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Version 1 (05/02)

Replaces

Operating Manual

This operating manual is meant for persons operating,


monitoring, or maintaining the boiler system.
It contains all information required by you for safe operation,
as well as for maintenance and servicing of the boiler system.

Version 1 (05/02)
Replaces

Impressum
All rights reserved
Copyright by LOOS INTERNATIONAL
Loos Deutschland GmbH
Nuernberger Str. 73, D-91710 Gunzenhausen
This operating manual may - even in excerpts - only be reprinted
or otherwise duplicated with the express written approval of the
company LOOS Deutschland GmbH.
Any type of duplication, publication or storage on storage media of
any type and manner not authorized by LOOS Deutschland GmbH
is in violation of current copyright law and will be prosecuted.
Publisher responsible for the content:
LOOS Deutschland GmbH, Nuernberger Str. 73, D-91710 Gunzenhausen
Editorial office/layout: text und bild Redaktion, Thomas-Schwarz-Strae 47, 85221 Dachau

Preface to the Operating Manual


Version 2 (06/02)
Replaces 1 (05/02)

Preface
Congratulations on the purchase of your new boiler system! Please take sufficient time and carefully and completely read
this operating manual before commissioning or operating the plant or individual parts of it. This operating manual contains all
the information needed for safe operation as well as for maintenance and servicing of the boiler system or individual parts of
this system. The hints on safety are based on the safety, health protection and legal regulations applicable at the time of
printing of this operating manual.

Spare Parts
Only original parts made by Loos International may be used and installed during maintenance work or repairs. These original
parts have been especially engineered and manufactured for our boiler systems. They comply with the high quality requirements of Loos International and provide safety and reliability. We expressly point out that spare parts not tested and approved by Loos International may not be used with this boiler system as this could massively impair the safety and function
of the boiler system. Loos International assumes no responsibility of any kind for such installation work and the resultant
consequences. Any warranty claim lapses if arbitrary modifications are made to the boiler system. It may also happen that
possible official approval may be questioned in this case. This also applies if lead seals applied by the works or sealing wax
applied by the works are damaged or removed.
The special order and inquiry form After Sales Services L006 may be found in register L (forms) for ordering or inquiring
about spare parts.
In addition, you can inquire about or order spare parts online at www.loos.de , or you can contact your customer service
engineer.

Customer Service
You will find the address of the person you should contact in the case of problems, faults or other questions on the service
sticker, which is generally fixed in the top right-hand corner of the control cabinet door.

Maintenance Contract
To ensure that your equipment runs safely and properly, regular maintenance is of crucial importance and will also prevent
equipment failure and save costs. Regular maintenance will help to maintain the value of your system and to guarantee the
long-term, optimum availability of your equipment. This is also backed in many countries by national regulations requiring
that the safety elements of your boiler system are inspected by a qualified person.
We therefore recommend that you take out a Maintenance Contract. Under this contract, our customer service engineers will
take over the regular inspection and maintenance of your boiler system. You can request a quotation for your maintenance
contract at www.loos.de or from your customer service engineer.

Page 1 of 1

Order number:
Boiler No.:
Product designation:

21068100
105495; 105496
LOOS Three-Pass Flame Tube Smoke Tube Boiler
UNIMAT, Type UT-HZ [36000;13,0]; LOOS Three-Pass
Flame Tube Smoke Tube Boiler UNIMAT, Type UT-HZ
[36000;13,0]
27.10.2009

Printing date:

General Informations

No.

Title

Edition

A002

Basic safety instructions

6(03/07)

Operation

No.

Title

Edition

B004

Directive water conditions for hot water boilers

4(10/09)

B006

Regular inspections for shell boilers Maximum permitted working pressure


greater than 1.0 bar or maximum permitted temperature greater than 120C

6(03/04)

B007

Check list for hot water boiler

2(06/05)

Boiler and Boiler components

No.

Title

Edition

C005

Lining of the front reversing chamber Lining of the front reversing chamber

1(01/09)

C007

Burner and flue gas side inspection openings for shell boilers for shell boilers 5(11/08)
with lateral flame tube

C014

Shell boiler for producing hot water

Burner

No.

Title

Edition

D001

Gas regulation module (GRM)

2(03/04)

D512

Combustion manager W-FM100

1/2004

D558

Regulators for gas and dual fuel burners with gas supply pressures up to 4 bar 2007

D673

VLT AutomationDrive FC 300

MG.33.AA.03

Weishaupt

industrial burner WKG80/4-A, version NR (NOX reduced)

1/2009

Equipment for water and steam supply

No.

Title

Edition

E016

Return flow temperature safeguard

2(07/09)

E538

Etaline

1.6.2007

E542

Frequency Converter PumpDrive

14.02.2006

Equipment for fuel supply and heat recovery

No.

Title

Edition

F514

High performance fan

N14-0105

7(12/08)

Page 1

Order number:
Boiler No.:
Product designation:

21068100
105495; 105496
LOOS Three-Pass Flame Tube Smoke Tube Boiler
UNIMAT, Type UT-HZ [36000;13,0]; LOOS Three-Pass
Flame Tube Smoke Tube Boiler UNIMAT, Type UT-HZ
[36000;13,0]
27.10.2009

Printing date:

Specification of procedure

No.

Title

Edition

G012

Wet and Dry Conservation

1(09/04)

G301

Loos-Boiler-Control LBC

2(02/08)

G316

Return flow temperature control with speed controlled lifting pump

1(11/07)

G328

Flue gas heat exchanger pump

1(11/07)

G339

Performance regulation infinitely variable load request via permanent signal


or load request via 3-step signal with positioner Double-flue boiler with oneflue operation

1(08/08)

G361

Burner activation twin fire tube boiler ZFR with individual operation of fire tubes 1(10/08)

G381

Return flow shut-off valve, controlled

Switch box components

No.

Title

Edition

H001

Switching Amplifier B3

4(09/09)

H024

Operating and Monitoring System TP10

1(10/07)

H026

Central Processing Unit CPU313C

1(11/07)

H030

Communication Module CP343-1 Lean Industrial Ethernet

2(10/09)

H032

Communication Module CP342-5 Profibus DP

1(07/08)

H037

Analogue Input Module

1(12/07)

H038

Analogue Output Module SM332

1(12/07)

H519

Measuring transducer IgT-MU

02.01.2008

H522

Universal Frequency Transducer

100240_en_05

Sensors

No.

Title

Edition

E+H

Proline Promag 50P, 53P

07/05

E+H

Energy Manager RMS621

09/07

E+H

Omnigrad M TR15

07/09

I001

Level limiter electrode Type E4B

5(03/09)

I003

Pressure transducer for liquid and gaseous media, with electric locking

5(05/05)

I509

Quantometer QA

09/04

I520

INSTALLATION INSTRUCTIONS Model 107 vLT / 107 vLHT with weighted


pendulum

01/2007

1(10/07)

Page 2

Order number:
Boiler No.:
Product designation:

21068100
105495; 105496
LOOS Three-Pass Flame Tube Smoke Tube Boiler
UNIMAT, Type UT-HZ [36000;13,0]; LOOS Three-Pass
Flame Tube Smoke Tube Boiler UNIMAT, Type UT-HZ
[36000;13,0]
27.10.2009

Printing date:

Armatures and servo units

No.

Title

ARI

Supape de trecere i reglare - STEVI 425/426

ARI

Servomotoare multitur SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 AUMA NORM 01/08

K002

Full-stroke safety valves

K004

Pressure gauge with test stop valve

K007

Stop valves

4(01/09)

K008

Non-return valves

K014

Temperature controller/limiter

K021

Flange gaskets

3(05/02)

K022

Inspection openings steam and water side

16(07/08)

K537

Gas filter HF 2000

K554

Electric multi-turn actuators SA07.1 - SA 48.1 / SAR 07.1 - SAR 30.1

07.06.2006

K557

High performance butterfly valves Series HP111 / HP114

07/08

Forms

No.

Title

Edition

L004

Form operating log book for hot water boiler

3(08/05)

L006

After Sales Service Enquiry/Order

3(04/07)

L007

Regular Inspections - External Inspections

3(08/09)

L008

Regular Inspections - Internal Inspections

3(08/09)

L009

Regular Inspections - Water Pressure Test

3(08/09)

L014

Return Note

2(10/09)

Technical data

No.

Title

Edition

M_KDP

Technical data

---

M_LPK

Project-oriented data sheets from LPK

---

TI012

Requirements for operation of high-pressure boiler systems without constant 3(08/08)


supervision

TI014

Dewpoint of flue gases

4(10/07)

TI024

Requirements for Boiler Installation Rooms

6(07/09)

TI034

Parameter for the Profibus DP Interface

3(10/09)

Edition

Page 3

General Information

Operating Instructions

Basic safety instructions


A002
Version 6 (03/07)

Contents
1

Scope of the Operating Instructions ........................................................................................................................ 2

Use in Accordance with Regulations....................................................................................................................... 2

Safety .......................................................................................................................................................................... 2

3.1

General ........................................................................................................................................................................ 2

3.2

Definition of terms........................................................................................................................................................ 3

3.2.1

Operating and maintenance staff................................................................................................................................. 3

3.2.2

Competent person ....................................................................................................................................................... 3

3.2.3

Expert .......................................................................................................................................................................... 3

3.3

General notes and symbols ......................................................................................................................................... 3

3.4

Safety and health protection ........................................................................................................................................ 4

3.5

Owner's obligations...................................................................................................................................................... 5

Operating and Maintenance Staff ............................................................................................................................. 6

General Risks and Accident Prevention .................................................................................................................. 6

5.1

Risks and dangers ....................................................................................................................................................... 6

5.1.1

Mechanical hazards ..................................................................................................................................................... 6

5.1.2

Electrical hazards ........................................................................................................................................................ 7

5.1.3

Working on live components........................................................................................................................................ 7

5.1.4

Dangers caused by heat .............................................................................................................................................. 8

5.1.5

Dangers from noise ..................................................................................................................................................... 8

5.1.6

Danger from vibrations ................................................................................................................................................ 8

5.1.7

Dangers caused by fuels, auxiliary substances, lubricants and cleaning products ...................................................... 9

5.1.8

Danger from gases ...................................................................................................................................................... 9

5.1.9

Dangers from explosions ........................................................................................................................................... 10

5.1.10 Residual dangers....................................................................................................................................................... 10


5.1.11 Danger analysis ......................................................................................................................................................... 10
5.2

Behaviour after accidents (damage to property) ........................................................................................................ 10

5.3

Behaviour in the event of accidents (personal injury) ................................................................................................ 10

5.4

Handling old parts, fuels and auxiliary substances .................................................................................................... 11

5.5

Danger area............................................................................................................................................................... 11

Description of Structure and Function / Description of Process ........................................................................ 11

Technical Data (Dimensions, Weight, Operating Conditions) ............................................................................. 11

Transport and Storage ............................................................................................................................................ 11

Assembly.................................................................................................................................................................. 11

10

Electrical Installation ............................................................................................................................................... 11

11

Setting and Adjustment........................................................................................................................................... 12

12

Controls .................................................................................................................................................................... 12

13

Start-up ..................................................................................................................................................................... 12

13.1

Testing before start-up............................................................................................................................................... 12

13.2

Initial start-up ............................................................................................................................................................. 12

14

Operation.................................................................................................................................................................. 12

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Version 6 (03/07)

14.1

Obligation to supervise .............................................................................................................................................. 12

14.2

Ban on operation ....................................................................................................................................................... 12

15

Shutting down .......................................................................................................................................................... 12

15.1

Disposal ..................................................................................................................................................................... 12

16

Measures in the event of unusual observations and operating faults ................................................................ 12

17

Care and Maintenance............................................................................................................................................. 13

17.1

Regular inspections (outside and inside inspections and water pressure tests) ........................................................ 13

17.2

Inspections by the operating and maintenance staff .................................................................................................. 13

17.3

Maintenance service contract .................................................................................................................................... 14

17.4

Teleservice ................................................................................................................................................................ 14

18

Replacement Parts................................................................................................................................................... 14

19

Lists and Tables....................................................................................................................................................... 14

Scope of the Operating Instructions

These Operating Instructions apply solely for parts and services supplied by Loos International. The supplier in question
must provide the appropriate operating instructions for parts of equipment on the boiler or system that were not supplied by
Loos International and carry out the necessary regulatory instruction of the operating and maintenance staff at the first startup.
If any changes are made to official regulations, Loos International does not provide any update service. The owner of the
boiler or system is obliged to inform the operating and maintenance staff of the latest version of the valid regulations
comprehensively and in good time.
We expressly point out that these Operating Instructions only contain the specific regulations issued by Loos International
for the operation of the boiler or system. Official regulations or requirements are quoted or mentioned only in passing, if at
all.

Use in Accordance with Regulations

A boiler or system or parts thereof that were supplied by Loos International may only be operated in accordance with the
present instructions. Any other use or operation is not in accordance with regulations and is therefore not allowed.
For the boiler system to be used in accordance with regulations, the owner must examine, on the basis of the valid
regulations, whether an operating permit is necessary for the boiler system to be installed and/or if the comments of local
authorities or supervisory organisations, as applicable, should be obtained.
If this is the case, the system may generally only be started up after the necessary documents have been submitted and
after the written notification from the supervisory authority has been obtained.

3
3.1

Safety
General

The components described in these Operating Instructions are manufactured according to the current state of the art and
meet the current safety regulations. If, according to the valid European regulations, a CE mark can be affixed, Loos
International confirms, for the free transport of goods within the European Economic Area, with the issue of the conformity
declaration and the affixing of the CE mark, that this system was manufactured in accordance with the valid European
directives.
Changes to this system may only be made with the express written permission of Loos International, since otherwise the
manufacturer's guarantee ceases to be valid. In addition, if changes are made independently to the system, compliance with

Page 2 of 14

Operating Instructions

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A002
Version 6 (03/07)

the conformity declaration and the relevant directives can no longer be guaranteed. In this case, the person who made the
changes to the system is obliged to obtain a new operating permit if necessary and to prepare a new conformity declaration
if applicable
Loos International is not liable for damages which are caused by operating mistakes, operation not as directed, use not in
accordance with regulations, inexpert maintenance or lack of maintenance, or inexpert repairs or servicing.

3.2
3.2.1

Definition of terms
Operating and maintenance staff

Operating and maintenance works may only be carried out by people who are physically and mentally suited thereto and
sufficiently qualified and who have the necessary specialist knowledge. Proof must be provided of this qualification.
Depending on the regional regulations, it may be necessary for these people to have been given a special training for these
activities by an officially recognised body and to have to prove that this training was successfully completed.
Minors may not carry out these works. If this is necessary for training purposes, minors must always be supervised in
operating the system by suitable, experienced and reliable adults who have the necessary authorisation for this.

3.2.2

Competent person

A competent person is a person who, on the basis of his or her specialist training and experience has particular knowledge
in the field of boiler systems and is familiar with the relevant national health and safety regulations, accident prevention
regulations, guidelines and generally recognised technical rules (e.g. DIN, EN, ISO, corresponding national standards, VDE
(or corresponding national regulations) in both theory and practice. He or she should be able to test boiler systems and also
evaluate them according to the regional regulations.
Competent people are people who are expressly authorised by the owner to carry out inspections and who hold the
necessary qualifications. Regional regulations on training must be taken into account.

