DIN EN ISO 13849-1 which are therefore not repro-
duced in this chapter.
6.10.1 Terms and abbreviations acc. to DIN EN ISO 13849
Formula symbol or Description Definition

abbreviation or location
PL (a, b, c, d, e) Description for the Performance Level Table 3
AOPD Active Opto-Electronic Protective Device (e.g. light barrier) Appendix H
B, 1, 2, 3, 4 Description for the categories Table 7
B10d Number of cycles in which a dangerous failure occurred in 10 % of a random Appendix C
sample of the observed pneumatic or electromechanical components that are
subject to wear (mean time to dangerous failure)
Cat. Category 3.1.2
CC Current converter Appendix I
CCF Common Cause Failure 3.1.6
DC Diagnostic Coverage 3.1.26
DCavg Average diagnostic coverage E.2
F, F1, F2 Frequency and/or duration of the exposure to danger A.2.2
FB Function block 4.6.3
FVL Programming language with unlimited language range 3.1.35
FMEA Failure Modes and Effects Analysis 7.2
I, I1, I2 Input device, e.g. sensor 6.2
i, j Index for counting Appendix D
I/O Inputs/outputs Table E.1
iab, ibc Fasteners Image 4
K1A, K1B Contactors Appendix I
L, L1, L2 Logic 6.2
LVL Programming language with limited language range 3.1.34


M Motor Appendix I
MTTF Mean Time To Failure Appendix C
MTTFc Mean time to critical failure 3.1.25
MTTFd Mean time to dangerous failure
n, N, N Number of units 6.3, D.1
Nlow Number of SRP/CS with PLlow in an SRP/CS combination 6.3
O, O1, O2, OTE Output device, e.g. drive unit 6.2
P, P1, P2 Possibility of avoiding the danger A.2.3
PES Programmable electronic system 3.1.22
PL Performance Level 3.1.23
PLC Programmable Logic Controller Appendix I
PLlow Lowest Performance Level of a SRP/CS in an SRP/CS combination 6.3
PLf Required Performance Level 3.1.24
ra Demand rate 3.1.30
RS Rotary encoder Appendix I
S, S1, S2 Severity of violation A.2.1
SW1A, SW1B, SW1 Position switch Appendix I
SIL Safety Integrity Level Table 4
SK (Cat.) Category (B, 1, 2, 3, 4), structure as basis to achieve a certain PL
SRASW Safety-Related Application Software 4.6.3
SRESW Safety-Related Embedded Software 4.6.2
SRP Safety-Related Part General
SRP/CS Safety-Related Part of (a) Control System(s) 3.1.1
Sub-PL/Sub-SIL PL or SIL at subsystem level. A subsystem a system that – based on a subtask –
already adequately performs a safety function (for example, an input module that
reliably records the inputs).
TE Test facilities 6.2
TM Functional life 3.1.28
TM Functional life, designated Mission Time
T10d-value Reference value for a preventative exchange (10 % of the B10d value). At this val-
ue, a dangerous failure has already occurred for approx. 63 % of all components.
In this case, the standard DIN EN ISO 13849-1:12006 recommends replacement.
6.11 Connection possibilities of the sensors (PL)

The JUMO safetyM STB/STW 701150 evaluation device structure is basically identical.
Various possibilities to connect the sensors are available. These possibilities are listed in the following table along with the
achievable PL level:

Sensor Logic
Variant Connected sensors system architectur Achievable PL
architecture e
1 1 × Pt100 in 2-wire circuit 1oo1 1oo2D PLd
individual sensor
1a 2x Pt100/1000 2-wire circuit 1oo2 1oo2D PLe
2 2x Pt100/1000 3-wire circuit 1oo2 1oo2D PLe
3 2x thermocouple 1oo2 1oo2D PLe
4 1x Pt100/1000 1oo2 1oo2D PLe
2-wire and 3-wire circuit
1x thermocouple
5 STB/STW 701150 without Sensors con- 1oo2D PL of the used Max. achievable Max. achievable
sensor system 1oo2D archi- nected by the sensor PL of the system PL of the system
tecture. system user with 1oo1 sensor with 1oo2 sen-
No probe or use 4 to 20 mA. Architecture system architec- sor system ar-
(means that the sensor is not acc. to con- ture chitecture
taken into account for the cal- nection 1oo1 DC701150  90 % DC701150  90
culation). or 1oo2 %
PLb PLd PLe
PLc PLd PLe
PLd PLd PLe
PLe PLe PLe
Variants 1 to 4 were evaluated with JUMO probes according to data sheets 901006 and 902006. For variant 5 no sensor sys-
tem was taken into account. In this case, the user selects the sensor system. For this reason, the user is responsible for evalu-
ating the achievable PL.
6.11.1 Calculations DIN EN ISO 13849-1 Performance Level - low voltage 230 V
Variant MTTFd DCavg CCF PL

1 100 years3 (337 years) 90 % 80 PLd
1a 100 years3 (337 years) 90 % 80 PLe
2 100 years3 (340 years) 90 % 80 PLe
3 100 years3 (317 years) 91 % 80 PLe
4 100 years3 (313 years) 91 % 80 PLe
5 100 years3 (327 years) 91 % 80 See above table
6.11.2 Calculations DIN EN ISO 13849-1 Performance Level - extra low voltage (ELV) 24 V
Variant MTTFd DCavg CCF PL

1 100 years3 (336 years) 90 % 80 PLd
1a 100 years3 (336 years) 90 % 80 PLe
2 100 years3 (339 years) 90 % 80 PLe
3 100 years3 (315 years) 90 % 80 PLe
4 100 years3 (311 years) 90 % 80 PLe 3. The MTTFd value of a partial system must be
limited to 100 years according to the DIN EN
5 100 years3 (318 years) 90 % 80 See above table ISO 13849-1 requirements.

6.11.3 Contribution to risk minimization through the control system

The objective of compliance with the overall draft procedure for the machine is to achieve the safety objectives (see 4.1). The
draft of the SRP/CS to provide the required risk minimization is an integral part of the overall draft procedure for the machine.
The SRP/CS provides the safety function(s) with a PL that achieves the required risk minimization. Through the provision of
safety functions, either as an inherently safe part of the construction or as the control of a protective guard or protective device,
the design of the SRP/CS is part of the risk minimization strategy. This is an iterative process and is depicted in images 1 and
3.
The features of each safety function (see section 5) and the required Performance Level must be described and documented in
the specification of the safety requirements.
In this part of DIN EN ISO 13849, the Performance Levels are defined in the form of the probability of a dangerous failure per
hour. Five Performance Levels (a to e) are specified with defined areas of the probability of a dangerous failure per hour (see ta-
ble).
Performance Level (PL) Average probability

of a dangerous failure per hour 1/h
a  10-5 to < 10-4
b  3 Þ 10-6 to < 10-5
c  10-6 to < 3 × 10-6
d  10-7 to < 10-6
e  10-8 to < 10-7
NOTE: in addition to the average probability of a dangerous failure per hour, further measures are required to achieve the PL.
Schematic representation of a combination of safety-related parts of controls for processing a typical safety function
1 i ab i bc 2
SRP/CS a SRP/CS b SRP/CS c
I L O
I Input
L Logic
O Output
1 Start event, e.g. manual actuation of a button, opening of a protective guard,
interruption of the beam of an AOPD
2 Drive unit of the machine, e.g. motor brake

6.12 Evaluating the achieved Performance Level PL and the relationship to the SIL
For application in this part of DIN EN ISO 13849, the capability of safety-related parts to perform a safety function is expressed
through the determination of a Performance Level.
The PL must be assessed for each selected SRP/CS and/or SRP/CS combination that performs a safety function. The PL of
the SRP/CS must be determined by assessing the following aspects:
- The MTTFc value of individual components (see Appendices C and D)
- The DC (see Appendix E)
- The CCF (see Appendix F)
- The structure (see section 6)
- The behavior of the safety function under failure conditions (see section 6)
- Safety-related software (see 4.6 and Appendix J)
- Systematic failures (see Appendix G)
- The capability to perform a safety function under predictable ambient conditions
The following diagram depicts the procedure for selecting the categories in combination with MTTFd for each channel and the
DCavg to achieve the required PL for each safety function.
Relationship between the categories DCavg, MTTFd of each channel and PL
PL Performance Level
1 MTTFd of each channel = low
2 MTTFd of each channel = medium
3 MTTFd of each channel = high

The diagram above shows the different possible combinations for assessing the category with DCavg (horizontal axis) and the
MTTFd of each channel (bars). The bars in the diagram show the three MTTFd areas of each channel (low, medium and high)
that can be selected to achieve the required PL.
Before the simplified procedure from the diagram shown is applied (which shows the results of different Markov models on the
basis of intended architectures from section 6), the category of the SRP/CS and the DCavg and the MTTFd of each channel
must have been determined (see section 6 and Appendices C to E).
For categories 2, 3, and 4, sufficient measures against failures due to combined failures must be fulfilled (see Appendix F). Tak-
ing these parameters into account, the diagram represents a graphical procedure for determining the PL achieved by the SRP/
CS. The combination of category (including failures due to combined failures) and DCavg determines which column must be se-
lected in image 5. In accordance with the MTTFd of each channel, one of the three differently hatched areas of the applicable
column must be selected.
The vertical position of these areas determines the achieved PL, which can be read off the vertical axis. If the area covers two
or three possible PLs, the achieved PL is specified in table 7. To select the exact PL on the basis of the precise value of the
MTTFd of each channel, see Appendix K.
6.13 Other applicable device documentation
For temperature monitoring unit 701150 the measures, values, and requirements specified in this Operating Manual regarding
installation, electrical connection, function, and startup must be observed.
6.14 Behavior during operation and in case of malfunction

Behavior during operation and in case of a malfunction is described in the Operating Manual.
A functional test must be performed after startup, repair in the safety system, or a change in safety-related parameters.
If an error is detected during a functional test, measures must be taken to once again ensure the functional capability of the
safety system. This, for example, can be done by replacing the logic unit.
Appropriate documentation of tests that are performed is recommended.
6.15 Regular tests
H
No test is required for SIL2 and SIL3 certified systems since the proof check equals the lifetime. Each is ten years.
After the lifetime expires, the systems no longer meet the requirements according to their SIL certification.
6.15.1 Recommended tests for temperature probes

To ensure safe and reliable operation of the thermometer, the following service and maintenance work must be performed:
The following tests are recommended at certain intervals:
Every 12 months, the leakage resistance of the measuring circuit must be measured against the protection fitting (for thermo-
couples: only for the insulated measuring circuit; in the case of multiple measuring circuits, the insulation test must also be per-
formed between the individual measuring circuits). The minimal leakage resistance at room temperature should be 100 M at
100 V.
- Damage and corrosion of thermometers – protection tubes
- Corrosion and correct positioning of the contacts and terminals of cable connections

- Seals of terminal heads and cable ducts

- Interruptions due to "knocking" on the thermometer/measuring insert
Since the maximum operating temperature influences the drift behavior, the thermometer should be recalibrated or replaced at
certain intervals to ensure reliable and precise temperature measurement.
The testing intervals are listed in the table below:
Maximum operating temper- Pt - RTD temperature probe Thermocouples
ature
200 °C 5 years 5 years
550 °C 2 years 5 years
700 °C 1 year 2 years
1000 °C Non-precious metal 1
year
Precious metal 2 years
1500 °C 1 year
H The testing intervals specified here are recommendations that must be adapted to the special conditions at the
operating location and, if necessary, the user should perform the tests more regularly.
V1.01/EN 7 Configuration level 64
7.1 Navigation principle
All the parameters are freely accessible at the factory, but they can be disabled via the setup program.
v Chapter 9.3 “Forgotten the code?”
Parameters of the configuration level which are not required are automatically hidden depending on the setting.
7.2 Analog inputs
7.2.1 Connection Comment

Two sensors This setting is provided for dual probes or for two different probes.
Each of the two analog inputs is monitored separately for probe break, probe
short-circuit.
V
Single Pt100 in 2-wire circuit Caution:
When only one probe (SIL2) is connected, the temperature limiter device is
reduced from SIL3 to SIL2!
However, the internal 2-channel structure (1oo2D) in the device still remains.
Both channels measure the same sensor due to the simplified external wiring.
V
Single 4 to 20 mA Caution:
When only one probe (SIL2) is connected, the temperature limiter device is
reduced from SIL3 to SIL2!
However, the internal 2-channel structure (1oo2D) in the device still remains.
Both channels measure the same current signal due to the simplified external
wiring.
k Factory setting

7.2.2 Sensor type 1 Setting range for limit

Limits for
For analog input 1 value:
Comment Underrange /
(can be restricted via
overrange
the setup)
Pt100 DIN EN 60751 In 3-wire circuit IEC 60751:2008 -1999 to +9999 °C -205 °C/ +855 °C
Pt100 DIN EN 60751 in 2-wire circuit IEC 60751:2008 -1999 to +9999 °C -205 °C/ +855 °C
W3Re-W25Re “D” Thermocouple ASTM E1751M-09 -1999 to +9999 °C -5 to +2500 °C
(bis 2315 °C): 2009
W5Re-W26Re „C“ Thermocouple ASTM E230M-11: 2011 -1999 ... +9999°C -5 ... +2320°C
Cu-CuNi “T” Thermocouple DIN EN 60584-1: -1999 to +9999 °C -205 to +405 °C
1996-10
Fe-CuNi “J” Thermocouple DIN EN 60584-1: -1999 to +9999 °C -205 to +1205 °C
1996-10
Cu-CuNi “U” Thermocouple DIN 43710: -1999 to +9999 °C -205 to +605 °C
1985-12
Fe-CuNi “L” Thermocouple DIN 43710: -1999 to +9999 °C -205 to +905 °C
1985-12
NiCr-Ni “K” Thermocouple DIN EN 60584-1: -1999 to +9999 °C -205 to +1377 °C
1996-10
Pt10Rh-Pt “S” Thermocouple DIN EN 60584-1: -1999 to +9999 °C -55 to +1773 °C
1996-10
Pt13Rh-Pt "R" Thermocouple DIN EN 60584-1: -1999 to +9999 °C -55 to +1773 °C
1996-10
Limits for
For analog input 1 value:
overrange
the setup)
Pt30Rh-Pt6Rh “B” Thermocouple DIN EN 60584-1: -1999 to +9999 °C 295 to 1825 °C
1996-10
NiCrSi-NiSi "N" Thermocouple DIN EN 60584-1: -1999 to +9999 °C -105 to +1305 °C
1996-10
4 to 20 mA Standard signal -1999 to +9999 °C 3.6 to 21 mA
k Factory setting
Value range
Parameter Comment
(factory-setting in bold)
7.2.3 Offset 1 Using Offset1, a measured value at the analog input -999.9 to 0.0 to 999.9
can be corrected by the value entered above the total
measuring range.
7.2.4 Lead wire resistance 1 Analog-input1 lead wire resistance 0.0 to 30.0 ohm
in 2-wire circuit
(resistivity) This value is used to compensate the resistance of the
probe line and depends on the line length.
Enter the ohmic resistance of the probe line here to
achieve the best possible temperature measurement.

Value range
Parameter Comment
7.2.5 Filter time 1 Time constant of the digital input filter 0.0 to 0.6 to 100 sec.
2nd order for analog input 1
If the input signal changes suddenly, approx. 26 % of
the change is recorded following a period that corre-
sponds to the filter time constant dF (2 x dF: approx.
59 %; 5 x dF: approx. 96 %).
Value 0 means: filter switched off
If the filter time is long:

- Interfering signals are better absorbed
- Measured value display responds more slowly to
changes
7.2.6 Scaling start 1 Important information: This setting only occurs if the -9999 to 0 to 9999
sensor type 1 was set to 4 to 20mA!
Here, the user selects which value (i.e. pressure)
should be displayed at 4 mA.
7.2.7 Scaling end 1 Here, the user selects which value (i.e. pressure) -9999 to 100 to 9999
Limits for
For analog input2 value:
overrange
the setup)
W3Re-W25Re “D” Thermocouple ASTM E1751M-09 -1999 to +9999 °C -5 to +2500 °C
(bis 2315 °C): 2009
W5Re-W26Re „C“ Thermocouple ASTM E230M-11: 2011 -1999 ... +9999°C -5 ... +2320°C
Cu-CuNi “T” Thermocouple DIN EN 60584-1: -1999 to +9999 °C -205 to +405 °C
1996-10
Fe-CuNi “J” Thermocouple DIN EN 60584-1: -1999 to +9999 °C -205 to +1205 °C
1996-10
Cu-CuNi “U” Thermocouple DIN 43710: -1999 to +9999 °C -205 to +605 °C
1985-12
Fe-CuNi “L” Thermocouple DIN 43710: -1999 to +9999 °C -205 to +905 °C
1985-12
NiCr-Ni “K” Thermocouple DIN EN 60584-1: -1999 to +9999 °C -205 to +1377 °C
1996-10
Pt10Rh-Pt “S” Thermocouple DIN EN 60584-1: -1999 to +9999 °C -55 to +1773 °C
1996-10
Pt13Rh-Pt "R" Thermocouple DIN EN 60584-1: -1999 to +9999 °C -55 to +1773 °C
1996-10


Limits for
For analog input2 value:
overrange
the setup)
Pt30Rh-Pt6Rh “B” Thermocouple DIN EN 60584-1: -1999 to +9999 °C 295 to 1825 °C
1996-10
NiCrSi-NiSi "N" Thermocouple DIN EN 60584-1: -1999 to +9999 °C -105 to +1305 °C
1996-10
4 to 20 mA Standard signal -1999 to +9999 °C 3.6 to 21 mA
k Factory setting
Value range
Parameter Comment
7.2.9 Offset 2 Using Offset2, a measured value at the analog input -999.9 to 0.0 to 999.9
can be corrected by the value entered over the total
measuring range.
7.2.10 Lead wire resistance 2 Lead wire resistance analog input 2 0.0 to 30.0 ohm
in 2-wire circuit
(resistivity) This value is used to compensate the resistance of the
probe line and depends on the line length.
Enter the ohmic resistance of the probe line here to
achieve the best possible temperature measurement.
Value range
Parameter Comment
7.2.11 Filter time 2 Time constant of the digital input filter 0.0 to 0.6 to 100 sec.
2nd order for analog input 2
If the input signal changes suddenly, approx. 26 % of
the change is recorded following a period that corre-
sponds to the filter time constant dF (2 x dF: approx.
59 %; 5 x dF: approx. 96 %).
Value 0 means: filter switched off
If the filter time is long:

- Interfering signals are better absorbed
- Measured value display responds more slowly to
changes
7.2.12 Scaling start 2 Important information: This setting only occurs if the -9999 to 0 to 9999
sensor type 2 was set to 4 to 20mA!
Here, the user selects which value (i.e. pressure)
7.2.13 Scaling end 2 Here, the user selects which value (i.e. pressure) -9999 to 100 to 9999

7.3 Limiter/monitor
Value range
Parameter Comment
7.3.1 Device function Safety temperature limiter (STB) initial startup: STB initial startup, STB,
Regardless of the switching status of the alarm relay STW
output prior to power failure, the STB remains locked
when power returns.
The purpose of this factory setting is to ensure that the
device will be in a safe switched-off state when the
voltage supply is switched on for the first time.
After this initial startup, the device function can be set
to STB or STW.
Safety temperature limiter STB:
The device must be manually reset using the keypad or
the binary input as soon as the main measured value is
back within the valid range.
Safety temperature monitor STW
The device is automatically reset as soon as the main
measured value is back within the valid range.
Value range
Parameter Comment
7.3.2 Switching behavior Min. alarm: Max. alarm, min. alarm
If the measured value falls below the limit value, the
relay output alarm switches to OFF. The LEDs K1 and
K2 light up red and the measured values flash in the
display.
Min. alarm (older devices: S-Function)
Relay output Alarm range Valid range

alarm active
Hysteresis
S S
P P
Ö Ö
3,15A 3,15A
Relay output 14 15 16 14 15 16
alarm inactive Measured value
LED K1, K2 light up red LED OK lights up green
Min. set.range Max. set.range

Limit Value
If set to the safety temperature limiter (STB) setting, this condition remains even when the main
measured value is back in the valid range. Only when the "Reset" key is pressed or a switch is
activated when the binary input is respectively configured will the alarm relay output switch on
again and the OK LED light up green.
When setting the safety temperature monitor (STW), the alarm relay output automatically
switches back to ON as soon as the main measured value is back within the valid range.