3.2.3

Expert

An expert is a person who, on the basis of his or her specialist training and experience has particular knowledge in the field
of boiler systems and is familiar with the relevant national health and safety regulations, accident prevention regulations,
guidelines and generally recognised technical rules (e.g. DIN, EN, ISO, corresponding national standards, VDE (or
corresponding national regulations) in both theory and practice. He or she should be able to test boiler systems and also
provide an expert's report on them according to the regional regulations.
Experts are people who are members of an organisation or a named department as defined in EU regulations or of a
supervisory organisation which is accredited and approved for this work according to the regional regulations.

3.3

General notes and symbols

The following symbols and notes are used in these Operating Instructions for safety notes. They warn against possible
personal injury or material damage or help you to simplify working procedures.
Danger! This symbol warns you of the immediate threat of a danger which could lead to the most severe physical
injury or death. These dangers can always occur if the operating or working instructions are ignored or not
followed precisely.

Warning! This symbol warns you of a possibly dangerous situation which could lead to severe physical injury or
death. These dangers can always occur if the operating or working instructions are ignored or not followed
precisely.

Attention! This symbol warns you of possibly dangerous situations which could lead to minor physical injury or
damage to the plant or other material damage. These dangers can always occur if the operating or working
instructions are ignored or not followed precisely. Failure to comply with these notes may invalidate the
guarantee.

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Important! This symbol warns of a possibly dangerous situation in which the boiler system or objects in the
surrounding area could be damaged.

Note: This symbol draws your attention to special points which will make your work easier.

Operating and maintenance staff: Maintenance and adjustment works which are marked by this symbol may be
undertaken by the trained user/operator of the machine (for definition, see section 3.2.1).

Competent/specialist staff: Maintenance and adjustment works which are marked by this symbol may only be
carried out by specially trained and instructed specialist staff with the corresponding mechanical and
electrical/electronic specialist knowledge and the necessary specific or special tools (for definition, see section
3.2.2).

Maintenance and adjustment works which are marked by this symbol may only be carried out by the
manufacturer of the system or by specially trained specialist staff who have been expressed authorised by Loos
International to do this work. If this instruction is ignored, any guarantee on the part of the manufacturer becomes
null and void.
Any failure to comply with safety instructions will result in danger to people or materials and can cause massive damage to
the environment and to the system. Failure to comply with safety instructions may lead to the loss of any right to claim
damages.
In detail, non-compliance may cause the following risks:

the failure of important system functions

the failure of prescribed methods of maintenance and repair

danger to people as a result of electrical and mechanical factors

3.4

Safety and health protection

The following provisions and regulations must be strictly followed to reduce the risk of personal injury and/or material
damage. In addition, the regionally valid requirements, regulations and conditions on safety at work and on the safe handling
of boiler system must be complied with absolutely.

Everyone who operates a boiler system must, for safety reasons, have read and also understood the present Operating
Instructions in full.

For the safe operation of the boiler system, the relevant health protection regulations, and the relevant state and other
regulations on safety at work must be strictly complied with.

The owner is obliged to provide all persons who work with systems or appliance which were supplied by Loos
International with the current version of the valid regulations in such a way that they are freely available to these persons
at all times.

The system may only be operated in accordance with regulations in compliance with these Operating Instructions.

The boiler, the boiler system and all parts must be used and operated in such a way that no danger may be caused by it
to people or the environment.

The effectiveness of operating and adjustment components may be not be impermissibly influenced or cancelled out.

All danger areas in the system are to be marked by the producer of the overall system by warning signs (pictograms).
These warning signs will indicate possible dangers. They form part of the Operating Instructions. They must always be

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kept in a clean, easily legible state. Warning signs which are damaged or no longer easy to read must be replaced
immediately. The meaning of every individual warning sign is explained precisely in the Operating Instructions.

3.5

Owner's obligations

The owner is obliged to prepare a set of operating orders on the basis of the present Operating Instructions and the
evaluation of the danger of this boiler or system.

The owner must ensure that the valid safety regulations, the official requirements and the notes in these Operating
Instructions are also actually complied with when operating the boiler or system.

The owner of the boiler or system must ensure that these Operating Instructions and/or the operating orders are always
available within reach, in full and in a readable condition at the workplace of the operating and maintenance staff and are
freely accessible at all times.

The owner may only allow the boiler or system to be operated by people who meet the requirements set out in
Section 3.2.1.

The owner must ensure that these people are so reliable that they can be expected also to actually carry out the tasks
assigned to them reliably and not to be under the influence of alcohol, medication, drugs or consciousness-limiting
substances when carrying out the operating and maintenance work.

The owner must ensure that work on the electrical components is only allowed to be carried out by trained and tested or
approved electricians. Work on gas equipment and components may only be carried out by correspondingly trained and
approved specialists.

The owner is obliged only to operate the boiler or system in a technically perfect condition. By means of corresponding
instructions and checks, the owner must ensure that the workplace is clean and tidy and that the areas by and around
the system are clean.

The owner must ensure that the operation of the boiler or system is monitored in a suitable way in accordance with the
official requirements.

The owner is obliged to inform the operating and maintenance staff in a suitable way about the regionally valid official
requirements and regulations on the operation of the boiler. He is also responsible for ensuring that tests, approvals,
records of the operation of the boiler or system (e.g. in the form of an operating log book), reports on operating faults etc.
which are required by official bodies (e.g. authorities) are carried out in good time and in accordance with regulations.

The owner of the boiler or system must ensure that the effectiveness of operating or adjustment components is not
affected. In addition, he must ensure that safety equipment and protective devices are always in a perfect condition and
in accordance with regulations. Safety equipment and protective devices may not under any circumstances be removed,
rendered inoperable or made ineffective in any other way.

The owner must that the safety equipment provided is fully functional and that this functioning capacity is checked at
regular intervals.

The owner of the boiler or system must ensure that everyone who works on the system possesses and also uses the
necessary or prescribed personal protective equipment.

All persons who work on the boiler or system must be informed of the location of the fire-fighting equipment available in
a suitable way.

The owner must always provided for sufficient exit routes in the event of an emergency (fire, leakage of medium,
development of flue gas, emergency stop, explosion). These emergency exit routes are vital. They must comply in full
with the regionally valid regulations, must be marked and may never be locked or moved.

The owner must, in accordance with the regional regulations, provide sufficient facilities and aids to be able to combat
any emergencies (fire, leakage of medium, development of flue gas, emergency stop, explosion) in their early stages. In
addition, he must ensure that a fire extinguisher that is ready to use is kept in an easily accessible location in the boiler
house in accordance with the regional regulations. This fire extinguisher must be checked regularly in accordance with
the regionally valid fire prevention regulations to ensure that it is in proper working order.

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The owner must, in accordance with the regional regulations, create sufficient ways of being able to report immediately
any emergencies (fire, leakage of medium, development of flue gas, emergency stop, explosion) and of being able to
obtain sufficiently qualified assistance.

Operating and Maintenance Staff

Obligations of the operating and maintenance staff:

Before starting work, you should read the owner's operating orders and the Operating Instructions in this file, especially
the safety and danger instructions. this applies in particular for people who are only occasionally employed on this
system.

Only use the boiler or system if you have been expressly instructed to do so by the owner.

Always take note of the safety and danger instructions affixed to the boiler and the system and in the Operating
Instructions.

Find out regularly about the possibilities that your workplace offers for being able to quickly report or fight any fires
occurring.

Find out regularly about the emergency exit routes available and check that these are not blocked.

Take note of the regionally valid statutory regulations on health protection and on protection of the environment (e.g.
when handling dangerous materials).

Always use the prescribed personal protective equipment (protective clothing etc.).

Your clothing must be such that it cannot be caught up by moving system components. Shirt and jacket sleeves must
either be buttoned up or turned over inwards.

Long hair should always be tied back. When working on the boiler or system, do not wear loose clothing or jewellery.
Always insert the end of neckcloths or scarves into your clothing.

You should not work on the boiler or system if you have taken medication which could adversely affect your
concentration or your reactions. Never operate the system whilst under the influence of alcohol or drugs.

Report faults immediately to the competent person or body; if necessary, switch off the boiler or system and secure
against being switched on again without authorisation.

All maintenance work that is not expressly authorised for the operator may only be carried out by persons with the
corresponding qualification.

General Risks and Accident Prevention

5.1

Risks and dangers

Despite being constructed in line with safety regulations, the operation of boilers or boiler systems always involves certain
risks and dangers. Loos International has, of its own accord, taken all measures and precautions to make its products as
safe as possible. Most operating faults or accidents are caused by incorrect operation or unsuitable operating conditions. In
the interests of your own safety, we ask you to follow the following safety instructions precisely. In the following, we point out
the main risks and dangers which may occur when operating a boiler or boiler system. The following list is not necessarily
complete, since individual operating conditions on which Loos International has no influences may cause additional risks
and dangers. Loos International cannot foresee or estimate these risks and dangers.

5.1.1

Mechanical hazards
Danger! Loss of consciousness and physical injury of varying severity may be caused by: parts that are flung out
e.g. during an explosion or after inexpertly executed maintenance or repairs to system components that are under
pressure.

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Protective measures:
Only operate the boiler or system in accordance with the Operating Instructions

Monitor the boiler or system regularly

Only operate the boiler with the permitted fuels and auxiliary substances

If firing components develop operating faults, following the relevant Operating Instructions precisely

Always observe the relevant safety regulations when carrying out maintenance and repair work on system components
that are under pressure. Before working on system components that are under pressure, you should depressurise and
secure these system components before starting the work.

Only allow maintenance, repair or servicing work to be carried out by specialists/competent people.

5.1.2

Electrical hazards
Danger! Electricity can cause fatal accidents. Cardiac arrest, ventricular fibrillation, arrhythmia and other injuries
may be caused by touching wires and live parts that are not insulated or not properly insulated and by inexpert
maintenance or repair work on electrical systems or equipment or parts thereof.

Causes:

e.g. contact with live and energised parts or immediate proximity to such parts

open, electrically conductive parts after damage to insulation

faulty execution of maintenance work

faulty or non-existent safety checks after maintenance work

installation of the incorrect fuses or improper repair (bridging) of fuses

Precaution: Maintenance and repair work to electrical equipment and live parts may only be carried out by an electrician
(according to the guidelines laid down by the VDE or comparable European or regionally competent institutions).
Protective measures in the case of work in a de-energised state:
Systems and system components on which maintenance and repair work has to be carried out must be disconnected
from the power supply before the work is started.

Systems and system components that have been disconnected from the power supply must be protected against being
switched back on again without authorisation and must be marked accordingly

Components that have been disconnected from the power must be checked for residual voltage/that they are not live
before the start of work.

Any residual voltage must be discharged according to the recognised rules of electrical engineering (earthing and shortcircuiting)

Adjacent live parts must be covered or safeguarded.

5.1.3

Working on live components


Danger! Electricity can cause fatal accidents. Cardiac arrest, ventricular fibrillation, arrhythmia and other injuries
may be caused by work on live components. Electric shocks and arcing are possible. This requires particular
technical and organisational measures and to some extent special protective clothing (according to the
guidelines laid down by the VDE or comparable European or regionally competent institutions).

Work on live components may only be carried out for really compelling reasons. Compelling reasons could be:

There is a risk that people's lives or health could be endangered.

There is a danger of major damage in commercial terms.

Work on live components may ONLY be carried out by trained, approved electricians. If necessary, these persons must war
the special, approved protective clothing that is prescribed for such work. They may only use tools and equipment that has
been tested and approved for the corresponding voltage range.

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Basic safety instructions


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Version 6 (03/07)

5.1.4

Dangers caused by heat


Danger! Boilers become very hot during operation. Although the boiler is very well insulated against heat loses,
individual system components may reach very high operating temperatures. Touching these components could
cause burns. If hot water or steam flows out of the boiler system, this can cause severe scalding. Contact with hot
burner components can also cause severe burns. When burner components are opened, any flames occurring
may cause clothing to catch fire.

Protective measures:
Before touching any part of the boiler, burner or system, check, by carefully bringing the hand closer, whether increased
heat radiation might indicate that the surface is hot.

If necessary, wear suitable protective gloves.

Wear suitable protective clothing.

Stay as far away as possible.

When opening shut-off valves, make sure that no-one is standing in the path of any outlet openings.

When opening inspection openings or doors, always stand behind the inspection opening cover or the door so that you
can use the cover or door as a protective shield.

5.1.5

Dangers from noise


Warning! Noise can cause a loss of hearing (deafness), hearing difficulties, health problems such as loss of
balance and giddiness and cardiovascular disturbances. Noise can lead to a drop in people's attention levels. In
addition, noise can disrupt spoken communication between the operating and maintenance staff and between the
staff and other people. The perception of audible warning signals can be adversely affected or destroyed.

Causes:
Pulsation noise (< 0.2 s; > 90 dB(A))

System noises over 90 dB (A)

Burner noises

Faulty burner settings

Inexpert installation of system components added later

Protective measures:
Suitable hearing protection (cotton wool, earplugs, ear covers, headphones) should be worn or carried so that they are
within reach at all times.

Burners must be correctly set by a specialist.

Possible sources of noise must be searched for and eliminated through the use of suitable measures.

Note: Unfavourable local conditions may cause the valid noise limits to be reached or exceeded. Because Loos
International generally has little or no influence on the individual noise situation on the spot, it is up to the owner
to carry out corresponding noise measurements and to oblige the operating and maintenance staff to wear
special personal noise protectors through the application of special operating orders.

5.1.6

Danger from vibrations


Warning! If people are constantly exposed to vibrations, this may cause health problems, and especially to
disturbances of the nervous system. It may also cause damage to buildings or adjacent systems and equipment.

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Basic safety instructions


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Causes: Vibrations in boiler systems are almost always caused by incorrect burner settings, dirt or inexpert installation.
Protective measures:
Have the burner checked and if necessary reset by an expert. Determine the cause of the vibrations that are not due to
the burner.

Make sure that the relevant system components are properly installed or separated from the system as regards
vibrations through suitable structural measures.

5.1.7

Dangers caused by fuels, auxiliary substances, lubricants and cleaning products


Warning! Fuels, auxiliary substances, lubricants and cleaning products may contain constituents that are
hazardous to health. In particular, the inexpert use of these substances and products can cause the following: the
triggering of allergies, severe caustic burns if these substances and products come into contact with the skin,
severe damage to the mucous membranes, poisoning or burns to the respiratory tract if these substances and
products are swallowed or if vapours emanating from these substances and products are inhaled, long-term
health problems if these substances and products are inexpertly handled and stored.

Protective measures:
Read the safety instructions on the packaging of these substances and products carefully before use and follow the
safety instructions given precisely.

Avoid skin contact with these substances.

Wear suitable protective clothing (e.g. gloves, apron, goggles, protective footwear).

If these substances and products come into contact with skin, clean the areas of skin affected carefully, remove any
residues with plenty of plain water and consult a doctor if necessary.

Remove any clothing soiled by these substances and products immediately and leave to air in a suitable location. Clean
the items of clothing in question, throw away if necessary.

Keep any rags that are soiled by these substances and products in suitable containers in accordance with regulations
and dispose of them ecologically.

If these substances need to be transferred to other containers, always use suitable funnels.

Only transfer chemicals in the open air or in well ventilated rooms. The prescribed protection and safety regulations
should be noted and followed precisely.
Attention! The leakage of fuels, auxiliary substances, lubricants or cleaning products may harm the environment.
Soil and water may become polluted. Accidents may be caused by people slipping or falling over if circulation
areas are dirty.

Protective measures:
Handle fuels, auxiliary substances, cleaning products, fats and oils carefully.

Carefully close containers filled with fuels, auxiliary substances, lubricants or cleaning products.

Dispose of empty containers ecologically and in accordance with regulations.

Keep suitable binders on hand and use them immediately if necessary.

Remove any leaked fuels, auxiliary substances, lubricants and cleaning products immediately with suitable binders (e.g.
special cloths) and dispose of ecologically and in accordance with regulations.

5.1.8

Danger from gases


Warning! Gases (including flue gases) can explode or cause irritation of the respiratory tract, severe poisoning or
death from suffocation if they are inhaled or swallowed.

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Protective measures:
Keep sources of fire away from gases. Comply with safety regulations when handling gases. These safety regulations may
vary, depending on the substance used. The owner is obliged to make available the regulations applicable for his operation.
When handling gases, personal protective equipment must be worn (e.g. suitable face masks, protective clothing, etc.).

5.1.9

Dangers from explosions


Danger! Danger from explosions. The operation of burner systems can, in extreme cases, cause explosions in
the burner room or in the flue gas ducting. The causes may include lack of maintenance, inexpert maintenance or
adjustment work on the burner or the inexpert installation or burner or flue gas ducting components. If fuels are
inexpertly handled, this may very well cause an explosion.

Protective measures:
Comply absolutely with safety regulations on the handling of fuels and gases.

Only have work on gas installations, supply lines or system components carried out by specialist staff/competent
persons.

Carry out maintenance at the required intervals.

In the event of ignition faults, follow the burner manufacturer's Operating Instructions precisely.

Only have work on parts carrying fuel carried out by specialist staff/competent persons.

Do not switch the burner back on again after an explosion! The boiler must remain out of operation until a competent
person allows the boiler to be started up after an appropriate inspection. Loos International recommends that this inspection
is carried out by suitably trained customer service engineers from Loos International unless a supervisory organisation has
been called in.

5.1.10 Residual dangers


Residual dangers are particular hazards which cannot be eliminated even though the system has been in line with safety
requirements. These residual dangers cannot be obviously detected and may cause injuries or be a health hazard.
If unforeseen residual dangers occur, operation of the boiler or system should be halted immediately and the competent
person in charge informed. This person will then take any further decisions and do everything necessary to eliminate the
danger that has arisen. The system manufacturer should be informed if necessary.

5.1.11 Danger analysis


The owner must check, within the scope of the valid regional regulations, whether a danger analysis is required for the boiler
or the system and have this prepared if necessary by specialist staff/competent persons.

5.2

Behaviour after accidents (damage to property)

If the boiler or the system is damaged or if parts of the boiler, Economizer, superheater or walls of pressure vessels are
overheated, burnt out or cooled down so suddenly that they might have developed faults, the system must be shut down
immediately.
Incidents of this type must be reported immediately, in accordance with regional regulations, to the supervisory authority
and/or the competent monitoring organisation for systems of this type. The supervisory authority may call for an
extraordinary inspection to be carried out in individual cases in the event of accidents or for special reasons.

5.3

Behaviour in the event of accidents (personal injury)

In the event of accidents involving personal injury, the necessary first-aid measures must be taken immediately, medical
help sought and the nearest available manager informed. If necessary, the system must be shut down using the emergency
off switch.

In the event of burns, the areas of skin affected must be cooled down immediately and lastingly.

A suitable extinguisher should be used immediately on people who are on fire.

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If clothing catches fire, do not run away under any circumstances. Throw the person on the floor immediately and
extinguish all flames immediately by rolling the person back and forth.

Any accident in which a person has been killed or injured in connection with the operation of the system must be reported
immediately, in accordance with the regionally valid regulations to the competent supervisory authority and/or the competent
monitoring organisation.

5.4

Handling old parts, fuels and auxiliary substances

When handling fuels and auxiliary substances, suitable protective clothing should be worn which prevents or reduces
possible skin contact with these substances. Faulty old parts that have been removed must be sorted by material and
collected and forwarded for proper recycling. Leftover oils, fats, metering products, solvents or cleaning agents must be
placed, safely and ecologically, in suitable collector containers that comply with regulations, stored and disposed
ecologically in accordance with the local regulations.

5.5

Danger area

If a danger area is defined for the boiler or the system, no-one may step into the danger area during operation. The danger
area must be designated as such by the manufacturer of the overall system through the use of yellow/black markings, as
shown in the drawing.

Description of Structure and Function / Description of Process

Please read the Operating Instructions for the component in question.

Technical Data (Dimensions, Weight, Operating Conditions)

In the design of a product manufactured by Loos International, standard regulations (e.g. EN 12953, Pressure Vessel
Guidelines, AD 2000, factory standards, etc.) are applied. If an acceptance documentation is agreed, this may be taken from
the specific regulations used. Characteristics which limit the working life of the equipoment, such as max. possible cold
starts or corrosion factors will be taken into account in accordance with the regulations applied.
The technical data are fixed in the order confirmation. A copy of the technical data forms part of the delivery documentation
and is generally found in Register M. For further information, please consult the enclosed data sheets.
Please read the Operating Instructions for the component in question.

Transport and Storage

Please read the Operating Instructions for the component in question.

Assembly

Please read the Operating Instructions for the component in question.

10 Electrical Installation
Please read the Operating Instructions for the component in question.

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11 Setting and Adjustment


Please read the Operating Instructions for the component in question.

12 Controls
Please read the Operating Instructions for the component in question.

13 Start-up
Please read the Operating Instructions for the component in question.

13.1 Testing before start-up


In general, a boiler may only be started up if it has been tested to ensure that it is in a proper state as regards assembly,
installation, erection conditions and reliable function and approved.
The owner is obliged to check, on the basis of the regionally valid regulations, whether these tests have to be carried out by
a monitoring organisation or expert.

13.2 Initial start-up


The initial start-up of components that were supplied by Loos International may only be carried out by Loos International
staff or by persons who have been expressly authorised by Loos International in writing to carry out these activities.

14 Operation
14.1 Obligation to supervise
Regional regulations govern the obligation to supervise boiler systems.
The system must be started up and shut down by the operating and maintenance staff unless separate devices for the safe
automation of these processes are provided and have been approved by an approved monitoring organisation.

14.2 Ban on operation


A boiler system or parts thereof may not be operated if they show faults which could endanger persons working there or
third parties.

15 Shutting down
Please read the Operating Instructions for the component in question.

15.1 Disposal
If the system or parts thereof are finally dismantled, the dismantled parts must be sorted by material type and disposed of in
accordance with the regionally valid environmental protection regulations in such a way that the environment is not
damaged and precious resources are protected. As far as possible, these parts should be taken for environmentally
appropriate recycling.

16 Measures in the event of unusual observations and operating faults


Please read sections

5.2 Behaviour after accidents (damage to property)

5.3 Behaviour in the event of accidents (personal injury)

Please read the Operating Instructions for the component in question.

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17 Care and Maintenance


Danger! Electricity can cause fatal accidents. Cardiac arrest, ventricular fibrillation, arrhythmia and other injuries
may be caused by touching wires and live parts that are not insulated or not properly insulated and by inexpert
maintenance or repair work on electrical systems or equipment or parts thereof.
Important! None of the components of the boiler system including all the attached components may be cleaned
with high-pressure cleaners, water jets or similar. If this is nonetheless done, it may cause failure and damage,
including subsequent damage especially to electrical, electronic and mechanical components.

17.1 Regular inspections (outside and inside inspections and water pressure tests)
Regular inspections should be carried out in accordance with the relevant Operating Instructions.
Operating Instructions covering regular
inspection
Shell boilers with
maximum permitted working pressure > 1 bar or
maximum permitted temperature > 120C

B006

Shell boilers with


maximum permitted working pressure 1 bar or
maximum permitted temperature 120C

B009

Shell boilers with


maximum permitted temperature 190C

B011

Quick steam generators

B008

The Overall Operating Instructions supplied for the specific order in question by Loos International only contain the
Operating Instructions necessary for the boiler supplied.

17.2 Inspections by the operating and maintenance staff


The time periods given in the check list and the operating log for maintenance works and regular inspections must be
complied with precisely. Written records must be kept of these maintenance works and inspections according to the
regionally valid regulations and the instructions laid down by Loos International. These records must be kept in accordance
with the regionally valid regulations. The precondition for any guarantee claim is that all prescribed maintenance work has
been carried out and recorded without omission in the operating logs.
Assignment of check lists and operating logs as a function of the boilers:

Steam generators

Hot water boilers

Check list
(Operating Instructions)

Operating log
(Operating Instructions)

Shell boilers

B001

L002

Quick steam generators

B005

L003

Heating boilers

B010

L005

Hot water boilers

B007

L004

The Overall Operating Instructions supplied for the specific order in question by Loos International only contain the
Operating Instructions necessary for the boiler supplied.

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17.3 Maintenance service contract


For proper, safe operation, regular maintenance must be carried out by specialist staff/competent persons in order to ensure
economical operation without breakdown. Regular maintenance will help your system retain its value and ensure the longterm, optimum availability of your system. In many countries, regular maintenance must be carried out by trained specialist
staff/competent persons and a regular inspection of the safety equipment on the boiler by experts is also required.
We therefore recommend that you conclude a maintenance service contract. Within the scope of this contract, specially
trained customer service engineers will take over the regular inspections and competently carry out all maintenance work on
the boiler. Our customers can obtain a quotation for a maintenance service contract by visiting www.loos.de or contacting
the relevant customer service engineer.

17.4 Teleservice
Using a modem, data from the boiler and system control are transmitted via a telephone line directly to Loos International.
Specialists:

prepare system analyses,

optimise regulating parameters,

provide support in the case of breakdowns

help with repairs and maintenance.

The solution of problems within the shortest possible time offer users considerable financial advantages and increase the
availability of the boiler system.
Teleservicing (remote servicing) is possible if the boiler system is fitted with Loos Boiler Control LBC and/or Loos System
Control LSC. Various service variants are possible, individually matched to the needs of the operator. Our customers can
obtain a quotation for a Teleservice Contract from www.loos.de or from the competent customer services engineer.

18 Replacement Parts
When repair and maintenance work is carried out, only original parts made by Loos International may be used and installed.
These original parts are specially designed and made for our boiler systems. The meet the high quality standards for Loos
International and offer safety and reliability. We expressly point out that spare parts that have not been examined and
approved by Loos International may not be used with this boiler system, since this would have a major adverse effect on the
safety and operability of the boiler system. Loos International cannot take any responsibility for installations of this type and
the resultant consequences. Changes made independently to the boiler system will invalidate any guarantee rights. Under
some circumstances, they may also invalidate any official permits that have been granted. This also applies if seals or
sealing paint applied at the factory are damaged or removed.
For spare parts orders or spare parts inquiries, please use the special ordering and inquiries form L006 After Sales Services
in Register L (Forms).
Alternatively, you can place your spare parts order or your spare parts offer online at www.loos.de / Kundendienst /
Ersatzteilversorgung (customer service / spare parts supply).

19 Lists and Tables


Please read the Operating Instructions for the component in question.

Page 14 of 14

Operation

Operating Instructions

Guideline on Water Characteristics


for heating boilers and hot water boilers

B004
Version 4 (10/09)

Contents
1

Scope of the Operating Instructions ........................................................................................................................ 1

Use in Accordance with Regulations ....................................................................................................................... 1

Safety .......................................................................................................................................................................... 2

Operating and Maintenance Staff ............................................................................................................................. 2

General Risks and Accident Prevention .................................................................................................................. 2

5.1

Dangerous situations.................................................................................................................................................... 2

5.1.1

Formation of deposits................................................................................................................................................... 2

5.1.2

Corrosion...................................................................................................................................................................... 3

Requirements for filling and make-up water and circuit water quality.................................................................. 3

6.1

Filling and make-up water 2) ......................................................................................................................................... 3

6.2

Circulating water .......................................................................................................................................................... 4

6.3

Notes on Tables 1 and 2 .............................................................................................................................................. 4

6.4

Addition of frost protection agents to circuit water ........................................................................................................ 5

Initial filling ................................................................................................................................................................. 5

Down times ................................................................................................................................................................. 5

Water investigation .................................................................................................................................................... 5

10

Measures in the event of unusual observations and operating faults .................................................................. 6

11

Guarantee notes ......................................................................................................................................................... 9

Scope of the Operating Instructions

These Operating Instructions contain basic information. They apply in combination with the following operating instructions:

A002 Basic Safety Instructions

For the operation of the system as a whole, the operating instructions for the individual components are binding along with
the relevant statutory provisions and official requirements.

Use in Accordance with Regulations

The specified limit values have been agreed with TV Sd and apply to hot water boilers and boilers made of non-alloy or
low-alloy steel. They are based on long-term experience and the binding safety minimum requirements of EN 12953 Part 10
and VdTV/AGFW Information Sheet TCh 1466 / FW 510 Edition 03/2004, on the reduction of:

RIsk of corrosion

Sludge waste and

Formation of deposits.

In so far as parts of the hot water boiler or heat consumer system need additional requirements, then the manufacturer of
the system shall specify this. During the planning of heating systems, the appropriate standards - in particular DIN 4751 and

Page 1 of 9

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Guideline on Water Characteristics


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4752, the boiler room guidelines and all the relevant regulations should be observed. If there is any doubt, we would ask you
to contact us.

Safety

Please read the Operating Instructions:

A002 Basic Safety Instructions

Operating and Maintenance Staff

Please read the Operating Instructions:

A002 Basic Safety Instructions

General Risks and Accident Prevention

Please read the Operating Instructions:

A002 Basic Safety Instructions

5.1

Dangerous situations

During the operation of the boiler plant dangerous situations may arise as a result of operation. Damage can only be avoided
if these situations are recognised in good time and if the correct measures are taken immediately. The following list of
dangerous situations makes no claim to be complete, but is based on values from experience that have been gathered
through decades of observing our products. If other installations or system components are present, the measures that apply
for these system components must be coordinated with the manufacturer of these installations or components.

The operating staff must report any dangerous situations immediately to the supervisor responsible.

According to the regional regulations, damage to pressure-bearing walls of the boilers and if provided the which, as
a result of a danger to the operating staff or third parties, leads to a halt in operation must be reported to the competent
supervisory authority and/or monitoring organisation which is responsible for safety tests on the boiler system.

5.1.1

Formation of deposits
Danger! There is a danger of deposits forming. The formation of deposits can destroy the boiler. There is an
acute risk to life for everyone in the vicinity of the boiler from flying parts and from the hot medium (steam, hot
water). Extremely serious damage can be caused to the boiler by insufficiently prepared water, unsuitable dosing
agents or dirty condensate. Deposits should not be regarded as harmless. The thickness of the deposits is no
indication of their effect in restricting heat.