Value range
Parameter Comment
Max. alarm:
If the measured value exceeds the limit value, the relay
output alarm switches OFF. The LEDs K1 and K2 light
up red and the measured values flash in the display.
If set to the safety temperature limiter (STB) setting, this condition remains even when the main
measured value is back in the valid range. Only when the "Reset" key is pressed or a switch is
activated when the binary input is respectively configured will the alarm relay output switch on
again and the OK LED light up green.
When setting the safety temperature monitor (STW), the alarm relay output automatically
switches back to ON as soon as the main measured value is back within the valid range.
Value range
Parameter Comment
7.3.3 Limit value, hysteresis Limit value alarm: -200 to 0 to 850
If this value is exceeded or not reached, this affects the Depends on setting range
alarm relay output depending on the switching behav- min. and max.
ior.
Hysteresis limit value: 0 to 2 to 100
Difference between the switch-off and switch-on
threshold, e.g. for rising and falling temperatures.
7.3.4 Pre-alarm function No function No function,
Pre-alarm relay output is inactive Absolute value,
Limit val. dist.
Absolute value:
H
Absolute value inverse
The pre-alarm responds according to
Pre-alarm relay output is triggered if the value for the Gap limit value inverse
its setting to the main measured val- Window
pre-alarm is exceeded.
ue Window inverse
Limit val. dist.
Here, the set value for the pre-alarm is used on a basis
that is relative to the limit value. If, for example, a pre-
alarm of 10 K is entered, the pre-alarm relay output
always switches at 10 K before the limit value, regard-
less of how the limit value is set.

Value range
Parameter Comment
Switching behavior of the relay output pre-alarm for the Min-Alarm setting
Value range
Parameter Comment
Switching behavior of the relay output pre-alarm for the Max-Alarm setting

Value range
Parameter Comment
The behavior of the relay output pre- Absolute value inverse:
alarm depends on the setting Min- The pre-alarm possesses inverse switching behavior
Alarm or Max-Alarm. in comparison to the “Absolute value“ setting and
becomes active if the value for pre-alarm is exceeded.
Gap limit value inverse:
Here, the set value for pre-alarm is used as a distance
to the limit value.
The pre-alarm possesses inverse switching behavior
in comparison to the “Limit val. dist.“ setting.
Value range
Parameter Comment
Switching behavior of the relay output pre-alarm for the Min-Alarm setting

Value range
Parameter Comment
Switching behavior of the relay output pre-alarm for the Max-Alarm setting
Value range
Parameter Comment
Window:
The set pre-alarm value determines the window width
symmetrically around the limit value.
Here it is irrelevant if Min-Alarm or Max-Alarm is set.
In a window symmetrically around the limit value the pre-alarm relay is active.

Value range
Parameter Comment
Window inverse:
The pre-alarm possesses inverse switching behavior
in comparison to the “Window“.
In a window symmetrically around the limit value the pre-alarm relay is inaktive.
Caution
V The pre-alarm function is not part of the safety function!

Value range
Parameter Comment
7.3.5 Pre-alarm, hysteresis Pre-alarm -9999 to 0 to 9999
The value that triggers the pre-alarm relay output as an
absolute value or relative to the limit value.
Pre-alarm hysteresis: 0 to 2 to 100
threshold, e.g. for rising and falling temperatures.
7.3.6 Error Pre-alarm, Relay Error pre-alarm: Sensor error
Here the user can define to which errors the pre-alarm Sens.error&diff.
pre-alarm should react. All errors
- Sensor error: see Chapter 8.5 “Measuring circuit
monitoring”
- Sens.error&diff.: same as sensor error above with
additional errors of differential monitoring.
- All errors: additional device errors see Chapter 11.
Relay pre-alarm: Active
Here the user can set which condition the relay output Inactive
pre-alarm should have when the errors above occur.
7.3.7 Limit value difference, Limit value difference monitoring: 0 to 50 to 100
If the value of the temperature difference of the analog
hysteresis input 1-2 is exceeded, the alarm relay output is
switched.
Hysteresis difference monitoring: 0 to 2 to 100
threshold, e.g. for rising and falling differential values.
If, for example, temperature differences arise as a result of the spatial arrangement of a dual probe, an alarm may be triggered
by the concurrency monitoring even though the temperature being monitored has not yet been exceeded.
In this case, the difference monitoring limit value can be adjusted accordingly.

Value range
Parameter Comment
7.3.8 Setting range min. (for- This value may not be lower than the lower end of the -9999 to -200 to limit value
connected probe or unit signal measuring range. It may °C
merly ALHI) also not be set higher than the setting for the alarm
This is the lower limit of the setting limit value.
range for the limit value.
7.3.9 Setting range max. (for- This value may not be greater than the higher end of Limit
the connected probe or unit signal measuring range. It value to 850 to 9999 °C
merly ALLO) may also not be set lower than the setting for the alarm
This is the upper limit of the setting limit value.
range for the limit value.
The admissible limits for DIN authorized probes:

v Chapter 8.12 “Probes for the operating medium air” and
v Chapter 8.13 “Probes for the operating medium water and oil”
7.4 Binary input
Value range
Parameter Comment
7.4.1 Function This sets the function that should be controlled by the binary
input.
The binary input does not have a function No function
The binary input performs a reset as described in Chapter 7.3.1 Unlocking
“Device function”.
The function only responds to the switching edge from "open" to
"closed" state.
Protection against unauthorized key operation Key lock
Configuration level is locked. Level lock

7.5 Analog output

Value range
Parameter Comment
7.5.1 Function Here, the measured value that is to be shown at the Main measured value
analog output is set. Measured value1
Measured value2
Main measured value: Difference
With the max-alarm switching behavior, the greater of
the two measured values is shown; with the min-alarm,
the lower of the two measured values is shown.
Measured value1:
Measured value of analog input 1 (E1) is shown
Measured value2:
Measured value of analog input 2 (E2) is shown
Difference:
E1-E2 is shown
The signal that should be output by the analog output
can be set with scaling start and end.
7.5.2 Signal type 4 to 20 mA 4 to 20 mA,
0 to 20 mA
0 to 20 mA 2 to 10 V
2 to 10 V 0 to 10 V
0 to 10 V
7.5.3 Scaling start v Picture in Chapter 7.5.7 -9999 to -200 to 9999
7.5.4 Scaling end v Picture in Chapter 7.5.7 -9999 to 800 to 9999
Value range
Parameter Comment
7.5.5 Error cases Here the user can set to which errors the analog output Sensor error 2x
relay output should react. Sensor error 1x
Sensor error 2x means: Sens.err. & diff.
Double sensor error can only be set if the main measu- All Errors
red value is set in Chapter 7.5.1 .
7.5.6 Error signal If, for the measured value 1 or 2, the value is exceeded,
not reached, or a diagnostic error occurs, the current or
voltage value set on the analog output is output as a
so-called error signal.
For signal type 4 to 20 mA 3.4 or 21.2 mA
For signal type 0 to 20 mA 0 or 21.2 mA
For signal type 2 to 10 V 1.7 or 10.4 V
For signal type 0 to 10 V 0 or 10.4 V

7.5.7 Behavior when leaving the scaling range

The standard signal range of the analog output is limited as follows according to recommendation of Namur NE 43:
Signal type Lower Upper

Standard signal
limit limit for analog output
0: 4 to 20 mA 3.8 mA 20.5 mA
20.5 mA
1: 0 to 20 mA 0 mA 20.5 mA 20 mA
2: 2 to 10 V 1.8 V 10.2 V
3: 0 to 10 V 0V 10.2 V
k Factory setting
4 mA
3.8 mA
Measured value
Caution The analog output is not part of the safety function!
V
7.6 Display/operation
Value range
Parameter Comment
7.6.1 Language German German, English, French
English
French
7.6.2 Unit Here a unit for the measured value can be assigned. °C, °F, %, text
°C
A When the measurement unit changes

°F
to °F, the measured value is convert- %
ed. Text:
All other values referring to the mea-
sured value (e.g. limit value) remain in Via the setup program, 2 characters can be entered
their value! here for another unit, e.g. Pa (Pascal).
7.6.3 Decimal place No decimal place No decimal place,

One decimal place
One decimal place
7.6.4 Normal display This sets the view that appears after the voltage supply Main measured value,
is switched on. measured values, limit
v Chapter “Operating overview” value, pre-alarm, difference
Main measured value
Measured values
Limit value
Pre-alarm
Difference

Value range
Parameter Comment
7.6.5 Contrast Screen contrast 0 to 5 to 10
Difference in brightness between black and
white pixels
7.6.6 Lighting Here the background lighting of the display is set. Off, On, During operation
Off:
Always switched off
On:
Always switched on
During operation:
The background illumination is only switched on when
the keys are operated and it lights up until the time for
the time-out light has expired.
7.6.7 Time-out light Here a waiting period for the switch-off of the back- 0 to 30 to 100 sec
ground lighting is set.
7.6.8 Time-out operation Here, the waiting period is set for the return from the 0 to 30 to 100 sec
configuration to normal display.
7.6.9 Code To protect against unauthorized manipulations, a code 0 to 9999
can be set here for locking the configuration level.
0 means: code request switched off
H If the code is forgotten, a new code can be

transferred to the device via the setup pro-
gram.
v Chapter 9.3 “Forgotten the code?”
7.7 Service
Value range
Parameter Comment
7.7.1 Limit switching cycle Limit value for relay switching cycles 0 to 99999
Here, the limit value for the admissible relay switching
cycles is set.
If the counter value for Current switching cycles is
greater than this value, the display values flash and the
alarm relay output secedes.
If "0" is set the function is inactive.
7.7.2 Current switching cycles Relay switching cycle counter 0 to 99999

Here, the switching cycles for the relay are only count-
ed if the top limit value for relay switching cycles is
not set to "0" and is thus inactive.
The value can then be adjusted as required and there-
fore adapted accordingly to the plant.
The switching cycle counter remains at 99999.
7.7.3 Operating hours Operating hour counter 0 to 99999

The counter adds up the operating hours during which
the device was connected to the voltage supply.
The value cannot be changed and can be used as a
measure of how long the device was actually in opera-
tion after leaving the plant.

V1.01/EN 8 Technical data 92
8 Technical data
8.1 Analog inputs
RTD temperature probe
Designation Measuring range Accuracy Ambient temperature

2/3-wire circuit1 influence
Pt100 -200 to +850 °C 0.5% / 0.1% 50 ppm/K
IEC 60751:2008
Pt1000 -200 to +850 °C 0.5% / 0.1% 50 ppm/K
IEC 60751:2008
Connection type Maximum lead wire resistance: 2-wire 15 , 3-wire circuit 30 
Measuring rate 210 ms
Error tolerance time  5s time taken into account for all diagnosis tests
Input filter Digital filter, 2nd priority; filter constant can be set from 0 to 100 s
Special features Individual probe Pt100 2-wire,
display can also be programmed in °F
Thermocouples
Designation Measuring range Accuracy1 Ambient temperature

influence
Fe-CuNi "L" -200 to +900 °C 0.4% 100 ppm/K
DIN 43710:1985-12
Fe-CuNi "J" -200 to +1200 °C 0.4% 100 ppm/K
DIN EN 60584-1:1996-10
Cu-CuNi "U" -200 to +600 °C 0.4% 100 ppm/K
DIN 43710:1985-12
Cu-CuNi "T" -200 to +400 °C 0.4% 100 ppm/K
DIN EN 60584-1:1996-10
NiCr-Ni "K" -200 to +1372 °C 0.4% 100 ppm/K
DIN EN 60584-1:1996-10
Pt10Rh-Pt "S" -50 to +1768 °C 0.4% 100 ppm/K
DIN EN 60584-1:1996-10
Pt13Rh-Pt "R" -50 to +1768 °C 0.4% 100 ppm/K
DIN EN 60584-1:1996-10
Pt30Rh-Pt6Rh "B" 0 to 1820 °C 0.4 2% 100 ppm/K
DIN EN 60584-1: 1996-10
NiCrSi-NiSi "N" -100 to +1300 °C 0.4 2% 100 ppm/K
DIN EN 60584-1: 1996-10
W3Re-W25Re "D" 0 to 2495 °C 0.4% 100 ppm/K
ASTM E1751M-09 (bis 2315 °C): 2009
W5Re-W26Re „C“ 0 to 2315 °C 0.4% 100 ppm/K
ASTM E230M-11: 2011
Cold junction Pt100 internal
Cold junction accuracy ±1K
Error tolerance time  5 s time taken into account for all diagnosis tests
1.The accuracy values refer to the maximum measuring range.
2.The accuracy is only guaranteed obove a temperature of 300° C

Direct current
Measuring range Accuracy Ambient temperature
influence
4 to 20 mA, voltage drop < 2 V 0.2 % 150 ppm/K
Scaling Can be freely programmed within the limits
Error tolerance time  5 s time taken into account for all diagnosis tests
Special features Individual probe 4 to 20 mA
8.2 Analog output
Type of sig- Accuracy Residual ripple Load influence Temperature influ- Load
nal ence resis-
tance
Current 4 to 20 mA  0.5 % ± 0.5 % at 300  ± 0.05 mA/ 100  150 ppm / K  500 
0 to 20 mA
Voltage 2 to 10 V  0.5 % ± 0.5 % ± 15 mV 150 ppm / K 500
0 to 10 V
8.3 Binary input
Connection Function
1 potential-free contact Unlocking, keyboard locking, level locking can be configured
8.4 Relay outputs
Relay output KV Relay (changeover contact) without shroud

30000 operations at a performance of 3 A /250 V, 50 Hz resistive load
or maximum DC 30 V / 3 A. Minimal current: DC 12 V / 100 mA.
Relay output alarm Changeover contact
Contact protection switching: safety fuse 3.15 AT, installed in the N/O contact arm
30000 operations at a performance of 3 A /230 V, 50 Hz resistive load
or maximum DC 30 V / 3 A. Minimal current: DC 12 V / 100 mA.

8.5 Measuring circuit monitoring
RTD temperature probe in Thermocouples Current 4 to 20mA

three-wire circuit and
double thermocouples
Overrange Is detected
and underrange LED K1, K2, KD and KV are lit;
">>>>" flashes in the display for overrange, "<<<<" for underrange.
Probe and wire break Is detected LED K1, K2, KD and KV are lit;
LED K1, K2, KD and KV are lit; ">>>>" flashes in the display;
">>>>" flashes in the display; relay output "Alarm" is inactive relay output "Alarm" is inactive
Probe short-circuit Is detected Is detected by difference LED K1, K2, KD and KV are lit;
LED K1, K2, KD and KV are lit; monitoring of the analog in- "<<<<" flashes in the display;
"<<<<" flashes in the display; puts relay output "Alarm" is inactive
relay output "Alarm" is inactive v Chapter 7.3.7 "Limit
value difference, hyster-
esis"
8.6 Voltage supply
Voltage supply AC/DC 20 to 30 V, 48 to 63 Hz AC 110 to 240 V, +10/-15 %, 48 to 63 Hz

Power consumption, Power loss max. 12 W max. 12 W
Power consumption, Power loss 5W 5W
for the following mode:
Analog output 10mA; background lighting Display
off; Relay output "Alarm" on;
Relay output pre-alarm off; Sensor: 2xPt100
8.7 Test voltages according to EN 60730, part 1
Input and output against voltage supply
- At a voltage supply AC 110 to 240 V +10 % /-15 % 3.7 kV/50 Hz
- At a voltage supply AC/DC 20 to 30 V, 48 to 63 Hz 3.7kV/50 Hz
8.8 Electrical safety
Clearances / creep paths

Mains to electronic components 6 mm8 mm
and probes
Mains to relays 6 mm8 mm
Relays to electronic components 6 mm8 mm
and probes
Electrical safety According to DIN EN 14597 (DIN EN 60730-2-9)
Overvoltage category III, pollution degree 2
Protection rating I With internal separation from SELV current circuits
8.9 Environmental influences

Ambient temperature range 0 to. +55 °C
Storage temperature range -30 to +70 °C
Temperature influence   0.005 % / K dev. from 23 °C 1 for RTD temperature probes
 ± 0.01% / K dev. from 23°C 1 for thermocouples and current

Terminal temperature Range If the temperature range of -10 °C to +80 °C is exceeded or undercut, the device shows
the error message “Terminal temperature Range“.
The output changes to a safe state (quiescent current principle).
The message can only be acknowledged, if the temperature is back again in the valid
range.
Environmental performance 85 % rel. humidity without condensation
(3K3 with extended temperature range according to DIN EN 60721-3-3)
EMC According to DIN EN 14597 and standards from the standard series DIN EN 61326
Emitted interference Class B
Interference resistance Evaluation criteria FS according to DIN EN 14597, regulation and control devices (RS)
1. All specifications refer to the measuring range limit value
8.10 Case
Material Polycarbonate
Flammability class UL 94 V0
Electrical connection On the front via screw terminals up to max. 2.5 mm 2
Installation On 35 mm DIN rail according to EN 60715
Installation position vertical
Weight Approx. 230 g
Protection class IP 20 according to DIN EN 60529
8.11 Approvals/approval marks
Approval marks Inspection author- Certificates/certification Inspection basics Valid for
ity numbers
DIN DIN CERTCO STB/STW1223 DIN EN 14597 All device versions:
SIL2, SIL3 TÜV Nord (German SEBS-A.102606/16-2 V1.0 DIN EN 61508 All device versions:
Technical Inspec-
PL e tion Agency) DIN EN ISO 13849-1 All device versions:
c UL us Underwriters Labo- E325456-20120611 Applied for UL 60730-2-9 All device versions:

ratories
GL Germanischer Lloyd 36 790-11HH All device versions:
Pressure equipment TÜV Süd (German 1045P0038/15/D0046 DGRL 97/23/EG All device versions:
directive Technical Inspec-
tion Agency)

8.12 Probes for the operating medium air

Note: Because of the high response accuracy, the use of thermowells (pockets) is not admissible.
Actual type designation Old type Probe type Temperature range Nom. length mm Process connection
designation
RTD temperature probe Data Sheet 90.2006
902006/65-228-1003-1-15-500-668/000 - 1 x Pt100 -170 ... +700°C 500
902006/65-228-1003-1-15-710-668/000 - 710
902006/65-228-1003-1-15-1000-668/000 - 1000
902006/55-228-1003-1-15-500-254/000 - 1 x Pt100 -170 ... +700°C 500
902006/55-228-1003-1-15-710-254/000 - 710
902006/55-228-1003-1-15-1000-254/000 - 1000
902006/65-228-2003-1-15-500-668/000 90.271-F01 2 x Pt100 -170 ... +700°C 500 Stop flange,
902006/65-228-2003-1-15-710-668/000 90.272-F01 710 movable
902006/65-228-2003-1-15-1000-668/000 90.273-F01 1000
902006/55-228-2003-1-15-500-254/000 - 2 x Pt100 -170 ... +700°C 500 movable
902006/55-228-2003-1-15-710-254/000 - 710 G1/2 compression
clamp
902006/55-228-2003-1-15-1000-254/000 - 1000
Thermocouples Data Sheet 90.1006
901006/65-547-2043-15-500-668/000 90.019-F01 2 x NiCr-Ni, TypE „K“ -35 ... +800°C 500 Stop flange,
901006/65-547-2043-15-710-668/000 90.020-F01 710 movable
901006/65-547-2043-15-1000-668/000 90.021-F01 1000
901006/65-546-2042-15-500-668/000 90.019-F11 2 x Fe-CuNi, TypE „L“ -35 ... +700°C 500
901006/65-546-2042-15-710-668/000 90.020-F11 710
901006/65-546-2042-15-1000-668/000 90.021-F11 1000
901006/66-550-2043-6-500-668/000 90.023-F01 2 x NiCr-Ni, TypE „K“ -35 ... +1000°C 500
901006/66-550-2043-6-355-668/000 90.023-F02 355
901006/66-550-2043-6-250-668/000 90.023-F03 250
901006/66-880-1044-6-250-668/000 90.021 1 x PT10Rh-PT, TypE „S“ 0 ... 1300°C 250
901006/66-880-1044-6-355-668/000 90.022 355
901006/66-880-1044-6-500-668/000 90.023 500
901006/66-880-2044-6-250-668/000 90-D-021 2 x PT10Rh-PT, TypE „S“ 0 ... 1300°C 250 Stop flange,
901006/66-880-2044-6-355-668/000 90-D-022 355 movable
901006/66-880-2044-6-500-668/000 90-D-023 500
901006/66-953-1046-6-250-668/000 90.027 1 x PT30Rh-PT6Rh, TypE „B“ 600 ... 1500°C 250
901006/66-953-1046-6-355-668/000 90.028 355
901006/66-953-1046-6-500-668/000 90.029 500
901006/66-953-2046-6-250-668/000 90-D-027 2 x PT30Rh-PT6Rh, TypE „B“ 600 ... 1500°C 250
901006/66-953-2046-6-355-668/000 90-D-028 355
901006/66-953-2046-6-500-668/000 90-D-029 500
8.13 Probes for the operating medium water and oil

designation
90.2006/10-402-1003-1-9-100-104/000 1 x Pt100 -40 ... +400°C 100 G1/2 screw connection
90.2006/10-402-2003-1-9-100-104/000 2 x Pt100 100
902006/54-227-2003-1-15-710-254/000 90.272-F02 2 x Pt100 -170 ... 550°C 65...670 movable
902006/54-227-1003-1-15-710-254/000 90.272-F03 1 x Pt100 65...670 G1/2 compression clamp
902006/10-226-1003-1-9-250-104/000 90.239 1 x Pt100 -170 ... 480°C 250 G1/2 screw connection
902006/10-226-2003-1-9-250-104/000 90-D-239 2 x Pt100 250
901006/54-544-2043-15-710-254/000 90.020-F02 2 x NiCr-Ni, Type „K“ -35 ... 550°C 65...670 movable
901006/54-544-1043-15-710-254/000 90.020-F03 1 x NiCr-Ni, Type „K“ 65...670 G1/2 compression clamp
901006/54-544-2042-15-710-254/000 90.020-F12 2 x FeCuNi, Type „L“ 65...670

901006/54-544-1042-15-710-254/000 90.020-F13 1 x FeCuNi, Type „L“ 65...670

Note: Because of the high response accuracy, only use thermowells (pockets) that are included in the scope of delivery.
designation
902006/53-505-2003-1-12-190-815/000 90D239-F03 2 x Pt100 -40 ... +400 °C 190
902006/53-507-2003-1-12-100-815/000 90.239-F02 2 x Pt100 -40 ... +480 °C 100
902006/53-507-2003-1-12-160-815/000 90.239-F12 (arranged one 160
below the other
902006/53-507-2003-1-12-190-815/000 in protection tube) 190
902006/53-507-2003-1-12-220-815/000 90.239-F22 220
902006/53-507-1003-1-12-100-815/000 90.239-F01 1 x Pt100 -40 ... +480 °C 100 weld-in sleeve
902006/53-507-1003-1-12-160-815/000 90.239-F11 160
902006/53-507-1003-1-12-220-815/000 90.239-F21 220
902006/53-505-1003-1-12-190-815/000 90.239-F03 1 x Pt100 -40 ... +400 °C 190
902006/53-505-3003-1-12-100-815/000 90.239-F07 3 x Pt100 -40 ... +400 °C 100
902006/53-505-3003-1-12-160-815/000 90.239-F17 160
902006/53-505-3003-1-12-220-815/000 90.239-F27 220
902006/40-226-1003-1-12-220-815/000 90.280-F30 1 x Pt100 -170 ... +480°C 220 weld-in sleeve
902006/40-226-1003-1-12-160-815/000 90.280-F31 160
902006/40-226-1003-1-12-100-815/000 90.280-F32 100
901006/53-543-1042-12-220-815/000 90.111-F01 1 x Fe-CuNi Type „L“ -35 ... 480°C 220 weld-in sleeve
901006/53-543-2042-12-220-815/000 90.111-F02 2 x Fe-CuNi Type „L“ 220
8.14 Probes for the operating medium water, oil and air
Actual type designation Old type Probe type Temperature range Install. length mm Process connection
designation
90.2006/10-390-1003-1-8-250-104/000 90.210-F95 1 x Pt100 max. 300°C 250
901006/45-551-2043-2-xxxx-11-xxxx 2 x NiCr-Ni, TypE „K“ max. 150°C 50...2000
A Probe short-circuit is only detectable with a double thermocouple.
H The probes described in data sheets 901006 and 902006 are also certified for the Pressure Equipment Directive.

V1.01/EN 9 Setup program 104
9 Setup program
The program and the connection cable are available as accessories and
offer the following possibilities:
- Easy and comfortable parameterization and archiving via PC
- Easy parameter duplication for identical types of devices
9.1 Minimum hardware and software prerequi-

sites:
- PC Pentium III or higher
- 128 MB RAM, 16 MB free on hard disk
- CD-ROM drive
- Free USB interface, mouse connection
- Microsoft1 Windows1 XP
h Connect the device to the PC using the USB cable
9.2 Displaying the device software version
h Simultaneously press the and keys and hold down
This version is also recognized by the setup program and displayed un-

der Info  Information about setup.
The software versions of the device and the setup program
must be compatible as otherwise an error message will appear!
1. Is a registered trademark of Microsoft Corporation

9.3 Forgotten the code?
If you forget the code, it can be read out via the USB interface and the setup program.
h Perform a data transfer  read-out from device.
The read-out code now appears in the setup program.

It can be retained or changed.
If "0" is set and transferred to the device, the code interrogation is deactivated and the configuration level is freely accessible.
9.4 Special function: thermocouple reverse polarity protection
If a thermocouple is incorrectly connected (reverse polarity), in-

correct measured values will be displayed, e.g. negative tem-
peratures instead of the expected positive temperatures may
be displayed.
This may lead to the set limit value never being reached. An ad-
ditional limit value will be defined that is factory set to -205 °C
and the relay alarm will be triggered if the actual value falls be-
low this limit.
This value must be effectively selected to ensure that a possi-
ble reverse polarity is detected.
V1.01/EN 9 Setup program 105

V1.01/EN 10 Alarm messages 106
10 Alarm messages
They can appear as follows:
Alarm display Cause Remedy

5 flashing horizontal lines: Measured value error h Check error messages on the screen
No valid value can be displayed h Please contact the JUMO Service department
v Chapter 2.5 "Service addresses"
Measured value overrange h Change the display to 2 measured values

The measured value is too high, is out- This makes it possible to detect which channel is de-
side the measuring range or the probe fective.
is broken. h Check the probe and connection line for damage or
short-circuit.
Measured value underrange v Chapter 4.2 "Connection diagram"
The measured value is too low, is out-
side the measuring range or a short-cir- h Check that the correct probe is set and/or connect-
cuit occurred at the probe. ed.
v Chapter 7.2 "Analog inputs"
5 flashing asterisks Display overflow h Check error messages on the screen
Value cannot be displayed h Please contact the JUMO Service department
11 Error messages
These error messages are displayed one below the other.
Error display (Err) Origin Cause/remedy

Internal The set limit value for relay switching operations has been reached
h Increase the limit value for the relay switching operations
v Chapter 7.7.1 "Limit switching cycle"
A tick appears in place of the bell and the error message can be acknowledged
Terminal temp. Internal The internal Pt100 is defective1, or the terminal temperature has fallen outside the ad-
missible range (-10 to 80 °C).
This error cannot be acknowledged until it is within the admissible range again.
Reference volt.1 Internal The reference voltage is outside the valid range.
Acknowledgement is not possible until it is within the valid range again.
Calibration const.1 Internal A calibration constant is outside the valid range.
Configuration Internal Configuration data outside the value range.
Measured value Internal The measured value 1 or 2 is outside the valid range.
V1.01/EN 11 Error messages 107


Measured value Internal When the error status "Measured value" is signaled by the channel
missing then the diagnosis function tries to show the precise error on the basis of the read mea-
Probe short-circ. External sured value.
Meas. range overr.
Meas. range underr.
Probe break
Operating access1 Internal The diagnosis function communicates with the STB/STW.
Acknowledgement is not possible until communication has finished.
Setup access Internal The setup program is communicating with the STB/STW.
Acknowledgement is not possible until communication has finished.
CRC calibr.1 Internal Checksum error of the EEPROM-calibration data.
CRC config.1 Internal Checksum error of the EEPROM-configuration data.
Registry 1 Internal A registry error has occurred.
Acknowledgement not possible until the error has been remedied.
RAM defective1 Internal A RAM error has occurred.
ROM defective1 Internal A ROM error has occurred.
Program sequence1 Internal A program sequence error has occurred.
Watchdog1 Internal A watchdog reset has occurred.
Acknowledgement is possible.
Overvoltage1 Internal The uncontrolled secondary supply voltage is too high. Acknowledgement is possible.
Frequency1 Internal Error of the independent time base
Acknowledgement is possible
EEPROM defective1 Internal Error during internal communication with the EEPROM.
Stack1 Internal Error in the memory area reserved for the stack
AD converter1 Internal Error during internal communication with the A/D converter.
Acknowledgement is possible
Simulation1 Internal Error during measured value simulation.

Zero point1 Internal The zero point voltage of the A/D converter is too low.
Limit value System The configured limit value has been exceeded or has fallen under.


Diagnosis function
FLASH defective1 Internal An error was detected during the cyclic memory test of the ROM.
RAM defective1 Internal An error was detected during the cyclic memory test of the RAM.
CRC config.1 Internal An error was detected by the checksum test (CRC16) in the configuration of the diagno-
sis function.
CRC calib.1 Internal An error was detected by the checksum test (CRC16) in the calibration data of the diag-
nosis function.
Configuration Internal The configuration contains invalid data.
SW version1 Internal The software versions are not valid.
Editing Internal An error has occurred during editing.
V too low Internal The internal voltage supply value has fallen below the permitted range.
V too high Internal The permitted range of the internal voltage supply has been exceeded.
Int. communic.1 Internal An error has occurred during internal communication.
No acces to channels Internal Communication to one or both channels doesn‘t work correctly.
Difference System The difference (channel 1 minus channel 2) of the measured values has exceeded the
maximum permitted value.
Switching operations Internal The configured limit of the switching operations has been exceeded (there is only one
counter as all alarm relays switch).The error can be acknowledged when the current
counter is reduced or the limit is increased (so that the switching operations are not ac-
cidentally set to 0 in the event of further errors).
USB communic. Internal An error has occurred during USB communication.
Footnote 1 If the error cannot be acknowledged despite repeated switching off and on, the device
must be repaired by JUMO.
h Return the device

V1.01/EN 12 What to do, if ... 112
12 What to do, if ...

Description Cause Remedy
The following appears in Setup program transmits data. - Wait until data transmission has finished.
the display: The monitoring function switches off briefly dur-
ing data transmission and the device re-starts.
The measured value The device is in the alarm range h Check the limit value in the configuration
flashes in the top display. LEDs K1, K2 are lit red. level.
The measured value flashes in the display and is h Find out the reason for the overrange or un-
higher or lower than the limit value depending on derrange.
the switching behavior set.
h If necessary, correct the limit value
- Measured value too high or too low
h If necessary, reduce an excessive hysteresis
- Excessive deviation between the because it might be too high in the OK
temperature values during difference moni- range.
toring v Chapter 7.7.3 "Operating hours"
LED K1 is lit red, The device is set as a safety temperature lim- h Press the (RESET) key for longer than 3
although the measured iter (STB). seconds to manually unlock the relay.
value is in the OK range Even if the measured value is already in the OK v Chapter 5.5 "Alarm acknowledgement
range after being exceeded, the relay of an auto- using the Reset key (only for temperature
matic reset temperature limiter does not auto- limiters STB)"
matically reset.
It must be unlocked manually.
Description Cause Remedy
... relay output "Alarm" - The integrated fuse cut-out is defective, h Measure terminal 14 and 16 of the relay
between terminal 14 and caused by an excessive relay current. when the LED K1 is lit green using a conti-
16 is not closed although nuity test device.
the LED OK is lit green (in h The device must be returned to JUMO for
the OK range). repair.
... the display is dark, - Display shut-down after timeout was activat- h Press any key
only the LEDs are lit ed or switch off timeout.
v Chapter 7.6.8 "Time-out operation"
V1.01/EN 12 What to do, if ... 113

V1.01/EN 13 Information for devices with extra code 062 GL 114
13 Information for devices with extra code 062 GL

The following information supplements or replaces the existing information.
13.1 Technical data

The ambient conditions according to application category C for closed areas
Temperature 0 to 55 °C
Relative humidity 100% rh
Vibration 0.7 g
Inspection basics: GL design specifications & directives:

EMC 1
Software requirement class: 4
13.2 Alarm messages

v Chapter 10 "Alarm messages"
13.3 Locks
The configuration level can be inhibited with a code.
v Chapter 7.6.9 "Code"
Intentional or unintentional adjustments are not possible without additional measures.
v Chapter 5.7 "Lead sealing the device"
H For service work, the device must be returned to the head office.
According to recommendation of the German Lloyd the availability of a replacement device must be guaranteed
for certain applications.
H We recommend keeping a printout of the configuration parameters (setup program) and the technical documents
of the STB/STW (connection diagram) on site (request a copy if necessary).
V1.01/EN 13 Information for devices with extra code 062 GL 115

V1.01/EN 14 Output behavior 116
14 Output behavior
Operating status Relay output alarm Relay output pre- Analog output
alarm KV
Initialization
Initialization phase after mains voltage – ON Inactive Inactive 0 mA,

(for approx. 10 seconds) 0V
Setup communication
During reading-writing of the configuration Inactive Pre-alarm monitoring Scaled analog signal is
(for approx. 5 seconds) active being output
v Chapter 7.3.4 v Chapter 7.5
Standard operation
After initialization phase system is in error- Inactive Pre-alarm monitoring Scaled analog signal is
free status Unlocking possible active being output
(STB - initial startup) v Chapter 7.3.4 v Chapter 7.5
After initialization phase system is in error-free Monitoring of the
status limit value active
(STB, STW) v Chapter 7.3.2
External error

alarm KV
Probe break, probe short circuit Inactive Error- and relay pre- Error cases can be
(e.g. input 1) alarm can be configu- configured
red v Chapter 7.5.5
v Chapter 7.3.6 Error signal output
v Chapter 7.5.6
After probe break, probe short circuit (STW) Monitoring of the Pre-alarm monitoring Scaled analog signal is
limit value active active being output
v Chapter 7.3.2 v Chapter 7.3.4 v Chapter 7.5
After probe break, probe short circuit Inactive
(e.g. input 1) (STB) Unlocking possible
After acknowledgement probe break Monitoring of the

Probe short circuit (STB) limit value active
v Chapter 7.3.2
Difference monitoring through diagnostics
Differential – Alarm (STW function) Inactive Error- and relay pre- Error cases can be
alarm can be configu- configured
red v Chapter 7.5.5
v Chapter 7.5.6
alarm KV
Differential – Alarm inactive again (STW func- Monitoring of the Pre-alarm monitoring Scaled analog signal is
tion) limit value active active being output
v Chapter 7.3.2 v Chapter 7.3.4 v Chapter 7.5
Differential – Alarm (STB function) Inactive Error- and relay pre- Error cases can be
red v Chapter 7.5.5
v Chapter 7.5.6
Differential – Alarm inactive again (STB function) Inactive Pre-alarm monitoring Scaled analog signal is
Unlocking possible active being output
After acknowledgement probe break – Alarm Monitoring of the
(STB function) limit value active
v Chapter 7.3.2
Internal errors
Internal errors diagnostic channel active Inactive Pre-alarm monitoring Scaled analog signal is
active being output
Internal errors diagnostic channel inactive again Monitoring of the
limit value active v Chapter 7.3.4 v Chapter 7.5
v Chapter 7.3.2

alarm KV
Internal errors safety channel active (STB) Inactive Error- and relay pre- Error cases can be
red v Chapter 7.5.5
v Chapter 7.5.6
Internal errors safety channel inactive again Inactive Pre-alarm monitoring Scaled analog signal is
(STB) Unlocking possible active being output
Internal errors safety channel after Monitoring of the
acknowledgement (STB) limit value active
v Chapter 7.3.2
V1.01/EN 15 Certificates 122
15 Certificates
DIN CERTCO STB/STW1223
Report E325456-20120611
SEBS-A.102606/16-1, V1.0
DGRL 07 202 1045 Z 0031/14/D0046

GL 36 790 11HH

Konformitätsbescheinigung
Konformitätsbescheinigung

15.1 China RoHS
ᴹ∂ᴹᇣ⢙䍘ᡆ‫ݳ‬㍐۷
䜘Ԧ਽〠
Κ۷ ۷
䫵˄˅ ⊎˄ ˅ 䭹˄˅ ‫ޝ‬ԧ䬜˄˅ ཊⓤ㚄㤟˄˅ ཊⓤҼ㤟䟊˄ ˅
እ኏
!ẇ

" #$
䗷〻䘎᧕
Κ۷ҟ!