If deposits are observed on the water side, further operation of th boiler system is not allowed.
The boiler may only be started up again once the deposits have been removed and if an expert allows the boiler to be fired
up after a suitable test has been carried out. Loos International rcommends that this inspection is carried out by a suitably
trained service engineer from Loos International, an expert or persons who have been expressly authorised by Loos
International to carry out this work.
It is recommended that an experienced specialist company is employed to remove the coating and/or deposits.. If chemical
cleaning is required, this must be noted in the operating log.
Note: Boilers may only be cleaned with boiler scale solvents which are approved under regional regulations. The
regulations on safety and environmental protection must be strictly complied with. These regulations and
instructions are given on the cleaning product containers or in the corresponding safety data sheets. These data
sheets are available from the supplier of the cleaning product.

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Version 4 (10/09)

5.1.2

Corrosion
Danger! Danger from corrosion. Corrosion can destroy the boiler. There is an acute risk to life for everyone in
the vicinity of the boiler from flying parts and from the hot medium (steam, hot water). Extremely serious damage
can be caused to the boiler by insufficiently prepared water, unsuitable dosing agents or dirty condensate.

If corrosion is observed on the water side, further operation of th boiler system is not allowed.
The boiler may only be started up again once the deposits have been removed and if an expert allows the boiler to be fired
up after a suitable test has been carried out and measures have been taken to repair the corrosion, or at least to prevent the
corrosion from spreading any further.
Loos International rcommends that this inspection is carried out by a suitably trained service engineer from Loos
International, an expert or persons who have been expressly authorised by Loos International to carry out this work.

6
6.1

Requirements for filling and make-up water and circuit water quality
Filling and make-up water 2)

Table 1: Requirements for filling and make-up water


Boiler design

Flame tube-fire tube boiler

Water chemical operation


Electrical conductivity in circuit water

Salty
[S/cm]

Column
General requirement
pH value at 25 C
Earth alkalis (total hardness)

1)

Low salt 1)

> 100-1500

> 30-100

30

Colourless, clear, free of insoluable matter


[-]

8.5-10.5

8-10.5

[mmol/l]

< 0.02

[ dH]

< 0.1

[mg/l]

< 0.1

Iron

[mg/l]

< 0.2

Copper

[mg/l]

< 0.1

Oil/grease

[mg/l]

<1

Oxygen (O2)

3)

8-10

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6.2

Circulating water

Table 2: Circuit water requirements


Boiler design

Flame tube-fire tube boiler

Water chemical operation

Salty

Electrical conductivity in circuit water

S/cm

1)

Low salt 1)

> 100-1500

> 30-100

30

Column
General requirement

Colourless, clear, free of insoluable matter

pH value at 25 C 4)

pH value

9.5-10.5

9-10.5

9-10

K S8.2 (p value)

mmol/l

< 0.5-5

0.1-0,5

Earth alkalis (total hardness)

mmol/l

< 0.02

dH

< 0.1

Oxygen (O2)

5)

Phosphate (PO4)

4) 5)

When oxygen binders are used

1)

< 0.02

< 0.05

< 0.1

mg/l

5-15

5-10

3-6

mg/l

5-10

5)

Soldium sulphite (Na2SO3)

6.3

mg/l

Notes on Tables 1 and 2


Low salt operation is advisble for:

Large pipe networks with lots of branches, such as in industrial or remote heating systems;

Longer periods of stagnation, also of parts of the heating network;

Greatly varying pressures and temperatures;

Systems with components made of various materials;

Operation without chemical oxygen binders (if necessary, in conjunction with partial flow overpressure degassing).

Operation with frost protection agents in a hot water system requires a particular method. The electrical conductivity limit
values do not usually need to be complied with. See Section 6.4.
2)

Usually, the filling water is a mixture of prepared make-up water from the circuit. Well-prepared, low-salt make-up water,
if necessary condensate, is required for low-salt operation.

3)

The guide value for oxygen is adjusted to automatically on boiling in the top-up tank (boiling degasser) and under
exclusion of air. The steam line for removing the vapour and toxic gases only needs to be open for make-up water
refilling, approx. 30 - 60 min. afterwards.

4)

Adjusting the alkalinity (pH value or KS 8.2):


For salty operation, the alkalinity is usually set automatically by the filling water composition. If this is not the case,
alkalify the water primarily using solid alkalis (trisodium phosphate or possibly addition of sodium hydroxide).
With low-salt operation, the pH value should be adjusted using trisodium phosphate or potassium phosphate.
Avoid ammonia.
If there are cupreous materials in the hot water network, the circuit water may not exceed pH 9.5.

5)

In permanent heating mode, the limit values are maintained automatically - oxygen binders are then not essential.
1)
Otherwise, physical methods see under and chemical agents are available.
A standard chemical agent is sodium sulphite. Film-forming aminos are not an oxygen agent. The use and type of the

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oxygen agent must be specified for each system.


With sodium sulphite in salty heating water, there should be an excess of 5...10 mg/l. Sulphide may occur in heating
networks, and has a corrosive effect on copper and copper alloys. The salt content of the water increases. There are no
hygienic or toxicological restrictions on sodium sulphite.
In heating water with a low salt content, the limit values for phosphate must be maintained, to avoid tension crack
corrosion do not go below the lower limit value concentration.
The use of other dosing agents and protective chemicals/inhibitors other than those specified should be agreed with
Loos International.
Important: When using oxygen binders or other protective chemicals the application regulations of the appropriate
manufacturer and suplier shall have sole validity. Damage to boiler systems caused by chemicals and insufficient
protective measures shall be outside the sphere of liability of the boiler manufacturer.

6.4

Addition of frost protection agents to circuit water

In some cases, a frost protection agent, e.g. on a base of monoethylene glycol or propylene glycol, is added to the circuit
water, in order to avoid freezing of the circuit water in the winter.
When using glycol-water mixtures, observe the following:

In conjunction with frost protection agents, it is often not possible to comply with the limit values for electrical
conductivity. Therefore use only completely desalinated water with a conductivity of < 10 S/cm as filling and make-up
water.

Due to their corrosion promotion properties, which are stronger than those of water, glycol-water mixtures may not be
used without the addition of corrosion inhibitors. However, these corrosion inhibitors must be contained in the frost
protection agent. Additional dosing agents may not be used!

Comply with the minimum concentration specified by the manufacturer of the frost protection agent, as, if not met, there
is the risk of insufficient inhibition. Also, always comply with the deadlines specified by the manufacturer for replacing
the frost protection agent.
Important! The mixing of frost protection agents changes the physical properties of the circuit water.
The effects on the heating system and boiler selection should, if necessary, be checked by Loos International.

Initial filling

Hot water systems may only be freshly filled with treated, at least softened, water, to which at least 50 g of trisodium
phosphate (20 % P2O5) should be added per 50 g. Low-salt water can, for example, be obtained from large power stations
by tanker.

Down times

To avoid corrosion during down times (during longer operational interruptions or delayed commissioning), conserve hot
water boilers, and if necessary the heating network, properly. For information on this, please refer to the operating manual of
the appropriate components and the operating manual G012 Wet and Dry Conservation.

Water investigation

Check the characteristics of the filling and make-up water and circuit water once a week.

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Guideline on Water Characteristics


for heating boilers and hot water boilers

B004
Version 4 (10/09)

Important: The water samples must only be taken from the system during normal operation, i.e. not in the cold
state or in start-up operation.
For the analysis, a representative sample is necessary which, via a suitable cooling device (e.g. Loos water
sample cooler) allows the water to be tested to be cooled to 25 C. For instructions on taking the water sample,
see Operating Instructions E004 Water sample cooler module SCM.
Scope of the water investigations:
Filling and make-up water:

pH value or KS 8.2

Earth alkalis (total hardness)

Oxygen or oxygen binder

Circuit water:

pH value or KS 8.2

Earth alkalis (total hardness)

Oxygen or oxygen binder

Phosphate or alkalising agent

Electrical conductivity

Appearance

The results should be entered in the logbook L004 for hot water boilers or L005 boilers. The investigations of the other
values and additional parameters, such as iron, copper or sulphides, should be carried out, as far as is relevant, on a
monthly basis, and, if possible, the methods of analysis mentioned in EN 12953-10 applied.
Important! Should national requirements require more frequent or more comprehensive water investigations,
these shall have priority over the manufacturer's requirements.

Note: Only experienced specialist companies should be asked to supply and install water treatment systems or
water treatment devices. We have found that the support provided by the customer service units of these
companies and/or departments specialising in water chemistry to be very useful.
Note: When using frost protection agents in the first year of operation, carry out a water-side investigation of the
boiler every three months. If the result is positive, the investigation periods can be increased to the normal levels.

10 Measures in the event of unusual observations and operating faults


If anything unusual is observed and/or operating faults are displayed, the following table provides initial information on
repair:

Observation/Fault:

Turbid circuit water

Cause

Elimination of the cause

Hardness precipitation (earth alkali phosphates)

Adjust the water values according to the Circuit


Water table

By whom?

Determine the cause of the hardness

Page 6 of 9

Operating Instructions

Guideline on Water Characteristics


for heating boilers and hot water boilers

B004
Version 4 (10/09)

Cause

Elimination of the cause

By whom?

Partial water exchange (increase clarification rate)

Entry of corrosion products

Testing of additional water treatment

Use of unsuitable chemicals

Engage a specialist company

Observation/Fault:

Operator

Corrosion in the boiler, flue gas heat exchanger

Damage elimination: Repair of damaged heating surfaces, removal of coating by a specialist company
Cause

Elimination of the cause

Improperly treated filling or make-up water

Testing of water treatment, for ion exchange plants,


trigger regeneration as necessary

By whom?

Adjust water treatment to different raw water values.


(Check and correct the throughput between two
regenerations)
Set a constant pressure in front of the water
treatment plant

Outside substance ingress into circuit water (oils,


greases, organic matter, acids, alkalis, hardness,
etc.)

Use a higher quality treatment method (e.g.


osmosis)

Operator

Plan for circuit water monitoring (conductivity,


turbidity).

Operator

Conductivity: Acids, alkalis, hardness, seawater


Turbidity: Oils, greases, milk, paints

Use of film-forming aminos in conjunction with saltfree or low-salt methods

Observation/Fault:

Precipitate film formation agent

Operator

Corrosion in the boiler, flue gas heat exchanger

Damage elimination: Build-up welding. Component replacement. This work may only be carried out by Loos International
or by personnel authorised by Loos.
Cause

Elimination of the cause

Oxygen ingress during down times.

During down times, carry out wet and dry


conservation according to the operation manual
G012. Keep the system pressurised during shorter
down times.

By whom?

Page 7 of 9

Operating Instructions

Guideline on Water Characteristics


for heating boilers and hot water boilers

B004
Version 4 (10/09)

Cause

Elimination of the cause

Insufficient degassing of the filling and make-up


water

Testing of the thermal degassing (constant pressure


and temperature, sufficient vapour volume)

By whom?

Checking of the excess of O2 binder

Insufficient chemical dosing

Checking of the excesses according to the Circuit


Water table
Check the chemical dosing

Overdose of dosing chemicals

Checking of the excesses according to the Circuit


Water table
Check the chemical dosing

Use of unsuitable chemicals

Engage a specialist company

Acid/alkali ingress through water treatment (in the


case of regeneration with acid/alkali)

Checking of water treatment

Outside substance ingress into circuit water (oils,


greases, organic matter, acids, alkalis, hardness,
etc.)

Plan monitoring of the circuit water (conductivity,


turbidity).

Operator

Operator

Conductivity: Acids, alkalis, hardness, seawater


Turbidity: Oils, greases, milk, paints

Increased Cu concentration in the circuit water

Remove cupriferous components

Operator

Keep the pH value in the circuit water between 9


and 10.5, see Table 2
Check the ammoniac dosing

Check the sulphide concentration

Page 8 of 9

Operating Instructions

Guideline on Water Characteristics


for heating boilers and hot water boilers

B004
Version 4 (10/09)

Observation/Fault:

Corrosion in the hot water network

Damage elimination: Replacement of the corroded pipe sections


Cause

Elimination of the cause

Oxygen ingress

Keep the system pressurised during down times.

By whom?

Find the causes for the oxygen ingress into the


system (e.g. gas-permeable plastics) and eliminate
them
Make lines in a corrosion-resistant material
Insufficient degassing of the filling and make-up
water

Operator

Testing of the thermal degassing (constant pressure


and temperature, sufficient vapour volume)
Checking of the excess of O2 binder

Outside substance ingress into circuit water (oils,


greases, organic matter, acids, alkalis, hardness,
etc.)

Plan monitoring of the circuit water (conductivity,


turbidity).

Operator

Conductivity: Acids, alkalis, hardness, seawater


Turbidity: Oils, greases, milk, paints

11 Guarantee notes
The guarantee becomes null and void:

Use of film-forming aminos in conjunction with low-salt methods (osmosis, partial or complete desalination)

if dosing agents are used which are not listed in this guideline or not agreed with Loos International.

if the limit values for water characteristics are not fulfilled.

if the measured water values are not documented.

In the case of special operating requirements (e.g. reduced working pressure, high level of steam purity), the limit values
must be agreed between the operator and Loos International.
Important: If protective chemicals are used, the regulations laid down by the appropriate manufacturer and
supplier apply exclusively. Damage to boilers caused by chemicals or faulty protective behaviour is basically not
covered by the liability of the boiler construction company.

Page 9 of 9

Operating Instructions

Regular inspections for shell boilers


Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)

Contents
1

Scope of the Operating Instructions ........................................................................................................................ 1

Use in Accordance with Regulations....................................................................................................................... 1

Safety .......................................................................................................................................................................... 2

Operating and Maintenance Staff ............................................................................................................................. 2

Operation.................................................................................................................................................................... 2

5.1

External inspection ...................................................................................................................................................... 2

5.1.1

General ........................................................................................................................................................................ 2

5.1.2

Inspection intervals ...................................................................................................................................................... 3

5.2

Internal inspection........................................................................................................................................................ 3

5.2.1

General ........................................................................................................................................................................ 3

5.2.2

Inspection intervals ...................................................................................................................................................... 3

5.3

Water pressure test ..................................................................................................................................................... 3

5.3.1

General ........................................................................................................................................................................ 3

5.3.2

Inspection intervals ...................................................................................................................................................... 3

5.3.3

Scope of the inspection ............................................................................................................................................... 4

5.3.4

Execution ..................................................................................................................................................................... 4

Measures in the event of unusual observations and operating faults.................................................................. 4

Replacement Parts .................................................................................................................................................... 9

Scope of the Operating Instructions

These Operating Instructions contain important information regarding the prescribed regular inspection of shell boiler type
steam and hot water generators made by Loos International with a maximum permitted working pressure greater than
1.0 bar for steam boilers or a maximum permitted temperature greater than 120 C for hot water generators.
It also applies for any associated flue gas heat exchangers provided (Economizers) and superheaters manufactured and
delivered by Loos International.
The inspections also cover the directly and indirectly attached components which are required for the operation of the
system and the switchgear cabinet and burner if these modules were supplied by Loos International.
All other parts of the system which were supplied and installed by third parties are covered by the regulations issued by the
suppliers in question.
These Operating Instructions only apply in combination with the following Operating Instructions:

A002 Basic Safety Instructions

B002 Guideline on water characteristics for steam boilers

B004 Guideline on water characteristics for hot water boilers

Use in Accordance with Regulations

For the running of certain tests and for behaviour in the event of operating faults, not only the relevant Operating Instructions
issued by Loos International but also the relevant statutory orders, official requirements and other regulations on the part of
the suppliers of other system components associated with Loos International boiler system must also be followed.