#%
Ͳ⼺ẕ
&
'۷
⼺䪹
(ȑ۷ ) ҟ

(ȑ#۷ ҟҟ
㦻嫷㫋∬㗽^:ͬdϭϭϯϲϰͲϮϬϭϰ䤓屓⸩冥Ⓟᇭ
;dŚŝƐƚĂďůĞŝƐƉƌĞƉĂƌĞĚŝŶĂĐĐŽƌĚĂŶĐĞǁŝƚŚƚŚĞƉƌŽǀŝƐŝŽŶƐŽĨ^:ͬdϭϭϯϲϰͲϮϬϭϰ͘Ϳ
K㸸⾲♧䈕ᴹᇣ⢙䍘൘䈕䜘Ԧᡰᴹ൷䍘ᶀᯉѝⲴਜ਼䟿൷൘'ͬdϮϲϱϳϮ㿴ᇊⲴ䲀䟿㾱≲ԕлǄ
;K͗/ŶĚŝĐĂƚĞƐƚŚĂƚƐĂŝĚŚĂǌĂƌĚŽƵƐƐƵďƐƚĂŶĐĞĐŽŶƚĂŝŶĞĚŝŶĂůůŽĨƚŚĞŚŽŵŽŐĞŶĞŽƵƐŵĂƚĞƌŝĂůƐĨŽƌƚŚŝƐƉĂƌƚŝƐďĞůŽǁƚŚĞůŝŵŝƚƌĞƋƵŝƌĞŵĞŶƚŽĨ'ͬdϮϲϱϳϮ͘Ϳ
y㸸⾲♧䈕ᴹᇣ⢙䍘㠣ቁ൘䈕䜘ԦⲴḀа൷䍘ᶀᯉѝⲴਜ਼䟿䎵ࠪ'ͬdϮϲϱϳϮ㿴ᇊⲴ䲀䟿㾱≲Ǆ
;y͗/ŶĚŝĐĂƚĞƐƚŚĂƚƐĂŝĚŚĂǌĂƌĚŽƵƐƐƵďƐƚĂŶĐĞĐŽŶƚĂŝŶĞĚŝŶŽŶĞŽĨƚŚĞŚŽŵŽŐĞŶĞŽƵƐŵĂƚĞƌŝĂůƐƵƐĞĚĨŽƌƚŚŝƐƉĂƌƚŝƐĂďŽǀĞƚŚĞůŝŵŝƚƌĞƋƵŝƌĞŵĞŶƚŽĨ'ͬdϮϲϱϳϮ͘Ϳ
JUMO GmbH & Co. KG JUMO Instrument Co. Ltd. JUMO Process Control, Inc.
Street address: JUMO House 6733 Myers Road
Moritz-Juchheim-Straße 1 Temple Bank, Riverway East Syracuse, NY 13057, USA
36039 Fulda, Germany Harlow, Essex CM 20 2DY, UK Phone: +1 315 437 5866
Delivery address: Phone: +44 1279 63 55 33 Fax: +1 315 437 5860
Mackenrodtstraße 14 Fax: +44 1279 62 50 29 Email: info.us@jumo.net
36039 Fulda, Germany Email: sales@jumo.co.uk Internet: www.jumousa.com
Postal address: Internet: www.jumo.co.uk
36035 Fulda, Germany
Phone: +49 661 6003-0
Fax: +49 661 6003-607
Email: mail@jumo.net
Internet: www.jumo.net
UNIFLEX CI 45
universal transmitter
UNIFLEX CI 45
UNIFLEX CI 45
Operating manual
English
9499-040-71711
rail line Valid from: 06/2009
û BlueControl
Ò
More efficiency in engineering,

more overview in operating:
â
The projecting environment for the BluePort controllers, indicators
rail line and measuring converter, controller, temperature limiter
on
N!
s
O date e
I
T Up e.d
N
E and nlin D
T
ATrsion ma-o A-C
Ve .p PM
i ni ww r on
M w o
Description of symbols:
g General information
a General warning
l Attention: ESD sensitive devices
Caution: read the operating instructions
Read the operating instructions
+ Hint
© 2004 PMA Prozeß- und Maschinen-Automation GmbH · Printed in Germany
All rights reserved. No part of this document may be reproduced or published in any form
or by any means without prior written permission from the copyright owner.
A publication of PMA Prozeß- und Maschinen Automation

P.O.Box 310229
D-34058 Kassel
Germany
Table of content
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1 Maintenance, repair, modification . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Connecting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Terminal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Connecting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Connection examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Hints for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5.1 cULus approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Operating structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Behaviour after supply voltage switch-on . . . . . . . . . . . . . . . . . . . . . . . 15
5.4 Operating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4.1 Display line1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4.2 Display line 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4.3 Switching over by means of the Enter key . . . . . . . . . . . . . . . . 16
5.4.4 Slave pointer function. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4.5 Selecting the units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4.6 Extended operating level . . . . . . . . . . . . . . . . . . . . . . . . . 18
6. Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Linearization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Input scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.1 Input fail detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.2 Two-wire measurement. . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.3 Scaling with potentiometer measurement . . . . . . . . . . . . . . . . 21
6.3 Temperature compensation, measured via INP2 (optional) . . . . . . . . . . . . . . 22
6.4 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.5 Substitue value for inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.6 Input forcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.7 O2 measurement (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.8 Counter (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.9 Frequency input (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.10 Arithmetic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.11 Tare function (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.12 Sample&hold amplifier (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.13 Integrator function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.14 Limit value processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.14.1 Measured value monitoring. . . . . . . . . . . . . . . . . . . . . . . . 30
6.14.2 Monitoring the number of operating hours and switching cycles . . . . 32
UNIFLEX CI 45 3
6.15 Analog output configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.15.1 Analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.15.2 Logic output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.15.3 Transmitter power supply. . . . . . . . . . . . . . . . . . . . . . . . . 34
6.15.4 Frequency output (optional) . . . . . . . . . . . . . . . . . . . . . . . . 35
6.15.5 Analog output forcing . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.16 Maintenance manager / error list . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.17 Reset to factory setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7. Configuration level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1 Configuration survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.2 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8. Parameter setting level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.1 Parameter survey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9. Calibrating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.1 Offset correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.2 2-point correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ò
10.BlueControl engineering tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

11.Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13.Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4 UNIFLEX CI 45
- preliminary - General
. 1 General
Thank you very much for buying a Universal Transmitter UNIFLEX CI 45.
UNIFLEX CI 45 transmitters are suitable for precise, cost-efficient signal detection and processing. Every CI 45 is
equipped with at least one universal input, one universal output and a relay. Optionally, the transmitter can be fitted
with an additional relay.
Galvanic isolation is provided between inputs and outputs as well as from the supply voltage and the communication
interfaces.
Applications
CI 45 is used for measurement, scaling and separation of electrical signals, e.g. for
w Heat treatment plants
w Drying equipment
w Furnace builders
w Metallurgy
w Kilns
w General machine building
w Research and development
w Energy measurement
w
...
Signal conversion
At-a-glance survey of advantages

Compact construction, only 22,5 mm wide
Clips onto top-hat DIN rail
Plug-in screw terminals or spring clamp connectors
Dual-line LC display with additional display elements
Process values always in view
Convenient 3-key operation
Direct communication between rail-mounted transmitters
Universal input with high signal resolution (>15 bits) reduces stock keeping
Universal output with high resolution (14 bits) as combined current / voltage output
Quick response, only 100 ms cycle time, i.e. also suitable for fast signals
One or two relay outputs
Customer-specific linearization
Measurement value correction (offset or 2-point)
Min/max indicator ('slave pointer')
Logical linking of digital outputs, e.g. for common alarms
Preset of output value
* This documentation includes already several options which will be available only with
operating version 2 instruments.
Further documentation for universal transmitter CI 45:

– Data sheet CI 45 9498 737 48313
– Operating note CI 45 9499 040 71441
– Interface description 9499 040 72011
UNIFLEX CI 45 5
Safety hints
. 2 Safety hints
This instrument was built and tested in accordance with VDE 0411-1 / EN 61010-1 and was shipped in safe condition.
The unit complies with European guideline 89/336/EEC (EMC) and is provided with the CE-marking.
The instrument was tested before delivery and has passed the tests required in the test plan. In order to maintain this
condition and to ensure safe operation, the user must follow the hints and warnings given in these operating
instructions and operate this instrument in compliance with the instructions given in this manual.
a The unit is intended exclusively for use as a measuring and control instrument in technical installations.
a Warning
If the instrument is so heavily damaged that safe operation seems impossible, the instrument must not be taken into
operation.
The electrical connections must conform to local standards (e.g. VDE 0100). The input leads must be kept separate
from signal and mains leads.
A circuit breaker or a power switch must be provided for the instrument and marked accordingly in the installation. The
circuit breaker or power switch must be installed near the instrument and easily accessible for the operator.
COMMISSIONING
Before instrument switch-on, ensure that the rules given below were followed:
w Ensure that the supply voltage corresponds to the specification on the type label.
w All covers required for contact safety must be fitted.
w Before instrument switch-on, check, if other equipment and/or facilities connected in the same signal loop is / are
not affected. If necessary, appropriate protective measures must be taken.
w The instrument may be operated only when mounted in its enclosure.
w The temperature limits specifed for operation of the unit must be met before and during operation.
a Warning
During operation, the ventilation slots of the housing must not be covered.
a The measurement inputs are designed for measurement of circuits which are not connected directly with
the mains supply (CAT I). The measurement inputs are designed for transient voltage peaks up to 800V
against PE.
SHUT-DOWN
For permanent shut-down, disconnect the instrument from all voltage sources and protect it against accidental
operation.
Before instrument switch-off, check that other equipment and / or facilities connected in the same signal loop is / are
not affected. If necessary, appropriate measures must be taken.
2.1 Maintenance, repair, modification

The instruments need no particular maintenance.
No operable controls are mounted inside the instrument, i.e. the operator must not open the unit.
Modification, maintenance and repair may be carried out only by trained, authorized persons. For this purpose, the user
is invited to contact the PMA service.
6 Maintenance, repair, modification UNIFLEX CI 45

Safety hints
a Warning
When opening the instruments, or when removing covers and components, live parts or terminals can be exposed.
l Caution
When opening the instruments, electrostatically sensitive components can be exposed.
g The PMA service can be contacted as follows:

Miramstraße 87
D-34123 Kassel
Tel. +49 (0)561 / 505-1257

Fax +49 (0)561 / 505-1357
e-mail: mailbox@pma-online.de
2.2 Cleaning
g Housing and front panel of the instrument can be cleansed using a dry, lintfree cloth.
2.3 Spare parts
The following accessories are permitted as spare parts for the transmitter:

Connector set with screw terminals 9407-998-07101
Connector set with spring clamp terminals 9407-998-07111
Bus connector for fitting in top-hat rail 9407-998-07121
UNIFLEX CI 45 Cleaning 7
- preliminary - Mounting
. 3 Mounting
Abmessungen / dimensions Montage / mounting
(0,20”)
5.5
4
8
in e /
rm m
3
7
al
te lem
2
6
K
1
5
2.3
(0,08”)
click
99 (3,90”)
11 al /
Demontage / dismantling
te lem 8
14
in e
K 71
rm m
13
61
12
1
15
111 (4,37”)
22.5
(0,87”) 117.5 (4,63”)
max. 55°C max.

95% rel. %
min. -10°C
1
The unit is provided for vertical mounting on 35 mm top-hat rails to EN 50022.

If possible, the place of installation should be exempt of vibration, aggressive media (e.g. acid, lye), liquid, dust or
aerosol.
The instruments of the rail line series can be mounted directly side by side. For mounting and dismounting, min. 8 cm
free space above and below the units should be provided.
For mounting, simply clip the unit onto the top-hat rail from top and click it in position.
To dismount the unit, pull the bottom catch down using a screwdriver and remove the unit upwards.
g Transmitter CI 45 does not contain any maintenance parts, i.e. the unit need not be opened by the
customer.
a The unit may be operated only in environments for which it is suitable due to its protection type.
a The housing ventilation slots must not be covered.
a In plants where transient voltage peaks are susceptible to occur, the instruments must be equipped with
additional protective filters or voltage limiters!
l Caution! The instrument contains electrostatically sensitive components .
a Please, follow the instructions given in the safety hints.
a To maintain contamination degree 2 acc. to EN 61010-1, the instrument must not be installed below
contactors or similar units from which conducting dust or particles might trickle down.
UNIFLEX CI 45 8
Mounting
3.1 Connectors
The four instrument connectors are of the plug-in type. They plug into the housing from top or bottom and click in
position. Releasing the connectors should be done by means of a screwdriver.
Two connector types are available:
2
• Screw terminals for max. 2,5 mm conductors
2
• Spring-clamp terminals for max. 2,5 mm conductors
g Before handling the connectors, the unit must be disconnected from the
supply voltage.
Tighten the screw terminals with a torque of 0,5 - 0,6 Nm.

With spring-clamp terminals, stiff and flexible wires with end crimp can be
introduced into the clamping hole directly. For releasing, actuate the (orange)
opening lever.
a Contact protection: Terminal blocks which are not connected should remain in the socket.
UNIFLEX CI 45 Connectors 9
Electrical connections - preliminary -
. 4 Electrical connections
e a (mV)
b b
c
d a
7 INP2 5 6 7 8 di1 3
1234
2 INP1 1 2 3 4
a
b top
c RGND RGND
d Data A Data A
e
Data B Data B
mV
f V
g RS 485 6
Logic
h
k i
j V
5 OUT3 11 12 13 14
11 12 13 14
PWR 15 16 17 18
OUT1
15 16 17 18
L N 4
1 90...260V AC OUT2
24V AC/DC
4.2 Terminal connections
a Faulty connection might cause destruction of the instrument !
1 Connecting the supply voltage

Dependend on order
w 90 … 260 V AC terminal: 15, 16
w 24 V AC / DC
For further information, see section "Technical data"
terminal: 15, 16
g Instruments with optional system interface:

Energization is via the bus connector of field bus coupler or power supply module. Terminals 15, 16 must
not be used.
10 Connecting diagram UNIFLEX CI 45

2 Connecting input INP1

Input for the measurement value
a resistance thermometer (Pt100/ Pt1000/ KTY/ ...), 3-wire connection terminal: 1, 2, 3
b resistance thermometer (Pt100/ Pt1000/ KTY/ ...), 4-wire connection terminal: 2, 3, 5, 6
c potentiometer terminal: 1, 2, 3
d current (0/4...20mA) terminal: 2, 3
e voltage (-2,5...115/-25...1150/-25...90/ -500...500mV) terminal: 1, 2
f voltage (0/2...10V/ -5...5V) terminal: 2, 4
g thermocouple terminal: 1, 3
3 Connecting input di1

Digital input,
a control input (as a contact) terminal: 7, 8
b control input (as an opto-coupler)(optional) terminal: 7, 8
c counter input (optional) terminal: 7, 8
d frequency input (optional) terminal: 7, 8
4 Connecting outputs OUT1 / OUT2 (optional)

Relay outputs max. 250V/2A NO contacts with a common terminal.
w OUT1 terminal: 17, 18
w OUT2 terminal: 17, 14
5 Connecting output OUT3

Universal output
h logic (0..20mA / 0..11,5V) terminal: 11, 12
i current (0...20mA) terminal: 11, 12
j voltage (-10/0...10V)) terminal: 12, 13
k transmitter power supply terminal: 11, 12
l frequency output terminal: 12, 13
6 Connecting the bus interface (optional)

RS 485 interface with MODBUS RTU protocol
* see interface description MODBUS RTU: (9499-040-72011)
7 Connecting input INP2 (optional)

Input for the second variable INP2.
a thermocouple terminal: 5, 6
b resistance thermometer (Pt100/ Pt1000/ KTY/ ...), 3-wire connection terminal: 2, 5, 6
c potentiometer terminal: 2, 5 6
d current (0/4...20mA) terminal: 2, 6
e voltage (-2,5...115/-25...1150/-25...90/ -500...500mV) terminal: 5, 6
UNIFLEX CI 45 Terminal connections 11


Ò
The instrument terminals used for the engineering can be displayed and printed out via BlueControl ( menu File \ Print
preview - Connection diagram).
Example
Connecting diagram
Connector 1
Name Description
Process value x1
Measurement
Frequency measurement
Connector 2
Name Description
Frequency
Limit value 2 signalling, INP2 error signalling
Limit value 1 signalling, INP1 error signalling
4.4 Connection examples
Example: Signal converter with output on indicator and alarm signal

L
INP2 5 6 7 8 di1
1 2 3 4
INP1
11 12 13 14 OUT2
PWR
PWR 15 16 17 18 OUT1
12 Connecting diagram UNIFLEX CI 45

Example: RS 485 interface with RS 485-RS 232 converter

See documentation 9499-040-72011
Master z.B. / e.g.

Converter RS 232-RS 485
(ADAM-4520-D)
RGND 3
DATA+ 1
Data A
(RS-485)
LT 1 DATA-
LT 1 Data B TX+
Data A
(RS-422)
TX-
RX+
2 Data B RX-
(R)+Vs
(B)GND 10
4.5 Hints for installation

w Measurement and data lines should be kept separate from control and power supply cables.
w Sensor measuring cables should be twisted and screened, with the screening connected to earth.
w External contactors, relays, motors, etc. must be fitted with RC snubber circuits to manufacturer specifications.
w The unit must not be installed near strong electric and magnetic fields.
w The temperature resistance of connecting cables should be selected in accordance with the local conditions.
a The unit is not suitable for installation in explosion-hazarded areas.
a Faulty connection can lead to the destruction of the instrument.
a The measurement inputs are designed for measurement of circuits which are not connected directly with
the mains supply (CAT I). The measurement inputs are designed for transient voltage peaks up to 800V
against PE.
a Please, follow the instructions given in the safety hints.
4.5.1 cULus approval

For compliance with cULus regulations, the following points must be taken into account:
q Use only copper (Cu) wires for 60 / 75 °C ambient temperature.

q The connecting terminals are designed for 0,5 – 2,5 mm 2 Cu conductors.
q The screw terminals must be tightened using a torque of 0,5 – 0,6 Nm.
q The instrument must be used exclusively for indoor applications.
q For max. ambient temperature: see technical data.
q Maximum operating voltage: see technical data.
UNIFLEX CI 45 Hints for installation 13

Operation
. 5 Operation
5.1 Front view
1 Line 1: process value display

2 Line 2: display of unit / extended operating level / error list /
Conf and PArA level values
3 Tare / sample & hold activated
4 Error list (2 x ô ), e.g.
· Fbf. x sensor fault INP. X
· sht. x short circuit INP. X
· Pol. x wrong polarity INP. X
· Lim. x limit value alarm
· ...
5 Increment key / slave pointer, maximum value
6 Enter key to select extended operating level or error list
7 LED indication of instrument status
· green: OK
· green blinking: no data exchange with bus coupler
(only on instruments with optional
system interface)
· red: limit value I triggered
· red blinking: instrument fault
8 Display elements, active as bars
9 Status of switching output OUT1 / INP1 active
0 Status of switching output OUT2 / INP2 active
! Decrement key / slave pointer, minimum value
Ò
§ PC connection for the BlueControl engineering tool
g The measurement value is displayed in LCD line 1. In the second line, the selected unit is displayed as
standard. When changing over to the parameter setting, configuration or calibration level and at the
extended operating level, the parameter name and value are displayed alternately.
+ § : To facilitate withdrawal of the PC connector from the instrument, please, press the cable left.
14 Front view UNIFLEX CI 45

Operation
The instrument operation is divided into four levels:
450.3 3s Operating level

ûC
äüüü
1 2 F E ô 450.3
PARA ô PASS
Parameter level
äüüü
1 2 F E
450.3
CONF
ô PASS
äüüü Configuration level
1 2 F E
450.3
CAL
äüüü
ô PASS
1 2 F E
Calibrating level
450.3
END
ô
äüüü
1 2 F E
The access to the parameter, configuration and calibrating level can be disabled using the following two methods:
w Level disabling by adjustment in the engineering tool (IPar, ICnf, ICal). Display of disabled levels is suppressed.
w The access to a level can be disabled by entry of a pass number (0 … 9999). After entry of the adjusted pass
number, all values of the level are available.
With faulty input, the unit returns to the operating level.
Adjusting the pass number is done via BlueControl Ò.
Individual parameters which must be accessible without pass number, or from a disabled
parameter level, must be copied into the extended operating level.
Factory-setting: all levels are accessible without restrictions,
pass number PASS = OFF
PASS
5.3 Behaviour after supply voltage switch-on
After switching on the supply voltage, the instrument starts with the operating level .
The operating status is as before power-off.
5.4 Operating level
5.4.1 Display line1

The display value is the value resulting from function.1, function.2, function.3 handling.
It is also called process value (see also section/page 6-19.)
UNIFLEX CI 45 Operating structure 15

Operation
5.4.2 Display line 2

Ò
The value to be displayed continuously in the second LCD line can be selected via the BlueControl engineering
tool.
As default, the adjusted engineering unit is displayed.
1 2
450.3 450.3 1
2
Engineering unit as default setting
Display of output OUT3 in % (with
ûC 55.0 corresponding scaling)
äüüü äüüü
1 2 F E 1 2 F E
g The values in display line 2 can only be displayed, but not changed.
g Reset to display of the engineering unit is possible by deleting the entry for line 2..
g With faulty input values, signals dependent on the inputs (e.g. Inp1, Inp2, display value, Out3) also
indicate FAIL.
5.4.3 Switching over by means of the Enter key

By pressing key Enter, various values can be indicated on display line 2.
w 1 Display of the defined display line 2 value

(via BlueControl®);
Limit value LC is set by default
1 278.3
°C
äüüä
1 2 F E
ô
w 2 Display of the error list, if it includes entries.
With several inputs, the following value is 278.3 ô
2 FbF. 1
displayed when pressing the Enter key.
äüüä
1 2 F E
ô
w 3 Display of the extended operating level, if
entries were made. With several inputs, the 278.3
following value is displayed when pressing the 3 ô
L.1
enter key. äüüäü
1 2 F E
ô
w 4 Return to the initial display

Unless a key is pressed during 30 s, the 4 278.3
instrument returns to the initial display. °C
äüüä
1 2 F E
16 Operating level UNIFLEX CI 45

Operation
5.4.4 Slave pointer function

The minimum and maximum input values are stored in the unit.
450.3 450.3
ûC ûC
äüüü äüüü
1 2 F E 1 2 F E
min max
450.3 450.3
26.7 502.4
äüüü äüüü
1 2 F E 1 2 F E
The minimum input value is displayed as long as key Ì is The maximum input value is displayed as long as key È
pressed. is pressed.
Deleting the minimum value

The minimum value is deleted by pressing key È whilst key Ì is kept pressed.
Whether the minimum value should be deleted also by the digital input (rES.L) can be determined during
configuration.
Deleting the maximum value
To delete the maximum value, press key Ì whilst keeping key È pressed.
Whether the maximum value should be deleted also by the digital input (rES.H) can be determined during
configuration.
Deleting the minimum and maximum values is possible also via interface.
g When de-energizing UNIFLEX CI 45, the minimum and maximum values are deleted.
g In case of error of the display value (e.g. input fail behaviour), the minimum and maximum values are also
set to FAIL. When a valid value is displayed again, the minimum and maximum value are deleted.
5.4.5 Selecting the units

The unit to be displayed is determined via configuration D.Unt.
With selection “1 = temperature unit” , the displayed unit is determined by configuration Unit with the relevant
conversions for Fahrenheit and Kelvin.
By selecting D.Unt = 22, display of any max. 5-digit unit or text can be determined.
1
4.5
kWh
äüüü 1 Unit (example): kilowatt hour
1 2 F E
2 2 Text (example): TAG no.
450.3
TI451
äüüü
1 2 F E
UNIFLEX CI 45 Operating level 17

Operation
5.4.6 Extended operating level

The operation of important or frequently used parameters and signals can be allocated to the extended operating level.
This facilitates the access, e.g. travelling through long menu trees is omitted, or only selected values are operable, the
other data of the parameter level are e.g. disabled.
Display of the max. 8 available values of the extended operating level is in the second LCD line.
Ò
The content of the extended operating level is determined by means of the BlueControl engineering tool. For this,
select entry "Operation level" in the "Mode" selection menu. Further information is given in the on-line help of the
engineering tool.
Press key ô to display the first value of the extended

450.3 operating level (after display of error list, if necessary).
The selected parameters can be changed by
ûC pressing keys Ì and È .
äüüü
1 2 F E
ô
450.3 450.3
H.I 500.0
äüüü äüüü
1 2 F E 1 2 F E
ô press to display the next parameter
ô
450.3 450.3
L.I 100.0
äüüü äüüü
1 2 F E 1 2 F E
ô ô return to normal display after the last parameter
Unless a key is pressed within a defined time (timeout = 30 s), the operating level is displayed again.
18 Operating level UNIFLEX CI 45

Functions
. 6 Functions
The signal data flow of transmitter CI 45 is shown in the following diagram:
6.1 Linearization
The input values of input INP1 or INP2 can be linearized via a table.
By means of tables, e.g. special linearizations for thermocouples or other non-linear input signals, e.g. a container
filling curve, are possible.
Table “ Lin” is always used with sensor type S.TYP= 18: "Special thermocouple" in INP1 or INP2, or if linearization
S.Lin = 1: “Special linearization” are adjusted.
w The input signals must be specified in mV, V, mA, % or Ohm dependent on input type.
w For special thermocouples (S.tYP = 18), specify the input values in mV, and the output values in the temperature
unit adjusted in U.LinT .
w For special resistance thermometer (KTY 11-6) (S.tYP = 23), specify the input values in Ohm, and the output values
in the temperature unit adjusted in U.LinT.
Non-linear signals can be linearized using up to 32 segment points. Each segment point comprises an input ( In.1
… In.32) and an output (Ou.1 … Ou.32). These segment points are interconnected automatically by straight
lines. The straight line between the first two segment points is extended downwards and the straight line between the
two highest segment points is extended upwards, i.e. a defined output value for each input value is provided.
With an In.x value switched to OFF, all further segments are switched off.
+ Condition for the input values is an ascending order.

In.1 < In.2 < ...< In.32.
g For linearization of special thermocouples, the ambient temperature range should be defined exactly,
becauseit is used to derive the internal temperature compensation.
See also page 46.
UNIFLEX CI 45 Linearization 19
Functions
Ou.32
.
.
.
.
.
.
Ou.1
In.1 In.32
g The same linearization table is used for input 1 and input 2.
6.2 Input scaling

Scaling of input values is possible. After any linearization, measurement value correction is according to the offset or
two-point method.
g When using current or voltage signals as input variables for InP.x, the input and display values should
be scaled at the parameter level. Specification of the input value of the lower and upper scaling point is in
units of the relevant physical quantity.
phys.
size
OuH.x
mA / V phys. size
OuL.x
InL.x InH.x mA/V

Example for mA/V
g Parameters InL, OuL, InH and OuH are visible only with ConF / InP / Corr = 3 selected.
Parameters InL and InH determine the input range.
Example with mA:

InL= 4 and InH = 20 means that measuring from 4 to 20 mA is required (life zero setting).
20 Input scaling UNIFLEX CI 45

Functions
a For using the pre-defined scaling with thermocouples and resistance thermometers (Pt100), the settings
for InL and OuL as well as for InH and OuH must correspond with each other.
+ correspond.
For resetting the input scaling, the settings for InL and OuL as well as InH and OuH must
6.2.1 Input fail detection

For life zero detection of connected input signals, variable adjustment of the response value for FAIL detection is
possible according to formula:
Fail response value £ In.L - 0,125 * (In.H - In.L)
Example 1: In.L = 4 mA, In.H = 20 mA Fail response value £ 2 mA
Example 2: In.L = 2 V, In.H = 6 V Fail response value £ 1,5 V
6.2.2 Two-wire measurement

Normally, resistance and resistance thermometer measurement is in three-wire connection, whereby the resistance of
all leads is equal.
Measurement in four-wire connection is also possible for input I. With this method, the lead resistance is determined
by means of reference measurement.
With two-wire measurement, the lead resistance is included directly as a falsification in the measurement result.
However, determination of the lead resistances by means of is possible.
g Besides the connection of the both leads of the RTD / R sensor the
3rd connector has to be short-circuited.
Procedure with Pt100, Pt1000 2

Connect a Pt100 simulator or a resistance decade instead of the sensor at
the test point so that the lead resistance is included and calibrate the
values by means of 2-point correction. INP2 5 6 7 8
+ By means of measurement value correction the resulting

temperature value will be corrected, but not the resistance input INP1 1 2 3 4
value. In this case the linearization error can increase.
Procedure with resistance measurement

Measure the lead resistance with an ohmmeter and subtract it from the 1
measured value via the scaling.
6.2.3 Scaling with potentiometer measurement

With potentiometer measurement (S.tYP = 50 … 53), a display value in 0% (lower stop value) to 100 % (upper stop
value) is normally expected.
For this, 2-point calibration at calibrating level (rp. 49) Is necessary.
Turn your potentiometer to the lower stop and specify value “0” for OuL.x. Now, turn the potentiometer to the upper
stop and set value OuH.x to “100”.
UNIFLEX CI 45 Input scaling 21

Functions - preliminary -
6.3 Temperature compensation, measured via INP2 (optional)
With thermocouple measurement via INP1, the required temperature compensation is possible by internal
measurement of the compensation temperature via an external reference (external TC) or by measurement via INP2.
With TC measurement via INP2, the following settings must be done:

• setting in the function for: ConF / Func / Fnc.1 = 10
• input 1 for thermocouple input : ConF / InP.1 / S.tYP = 0 … 18
• Switch on input 2 for measurement : ConF / InP.2 / I.Fnc = 1
• Select suitable sensor element for input 2: ConF / InP.2 / S.tYP
Example:
– For saving compensating cable, or unless suitable cables for special thermocouples are available, the
termperature at the thermocouple connecting terminal must be measured exactly by means of a resistance
thermometer (e.g. Pt100).
g Unless input 2 is enabled for measurement, the unit generates error E.3 (configuration error).
Please, note that there may be increased errors or even polarity errors with a thermocouple measuring range starting
only at 0°C (32°F), when the outside temperature is low.
Connection example
INP2 5 6 7 8 di1
1 2 3 4
INP1
22 Temperature compensation, measured via INP2 (optional) UNIFLEX CI 45

- preliminary - Functions
6.4 Filter
A 1st order mathematical filter with adjustable time constant and bandwidth is built in.
Output
Input
b.F
The filter bandwidth b.Fx is the adjustable tolerance around the measured value within which the filter is active.
Measurement value changes in excess of the adjusted bandwidth are not filtered.
6.5 Substitue value for inputs

If a substitute value for an input is activated, this value is used for further calculation with a sensor fault, independent
of the selected input function. The selected controller output reaction on sensor fault, configuration FAIL, is omitted.
With factory setting, the substitute value is switched off.
a Before activation of a substitute value In.F, the effect on the control loop must be considered.
6.6 Input forcing

®
Setting f.AIx = 1 (only via BlueControl ) can be used for configuring the input for value entry via the interface
(=forcing).
a Please, check the effect on the control loop in case of failure of input value / communication and
exceeded measuring range.
6.7 O2 measurement (optional)

This function is available only on instrument versions with INP2 .
Lambda probes (l probes) are used as input signals. The electromotive force (in volt) delivered by lambda probes is
dependent on the instantaneous oxygen content and on the temperature. Therefore, transmitter CI 45 can only display
accurate measurement results, if the probe temperature is known.
Distinction of heated and non-heated lambda probes is made.
Signals from both types can be handled by CI 45.
Heated lambda probes

Heated l probes are fitted with a controlled heating, which ensures a continuous temperature. This temperature must
be specified in parameter Probe temperature in transmitter CI 45.
Parameters ® Functions ® Pro be temperature tEmP ® ...°C (/°F/K - dependent on configuration)
Non-heated lambda probes

When the probe is always operated at a fixed, known temperature, the procedure is as with a heated probe.
UNIFLEX CI 45 Filter 23
A non-heated l probe is used, if the temperature is not constant. In this case, the temperature in addition to the
probe mV value must be measured. For this purpose, any temperature measurement with analog input INP2 can be
used. During function selection, input INP2 must be set for measurement (CONF/InP.2/I.Fnc=1).
Configuration:
O2 -measurement must be adjusted in function 1 :
O2-measurement with constant probe temperature

Func r Fnc.1 7
(heated probe)
O2-measurement with probe temperature measurement
8
(non-heated probe)
Connection
Connect the input for the lambda probe to INP1 . Use terminals I and 2.
If necessary, temperature measurement is connected to INP2.
Input 1 is used to adjust one of the high-impedance voltage inputs as sensor type:
41 special ( -2,5...115 mV)

42 special ( -25...1150 mV)
Inp.1r S.tYP 43 special ( -25...90 mV)
44 special ( -500...500 mV)
47 special ( -200...200 mV)
These high-impedance inputs are without break monitoring. If necessary, input signal monitoring is possible via the
limit values.
Further recommendations for adjustment:
g Input 1 must be operated without linearization:

Inp.1r S.Lin 0 no linearization
g With O2 measurement, specification if parameters related to the measured value should be output in ppm
or % is required. This is done centrally during configuration.
othrr O2 0 Unit: ppm

1 Unit: %
g Whether the temperature of the non-heated l probe is entered in °C, °F or K can be selected during
configuration.
othrr Unit 1 °C
2 °F
3 K
24 O2 measurement (optional) UNIFLEX CI 45

Functions
Displays
With configuration for O 2 measurement (see above), the oxygen content is displayed as process value with the selected
unit (see above) on line 1. Max. 4 characters can be displayed.
With display range overflow, “EEEE” is displayed .