Page 1 of 9

Operating Instructions

Regular inspections for shell boilers


Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)

Important! All the inspections and inspection periods given here are minimum requirements laid down by Loos
International for the safe operation of the boiler system.
Important! If a smaller number of inspections or other inspection concepts are usual throughout the country or
industry, these will be accepted by Loos International if the regionally competent supervisory authorities have so
far agreed to these.
Important! If the regional supervisory authorities lay down shorter inspection periods a higher number of
inspections or a wider scope of inspection, these must definitely be complied with.
Important! If the regional supervisory authorities require an official expert instead of a competent person, this
requirement must definitely be met.

Safety

Please read the Operating Instructions:

A002 Basic Safety Instructions


Important! If the boiler system has to be shut down, the operating and maintenance staff must be suitably
informed of this. In addition, a sign is to be affixed to the system and to the switchgear cabinet if necessary which
expressly points out that the system has been shut down and is thus not operational. This sign should also state
the time when the system was shut down and the name of the person who is allowed to start the boiler system
up again or who may give the instructions for the start-up.

Operating and Maintenance Staff

For a definition of the terms operating and maintenance staff, competent person and official expert, please read the
Operating Instructions:

A002 Basic Safety Instructions

For proper, safe operation, regular maintenance must be carried out by specialist staff/competent persons in order to ensure
economical operation without breakdown. Regular maintenance will help your system retain its value and ensure the longterm, optimum availability of your system. In many countries, regular maintenance must be carried out by trained specialist
staff/competent persons and a regular inspection of the safety equipment on the boiler by experts is also required.
We therefore recommend that you conclude a maintenance service contract. Within the scope of this contract, specially
trained customer service engineers will take over the regular inspections and competently carry out all maintenance work on
the boiler. Our customers can obtain a quotation for a maintenance service contract by visiting www.loos.de or contacting
the relevant customer service engineer.

Operation

The basic requirement for the proper, safe operation of the boiler system is compliance with the inspections and inspection
periods laid down regionally, nationally, internationally or by Loos International.

5.1
5.1.1

External inspection
General

The external inspection covers regular monitoring by means of visual examination, the observation of work sequences and
any functional tests.
The external inspection is carried out by a competent person.

Page 2 of 9

Operating Instructions

Regular inspections for shell boilers


Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)

5.1.2

Inspection intervals

The interval for regular external inspections begins with the start-up of the boiler system, or 2 years after delivery from the
manufacturer's factory at the latest; the maximum interval between two inspections is one year unless regional or national
regulations specify a shorter period of time.
The deadline for the external inspection is considered to be met if this inspection is carried out during the course of the
calendar year in which the deadline expires.
If internal inspections are due at the same time, the external inspection should follow on after this inspection.

5.2
5.2.1

Internal inspection
General

For an internal inspection, the boiler must be shut down and at least partly emptied and partly cooled down.
During an internal inspection, the inside surfaces of the boiler are examined for possible damage. If wished and if
necessary, prevent measures which may be required on the basis of these observations may be taken. Because of the
pressure loads during operation, essentially welded seams and the surfaces inside the boiler must be examined.
There is no need to remove the insulation or any brick linings.
After each internal inspection, an external inspection must be carried out.
The internal inspection is carried out by a competent person.

5.2.2

Inspection intervals

The interval for regular internal inspections is maximum three years unless regional and/or national regulations prescribe a
shorter period of time. It begins with the start-up of the boiler system, or 4 years after delivery from the manufacturer's
factory at the latest.
If the deadline for the water pressure test is extended alternatively to a maximum of 12 instead of 9 years, the interval for the
regular internal inspection must be shortened to two years at most.
The inspection does not need to be carried out if the boiler is out of operation when the deadline passes. However, it must
then be carried out before the boiler is started up again.
If a boiler is out of operation for longer than two years, an internal inspection must always be carried out by a competent
person before it is started up again.

5.3
5.3.1

Water pressure test


General

The boiler must be shut down and cooled off for the water pressure test. If necessary, the boiler may be cooled to the
required temperature more quickly by draining it and carefully refilling it with cold water.
Caution! Danger of thermal shock. To prevent any tension cracks forming in the boiler wall, the temperature of
the boiler when cold water is added should not be reduced faster than 3 K/min.
It is not necessary to remove the insulation or any wall linings for the water pressure test.
The water pressure test is carried out by a competent person.
After the water pressure test, an internal and external inspection must be carried out.

5.3.2

Inspection intervals

The inspection interval for the regular water pressure test is nine years at the most, unless local and/or national regulations
require a shorter period of time.
If the deadline for the water pressure test is extended alternatively to a maximum of 12 instead of 9 years, the interval for the
regular internal inspection must be shortened to two years at most.
The inspection interval begins with the start-up of the boiler system, and no more than 10 years (or, in application of the
above exception provision) 13 years after delivery from the manufacturer. The intervals may be extended by a maximum of

Page 3 of 9

Operating Instructions

Regular inspections for shell boilers


Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)

three months, provided the competent person is notified, if important operating reasons mean that it is difficult to carry out
the inspection at the end of the inspection interval.
The inspection need not be carried out if the boiler is not in operation when the interval expires. The inspection must
definitely be carried out before the boiler is started up again.
If the boiler is out of operation for longer than two years, a water pressure test must be carried out before it is started up
again.

5.3.3

Scope of the inspection

The regular water pressure test covers the boiler and the flue gas heat exchanger (economizer) and superheater (if
provided) positioned in the flue gas current from the firing.

5.3.4

Execution

Level of test pressure


The test pressure applied may not be higher than the test pressure for the first water pressure test. The test pressure
applied for the first time during manufacture is given on the manufacturer's plate and/or in the technical documentation.
With flue gas heat exchangers (Economizers), the level of the test pressure is the same as the level of the test pressure in
the associated boiler.
Applying and maintaining the test pressure
The test pressure must be monitored with a calibrated manometer.
The test pressure is applied in the presence of the competent person. The speed of the change in pressure may not be
more than 10 bar per minute up to approx. 75% of the test pressure and after this no more than 2 bar per minute.
The test pressure must be maintained constantly for half an hour. At the end of the half hour, the pressure should be
reduced slowly and then applied again as described above. After a second period of half an hour, the competent person will
start to test the components under pressure.
Requirements for the water
The water used for filling may not contain any impurities. Taking the operating conditions into account, the water may not
contain any components which could attack or change the surfaces of the parts to be tested. The temperature of the water
added may not exceed 50C during the inspection on the flue gas side.
At lower ambient temperatures, measures should be taken to ensure that no damage is caused by fractures due to thermal
shock, freezing or brittleness. Suitable measures are, for example, heating the installation room for a few days before filling
the boiler, slow filling with water which is not too different in temperature from the temperature of the material (< 20 K).
Examination of walls
Components under pressure must be examined by a visual inspection to detect cracks, impermissible changes in shape or
leaks. Wall linings and heat insulation should be removed to an appropriate extent only if there are justified reasons for
suspecting damage.

Measures in the event of unusual observations and operating faults

If unusual observations are made and/or defects found in valves or fittings or the equipment, the procedure described in the
Operating Instructions for the equipment should be followed.
If deposits are found on the water side, the procedure described in the following Operating Instructions should be followed:
B002 Guideline on water characteristics for steam boilers

B004 Guideline on water characteristics for hot water boilers

The following table lists possible faults which could be found during an internal or external inspection and which are
generally found at the pressure hull. If faults are found, this table provides some initial hints on how to deal with them.

Page 4 of 9

Operating Instructions

Regular inspections for shell boilers


Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)

Observation/fault:

Tears in weld seams on water side

Repair of fault: The faults are normally repaired by reboring and rewelding the cracks. Components may be patched or
partially replaced. These works may only be carried out by Loos International or staff authorised by Loos International.
Cause

Repair of cause

Unsatisfactory burner operation

Set performance control according to Operating


Instructions for performance control

Starting up frequently with cold feed water

Check feed water system according to Operating


Instructions E008, E009, E010 or E011

Use of non-approved added chemicals

Use approved chemicals according to Operating


Instructions B002

Starting up frequently from the cold state

Keep boiler warm

Unsatisfactory load assumptions

Avoid simultaneous load peaks from several


consumer units

By whom?

Reduce extraction

Lower load change speeds

Start up only with load limitation

Unsatisfactory burner operation

Observation/fault:

Set performance control according to Operating


Instructions for performance control

Tears in weld seams at points in contact with fire in steam boilers

Repair of fault: The faults are normally repaired by reboring and rewelding the cracks. Components may be patched or
partially replaced. These works may only be carried out by Loos International or staff authorised by Loos International.
Cause

Repair of cause

Deposit on the water side

Use suitable boiler, infeed and make-up water

By whom?

Increase desalting rate or blow-down more often

Prevent foreign matter from entering the


condensate
Unsatisfactory burner operation

Set performance control according to Operating


Instructions for performance control

Page 5 of 9

Operating Instructions

Regular inspections for shell boilers


Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)

Cause

Repair of cause

By whom?

Avoid frequent burner cycles

Avoid switching the secondary boilers on and off too


frequently
Unsatisfactory load assumptions

Avoid simultaneous load peaks from several


consumer units
Reduce extraction

Lower load change speeds

Starting up frequently with cold feed water

Observation/fault:

Check feed water system according to Operating


Instructions E008, E009, E010 or E011

Tears in weld seams at points in contact with fire in hot water boilers

Repair of fault: The faults are normally repaired by reboring and rewelding the cracks. Components may be patched or
partially replaced. These works may only be carried out by Loos International or staff authorised by Loos International.
Cause

Repair of cause

Deposit on the water side

Use suitable boiler, infeed and make-up water

Starting up frequently from the cold state

Keep boiler warm

Unsatisfactory burner operation

Set performance control according to Operating


Instructions for performance control

By whom?

Avoid frequent burner cycles

Avoid switching the secondary boilers on and off too


frequently
Lack of flow through boiler

Ensure minimum throughput with burner operation,


see contract

Page 6 of 9

Operating Instructions

Regular inspections for shell boilers


Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)

Observation/fault:

Deposits on flue gas side

Repair of damage: Have boiler cleaned on flue gas side by specialist staff
Cause

Repair of cause

Incorrect burner setting

Correct burner setting

Unsatisfactory burner operation

Set performance control according to Operating


Instructions for performance control

Wrong fuel

Use fuel according to contract

Insufficient boiler house ventilation

Clear intake and outlet openings

Outlet blockages in flue gas system

Adjust flue gas system, clean if sooted up

Observation/fault:

By whom?

Corrosion on flue gas side

Repair of fault: The damage is generally repaired by reboring and rewelding local material corrosion. If necessary, smoke
tubes or flue tubing can be replaced or components patched or partly replaced. These works may only be carried out by
Loos International or staff authorised by Loos International.
Cause

Repair of cause

Boiler started up and shut down too frequently (dew


points crossed too frequently)

Keep boiler in operation longer, keep warm if nec.

Unsatisfactory burner operation

Set performance control according to Operating


Instructions for performance control

Sulphur content of fuel too high temperature falls


below acid dew point

Use fuel according to contract

By whom?

Disable eco-operation or use feed water preheating

Increase boiler return flow temperature

Feed water temperature too low falls below acid


dew point (with steam boilers)

Test feed water system according to Operating


Instructions E008, E009, E010 and E011

Return flow temperature too low falls below acid


dew point (with hot water boilers)

Check return flow temperature control

Aggressive intake air polluted by chemicals

Change intake air supply to burner

Page 7 of 9

Operating Instructions

Regular inspections for shell boilers


Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)

Observation/fault:

Corrosion on water side

Repair of fault: The damage is generally repaired by reboring and rewelding local material corrosion. If necessary, smoke
tubes or flue tubing can be replaced or components patched or partly replaced. These works may only be carried out by
Loos International or staff authorised by Loos International.
Cause

Repair of cause

Frequent start-up with cold feed water (with steam


boilers)

Test feed water system according to Operating


Instructions E008, E009, E010 and E011

Insufficient addition of chemicals

Follow Operating Instructions B002

Thermal feed water system not working properly (in


steam boilers)

Follow Operating Instructions E008, E009, E010


and E011

Use of non-allowed or unsuitable additional


chemicals

Use other products

Insufficient preservation when idle

Follow Operating Instructions C008

Make-up volumes too large with insufficient


treatment or metering (with hot water boilers)

Seal system, add chemicals according to Operating


Instructions B004 and/or B010

Observation/fault:

By whom?

Sludge collects at the bottom of the boiler

Repair of damage: Have the sludge removed from the boiler by the operating and maintenance staff
Cause

Repair of cause

Insufficient blow-down operations

Increase blow-down rate

Unsuitable boiler, feed or make-up water

Use suitable boiler, feed and make-up water

Addition of too many film-forming chemicals

Add additives (if allowed by Loos in the first place)


according to manufacturer's instructions

By whom?

Page 8 of 9

Operating Instructions

Regular inspections for shell boilers


Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)

Observation/fault:

Peeling at the base of the boiler

Repair of damage: Have the deposits analysed and removed by a specialist company
Cause

Repair of cause

Hardness and/or silicates in water

Use suitable boiler, feed and make-up water

Observation/fault:

By whom?

Deposits and discolouration on water side

Repair of damage: Have the deposits analysed and removed by a specialist company
Cause

Repair of cause

Hardness and/or silicates in water

Use suitable boiler, feed and make-up water

Foreign matter in water (e.g. oils, fats, milk)

Install devices to monitor returning condensate or, if


these already exist, check function

Observation/fault:

By whom?

Grooves and impressions in smoke tubes on boilers with rotational flow devices

Repair of fault: The damage is generally repaired by welding the grooves. These works may only be carried out by Loos
International or staff authorised by Loos International.
Cause

Repair of cause

Deposits on water side

Repair water treatment plant

Use of unsuitable additional chemicals

Use chemicals recommended by Loos

Unsatisfactory burner behaviour

Adjust burner setting

By whom?

Replacement Parts

After opening the inspection openings on the steam and water sides, replace the seals in question.
Please read the Operating Instructions:

K022 Inspection openings (steam and water sides)

To order replacement parts, please use the After-Sales Service order form L006 supplied by Loos International, giving the
factory number, product type and order number.

Page 9 of 9

Operating Instructions

Check list
for Hot Water Boilers

B007
Version 2 (06/05)

Contents
1

Scope of the Operating Instructions ........................................................................................................................ 1

Care and Maintenance ............................................................................................................................................... 1

Scope of the Operating Instructions

These Operating Instructions contain basic information. They apply in combination with the following operating instructions:

A002 Basic Safety Instructions

For the operation of the system as a whole, the operating instructions for the individual components are binding along with
the relevant statutory provisions and official requirements.

Care and Maintenance

Following, the minimum operating, maintenance and test requirements for the boiler system will be listed in the form of a
checklist by the operating and maintenance staff.
The inspection intervals listed below are minimum requirements set by Loos International. The inspection intervals must be
defined on the basis of the operating conditions and the water treatment products used.
Explanation of symbols:

Observation (O) Observation of abnormal noises, smells or other noticeable factors

12 months

6 months

3 months

1 month

1 Week

Operating, maintenance and testing work

3 days

Function test (F) Testing the functional behaviour of equipment parts, incl. observation

Test

Boiler
Safety valves

Filling testing device

Emptying and Blow-down device

Armatures

Pipes

Start *)
F

Functioning, free passage

Functioning and sealing,


availability auxiliary power - if
required

Sealing

Niveau limiter

Lower to switching poing

Flow monitor

Operate to switching point

Pressure indicator respectively temperature


indicator

Zero point check respectively


comparativce measurement,
free passage connecting pipe

Temperature controller

Monitor switching points;


comparative measurement

Page 1 of 3

Operating Instructions

Check list
for Hot Water Boilers

B007

Feed and circulation devices

Test

Operate to switching point, free


passage connecting pipe

F
F

Sealing, possibly retighten

Short-term switching
Analytical monitoring, observe
operating manual B004

Feed water, boiler water respectively circuit water


Devices for monitoring boiler water for ingress of
foreign materials

12 months

6 months

Inspection openings

3 months

1 month

Pressure limiter respectively temperature limiter

1 Week

Operating, maintenance and testing work

3 days

Version 2 (06/05)

Function
F

Back-up battery Programmable Controller C7-633

Changing the back-up battery

Firing unit
Flue gas valve limit switch

Control element for air and fuel (network)

Combustion air blower, ignition and/or cooling air


blower

Air pressure volume display and air pressure


monitor

Fuel shut-off devices

Function
Free movement, check
switching points

Quiet running, power


transmission
F

Free movement and clear


opening of connecting pipe

Free movement and leaktightness, availability of


secondary energy if necessary

Fuel pressure display

Zero-point monitoring or
comparative measurement,
clear opening of connecting
pipe

Fuel safety shut-off device in front of burner

Free movement, Leak-tightness

Leak-tightness monitor with gas valves

Function

Ventilation of fire areas and flue gas lines

Function

Ignition

Noises

Flame monitoring

Assessment of combustion

Assessment of fire areas and flue gas tubing

If sensor turns dark


F

Flue gas measurement

Check

Page 2 of 3

Operating Instructions

Check list
for Hot Water Boilers

B007
Version 2 (06/05)

Firing unit
Emergency switch

Function

If defects are found, the foreman should be informed and Operating Instructions A002 followed.
*) Note on starting up the safety valve:
To test the boiler safety valve, the firing is switched off and the boiler water is cold. The supply and removal lines to the
boiler are closed. Using the hand pump, the boiler pressure is increased until it reaches the safety valve trigger pressure.
After the safety valve is triggered, the pressure in the boiler is lowered to 0 bar.

Page 3 of 3

Boiler and
Boiler components

Operating instructions

Lining of the front reversing chamber


Lining of the front reversing chamber
for Shell Boilers

C005
Version 1 (01/09)

Contents
1

Scope of the Operating Instructions ........................................................................................................................ 1

Use in Accordance with Regulations ....................................................................................................................... 1

Safety .......................................................................................................................................................................... 1

Operating and Maintenance Staff ............................................................................................................................. 1

General Risks and Accident Prevention .................................................................................................................. 2

Technical Data (Dimensions, Weight, Operating Conditions)................................................................................ 2

Assembly .................................................................................................................................................................... 2

7.1

Pre-cleaning and preliminary works ............................................................................................................................. 2

7.2

Applying the adhesive .................................................................................................................................................. 3

7.3

Affixing the insulation ................................................................................................................................................... 4

Measures in the event of unusual observations and operating faults .................................................................. 5

Replacement Parts ..................................................................................................................................................... 6

Scope of the Operating Instructions

These Operating Instructions contain basic information. They apply in combination with the following operating instructions:

A002 Basic Safety Instructions

C007 Closures on the firing and flue gas sides

For the operation of the system as a whole, the operating instructions for the individual components are binding along with
the relevant statutory provisions and official requirements.

Use in Accordance with Regulations

The front reversing chambers (chamber and door) of the boiler series UL-S, ZFR, UT-H and UT-HZ are made in two layers
with thermal insulation mats. This means that the surface temperatures, the radiation losses and the boiler house
temperatures are lowered.

Safety

Please read the Operating Instructions:

A002 Basic Safety Instructions

Operating and Maintenance Staff

Please read the Operating Instructions:

A002 Basic Safety Instructions

Page 1 of 6

Operating instructions

Lining of the front reversing chamber


Lining of the front reversing chamber
for Shell Boilers

C005
Version 1 (01/09)

General Risks and Accident Prevention

Please read the Operating Instructions:

A002 Basic Safety Instructions

Technical Data (Dimensions, Weight, Operating Conditions)

The thermal insulation mats consist of glass needle mats/needle-punched web made from several mats needle-punched to
each other. The mat width is approx. 1000 mm and the mats are around 20 - 25 mm thick per layer.
Threaded pins M5x50 and clips with suitable tapped holes are used to secure the thermal insulation mats.
The thermal insulation mats are non-combustible.
The thermal insulation mats do not contain any toxic or hazardous substances or compositions. They are neither
carcinogenic nor harmful to health and therefore, they are not subject to labelling requirements.
Humidity caused by the formation of condensate during start-up does not influence the insulating qualities of the mats after
drying.
The thermal insulation mats have an infinite durability. They only need to be replaced in case of damage.
The high-temperature adhesive is based on aluminium silicates.

7
7.1

Assembly
Pre-cleaning and preliminary works
Caution! Before repairing or attaching the insulation, the boiler should be cooled down to room temperature
(< 40 C) so that the adhesive does not harden too quickly and the competent persons who are carrying out the
assembly work are not in danger of being burned.

All dust and grease must be removed from the surfaces of the chambers and doors to be glued (dry wipe or wash down with
cleaning product) so that the adhesive can stick properly.
Before the thermal insulation mats are stuck in, the threaded pins to secure the mats must be welded on. A bolt welding unit
is recommended for affixing the threaded pins, but is not absolutely essential.
The threaded pins with clips are positioned max. 100 mm to the left and right of each butt joint in the upper thermal
insulation mat on the flue gas side, with a distance of max. 400 mm between them.
The following table applies for smooth large areas (no threaded pins and clips are necessary for the side and lower
reversing chamber walls, unless there are problems here):

Position of threaded pins and clips to hold the insulation mats in place
Boiler type

Number

Position

Reversing
chamber wall,
top

Reversing
chamber door

Reversing chamber wall,


top

Reversing chamber door

UL-S 1250 - 5000


UT-H 820 - 3270

Page 2 of 6

Operating instructions

Lining of the front reversing chamber


Lining of the front reversing chamber
for Shell Boilers

C005
Version 1 (01/09)

Boiler type

Number

Position

Reversing
chamber wall,
top

Reversing
chamber door

Reversing chamber wall,


top

Reversing chamber door

UL-S 6000 - 12000


UT-H 3950 - 7850

UL-S 13000 - 18000


5
UT-H 8500 - 11800
6
UL-S 22000 - 28000
6
UT-H 14400 - 18300

ZFR 20000 - 55000


6

UT-HZ 13000 - 38000

7.2

Applying the adhesive


Caution! Before repairing or attaching the insulation, the boiler should be cooled down to room temperature
(< 40 C) so that the adhesive does not harden too quickly and the competent persons who are carrying out the
assembly work are not in danger of being burned.

The adhesive must be applied to the metal in sufficient quantity on one side and in strips. The adhesive strips can be applied
horizontally or vertically and should be approx. 150 mm wide in each case. Adhesive tape must be available on the edges.
When fibre mats are to be glued to fibre mats, on the other hand, it is essential that the adhesive is applied over the full
surface. The reasons for this are the different coefficients of expansion of steel and the hardened adhesive which can, if the
adjoining surfaces are too large, cause tensions on hardening and thus to the loosening of the adhesive.
A triple toothed spatula is recommended for application.
Note: The adhesive is dry on the surface after about 1 hour and, with an adhesive thickness of approx. 1-2 mm,
hardened after about 2 hours. The air humidity, temperature and thickness of the layer of adhesive will have a
corresponding effect on times.

Page 3 of 6

Operating instructions

Lining of the front reversing chamber


Lining of the front reversing chamber
for Shell Boilers

C005
Version 1 (01/09)

7.3

Affixing the insulation

The two layers of the thermal insulation mats should be glued if possible with the butt joints offset by at least 100 mm in a
cross-jointing pattern (especially at doors).
Since, with normal operating temperatures, the mat can be expected to shrink by 0.4 - 0.5% (5 mm/1 m length), an
allowance of approx. 1 cm should generally be made at the mat joint (i.e. to allow for the shrinkage, the mats must be slightly
stacked when they are installed so that they then adjoin each other precisely).
The mats must be affixed on the reversing chambers on the door side in such a way that when the doors are closed, the
mats provide a closed insulation surface inside (see Figure 1).

Figure 1: Front reversing chamber - view of lower section


Once they have been glued in, the mats are secured at the door and at the reversing chamber cover with threaded pins and
clips. (see table in chapter 7.1).
to the ends in operation (see Figure 1 and 2). Where the mats join between the door and the reversing chamber, the ends of
the insulation should be coated thinly with the adhesive flush with the frame so that the edges do not fray if the doors are
opened repeatedly (see Figure 1). If the mats are bent over for a short distance at the transition to the door, these must be
coated thickly so that the shape is maintained. Care must be taken to ensure that the adhesive joints are round (see Figure
2)

Page 4 of 6

Operating instructions

Lining of the front reversing chamber


Lining of the front reversing chamber
for Shell Boilers

C005
Version 1 (01/09)

Figure 2: Front reversing chamber - view of join with door frame

Note: The adhesive must be left to dry for at least 8-10 hours, depending on air humidity, temperature and
thickness of application and with the reversing chamber door open before the boiler can be used again, so that
the adhesive does not harden too quickly, thus preventing the door mat from sticking to the adhesive on the
reversing chamber side.

Measures in the event of unusual observations and operating faults

A visual inspection must be carried out as part of the regular inspection.


Please read the Operating Instructions:

B006 Regular inspections for shell boilers


(Maximum permitted operating pressure 1 bar or maximum permitted temperature 120 C)

An inspection by a Customer Service Engineer only needs to be carried out if there are external signs of damage (see
Table).

Page 5 of 6

Operating instructions

Lining of the front reversing chamber


Lining of the front reversing chamber
for Shell Boilers

C005
Version 1 (01/09)

Observation/Fault:

Hot areas near the front reversing chamber(> 85C in door area)

Cause

Repair of cause

By whom?

Loosening of thermal insulation mats

Repair smaller areas by gluing down again


Completely re-line larger areas

Observation/Fault:

Discoloration of front reversing chamber

Cause

Repair of cause

By whom?

Loosening of thermal insulation mats

Repair smaller areas by gluing down again


Completely re-line larger areas

Observation/Fault:

Faults in burner operation or change in burner behaviour

Cause

Repair of cause

Thermal insulation mats are coming loose and


blocking one or more pipes

Completely re-line larger areas

By whom?

Replacement Parts

For spare parts orders or spare parts inquiries, please use the special ordering and inquiries form L006 After Sales Services
in Register L (Forms).
Alternatively, you can place your spare parts order or your spare parts offer online at www.loos.de / Kundendienst /
Ersatzteilversorgung (customer service / spare parts supply).
When ordering replacement parts, please use the following material numbers:

Material number

Designation/object

Quantity

011629.1

Thermal insulation mat 25 mm x 1000 mm

Length or area in m depending on boiler size and


requirement

007456.1

High-temperature adhesive

Quantity in kg depending on boiler size and


requirement

011650.1

Threaded pins M5x50

see table in chapter on Assembly

011651.1

Matching clips for threaded pins M5x50

see table in chapter on Assembly

Page 6 of 6

Operating instructions

Burner and flue gas side inspection openings


for shell boilers with lateral flame tube

C007
Version 5 (11/08)

Contents
1

Scope of the Operating Instructions ........................................................................................................................ 1

Use in Accordance with Regulations ....................................................................................................................... 1

Safety .......................................................................................................................................................................... 2

Operating and Maintenance Staff ............................................................................................................................. 2

General Risks and Accident Prevention .................................................................................................................. 2

Description of Structure and Function / Description of Process ........................................................................... 2

6.1

Rear flame tube inspection opening ............................................................................................................................. 2

6.2

Front reversing chamber .............................................................................................................................................. 3

6.3

Sight hole ..................................................................................................................................................................... 3

6.4

Flue gas side inspection openings on flue gas chambers and economizers ................................................................ 4

Transport and Storage............................................................................................................................................... 4

Start-up ....................................................................................................................................................................... 4

8.1

Inspection of seals on the front reversing chamber door.............................................................................................. 4

8.2

Inspection of the seals on flue gas side inspection openings ....................................................................................... 4

Measures in the event of unusual observations and operating faults .................................................................. 5

10

Care and Maintenance ............................................................................................................................................... 7

10.1

Inspection of thermal insulation.................................................................................................................................... 7

11

Replacement Parts ..................................................................................................................................................... 7

Scope of the Operating Instructions

These Operating Instructions contain basic information. They apply in combination with the following operating instructions:

A002 Basic Safety Instructions

For the operation of the system as a whole, the operating instructions for the individual components are binding along with
the relevant statutory provisions and official requirements.

Use in Accordance with Regulations

For the cleaning and inspection of furnaces and flue gas lines, the boilers are provided with suitably dimensioned inspection
openings or doors.
On the basis of the sometimes very high temperatures which occur in this area, the care and replacement of the sealing and
thermal insulation elements used here require special attention. Seals or spare parts for burner-side inspection openings
which are supplied by Loos International may only be installed at the corresponding openings, since they have been
calculated and designed specially for these products. Any other use is not in accordance with the intended purpose and is
therefore not allowed.

Page 1 of 7

Operating instructions

Burner and flue gas side inspection openings


for shell boilers with lateral flame tube

C007
Version 5 (11/08)

Safety

Please read the Operating Instructions:

A002 Basic Safety Instructions

Seals that have been removed must be disposed of according to the regionally valid environmental protection regulations so
that they cause no danger to people or the environment.

Operating and Maintenance Staff

Please read the Operating Instructions:

A002 Basic Safety Instructions

General Risks and Accident Prevention

Please read the Operating Instructions:

A002 Basic Safety Instructions


Danger! As a result of operation, high temperatures may occur at inspection openings which may cause burns.
In addition, leaking or faulty seals may cause flue gases to leak out, which can also cause burning. In this case,
the boiler system must be turned off immediately.

Description of Structure and Function / Description of Process

The inspection and viewing openings allow the flue tubing to be inspected and cleaned inside.
Caution: Before opening inspection openings, the burner must be switched off and the fuel lines securely closed
off.