Example: the ppm range is selected, but the value is a % value.
When exceeding the display span start, 0 is displayed.
20.95
+ Tip: the unit can be displayed on line 2.
üû/o
6.8 Counter (optional)
Digital input di1 can be configured as a counter input (dependent on ordering code).
The function operating as a pulse counter is set as

• Up counter ( ConF / Cn.Fr / I.Fnc = 1, 2 )
• Down counter ( ConF / Cn.Fr / I.Fnc = 3, 4 )
• Active edge is configurable
g The counter state is updated continuously in the background with the sample & hold function activated
(r p. ) .
a The counter state is not stored permanently. It is reset to the counter start value (Cnt.S) after supply
voltage switch-on.
Up counter function
• The counter starts with start value Cnt.S,
adjustable via ConF / Cn.Fr / Cnt.S. cnt
• With every edge at input di1, the counter is incremented by 1. Cnt.E = off
• A counter end value can be defined via ConF / Cn.Fr / Cnt.E. Cnt.E
Pulses in excess are not counted.
With the counter end value switched off, incrementing is done up to
the max. coun ter value.
g Please, note that the counter end value must be higher than the
counter start value (Cnt.E > Cnt.S).
Cnt.S
Down counter
• The counter starts at counter start value Cnt.S,
adjustable via ConF / Cn.Fr / Cnt.S. cnt
• The counter is decremented by 1 with every edge at input di1.
• The counter end value can be defined via ConF / Cn.Fr / Cnt.S
Cnt.E.
Pulses in excess are not counted.
With the counter end value switched off, decrementing is done down
Cnt.E
to 0. Cnt.E = off
UNIFLEX CI 45 Counter (optional) 25

Functions
g Note that the counter end must be set to a lower value than the counter start (Cnt.S > Cnt.E)
Resetting the counter

450
cnts
The counter can be reset to the start value by 1 2 F E
w Reset via key combination Enter + increment key
(keep the Enter key pressed and actuate the increment key)
w An activated limit value Lim1 … Lim3.
+ Tip: When resetting the counter via a limit value, cyclic counting can be realized. Thereby, a pulse divider
is created when the limit value is provided at an output.
Counter divisor
The incoming pulses can be stepped down using parameter Cnt.d . This function is used for
• Scaling the display range, e.g. to prevent display overflow, or for

• Display value dimensioning.
+ With a counter divisor of 1000.0 and integration of the least significant digits of the counter value at
extended operating level, e.g. value 9999.9999 can be displayed.
Example:
– Adjusted counter divisor Cnt.d = 100.0 (100 pulses increment the process value by
1)
– Line 1: process value display
– Line 2: display of the least significant digits of the counter value (Cnt.L) at extended
operating level
24
– Example value: 24 / 56 = 24x 100 + 56 = 2456
56
Display overflow
An overflow of the display range is shown by EEEE on the display. Hoverever, the unit continues incrementing until
reaching the maximum counter width.
Simulation
For simulation of the counter input in the BlueControl ® engineering tool, a counter pulse can be simulated using the
checkbox of digital input di1 or via input window “Freq”. The input value must be specified in kHz.
6.9 Frequency input (optional)
Digital input di1 can be configured as a frequency input (dependent on ordering code). The frequency is a function of
the number of pulses counted during the gate time.
The display value is updated at the earliest after elapse of the gate time.
Settings:
• Frequency measurement ( ConF / Cn.Fr / I.Fnc = 5 )
• Gate time ( ConF / Cn.Fr / Frq.t)
+ During frequency measurement, measurements can be realized, monitored and output via universal inputs
INP1 / INP2, if necessary.
26 Frequency input (optional) UNIFLEX CI 45

Functions
Scaling
The frequency input value can be scaled to a physical value in two points.
1st value:
– input Frq.L (value specified in kHz)
– physical value Ou.L
2nd value:
– input Frq.H (value specified in kHz)
– physical value Ou.H
Example:
5 Hz = 2 l/min
20 Hz = 30 l/min
Settings: Frq.L = 0,002; Ou.L = 5
Frq.H = 0,020; Ou.H = 30
Filter
The frequency input value can be filtered (Parameter Frq.F).
Exceeded frequency range
g When exceeding the frequency input range end, measurements are switched off during approx. 1 s.
Out-of-range signalling is possible via an output signal: ConF / Out.x / FAi.F = 1
Simulation
A special “Freq” input window is provided for simulation of the frequency input in the BlueControl ® engineering tool.
It should be specified in kHz.
6.10 Arithmetic functions

The following arithmetic functions are available in configuration setting CONF / Fnc.2 :
Square function
2
• Formula: x
The display value which is squared is output.
Square root extraction

• Formula: Öx
For output, the square root of the display value is extracted.
For values x £ 0 , value 0 is output.
UNIFLEX CI 45 Arithmetic functions 27

6.11 Tare function (optional)

Switching on the tare function sets the instantaneous input value to zero and measurement is continued with this
offset. By switching off the tare function, the actual measurement value is displayed again .
Measurement value
Effective value
450.3 75.9 617.2

ûC ûC ûC
äüüü äüäü äüüü
1 2 F E 1 2 F E 1 2 F E
The tare function is enabled during configuration (Func r Fnc.3 = 1).

Dependent on configuration, the tare function can be activated by digital input di1 or interface ( LOGI r
tArA).
An active tare function is displayed as an active bar for display element ‘F’ .
6.12 Sample&hold amplifier (optional)

With the sample & hold function activated, the measured value is held on the display. After de-activating the s ample &
hold function, the actual measurement value is displayed again.
Measurement value
Effective value
450.3 450.3 450.3 450.3 450.3

ûC ûC ûC ûC ûC
äüüü äüäü äüüü äüäü äüüü
1 2 F E 1 2 F E 1 2 F E 1 2 F E 1 2 F E
The sample&hold amplifier function can be activated during configuration (Func r Fnc.3 = 2).
Dependent on configuration, the sample&hold function can be made effective via digital input di1 or via the interface
(LOGI r HOLd).
An active sample&hold amplifier function is displayed as an active bar for display element ‘F’ .
28 Tare function (optional) UNIFLEX CI 45

Functions
6.13 Integrator function

The input signal can be totalized by means of a selectable integrator (ConF \ Func \ Fnc.3 = 3).
Function:
Integrator with adjustable time constant (PArA \ Func \ t.I) [specified in minutes] and adjustable input offset
(PArA \ Func \ P.I)
Formula:
y(t) = y(t-Tr) + Tr/t * (x +P.I)
y(t) = integrator output

y(t-Tr) = integrator output of the last cycle
Tr = cycle time (100ms INP1, 140ms INP1 + INP2)
t = time constant
x = integrator input
P.I = input offset (zero offset)
g With a constant input value, the integrator output reaches the specified value after elapse of the adjusted time
constant t.I.
Reset:
Dependent on selection (ConF\Logi\rES.I), the integrator can be reset via:
w Digital input di1

w Key combination Enter + increment key
(keep the Enter key pressed and actuate the increment key)
w Limit values Limit1 to Limit3
Example 1:
3
A flow in m /h is measured. The integrator should measure the overall flow quantity. The measured flow is related to
time unit hours, i.e. time constant t.I = 1 hour = 60 min must be used. Parameter P.I can be used for zero correction.
Example 2: pulse output

The integrator is activated. The resulting process value is monitored using a limit value (without memory) , e.g. Lim1.
Lim.1 is defined as integrator reset function. Limit value Lim.1 is output e.g. on ouput 1 (OUT.1).
When exceeding limit value Lim1, there is a signal change at OUT1 during a period (100ms INP1, 140ms INP1 + INP2).
x
H.1
P.I
t (cycle)
Lim.1
Out.1
6.14 Limit value processing

Max. three limit values can be configured for the outputs. Generally, each one of outputs Out.1... Out.3 can be
used for limit value or alarm signalling. Several signals allocated to an output are linked by a logic OR function.
UNIFLEX CI 45 Integrator function 29

Functions
6.14.1 Measured value monitoring
g The signal to be monitored can be selected separately for each alarm in the configuration. The following
signals are available:
• Process value (display value)
• Measurement value INP1
• Measurement value INP2 (option)
• Counter / frequency measurement value (optional)
Each of the 3 limit values Lim.1 … Lim.3 has 2 trigger points H.x (Max) and L.x (Min), which can be switched off
individually (parameter = “OFF”). The hysteresis HYS.x of each limit value is adjustable.
Input value monitoring

Input value monitoring is as shown below:
Operating principle with absolute alarm (ex. Lim.1)
L.1 = OFF
-1999 H.1 9999
Display range
H.1
HYS.1
Limit value 1
Outputs
LED rot / red
H.1 = OFF
-1999 L.1 9999

Display range
L.1
Limit value 1
HYS.1
Outputs
LED rot / red
-1999 L.1 H.1 9999

Display range
H.1
Limit value 1 L.1 HYS.1 HYS.1
Outputs LED LED

rot / red rot / red
Normally open: ( ConF / Out.x / O.Act = 0 ) (as shown in the example)

Normally closed: ( ConF / Out.x / O.Act = 1 ) (inverted output relay action)
30 Limit value processing UNIFLEX CI 45

Functions
Alarm delay
An alarm can become effective with a delay: the alarm output is set only after elapse of the adjusted delay time,
provided that the limit value is still exceeded. Shorter alarms than the adjusted delay are ignored.
Example: Alarm delay
Signal change monitoring

Another limit value processing function is signal change monitoring (per minute).
Behaviour with signal change (Ex. Lim1)

L.1 = Off
{x {x
{t >H.1 {t >H.1
t [min]
Lim.1
LED LED
rot / red rot / red
UNIFLEX CI 45 Limit value processing 31

Functions
x H.1 = OFF
{x
{t <L.1
t [min]
Lim.1
LED
rot / red
g With measurement value or signal change with latch selected ( ConF / Lim / Fnc.x = 2, 4),
the alarm relay remains set, until the alarm was reset in the error list, via di1 or via the
interface (Lim1 ... Lim3 = 1).
For this, reset value 0 must be specified in the error list or via the interface.
g After power on or an engineering download an used input filter has an effect on the gradient of the input
signal. Therefore a valid alarm monitoring can only be processed after a certain rise up time. This time
depends on the value of the filter time constant t.F.
For t.F = 0 the monitoring results are valid immediately.
6.14.2 Monitoring the number of operating hours and switching cycles

Operating hours
The number of operating hours can be monitored. When reaching or exceeding the adjusted value, signal InF.1 is
activated (in the error list and via an output, if configured).
The monitoring timer starts when setting limit value C.Std. Reset of signal InF.1 in the error list will start a new
monitoring timer. Monitoring can be stopped by switching off limit value C.Std.
g Adjusting the limit value for operating hours C.Std can be done only via BlueControl ® .
The current counter state can be displayed in the BlueControl ® expert version.
g The number of operating hours is saved once per hour. Intermediate values are lost when switching off.
Number of switching cycles

The output number of switching cycles can be monitored. When reaching or exceeding the adjusted limit value, signal
InF.2 is activated (in the error list and via an output, if configured).
The monitoring timer starts when setting limit value C.Sch. Reset of signal InF.2 in the error list will start a new
monitoring timer. Monitoring can be stopped by switching off limit value C.Sch.
g A switching cycle counter is allocated to each output. Limit value C.Sch acts on all switching cycle counters.
g Adjusting the limit value for the number of switching cycles C.Sch can be done only via BlueControl ®.
The current counter state can be displayed in the BlueControl ® expert version.
g The number of switching cycles is saved once per hour. When switching off, intermediate values are lost.
32 Limit value processing UNIFLEX CI 45

Functions
6.15 Analog output configuration
6.15.1 Analog output

The two output signals (current and voltage) are available simultaneously. Adjust ConF / Out.3 / O.tYP to
select the output type which should be calibrated.
ConF / Out.3: O.tYP = 1 Out.3 0...20mA continuous

= 2 Out.3 4...20mA continuous
phys.
size
Out.1
phys. size mA / V
Out.0
0/4mA 20mA
0/2V 10V
Parameter O.Src defines the signal source of the output value.

Example:
O.Src = 3 signal source for Out.3 is
the process value
Scaling of the output range is done via parameters Out.0 and Out.1. The values are specified in units of the
physical quantity.
Out.0 = -1999...9999 scaling Out.3
for 0/4mA or 0/2V
Out.1 = -1999...9999 scaling Out.3
for 20mA or 10V
Example: output of the full input range of thermocouple type J (-100 … 1200 °C)
Out.0 = -100
Out.1 = 1200
Example: output of a limited input range, e.g. 60.5 … 63.7 °C)
Out.0 = 60.5
Out.1 = 63.7
+ Please, note: the smaller the span, the higher the effect of input variations and resolution.
g Using current and voltage output in parallel is possible only in galvanically isolated circuits.
g Configuration O.tYP = 2 (4 … 20mA) or 4 (2...10V) means only allocation of the reference value (4 mA or 2V)
for scaling of output configuration Out.0. Therefore, output of smaller values is also possible rather than
output limiting by reference value 4mA / 2V.
g Configuration O.tYP = 0/1 (0/4...20mA) or 2/3 (0/2...10V) determines, which output should be used as a
calibrated reference output.
UNIFLEX CI 45 Analog output configuration 33

Functions
6.15.2 Logic output

The output can be used also as a logic output (O.typ = 0). In this case, e.g. alarms or limit values can be output.
6.15.3 Transmitter power supply

Two-wire transmitter power supply can be selected by adjusting O.typ = 5.
In this case, the analog output of UNIFLEX CI 45 is not available any more, but the input signal can be monitored or
read out via the interface.
Connection example:
INP2 5 6 7 8 di1
INP1 1 2 3 4
- +
13V
22mA
+ - 3
K
OUT3 11 12 13 14 1
PWR 15 16 17 18
OUT1
OUT2
34 Analog output configuration UNIFLEX CI 45

Functions
6.15.4 Frequency output (optional)

The analog output signal for voltage can be selected also as a frequency output with setting:
ConF / Out.3: O.tYP = 6 Out.3 0...10V frequency output
f [Hz]
Frq.H
Quelle (V)
source
Frq.L
Out.L Out.H phys. Größe

phys. size
Setting O.Src defines the signal source of the frequency output value.
Example: O.Src = 3 signal source for Out.3 is the process value
Output range scaling is done via parameter pairs Out.L/ FrQ.L and Out.H/ FrQ.H. Values Out.L and
Out.H are specified in physical units, FrQ.L and FrQ.H are specified in Hz.
Example:
20°C = 5 Hz
200°C = 500 Hz
Settings: Ou.L = 20; Frq.L = 5,0
Ou.H = 200; Frq.H = 500,0
The output behaviour in case of input value error can be defined via O.FAI .
g Please, note that the lower the span the higher the effect of input variations and resolution steps
g Signals exceeding the permissible frequency range cause deviations from the square shape of frequency
waves.
6.15.5 Analog output forcing

By adjusting f.Out = 1 (only via BlueControl), the output can be configured for value input via interface, or by means of
an input value at extended operating level (=Forcing).
g This setting can be used also for e.g. testing the cables and units connected in the output circuit.
g This function can also realize a setpoint potentiometer.
UNIFLEX CI 45 Analog output configuration 35

Functions
6.16 Maintenance manager / error list

In case of one or several errors, the error list is always displayed at the
beginning of the extended operating level .
A current input in the error list (alarm or error) is always indicated by display of
letter E . 450.3
ûC
For display of the error list, press key ô once. äüüä
1 2 F E
E- display element Signification Further procedure
blinks Alarm is pending, error - The error number in the error list indicates the error type
-Remove the error.
on Error was removed, alarm not - Acknowledge the error in the error list by pressing
acknowledged È or Ì - key.
- The alarm entry is deleted.
off No error, all alarm entries are deleted
Error list:
Name Description Cause Possible remedial action

E.1 Internal error, E.g. defective EEPROM Contact PMA service
cannot be corrected Return instrument to manufacturer
E.2 Internal error, resettable E.g. EMC trouble Keep measuring and supply cables
separate. Protect contactors by means of
RC snubber circuits
E.3 Configuration error, Missing or faulty configuration Check interdependencies for
resettable configurations and parameters
E.4 Hardware error Code number and hardware not Contact PMA service
identical Replace electronics/options card
FbF.1 INP1 sensor break Defective sensor Replace INP1 sensor
Wiring error Check INP1 connection
Sht.1 INP1 short circuit Defective sensor Replace INP1 sensor
POL.1 INP1 polarity error Wiring error Change INP1 polarity
FbF.2 INP2 sensor break Defective sensor Replace INP2 sensor
Sht.2 INP2 short circuit Defective sensor Replace INP2 sensor
POL.2 INP2 polarity error Wiring error Change INP2 polarity
Lim.1 Latched limit value alarm 1 Adjusted limit value 1 exceeded Check process
Lim.2 Latched limit value alarm 2 Adjusted limit value 2 exceeded Check process
Lim.3 Latched limit value 3 Adjusted limit value 3 exceeded Check process
Inf.1 Time limit value message Preset number of operating hours Application-specific
reached
Inf.2 Switching cycle message Preset number of switching Application-specific
(digital outputs) cycles reached
36 Maintenance manager / error list UNIFLEX CI 45

Functions
g Latched alarms Lim1/2/3 (E element displayed) can be acknowledged, i.e. reset via digital alarm di1.
For Configuration, see page 46: ConF / LOGI / Err.r
g When an alarm is still pending, i.e. unless the error cause was removed ( E display blinks), latched alarms
cannot be acknowledged and reset.
Error-state Signification
2 Pending error Change to error status 1after error removal
1 Stored error Change to error status 0 after acknowledgement in error list 0
0 no error/message Not visible, except during acknowledgement
g If sensor errors should not be on the error list any more after error correction without manual reset in the
error list, suppression via BlueControl is possible by means of setting ILat.
CONF / othr / ILat 1 blocked

This setting is without effect on limit values Lim.1 … 3 configured for storage.
6.17 Reset to factory setting
In case of faulty configuration, UNIFLEX CI 45 can

be reset to its factory setting.
Ü For this, the operator must keep the keys 1 + Power on

increment and decrement pressed during
power-on.
* For confirmation, press key increment to
select YES
FAC
torY
Ö Confirm factory resetting with Enter and the
copy procedure isl started (display COPY).
ä Afterwards the device restarts.
FAC
In all other cases, no reset will occur(timeout no
abortion).
g If one of the operating levels was blocked,

reset to factory setting is not possible. 2
g If a pass number was defined (via FAC
BlueControl®) but no operating level was yEs
blocked, enter the correct pass number
when prompted in 3. A wrong pass numbers
aborts the reset action.
3 ô
g The copy procedure (COPY) can take some
seconds.
FAC
COPY
Now, the transmitter is in normal operation.
8.8.8.8
#:#:#:#:#
ääää
4
UNIFLEX CI 45 Reset to factory setting 37

Configuration level
. 7 Configuration level
7.1 Configuration survey

Dependent on the device version and further adjusted configurations, configurationdata can be hidden.
Data operable via the instrument front panel are shown in the following figure.
st st st st st st st st st
Func Inp.1 Inp.2 Lim OUt.1 OUt.2 OUt.3 LOGI othr End
ô ô ô ô ô ô ô ô ô ô
Fnc.1 StYP I.Fnc Fnc.1 0.Act 0.Act O.tYP di.Fn bAud
Fnc.2 4wir StYP Src.1 Lim.1 Lim.1 0.Act L_r Addr
Fnc.3 S.Lin S.Lin Fnc.2 Lim.2 Lim.2 Lim.1 Err.r PrtY
ô Corr Corr Src.2 Lim.3 Lim.3 Lim.2 I.ChG dELY
In.F In.F Fnc.3 FAi.1 FAi.1 Lim.3 tArA d.Unt
ô ô Src.3 FAi.2 FAi.2 FAi.1 HOLd 02
ô ô ô FAi.2 rES.L Unit
Out.0 rES.H dP
Out.1 ô SEGm
O.src C.dEL
O.FAI ô
ô
Setting:
• The configurations can be adjusted by means of keys ÈÌ .

• Transition to the next configuration element is by pressing key ô .
• After the last configuration of a group, donE is displayed and an automatic change to the next group is made.
g Return to the start of a group is by pressing key ô during 3 sec.
g With configuration changes, please, check all dependent parameters for validity.
38 Configuration survey UNIFLEX CI 45

Configuration level
7.2 Configurations
Dependent on instrument version and configuration settings, display of values which are not required is suppressed.
µ The entries marked with this symbol are selectable only, if the instrument option is fitted.
Function selection Func

Name Value range Description
Fnc.1 Function 1 µ
0 Process value = INP1
2 Difference (INP1 -INP2)
3 Max (INP1, INP2)
4 Min (INP1, INP2)
5 Mean value (INP1, INP2)
6 Switch-over (INP1, INP2)
7 O2-Function with constant probe temperature
8 O2-Function with measured probe temperature
9 Counter / frequency
10 Process value = INP1 ( TC of INP2)
Fnc.2 Function 2
0 No function
1 Squarer
2 Square root
Fnc.3 Function 3 µ
0 No function
1 Tare
2 Sample & Hold
Inputs InP.1 and InP.2 (µ)

I.Fnc Input function (µ with 2nd universal input only )
0 No measurement
1 measurement
S.tYP Sensor type
0 Thermocouple type L (-100...900°C), Fe-CuNi DIN
1 Thermocouple type J (-100...1200°C), Fe-CuNi
6 Thermocouple type T (-200...400°C), Cu-CuNi
7 Thermocouple type C (0...2315°C), W5%Re-W26%Re
8 Thermocouple type D (0...2315°C), W3%Re-W25%Re
9 Thermocouple type E (-100...1000°C), NiCr-CuNi
10 Thermocouple type B (0/100...1820°C), PtRh-Pt6%
18 Special thermocouple (linearization necessary)
20 Pt100 (-200.0 ... 100,0 °C) (150°C with reduced lead resistance)
21 Pt100 (-200.0 ... 850,0 °C)
22 Pt1000 (-200.0...850.0 °C)
23 Special 0...4500 Ohm (preset KTY11-6)
UNIFLEX CI 45 Configurations 39
Configuration level

24 Special 0...450 Ohm
30 0...20mA / 4...20 mA
40 0...10V / 2...10 V (Inp.1 only)
41 Special (-2,5...115 mV)
42 Special (-25...1150 mV)
43 Special (-25...90 mV)
44 Special (-500...500 mV)
45 Special (-5...5 V) (Inp.1 only)
46 Special (-10...10 V) (Inp.1 only)
47 Special (-200..200 mV)
50 Potentiometer 0...160 Ohm
4wir Resistance connection type (Inp.1 only)
0 3-wire connection
1 4-wire connection
S.Lin Linearization only adjustable with S.tYP:18, 23 ... 47
0 none
1 Special linearization. Producing a linearization table is possible via BlueControl
(Engineering-Tool). Preset is the characteristic for KTY 11-6 temperature sensors.
Corr Measured value correction / scaling
0 No correction
1 Offset correction (at CAL -level)
2 2-point correction (at CAL -level)
3 Scaling (at PArA -level)
In.F OFF, Substitute value in case of a fault. This value is used for calculations, if there is a
-1999...9999 fault at the input (e.g. FAIL).
fAI1 Forcing of analog input INP1, INP2 µ (only visible with BlueControl!)
(fAI2) 0 Not active
1 The value for this analog input is preset via interface
Counter / frequency input µ

I.Fnc Function selection µ
0 Control input
1 Up counter, positive edge
2 Up counter, negative edge
3 Down counter, positive edge
4 Down counter, negative edge
5 Frequency measurement
Frq.t 0,1 … 20 Frequency gate time [s] µ
40 Configurations UNIFLEX CI 45
Configuration level
Limit values Lim1 … Lim3

Fnc.1 Function of limit 1 (2, 3)
(Fnc.2) 0 Switched off
1 Measured value monitoring
(Fnc.3) 2 Measured value monitoring + alarm status latch. A stored limit value can
be reset via error list or a digital input ( -> LOGI/Err.r)
3 Signal change (in minutes).
4 Signal monitoring for rate of change (per minute) + storage of the alarm
status. A stored limit value can be reset via error list or a digital input (
->LOGI/Err.r)
Src.1 Source of limit 1 (2, 3)
(Src.2) 0 Process value= displayed value
3 Measured value of the analog input INP1
(Src.3) 4 Measured value of the analog input INP2
10 Counter/frequency measurement value
C.Std OFF; 1 … 9999999 Monitoring operating hour (only visible with BlueControl!)
C.Sch OFF; 1 … 9999999 Monitoring duty cycle (only visible with BlueControl!)
Outputs Out.1 and Out.2 µ (Relay)

O.Act Direction of operation OUT1
0 Direct / normally open
1 Inverse / normally closed
Lim.1 Signal limit 1
0 Not active
1 Active
0 Not active
1 Active
0 Not active
1 Active
FAi.1 Signal INP1 fail
0 Not active
1 Active
FAi.2 Signal INP1 fail µ
0 Not active
1 Active
FAi.F Frequency error µ message
0 Not active
1 Active
Sb.Er System bus error µ message
0 Not active
1 Active
fOut Forcing of analog output OUT 1 (only visible with BlueControl!)
0 Not active
1 The value for this output is preset via interface
Inf.1 Status message Inf.1 (operating hours) (only visible with BlueControl!)
0 Not active
1 active
Configuration level

Inf.2 Status message Inf.2 (number of switching cycles) (visible only with BlueControl!)
0 Not active
1 Active
Output Out.3 (analog)

O.tYP Type of OUT3
0 Relay / logic (only visible with current/logic/voltage)
1 0 ... 20 mA continuous (only visible with current/logic/voltage)
2 4 ... 20 mA continuous (only visible with current/logic/voltage)
3 0...10 V continuous (only visible with current/logic/voltage)
4 2...10 V continuous (only visible with current/logic/voltage)
5 Transmitter supply (only visible with current/logic/voltage)
6 Frequency µ
O.Act Direction of operation OUT3 (only visible with O.TYP=0 )
0 Direct / normally open
1 Inverse / normally closed
Lim.1 Signal limit 1 (only visible with O.TYP=0 )
0 Not active
1 Active
0 Not active
1 Active
0 Not active
1 Active
FAi.1 Signal INP1 fail (only visible with O.TYP=0 )
0 Not active
1 Active
FAi.2 Signal INP2 fail (only visible with O.TYP=0 ) µ
0 Not active
1 Active
FAi.F Frequency error µ message
0 Not active
1 Active
Sb.Er System bus error µ message
0 Not active
1 Active
Out.0 -1999 Lower scaling limit of the analog output (corresponds to 0% (0/4mA bzw. 0/2V, only
...9999 visible with O.TYP=1..4)).
Out.1 -1999 Upper scaling limit of the analog output (corresponds to 100% (20mA bzw. 10V,
...9999 only visible with O.TYP=1..4 )).
Out.L -1999 Input value for min. output frequency (visible only with O.TYP=6)µ
...9999
FrQ.L -1999 Min. output frequency in Hz (visible only with O.TYP=6)µ
...9999
Out.H -1999 Input value for max. output frequency (visible only with O.TYP=6)µ
...9999
FrQ.H 0.0...9999 Max. output frequency in Hz (visible only with O.TYP=6)µ
Configuration level

O.Src Signal source for analog output OUT3 (only visible with O.TYP=1..4 )
0 Not active
3 Process value
7 Measured value INP1
8 Measured value INP2 µ
O.FAI Fail behaviour
0 Upscale
1 Downscale
Inf.1 Status message Inf.1 (operating hours) (visible only with BlueControl!)
0 Not active
1 Active
Inf.2 Status message Inf.2 (number of switching cycles) (visible only with BlueControl!)
0 Not active
1 Active
fOut Forcing OUT3 (only visible with BlueControl!)
0 Not active
Logic LOGI
di.Fn Function of inputs (valid for all inputs)
0 Direct
1 Invers
2 toggle key function (adjustable for 2-point-operation with interface and di1)
L_r Local / remote switchover
(Remote: Adjustment of all values via the front panel is blocked)
0 No function (switch-over via interface is possible)
1 Always active.
2 Di1 switches.
7 Limit 1 switches
8 Limit 2 switches
9 Limit 3 switches
Err.r Source for resetting all stored entries in the error list
0 No function (switch-over via interface is possible)
2 Di1 switches.
7 Limit 1 switches
8 Limit 2 switches
9 Limit 3 switches
I.ChG Switching the effective process value between INP1 and INP2.
µ (input 2 must be released (CONF / Inp.2 / I.Fnc = 1))
0 No function (switch-over via interface is possible).
2 Di1 switches.
7 Limit 1 switches
8 Limit 2 switches
9 Limit 3 switches
Configuration level

tArA Tare-function µ (function must be activated (CONF /FUNC / Fnc.3 = 1))
2 Di1 switches.
7 Limit 1 switches
8 Limit 2 switches
9 Limit 3 switches
HoLd Sample & hold -function µ(function must be activated (CONF /FUNC / Fnc.3 = 2))
2 Di1 switches.
7 Limit 1 switches
8 Limit 2 switches
9 Limit 3 switches
rES.L Reset minimum value
2 Di1 switches.
7 Limit 1 switches
8 Limit 2 switches
9 Limit 3 switches
rES.H Reset maximum value
2 Di1 switches.
7 Limit 1 switches
8 Limit 2 switches
9 Limit 3 switches
rES.I Reset Integrator
2 Di1 switches
6 Reset-key switches
7 Limit 1 switches
8 Limit 2 switches
9 Limit 3 switches
rES.C Zähler-Reset
6 Reset-key switches
7 Limit 1 switches
8 Limit 2 switches
9 Limit 3 switches
fDI1 Forcing of digital input di 1 (only visible with BlueControl!)
0 Not active
Other othr
bAud Bit rate of the interface µ
0 2400 Baud
1 4800 Baud
2 9600 Baud
3 19200 Baud
4 38400 Baud
Addr 1...247 Address on the interface µ
Configuration level

PrtY Data parity on the interface µ
0 no parity (2 stop bits)
1 Even parity
2 odd parity
3 no parity (1 stop bit)
dELY 0...200 Delay of response signal [ms] µ
S.IF System interface µ
0 off
1 on
D.Unt display unit
0 without unit
1 Temperature unit (see Data Unit)
2 O2 unit (see Data O2)
3 %
4 bar
5 mbar
6 Pa
7 kPa
8 psi
9 l
10 l/s
11 l/min
12 Ohm
13 kOhm
14 m
15 A
16 mA
17 V
18 mV
19 kg
20 g
21 t
22 Text of phys. Unit (default in T.Unit / preset via BlueControl)
O2 Parameter unit for O2 µ
0 Parameter for O2 function in ppm
1 Parameter for O2 function in %
Unit Temperature-unit
0 No unit
1 °C
2 °F
3 Kelvin
dP Decimal point (max. no of decimals)
0 no digit behind the decimal point
1 1 digit behind the decimal point
SEGm Meaning of the display elements 1 and 2
0 OUT1, OUT2
1 INP1, INP2
C.dEl 0..200 Modem delay [ms]
Configuration level

FrEq Switching 50/60 Hz (only visible with BlueControl!)
0 Mains frequency 50 Hz
1 Mains frequency 60 Hz
ILat suppress error latch (only visible with BlueControl!)
0 Enabled
1 Blocked
IExo Access to extended operation level (only visible with BlueControl!)
0 Enabled
1 Blocked
Pass OFF...9999 Password (only visible with BlueControl!)
IPar Access to parameter level (only visible with BlueControl!)
0 Enabled
1 Blocked
ICnf Access to configuration level (only visible with BlueControl!)
0 Enabled
1 Blocked
ICal Access to calibration level (only visible with BlueControl!)
0 Enabled
1 Blocked
T.Dis2 Entries for the text in display 2 (max. 5 digits)
(only visible with BlueControl!)
Linearization Lin
Only visible with BlueControl!

U.LinT Temperature-unit of linearization table
0 No unit
1 °C
2 °F
3 Kelvin
In.1 … In.32 OFF (from In.3)-1999...9999 Input 1 … Input 32
Ou.1 … Ou.32 -999.0 … 9999 Output 1 … Output 32
g Value U.LinT defines the unit of input values specified for linearization of temperature values . Value entry
in Celsius despite display of the measured value in Fahrenheit is possible.
w Specify the input signals mV, V, mA, % or Ohm dependent on input type.
w For special thermocouples (S.tYP = 18), specify the input values in mV and the output values in the temperature
unit adjusted in U.LinT.
w For special resistance thermometer (KTY 11-6) (S.tYP = 23), specify the input values in Ohm and the output value
in the temperature unit adjusted in U.LinT .
g For resetting the instrument configuration to factory setting (default ),

r section 12.4, 6.17 (page 37)
. 8 Parameter setting level
8.1 Parameter survey

Dependent on instrument version, display of parameters which are not required is suppressed.
8.2 Adjustment
• The parameters can be adjusted by means of keys ÈÌ .

• Transition to the next parameter is by pressing key ô.
• After the last parameter of a group, donE is displayed and the transmitter changes to the next group
automatically.
g Press key ô during 3 s to return to the beginning of a group.
Unless a key is pressed during 30 sec., the transmitter returns to the operating level (timeout = 30 s) .
UNIFLEX CI 45 Parameter survey 47

8.3 Parameters
µ The entries marked with this symbol are selectable only with the instrument option fitted.
Function selection Func

tEmP 0...9999 Probe temperature for O 2 -measurement µ
t.I 0,1...9999 Integrator-Zeitkonstante in Minuten µ
P.I -1999...9999 Integrator-Offsetµ
Inputs InP.1 and InP.2 µ

InL.1(InL.2) -1999...9999 Input value of the lower scaling point
Oul.1 (OuL.2) -1999...9999 Display value of the lower scaling point
InH.1 (InH.2) -1999...9999 Input value of the upper scaling point
OuH.1 (OuH.2) -1999...9999 Display value of the upper scaling point
T.F1 (t.F2) 0...999,9 Filter time 1 [s]
B.F1 (b.F2) 0...9999 Filter bandwidth
E.tc1(E.tc2) OFF, 0...100 external cold junction compensation, range depends on temperature unit
Counter/frequency input µ
Cnt.d 0,1...9999 Counter divider
Cnt.S 0...9999 Counter start value
Cnt.E 0...9999 Counter end value
Frq.L 0.000...100.0 Lower input value in kHz
Ou.L -1999...9999 Lower output value in phys. units
Frq.H 0.000...100.0 Upper input value in kHz
Ou.H -1999...9999 Upper output value in phys. units
Frq.F 0...9999 Filter time constant in s
Limit values Lim1 … Lim 3

L.1 -1999...9999 Lower limit 1 (L.1< -1999 = off)
H.1 -1999...9999 Upper limit 1 (H.1< -1999 = off)
HYS.1 0...9999 Hysteresis 1
dEL.1 0...9999 Limit 1 delay
g For resetting the parameters to factory setting (default ),

r section 12.4, 6.17 (page 37)
48 Parameters UNIFLEX CI 45
Calibrating level
. 9 Calibrating level
Adaptation of the measurement value is possible in the calibrating menu ( CAL).
g Measured value correction ( CAL) is accessible only, if ConF / InP/ Corr = 1 or 2 was selected.
Two methods are possible :

• offset correction
• 2-point correction
g Values InL.x and InH.x are displayed with one digit behind the decimal point. However, the full
resolution is used as a reference for calculating the correction.
g The easiest way to delete the corrective values is by switching off the measured value correction
Corr = 0 or by setting the scaling parameters to a linear curve.
+ Values InL.x and InH.x indicate the actual measurement value. Output values OuL.x and
OuH.x start with the previously adjusted value.
UNIFLEX CI 45 49
Calibrating level
9.1 Offset correction
Offset correction shifts the input value by a pre-defined value.

Parameter setting:
( ConF/ InP/ Corr =1 ): display standard setting
offset correction
w On-line offset correction at the process is possible.
OuLnew
OuLold
450.3
450.0 rô r PArA InL X
äüüü 3 sec.
r
ConF
r
CALr ô r InPr ô r InL r ô
InL
ô
r OuL ô
r End r ô
InL: The actual input value of the scaling point is displayed.

The correction function is activated by means of keys ÈÌ ; the display changes from Off to
the measured value.
Subsequently, the input value has to be confirmed by pressing key ô .
OuL: The scaling point display value is indicated.
The operator can correct the display value by pressing keys ÈÌ. Subsequently, he presses key
ô to confirm the display value.
50 Offset correction UNIFLEX CI 45

Calibrating level
9.2 2-point correction

display standard setting
2-point correction can change the offset and gradient 2-point correction
of
the input curve.
Parameter setting:
( ConF/ InP/ Corr = 2 ):
OuHold
w 2-point correction is possible off-line by means

of
OuHnew
an input signal simulator,

w or on-line in 2 steps: correct one value first and
the second value subsequently, e.g. after heating
up the furnace. OuLnew
OuLold
InL InH X
450.3 r ô r PArA
450.0 3 sec.
r
äüüü ConF
r
CAL rô r InPr ô r InL rô
InL
ô
OuL rô
InH rô
InH
ô
OuH rô
r End rô
InL: The input value of the lower scaling point is displayed.

The correction function is activated via keys ÈÌ ; the display changes from Off to the
measurement value.
Adjust the lower input value by means of an input signal simulator and press key ô to confirm
the input value.
OuL: The display value of the lower scaling point is indicated.
Press keys ÈÌ to correct the lower display value and press key ô to confirm the display
value.
InH: The input value of the second scaling point is displayed.
Activate the corrective function by pressing keys ÈÌ ; the display changes from Off to the
measured value.
Adjust the upper input value by means of the input signal simulator and confirm the input
value by pressing key ô .
OuH: The display value of the upper scaling point is indicated.
Correct the upper display value by pressing keys ÈÌ and press key ô to confirm the
display value.
UNIFLEX CI 45 2-point correction 51

Ò
BlueControl engineering tool
. 10
Ò
BlueControl engineering tool

Ò â
The BlueControl engineering tool is the projecting environment for the PMA BluePort instrument series and for the
rail line series. The following versions with different functionalities are available:
Functions Mini Basic Expert*

Parameter and configuration setting yes yes yes
Download: Writing an engineering to the transmitter yes yes yes
Online-Mode / visualisation SIM only yes yes
Creation of user-specific linearization SIM only yes yes
Configuration of extended operating level yes yes yes
Upload: Reading an engineering from the transmitter SIM only yes yes
Basic diagnosis function no nein yes
Storage of data, engineerings no yes yes
Printer function no yes yes
Onlinedocumentation / help yes yes yes
Measurement correction yes yes yes
Data aquisition and trend-recording SIM only yes yes
Net- / Multiuserlicence no no yes
Personal assistant function
* on request
A free-of-charge mini version is

available for download on the
PMA homepage
www.pma-online.de or on PMA
CD (on request).
At the end of installation, enter

the licence number delivered
with BlueControl or select
DEMO mode. In DEMO mode,
subsequent entry of the licence
number is also possible in Help
r Licence r Add .
52 UNIFLEX CI 45
Versions
. 11 Versions
Universal transmitter
CI 45 C I 4 5 1 0 0 00
1 universal-input, control-input
with display and BluePort®-interface
no plug-in connectors 0
with screw-terminal plug-in connectors 1
90..260V AC, mA/V/Logik +1 relay 2
18...30VAC/18..31VDC, mA/V/logic+1 relay 3
90..260V AC, mA/V/logic + 2 relay 4
18...30VAC/18..31VDC, mA/V/logic+2 relay 5
noOption 0
RS 485 / MODBUS - protocol 1
systeminterface for 24V versions only 2
noOption 0
Optionpack 1* 1
Optionpack 2** 2
Standardconfiguration 0
Configuration to specification 9
Standard (CE-certification) 0
cULus - certification U
* Optionspaket 1: zusätzlicher Universaleingang INP2,

zusätzlich: O2-Messung, Zählereingang, Funktionen Tara, Abtast-Halteverstärker, Integrator
** Optionspaket 2: zusätzlich zu Optionspaket 1:
Digitaleingang als Optokoppler, Frequenzeingang, Frequenzausgang
Accessories delivered with the transmitter:

• Operating note
• Rail-to-bus connector for the interface option
Additional equipment with ordering data.