6.1

Rear flame tube inspection opening

The inspection opening for the flame tube is on the back of the boiler at the flame tube end. On the inside of the cover, the
thermal insulation is fixed in several layers firmly to the cover. The total weight is about 80 kg.
For the inspection of the furnace and for cleaning purposes, nuts (M16) must be loosened and the inspection cover
removed. The complete component can be pulled out by the handles. For removal and re-installation, suitable lifting
equipment, e.g. forklift truck, must be provided, or a frame provided up to the lower edge of the cover.
The seal (5) is firmly glued to the inspection cover, which means that the seal does not need to be changed after the
inspection opening has been dismantled. When the inspection cover is replaced, care must be taken to ensure that the
cover with the thermal insulation material is pushed straight into the inspection opening.
Warning! Injuries may be caused during removal and replacement by the cover falling down.
To secure, the washers must be put back in place and the nuts tightened evenly crosswise (maximum torque of 80 Nm).

Page 2 of 7

Operating instructions

Burner and flue gas side inspection openings


for shell boilers with lateral flame tube

C007
Version 5 (11/08)

Flame tube cover

Inspection cover

Flame inspection hole

Internal thermal insulation

Sealing

Fixing nut

Figure 1: Flame tube inspection opening

6.2

Front reversing chamber

The screwed, swivel door on the outer reversing chamber on the front end of the boiler is used for the flue-gas cleaning and
inspection of the smoke tubes. On the inside, the door is provided with thermal insulation mats. These reduce the surface
temperatures of the component, radiation losses and the boiler house temperatures.
To open the door, the nuts M16 must be loosened and the washers removed.
The sealing against the smoke gas area is by means of a sealing cord inserted in the reversing chamber frame. Before the
door is closed, the sealing must be checked and replaced if necessary (see Chapter 8.1).
After the door has been closed, the washers must be replaced and the nuts tightened evenly, alternating crossways
(maximum torque: 80 Nm).

6.3

Sight hole

To observe the shape of the flame and the burn-out rate during burner operation, a closable flame sight hole is provided per
flame tube. This is located in the rear flame tube inspection opening.
To protect the glass from soiling and excessive temperatures, a hand-operated damper, operated from the outside, is
provided, which allows a clear view into the furnace when opened. The flame inspection hole may only be opened briefly to
observe the flame. After the flame has been inspected, the lame inspection hold must be closed again to prevent the glass
from being soiled or damaged by the effects of temperature.
The burner must be switched off for cleaning purposes. The locking screw can then be loosened and the glass removed.
When re-assembling, the seals in front of and behind the glass must be replaced and the locking screw tightened o that the
smoke gas cannot leak. If the screw is not tightened enough, it may happen that gas comes out between the sealing
surfaces, which can then lead to overheating in the entire area of the sight hole; this may even cause the flame sight hole to
be destroyed, with the consequent risk of damage to component parts attached to the boiler.
If work is being carried out on the hand-operated damper, care must be taken to ensure that the shaft passageway is as tight
as possible, which will prevent any gas from coming out through the shaft opening.

Page 3 of 7

Operating instructions

Burner and flue gas side inspection openings


for shell boilers with lateral flame tube

C007
Version 5 (11/08)

6.4

Flue gas side inspection openings on flue gas chambers and economizers

According to the type of boiler there are further flue gas side inspection openings on the rear of the boiler on the flue gas
chambers or on the rear of the economizers, which serve for flue gas side cleaning and inspection.
To open the flue gas side inspection openings, any insulation present must be removed, the nuts loosened and any washers
removed.
A glued sealing cord seals the opening to the flue gas chamber. The seal should be checked and replaced if necessary
before closing the flue gas side inspection openings.
(see chapter 8.2).
After closing the flue gas side inspection openings, any necessary washers must be put back in place and the nuts tightened
evenly diagonally (maximum torque of M12:30 Nm).

Transport and Storage

Because of the residual moisture in brick linings after the manufacturing process, care must be taken to ensure that
transport and storage are frost-free in order to prevent damage from frost (cracks, flaking).

Start-up

Please read the Operating Instructions:

C003 Shell Boilers for the production of saturated and superheated steam

C014 Shell Boilers for the producing of hot water


For safety reasons, the first start-up should be carried out solely by Loos International or by specialist staff
authorised by Loos.

Because of the residual moisture in the brick linings after the manufacturing process, water vapours may form in the brick
lining material if warming up is too fast, and these may not be able to escape through the pores available if heating up is too
rapid. This may cause flaking of the stones (see also Operating Instructions C003/C014 Shell boilers, Chapter
Commissioning).

8.1

Inspection of seals on the front reversing chamber door

The sealing of the front reversing chamber door is provided by sealing cord. Because of the temperature stresses, the
sealing cord hardens after a certain operating time and loses its elasticity. It is therefore necessary, after initial
commissioning and after replacement of the sealing cords, to tighten the reversing chamber doors evenly, alternating
crossways, using a ring wrench. After a week in operation, the doors must be tightened again. To achieve leak tightness, it is
important to tighten the screws evenly, which is only possible by moving crossways each time a screw has been tightened a
little; the amount of tightening torque is not the deciding factor.
When inserting new sealing cords, make sure that the overlap is sufficient by cutting the sealing cord ends at an angle.
In addition to this the sealing cord must be adequately wrapped with adhesive tape before cutting so that the cord does not
fray at the cut ends.
Caution: If the medium leaks out, this may cause injury. Sealing cords which have been installed for more than
six months must basically be replaced once the doors are opened.

8.2

Inspection of the seals on flue gas side inspection openings

The flue gas side inspection openings are sealed by means of a sealing cord. Because of thermal stress, the sealing cord
hardens after a certain operating time and loses its elasticity. It is therefore necessary after initial commissioning and after
replacement of the sealing cords to tighten the inspection openings on the flue gas side evenly, alternating diagonally, using
a ring wrench. After a week in operation, the openings must be tightened again.

Page 4 of 7

Operating instructions

Burner and flue gas side inspection openings


for shell boilers with lateral flame tube

C007
Version 5 (11/08)

To achieve leak tightness, it is important to tighten the screws evenly, which is only possible by moving crosswise each time
a screw has been tightened a little; the amount of tightening torque is not the deciding factor.When inserting new sealing
cords, a sufficient overlap must be ensured (at least 30mm and the overlap on top).
The sealing cord itself is glued with an industrial glue (e.g. Sikaflex) to prevent shifting of the cord during closing.
Caution: If the medium leaks out, this may cause injury. Sealing cords which have been installed for more than
six months must basically be replaced once the doors are opened.

Measures in the event of unusual observations and operating faults

If anything unusual is observed and/or operating faults are displayed, the following table provides initial information on
repair:

Observation/fault:

Seal slips out

Cause

Repair

Excessive tightening required at start-up

Insert new seal

Seal not positioned in the middle

Adjust seal and stick in place if necessary

Observation/fault:

Leaks when boiler heats up

Fault

Repair

Nuts not tightened after start-up

Tighten nuts; it may even be necessary to insert a


new seal

Unsuitable sealing surface

Clean sealing surface

Incorrect installation of sealing cords

Insert seal again

Observation/fault:

By whom

By whom?

Moisture leaking out

Fault

Repair

Condensation occurring in start-up state

Take boiler into operating state

By whom?

Condensation (air intake openings in the area of the Move air intake openings
reversing chamber door, so that cold fresh air
passes by warm boiler doors)

Page 5 of 7

Operating instructions

Burner and flue gas side inspection openings


for shell boilers with lateral flame tube

C007
Version 5 (11/08)

Observation/Fault:

Hot areas near the front reversing chamber(> 85C in door area)

Cause

Repair of cause

Loosening of thermal insulation mats

Repair smaller areas by gluing down again

By whom?

Completely re-line larger areas

Observation/Fault:

Discoloration of front reversing chamber

Cause

Repair of cause

Loosening of thermal insulation mats

Repair smaller areas by gluing down again

By whom?

Completely re-line larger areas

Observation/Fault:

Faults in burner operation or change in burner behaviour

Cause

Repair of cause

Thermal insulation mats are coming loose and


blocking one or more pipes

Completely re-line larger areas

Observation/fault:

Vibrations at front reversing chamber

Fault

Repair

Vibrations or pulsation triggered by the burner

Optimise burner setting

Observation/fault:

By whom?

By whom?

Faulty brick lining (flaking, cracks)

Fault

Repair

Frost damage

Replace brick lining

Non-compliance with required boiler start-up times


according to Operating Instructions C003/C014
Shell boilers, Chapter Commissioning

Replace brick lining

Vibrations or pulsations triggered by the burner

Optimise burner settings

By whom?

Replace brick lining

Page 6 of 7

Operating instructions

Burner and flue gas side inspection openings


for shell boilers with lateral flame tube

C007
Version 5 (11/08)

Flame too long; flame burning onto brick lining

Optimise burner settings; if necessary replace or


modify flame head
Replace brick lining

10 Care and Maintenance


Burner and flue gas side inspection openings must be checked at least every three months and during commissioning and if
there is any suspicion of leaks. Covered inspection openings must be revealed first. Otherwise, during the maintenance,
attention should be paid to the proper positioning and the inspection openings must be checked for unusual phenomena.
After leaks, inspections must be carried out more frequently.

10.1 Inspection of thermal insulation


To protect against heat and temperature, various different thermal insulation materials are used, depending on the
temperatures which occur. In the area of high temperatures, e.g. in the flame tube, extremely fire-resistant cast materials are
used which have a sufficient surface resistance for the fuels used.
Because of the residual moisture in the stone after the manufacturing process, water vapours may arise in the stone if
warming up is carried out too quickly; these may not be able to escape via the pores available if heating up is too fast, which
causes the stones to flake (see also Operating Instructions C003/C014 Shell boilers, Chapter Commissioning).
In the case of fuels with a high sulphur level, corrosion of the surface may occur over the years. Minor shrinkage cracks or
flaking will not affect function and are unavoidable.
The front reversing chamber door is provided with thermal insulation mats. These reduce the surface temperatures of the
component, radiation losses and the boiler house temperatures. The mats must be fixed firmly to the door.
The proper function of the thermal insulation can be determined by the temperature of the external surfaces. A reduction in
the insulation effect can be noticed by an increase in the temperature of the surface. If a temperature rise of more than 50C
is determined, replacement of the insulation is urgently required.

11 Replacement Parts
Note: All inspection openings closures are provided with special seals. Standard trade seals must not be used
as a substitute under any circumstances. Only Loos International seals may be used.

For spare parts orders or spare parts inquiries, please use the special ordering and inquiries form L006 After Sales Services
in Register L (Forms).
Alternatively, you can place your spare parts order or your spare parts offer online at www.loos.de / Kundendienst /
Ersatzteilversorgung (customer service / spare parts supply).

Page 7 of 7

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Contents
1

Scope of the Operating Instructions ........................................................................................................................ 2

Use in Accordance with Regulations ....................................................................................................................... 3

Safety .......................................................................................................................................................................... 3

Operating and Maintenance Staff ............................................................................................................................. 3

General Risks and Accident Prevention .................................................................................................................. 3

5.1

Dangerous situations.................................................................................................................................................... 4

5.1.1

Exceeding the pressure................................................................................................................................................ 4

5.1.2

Lack of pressure........................................................................................................................................................... 4

5.1.3

Excessively high temperatures..................................................................................................................................... 4

5.1.4

Lack of water ................................................................................................................................................................ 5

5.1.5

Insufficient water flow ................................................................................................................................................... 5

Description of Structure and Function / Description of Process ........................................................................... 5

6.1

Construction ................................................................................................................................................................. 5

6.2

Function ....................................................................................................................................................................... 5

6.3

Optional additional equipment...................................................................................................................................... 6

6.3.1

Flue gas heat exchanger.............................................................................................................................................. 6

6.3.2

Systems for maintaining the return flow temperature ................................................................................................... 6

Technical Data (Dimensions, Weight, Operating Conditions)................................................................................ 6

7.1

Rating plate .................................................................................................................................................................. 6

Transport and Storage............................................................................................................................................... 6

8.1

General notes on transport........................................................................................................................................... 6

8.2

Special transport regulations........................................................................................................................................ 7

8.3

Interim storage ............................................................................................................................................................. 7

Assembly .................................................................................................................................................................... 8

9.1

Place of installation ...................................................................................................................................................... 8

9.2

Assembly staff .............................................................................................................................................................. 8

9.3

Installation .................................................................................................................................................................... 8

9.4

Feed and discharge pipes, valves ................................................................................................................................ 8

10

Electrical Installation ................................................................................................................................................. 9

11

Setting and Adjustment ............................................................................................................................................. 9

12

Controls ...................................................................................................................................................................... 9

13

Start-up ....................................................................................................................................................................... 9

13.1

General ........................................................................................................................................................................ 9

13.2

Start-up preparation ..................................................................................................................................................... 9

13.3

Conditions required on site......................................................................................................................................... 10

13.4

Start-up times when commissioning for the first time ................................................................................................. 10

13.5

General instructions on carrying out the start-up........................................................................................................ 11

Page 1 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

13.6

Trial run and instruction ............................................................................................................................................. 12

14

Operation.................................................................................................................................................................. 12

14.1

Boiler water ................................................................................................................................................................ 12

14.1.1 General ...................................................................................................................................................................... 12


14.1.2 Water samples ........................................................................................................................................................... 13
14.1.3 Blow-down ................................................................................................................................................................. 13
14.2

Recurrent start-ups .................................................................................................................................................... 13

14.3

Normal operation ....................................................................................................................................................... 15

14.4

Keeping warm ............................................................................................................................................................ 15

14.5

Behaviour in the event of operating faults.................................................................................................................. 15

15

Shutting down .......................................................................................................................................................... 15

15.1

Recurrent shutting down ............................................................................................................................................ 15

15.2

Shutting down using the emergency stop switch ....................................................................................................... 16

15.3

Corrosion protection in the event of longer down times ............................................................................................. 16

15.3.1 Water-side preservation through pressure monitoring (independent of time): ........................................................... 16


15.3.2 Wet preservation on the water side for down times of up to approx. 3 months.......................................................... 16
15.3.3 Dry preservation on the water side for down times of more than approx. 3 months: ................................................. 16
15.3.4 Preservation on the flue gas and burner side ............................................................................................................ 17
16

Measures in the event of unusual observations and operating faults ................................................................ 17

17

Care and Maintenance............................................................................................................................................. 20

17.1

Operating Log ............................................................................................................................................................ 20

17.2

Entering the boiler...................................................................................................................................................... 20

17.3

Repeated, regular inspections and maintenance by the operating and maintenance staff ........................................ 21

17.4

Irregular inspections and maintenance by the operating and maintenance staff ....................................................... 21

17.4.1 Boiler valves and boiler parts ..................................................................................................................................... 21


17.4.2 Boiler cleaning on the burner and heating gas side ................................................................................................... 21
17.4.3 Boiler cleaning on the water side ............................................................................................................................... 21
17.5

Repeated, regular inspections and maintenance by experts or competent persons .................................................. 22

18

Replacement Parts................................................................................................................................................... 22

Scope of the Operating Instructions

These Operating Instructions contain basic information. They apply in combination with the following operating instructions:

A002 Basic Safety Instructions

B004 Guideline on water characteristics for hot water boilers

B006/B009/B011 Recurring inspections for shell boilers (external and internal inspections and water pressure tests)

B007 Checklist, hot water boilers

B010 Check list for heating boilers

G012 Wet and Dry Conservation

Page 2 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

For the operation of the system as a whole, the operating instructions for the individual components are binding along with
the relevant statutory provisions and official requirements.