PC adaptor for the BluePort® front interface 9407-998-00001
Operating instructions for CI 45 German 9499-040-71718
Operating instructions for CI 45 English 9499-040-71711
Interface description MODBUS rail line German 9499-040-72018
Interface description MODBUS rail line English 9499-040-72011
BlueControl® Mini German/English www.pma-online.de
BlueControl® with basic licence rail line German/English 9407-999-12001
BlueControl® with expert licence rail line German/English 9407-999-12011
53 UNIFLEX CI 45
Technical Data
. 12 Technical Data Measurement span

The BlueControl® software enables the internal characteristic
INPUTS curve for the KTY 11-6 temperature sensor to be adapted.
Divided into ranges
UNIVERSAL INPUT INP1 Physical measurement range: 0...4500 W
Resolution: >15 bits Current and voltage measurement
Decimal point: 0 to 3 decimals
(Table 3)
Digital input filter: adjustable 0.0...999.9 s
Span start and span: anywhere within the
Scanning cycle: 100 ms measurement range
Linearization: 31 segments, adaptable with BlueControl® Scaling: freely selectable –1999...9999
Measurement value correction: 2-point or offset Input circuit monitoring (current): 12.5% below span start (2 mA)
Limiting frequency: 1.7 Hz
O2-measurement (optional)
Thermocouples (Table 1) EMI-measuring by means of INP1 (high-impedance mV-inputs)
Input resistance: ³ 1 MW suitable for probes with
Influence of source resistance: 1 µV/W -constant sensor temperature (heated probes), setting by means
Input circuit monitor: break, polarity of parameter
- -measured sensor temperature (non-heated probes), measuring
Cold-junction compensation by means of INP2
- Iinternal,
- additional error: typ.: ß_ 0,5 K ADDITIONAL INPUT INP2
max.: ß +1,2 K (UNIVERSAL, OPTION)
External: Resolution: > 15 bits
- value setting: 0 ...100 °C dig. input filter: adjustable 0,0...999,9 s
-measured via INP2 (option) Scanning cycle: 140 ms
Linearization: as for INP1
Break monitoring Meas. value correction: 2-point or offset correction
Sensor current: ß 1 µA Type: single ended except thermocouples
Operating sense configurable
Resistance thermometer (Table 2)

Connection technique: 3 or 4-wire
Lead resistance: max. 30 W
Input circuit monitoring: break and short circuit
Table 1: Thermocouple input

Thermocouple type Measurement range Error Typical resol.
L Fe-CuNi (DIN) -100...900°C -148...1652°F ß 2K 0.05 K
J Fe-CuNi -100...1200°C -148...2192°F ß 2K 0.05 K
K NiCr-Ni -100...1350°C -148...2462°F ß 2K 0.1 K
N Nicrosil/Nisil -100...1300°C -148...2372°F ß 2K 0.1 K
S PtRh-Pt 10% 0...1760°C 32...3200°F ß 3K 0.1 K
R PtRh-Pt 13% 0...1760°C 32...3200°F ß 3K 0.1 K
T Cu-CuNi -200...400°C -328...752°F ß 2K 0.03 K
C W5%Re-W26%Re 0...2315°C 32...4199°F ß 3K 0.2 K
D W3%Re-W25%Re 0...2315°C 32...4199°F ß 3K 0.2 K
E NiCr-CuNi -100...1000°C -148...1832°F ß 2K 0.05 K
B* PtRh-Pt6% 0(400)...1820°C 32(752)...3308°F ß 3K 0.2 K
Special -25 … 75 mV ß 0.1% 0.005%
* Values apply from 400°C upwards.
54 UNIFLEX CI 45
Technical Data
Table 2: Resistive inputs

Type Sensor current Measurement range Error Typical resol.
Pt100*** -200...100(150)°C -328...212(302)°F ß1K 0.05 K
Pt100 -200...850°C -328...1562°F ß2K 0.05 K
Pt1000 -200...850°C -328...1562°F ß2K 0.05 K
KTY 11-6* -50...150°C -58...302°F ß2K 0.05 K
Special* 0...4500 [** ß 0.1% 0.005%
ß 0,25mA
Special* 0...450 [** ß 0.1% 0.005%
Potentiom. 0...160 [** ß 0.1% 0.005%
Potentiom. 0...450 [** ß 0.1% 0.005%
Potentiom. 0...1600 [** ß 0.1% 0.005%
Potentiom. 0...4500 [** ß 0.1% 0.005%
* Default setting is the characteristic for KTY 11-6 (-50...150°C)
** Including lead resistance
*** up to 150°C at reduced lead resistance (max. 160 [)
Table 3: Current and voltage input
Measurement range Input resistance Error Typical resol.(Æ)

0...10 V ~ 110 k[ ß 0.1 % 0.3 mV
-10...10 V ~ 110 k[ ß 0.1 % 0.6 mV
-5...5 V ~ 110 k[ ß 0.1 % 0.3 mV
-2,5...115 mV* ? 1 M[ ß 0.1 % 4 úV
-25...1150 mV* ?1 M[ ß 0.1 % 40 úV
-25...90 mV* ?1 M[ ß 0.1 % 4 úV
-500...500 mV* ?1 M[ ß 0.1 % 40 úV
-200...200 mV* ?1 M[ ß 0.1 % 20 úV
0...20 mA 20 [ ß 0.1 % 0.8 úA
* For INP1: high-impedance, without break monitoring
Current and voltage measuring ranges

Thermocouples (Table 1) (Table 3)
Cold-junction compensation Remaining technical data as for INP1 except:
- Voltage input ranges –10 / 0...+10V and -5...+5V not possible.
- Internal, - Millivolt input ranges: break monitoring always active.
Additional error:
typ.: ß_ 0,5 K DIGITAL INPUT DI1
max.: ß -2,5 K
Designed as:
- external,
- constant value 0...100 °C a) Contact input
Further technical data as INP1 Connection of a potential-free contact suitable for switching “dry”
circuits.
Resistive sensors (Table 2)
Switched voltage: 5V
Connection technique: 3-wire
Current: 1 mA
Measurement span
b) Opto-coupler input (optional)
Further technical data as INP1.
For active control signals.
Rated voltage: 24 V DC external
Logic “0”: -3 V … 5 V
Logic “1”: 15 V… 30 V
Current requirement : max. 6 mA
UNIFLEX CI 45 55
- preliminary - Technical Data
Control input Number of electrical for I= 1A/2A:

Configurable as a direct or inverse switch or key! switching cycles: ? 800.000 / 500.000
(at ~ 250V (resistive load))
Functions: Locking front operating, Note:
resetting of latched alarms, slave pointers, If the relays OUT1 and OUT2 operate external contactors, these
integrator; must be fitted with RC snubber circuits to manufacturer
activating tare-, sample&hold function; specifications to prevent excessive voltage peaks at switch-off.
switchover between inputs
Counter input (optional) OUT3 AS UNIVERSAL OUTPUT

Pulse counter for up or down counting, non storing Galvanically isolated from the inputs. Parallel current/voltage
output with common ‘minus’ terminal (combined use only in
Active edge: configurable galvanically isolated circuits).
Width of counter register: 31 bits Freely scalable
Display range: Configurable via counter divisor, Resolution: 14 bits
8-digits
can be repartitioned to 2 lines Dynamic response (step change
of input signal) T90: Output follows the input
Counter divisor: adjustable 0.1...9999
ß 540 ms
Start value: adjustable
Tracking error I/U: ß 2%
End value: adjustable; reaching can be
signalled via output Residual ripple: ß_1%
Counter evaluation: At intervals of 100 ms (rel. to range end) 0...130 kHz
(140 ms with INP2 measurement) Current output
Reset: Via key combination,
0/4...20 mA, configurable.
Limit value
short circuit proof
Counter input with option contact Linear range: -0.5...23 mA
Count frequency, max.: 5 Hz with square wave 1:1 Load: ß 700 [
pulse duration, min.: 100ms Load effect: ß0,02%
Resolution: ß 1,5 µA
Counter input with option optocoupler Error: ß0.1%
Count frequency, max.: 100 kHz
with square wave 1:1 Voltage output
Pulse duration, min.: 5µs 0/2...10V, configurable
Effects to active transmitters connected to INP1, INP2 can occur. not continous short-circuit proof
Linear range: -0,15...11,5 V
Frequency input (optional) Load: ? 2 k[
Input with option optocoupler Load effect: ß0.06%
Frequency range: 0...100 kHz with square wave 1:1 Resolution: ß 0.75 mV
Gate time: adjustable, 0.1... 20s Error: ß 0.1%
Process value: scalable Additional error when using ß+0.09%
Effects to active transmitters simultaneously the current
connected to INP1, INP2 can output:
occur.
OUT3 as transmitter supply
Output: 22 mA / ? 13 V DC
OUTPUTS
OUT3 as logic signal
RELAY OUTPUTS OUT1, OUT2 Load ß 700 [ 0/ß 23 mA
Load > 500 [ 0/> 13 V
Contact type: 2 normally open contacts with
common connection
Maximum contact rating: 500 VA, max. 250 V, max. 2A at
48...62 Hz, resistive load
Minimum contact rating: 6V, 1 mA DC
UNIFLEX CI 45 56
Technical Data
Frequency output
POWER SUPPLY
Depending on ordered version
Output by means of voltage output
Frequency range: 0, 0.25 ...1000 Hz (square-wave signal) AC supply
Output value: scalable Voltage: 90...260 V AC
Level: 0 / 11,5V Frequency: 48...62 Hz
Consumption: approx. 7 VA max.
Pulse output
by means of integrator with automatic resetting
Universal supply 24 V UC
Frequency range: 0 ...5 Hz AC supply: 18...30 V AC
(max. 5 pulses/s) Frequency: 48...62 Hz
Pulse duration: 100 ms (INP1 measurement) DC supply: 18...31 V DC
140 ms (INP1 + INP2 measurement) Consumption: approx. 3 VA / W max.
Supply only from safety electrical low voltage (SELV).
Galvanic isolation
* Instruments with optional system interface:
Energization via the bus connector of field bus coupler or power
Fig. 1: Galvanic isolation supply module
Behaviour with power failure

Configuration and parameter settings:
RS 485 Permanent storage in EEPROM
input 1
front interface BLUEPORT® FRONT INTERFACE
power
Connection to the transmitter front via a PC adapter (see
di1 (contact) ‘Accessories’). The BlueControl ® software enables the CI 45 to be
configured, parameters set, and operated.
relay 1
relay 2 output 3 BUS INTERFACE (OPTIONAL)
RS 485
Connection via bus connector fitted in the top-hat rail. Screened
safety isolation cables should be used.
functional isolation Galvanically isolated
Type: RS 485
Transmission speed: 2400, 4800, 9600, 19.200,
permissible voltages: 38.400 bits/sec
safety isolation ß 300 Vrmsf AC against earth Parity: even, uneven, none
functional isolation ß 30 Vrmsf AC against earth Address range: 1...247
Number of transmitters per bus segment: 32
Galvanic isolation of inputs, outputs and supply voltage
Protocol
Test voltages: Modbus RTU
Between power supply and in-/outputs: 2,3 kV AC, 1 min SYSTEM INTERFACE
Between input and output: 500 V AC; 1min For connection to field bus coupler (s. system components)
Connection via bus connector in the top-hat rail.
Max. permissible voltages:
Between inputs/outputs against earth: ß 33 V AC ENVIRONMENTAL CONDITIONS
Protection mode
Front panel: IP 20
Housing: IP 20
Terminals: IP 20
UNIFLEX CI 45 57
Technical Data
Permissible temperatures Electrical safety

For specified accuracy: -10...55°C Complies with EN 61010-1:
Warm-up time: < 20 minutes Over-voltage category II
Temperature effect: ß 0.05% / 10 K Contamination degree 2
add. influence to cold Protection class II
junction compensation: ß 0.75 K / 10 K
Operating limits: -20...60°C
Storage: -30...70°C Certifications
Humidity CE certified
Max. 95%, 75% yearly average, no condensation
cULus-certification
Shock and vibration (Type 1, indoor use)
File: E 208286
Vibration test Fc (DIN EN 60068-2-6)
Unit in operation: 1g or 0.075 mm Electrical connections
Plug-in connector strips with terminals for lead cross-sections
Unit not in operation: 2g or 0.15 mm
from 0,2 to 2,5 mm2. Choice of screw terminals or spring-clamp
terminals.
Shock test Ea (DIN EN 60068-2-27)
Shock: 15 g
Mounting method
Duration: 11 ms Clip-on rail mounting (35 mm top-hat rail to EN 50 022). Locked by
means of metal catch in housing base. Close-packed mounting
possible.
Mounting position: vertical
Meets EN 61326-1 for continuous, unattended operation.
Interference radiation: Weight: 0,18 kg
- Within the limits for Class B devices.
Immunity to interference:
Meets the test requirements for devices in industrial areas. Standard accessories
Operating instructions
Evaluation criteria: With ‘Interface’ option: bus connector for fitting into top-hat rail
- Surge interference partly has marked effects, which decay
after the interference stops.
- With high levels of surge interference on 24 V AC mains leads,
it is possible that the device is reset.
With HF interference, effects up to 50 µV can occur.
GENERAL
Housing front
Material: Polyamide PA 6.6
Flammability class: VO (UL 94)
Connecting terminals
Material: Polyamide PA
Flammability class: V2 (UL 94) for screw terminals
V0 (UL 94) for spring-terminal terminals,
bus connector
58 UNIFLEX CI 45
. 13 Index
L
0-9 - limit 29 - 32
- 2-point-correction 51 - linearization 19, 46
- logic - output 34
A
- accessories 53 M
- additional equipment 53 - maintenance 6
- alarm delay 30 - maintenance manager 36
- analog output 33 - maximum value 17
- applications 5 - minimum value 17
- arithmetic functions 27 - mounting 8-9
B N
- behaviour after switch on 15 - Number of switching cycles 32
- BlueControl 52 O
C - O2-measurement 23 - 24
- calibrating level 49 - 51 - offset correction 50
- calibration 49 - offset-correction 50
- cleaning 7 - Operating hours 32
- configuration 38 - 46 - operating level 15 - 18
- Connecting - operating structure 15
bus interface 11 - operation 14 - 18
di1 11 P
Inp1 11
- parameter-level 47 - 48
Inp2 11
Out1, Out2 11 R
Out3 11 - Resetting the counter 26
- connecting diagram 10
- connectors 9 S
- Counter divisor 26 - safety hints 6-7
- Sample & hold amplifier 28
D - slave pointer function 17
- dismounting 8 - Substitue value for inputs 23
- Display overflow 26
T
E - TAG - No. 17
- extended operating level 18 - tare function 28
F - technical data 54 - 58
- terminal connections 10 - 11
- filter 23
- transmitter power supply 34
- forcing 35
- two-wire measurement 21
- Forcing of the inputs 23
- Frequency filter 27 U
- Frequency scaling 27 - units 17
- front view 14
- functions 19 - 37 V
- versions 53
I
- input fail detection 21
- input scaling 20 - 21
- input value monitoring 30
- installation hints 13
59 UNIFLEX CI 45
A4, geheftet, SW-Druck, Normalpapier 80g weiß
9499- 040- 71711

Subject to alterations without notice © PMA Prozeß- und Maschinen-Automation GmbH
Änderungen vorbehalten P.O.B. 310 229, D-34058 Kassel, Germany
Sours réserve de toutes modifications Printed in Germany 9499-040-71711 (06/2009)

11-12-Bruner - FINAL27 12 23

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

11-12-Bruner - FINAL27 12 23

Uploaded by

Copyright:

Available Formats

Page 2-50 Wiring diagram

Page 405 Conformity certification burner

Page 406 Conformity certification control panel

Page 407-514 Manual controller KS 40-1 for Weishaupt-burner

Page 515-563 Manual Digital 280-1

Page 564 Drawing

Page 565-696 Safety temperature limiter

Page 697-756 Manual UNIFLEX CI 45 universal transmitter

20170505_084835 100100104 634

WIRING DIAGRAM weishaupt

In case of mistakes in this wiring diagram, responcibility will

No responcibility will be accepted for control panels, which

- - - Date Name Title

1 Delivery status - Checked Drawing-No. Max Weishaupt GmbH

20170505_084835 100100104 634

Sheet Designation Sheet Designation Sheet Designation

B01/39 WM-GL30/2 B27/39 Capacity regulation

B02/39 Table of contents B28/39 Capacity regulation

B03/39 Door plan B29/39 Uniflex

B07/39 Burner connection B33/39 Mixed Air Fan

B08/39 Burner connection B34/39 Mixed Air Fan

B17/39 Emergency stop

B18/39 Temperature limit control

B19/39 Temperature limit control

B21/39 Voltage supply

Date Name Title Table of contents

Checked Drawing-No. Max Weishaupt GmbH

20170505_084835 100100104 634

Date Name Title Door plan

Checked Drawing-No. Max Weishaupt GmbH

20170505_084835 100100104 634

-Q3 =B1 -F1 =A1 -T1

=V1 -K23 =B1 -K22

Mounting plate distribution

20170505_084835 100100104 634

Panel version Wiring colors and cross sections

Panel type WSW-008-12-030

Version Cabinet control

Hinge Left X Right

-X10 = Terminals PLC / PLC-indications (pot.free)

Terminals panel ventilation

Wire marking Ongoing Terminals panel horn

Terminals -X99 = Direct at instrument connect lines

F Potential identification Constr.-

Checked Drawing-No. Max Weishaupt GmbH

20170505_084835 100100104 634

B35 Max. pressure switch in oil return line

E M B31 Low pressure switch gas E

M38 Servomotor gas-throttle

-B31 -B32 Constr.-

Date Name Title WM-GL30 ZM-R

Checked Drawing-No. Max Weishaupt GmbH

20170505_084835 100100104 634

1: Oil Start conditions chain

Date Name Title Burner connection

Checked Drawing-No. Max Weishaupt GmbH

20170505_084835 100100104 634

B10 Air pressure switch

Date Name Title Burner connection

Checked Drawing-No. Max Weishaupt GmbH

20170505_084835 100100104 634

B31 Low pressure switch gas

Date Name Title Burner connection