Use in Accordance with Regulations

The shell boiler (called the boiler in the following) is used to product warm water or high-pressure hot water.
The marginal parameters defined in the technical data with the order confirmation must be followed. A list of these
parameters is given in Register M. This applies in particular for:

Water parameters

Fuel parameters

Ambient parameters

During the operating phase, load fluctuations beyond the boiler's nominal output should be avoided. Any change in the heat
reduction (= load change speed) must be less than or equal to the speed of change of the incorporated burner output. Care
must be taken to ensure that the switching frequency of the burner on average does not exceed four starts per hour.
During burner operation, a continuous induced circulation of the boiler must be ensured.
Flow monitoring is necessary to monitor this minimum water flow rate. If the flow rate falls below the prescribed minimum
water flow rate, the boiler firing must be switched off.
Furthermore, the temperatures may not fall below the minimum permitted boiler supply and return flow temperatures
(exception: start-up mode)
Information on the necessary minimum water throughput in burner operation and the minimum permitted boiler supply and
return flow temperatures are given in the technical data in the order confirmation.
The requirements for the filling, make-up and circulating water are defined in the Operating Instructions B004 Guideline on
water characteristics. These requirements must be complied with completely at all times.
The system may only be used in a technically perfect state, with full awareness of safety and dangers, by trained specialist
staff who have read and understand the operating instructions in full.
Changes to the boiler, its equipment and controls if these were supplied by Loos International may only be carried out after
written approval has been obtained from Loos International. Any change made independently will invalidate any claims
under the guarantee. In addition, an official operating permit may be cancelled in such cases.

Safety

Please read the Operating Instructions:

A002 Basic Safety Instructions

Operating and Maintenance Staff

Please read the Operating Instructions:

A002 Basic Safety Instructions

General Risks and Accident Prevention

Please read the Operating Instructions:

A002 Basic Safety Instructions

Page 3 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

5.1

Dangerous situations

During the operation of this system dangerous situations may arise as a result of operation. Damage can only be avoided if
these situations are recognised in good time and if the correct measures are taken immediately. The following list of
dangerous situations makes no claim to be complete, but is based on values from experience that have been gathered
through decades of observing our products. If other installations or system components are present, the measures that apply
for these system components must be coordinated with the manufacturer of these installations or components.
The operating staff must inform their competent superior of dangerous situations immediately.

According to the regional regulations, damage to pressure-bearing walls of the boilers and if provided the Type of
flue gas heat exchanger which, as a result of a danger to the operating staff or third parties, leads to a halt in operation
must be reported to the competent supervisory authority and/or monitoring organisation which is responsible for safety
tests on the boiler system.

The safety equipment affected must be inspected immediately by a competent person and repaired if necessary (if
possible) or replaced. We strongly recommend that such inspections and repair work are carried out by suitably trained
Loos International service engineers or by people who have expressly authorised by Loos International to carry out such
work.

5.1.1

Exceeding the pressure


Danger! Danger if pressure is exceeded. Exceeding the pressure may lead to the destruction of the boiler. Parts
that are flung out and the leakage of the hot medium (steam, hot water) can cause fatal injuries to persons in the
vicinity of the boiler.

If the pressure is exceeded, the pressure limiter must be triggered, causing the firing to be switched off and locked. If the
pressure limiter fails, the pressure safeguard valve is triggered and releases the excess pressure. If the pressure safeguard
valve does not respond or if the pressure in the boiler rises above the red line marking on the pressure indicator in spite of
the blow-off from the pressure safeguard valve, the boiler heating must be switched off immediately. If necessary, the
emergency stop switch must be used.
The boiler may only be started up again when the causes for the failure of the pressure limiter and/or the failure of the
pressure safeguard valve have been properly removed and a competent person allows the boiler to be fired again after a
corresponding inspection. Loos International recommends that this inspection is carried out by suitably trained Loos
International service engineers or by people who have expressly authorised by Loos International to carry out such work.

5.1.2

Lack of pressure
Danger! Danger from lack of pressure. If there is insufficient pressure, water may vaporise in the boiler and get
into the pipes. In extreme cases, this may ultimately cause damage to the system, causing potentially fatal
injuries.

If there is a lack of pressure, the pressure limiter must be triggered, causing the firing to be switched off and locked. If the
pressure limiter fails, the boiler heating should be switched off immediately. If necessary, switch off using the emergency
stop.
The boiler may only be started up again when the causes of the pressure limiter's failure have been expertly repaired and a
competent person allows the boiler to be fired again after a suitable inspection. Loos International recommends that this
inspection is carried out by suitably trained Loos International service engineers or by persons who have been expressly
authorised by Loos International to carry out this work.

5.1.3

Excessively high temperatures


Danger! Excessively high temperatures can be dangerous. They can cause serious damage to the boiler, or
even completely destroy the boiler. In extreme cases, this may ultimately lead to very serious damage to the
system, causing potentially fatal injuries.

If the temperature becomes excessively high, the temperature limiter must be triggered, causing the firing to be switched off
and locked. If the pressure limiter fails or if the temperature in the boiler rises above the permitted temperature, the boiler
heating should switched off immediately. If necessary, switch off using the emergency stop.

Page 4 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

The boiler may only be started up again when the causes of the temperature limiter's failure have been expertly repaired and
a competent person allows the boiler to be fired again after a suitable inspection. Loos International recommends that this
inspection is carried out by suitably trained Loos International service engineers or by persons who have been expressly
authorised by Loos International to carry out this work.

5.1.4

Lack of water
Danger! There is a danger from lack of water. It can cause serious damage to the boiler, or even completely
destroy the boiler. In extreme cases, it may cause extremely serious damage to the plant, and people may suffer
fatal injuries.

If there is a shortage of water, the level limiting device should be triggered, causing the firing to be switched off and locked. If
the level limiter fails, the boiler heating must be switched off immediately. If necessary, the emergency stop switch must be
used.
The boiler may only be started up again when the causes for the failure of the level limiter have been properly removed and
a competent person allows the boiler to be fired again after a corresponding inspection. Loos International recommends that
this inspection is carried out by suitably trained Loos International service engineers or by people who have expressly
authorised by Loos International to carry out such work.
If lack of water has caused damaged to the boiler (e.g. deformation of the flame tube or similar), the boiler must be shut
down immediately. The boiler may only be started up again when the damage that has occurred has been properly repaired
and a competent person allows the boiler to be fired again after a corresponding inspection. Loos International recommends
that this inspection is carried out by suitably trained Loos International service engineers, unless a monitoring organisation
has been consulted.

5.1.5

Insufficient water flow


Danger! There is a danger if insufficient water flows through the boiler. If this happens, it may cause
overheating, temperature lamination in the boiler and incorrect switching of temperature regulators and limiters.
In extreme cases, this may ultimately lead to very serious damage to the system, causing potentially fatal
injuries.

If the water flow falls below the minimum, the flow monitoring system must respond and switch off the firing. If it is not
switched off automatically in the event of an insufficient water flow, the boiler heating must be switched off immediately. If
necessary, switch off using the emergency stop.
The boiler may only be started up again when sufficient water is flowing through the boiler again.

6
6.1

Description of Structure and Function / Description of Process


Construction

The boiler pressure hull is a horizontal cylinder, closed off with boiler ends on both sides and insulated all round. The entire
boiler is filled with water during operation. The flame tube and the smoke tubes run lengthways through the cylindrical body.
The flame is blown by the burner into the flame tube from the front end of the boiler. It burns out in the flame tube. The hot
flue gases created when the flame burns out are forwarded into lots of small smoke tubes. The gases are passed by these
pipes through the boiler to the rear end of the boiler.

6.2

Function

The flame and the resultant flue gases flow through the flame tube and the smoke tubes. The boiler pressure hull itself is
filled with water, and the water flows into the boiler via the return flow connection and back into the network via the forward
flow connection. The water cools the outside of the flame and smoke tubes lying lengthways in the boiler pressure hull.
During this "cooling process", the boiler water warms up, so that warm or high-pressure hot water can be provided to the
consumer unit. A sufficient flow through the boiler is maintained by a circulating pump.
To ensure that the warmed or heated water does not evaporate in the boiler, a pressure-monitoring device is required to
maintain the boiler operating pressure.

Page 5 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

The burner capacity and thus the required boiler output are regulated via the set mean supply flow temperature. If the
temperature of the boiler water at the boiler outlet falls below the set value, the burner is switched on or the burner capacity
increased. If the boiler output temperature reaches the set maximum value, the burner is switched off, since no heat is
required. If this regulation mechanism fails, a temperature limiter switches off and locks the burner.

6.3

Optional additional equipment

6.3.1

Flue gas heat exchanger

In the flue gas heat exchanger, warmth is recovered from the boiler flue gases which would otherwise be lost through the
chimney without being used. The energy recovered in this way makes the boiler more efficient and reduces fuel
consumption whilst improving flue gas emission levels.
Please read the Operating Instructions:

F012 Flue gas heat exchanger

6.3.2

Systems for maintaining the return flow temperature

In order to avoid impermissibly low boiler return flow temperatures or impermissibly high temperature differences between
the boiler return flow and forward flow, systems to maintain the return flow temperature are necessary.
Please read the Operating Instructions.

E016 Maintaining the return flow temperature

Technical Data (Dimensions, Weight, Operating Conditions)

The technical data are fixed in the order confirmation. A copy of the technical data forms part of the delivery documentation
and is generally found in Register M. For further information, please consult the enclosed data sheets.

7.1

Rating plate

The parameters specified on the rating plate must not be exceeded. The rating plate is either located on the top right of the
front end or at the boiler shell in 3 oclock position at a distance of approx. 300 mm from the front end.

8
8.1

Transport and Storage


General notes on transport

When transporting the systems, suitable protective measures should be taken, which will depend on the type of transport
chosen. If necessary, Loos International will advise you on the choice of suitable protective measures. In any case, transport
must be carried out with due caution. Unnecessary loads on the components should be avoided. If required, and for a
charge, the delivery can be packed for transport by Loos International and delivered with the appropriate protection.
Caution! Incorrect lifting can seriously damage the equipment. Lifting equipment and stop devices should only
be fixed to the attachment points described below. Only use lifting equipment and stop devices that are suitable
for the weight loads which will occur.

If a crane is used, the boiler may only be lifted at the marked lifting rings (see figure) on the cylindrical part of the boiler;
it is essential that all the lifting rings affixed to the cylindrical part must be used.

Page 6 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Important! The angle of inclination of the lifting accessories must be 90 .

If the location of the boiler has to be changed, the boiler may only be lifted at the lifting jacks, which are attached to the
boiler feet. Small boilers (transport weight < 4 t) may be lifted by suitable means (e.g. conveyor vehicles, lifting
equipment) at the points where the boiler feet are fixed to the base frame.
Important! For floor-level boiler transport, means of transport under the base frame may exclusively be placed
below the boiler feet.
The use of tank steel rollers below the base frame is inadmissible for floor-level transport. Danger of base
frame deflexion!

If the location only needs to be changed approximately in the direction of the boiler's longitudinal axis, only the bored
holes at the front and back of the base frame may be used.

Stop points on buildings or parts of buildings for pulling the boiler must be suitable for the forces arising and may only
be used after they have been approved beforehand by the manufacturer of the system.

If the boiler, because of the situation on site, cannot be transported as described above, it is essential that Loos
International is consulted.

8.2

Special transport regulations

The following instructions must be followed under all circumstances:

Avoid wet or damp situations

When transporting insulated systems or system components on open vehicles, suitable packaging should be provided
to protect the equipment from the effects of water and weather.

Avoid vibrations as far as possible

Do not under any circumstances expose the systems or system components to temperatures below -20 C (danger of
embrittlement fractures).

For transport by sea, use suitable packaging (overseas containers). If the system is packed in a wooden crate, it may
not under any circumstances be transported on deck.

Make sure that sufficient suitable corrosion protection is provided whatever form of transport is chosen.

Transport vehicles must be fitted with pneumatic or hydraulic suspension to prevent vibration cracking.

8.3

Interim storage

If the system has to be stored, the following instructions must be followed under all circumstances:

Store in a dry (humidity < 60%), dust-free place.

Temperature change in the store < 10 K/h.

Never expose the system to temperatures below - 50C. Restrictivy applies: Items of equipment, sensors and the
control cabinet should never be exposed to temperatures below - 20C.

Page 7 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

9
9.1

If the system is stored insulated and covered with the protective wrapping provided for transport, the protective
wrapping should be cut open at the base for the full length to prevent condensation and thus oxidation on the insulation
surface.

Assembly
Place of installation

the system may only be erected in a room that meets the local regulations for the erection of boiler systems. In any case,
care should be taken to ensure that the floor at the place of installation is absolutely flat (evenness tolerance in according to
DIN 18202: 10 mm) and sufficiently strong. The room must be frost-free and large enough for access to the system to be
ensured in accordance with the local regulations.
The place where system is installed must be designed in terms of building physics in such a way that vibrations caused by
the process cannot cause any damage to buildings or neighbouring systems.
An adequate ventilation for air intake and removal must be provided.

9.2

Assembly staff

Transport to the site, assembly and later disassembly of the system should exclusively be carried out by appropriately
trained and qualified personnel with the necessary technical know-how and authorisation for this task from the installer of the
entire system.

9.3

Installation

When the plant is installed, the regional regulations must be complied with (e.g. structural requirements, open spaces for
operation and maintenance, emergency exit routes, etc.).
The boiler does not need to be anchored to the place of installation.
Note: It should be noted that with particular types, the rear boiler support (seen from the burner side) is made as
a fixed point on the longitudinal support. The front boiler support is made as a loose bearing, i.e. the boiler
expands forwards as it heats up.
If the place of installation and the boiler have to be separated due to structure-borne sound, sound insulation strips must be
affixed before the boiler is erected.
If the boiler is installed on steel supports or other materials that are good heat conductors, insulation must be provided
between the boiler longitudinal supports and the installation surface, e.g. using sound insulation strips.
Note: If a boiler with waste gas connection socket arranged to the top has the chimney mounted directly on the
waste gas connection socket respectively the incorporated flue gas heat exchanger, then it must be considered
that the load and the horizontal forces (e.g. caused by wind load) cannot affect the boiler. Therefore, a separate
support for the chimney is required. In addition, we recommend a decoupled arrangement for the chimney (e.g.
with expansion joint) from the boiler- flue gas heat exchanger system in order to interrupt the structure-borne
sound.
Furthermore, it must be prevented by a cover on the chimney or a certain device inside the chimney or the waste
gas line that rain enters into the boiler. Depending on the operating conditions, the moisture might lead to
corrosions in the boiler and the flue gas heat exchanger.

9.4

Feed and discharge pipes, valves

All feed and discharge pipes must be laid in accordance with the regional regulations and in line with the accepted technical
rules.
For further information, please read the technical information sheet TI024 Requirements for Boiler Installation Rooms (notes
for the installation of boilers and boiler house components).

Page 8 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

10 Electrical Installation
The electrical installation work may only be carried out by trained, qualified electricians (e.g. according to the
guidelines laid down by the VDE or comparable institutions at the place where the system is to be installed). It
must be done in accordance with the recognised electrotechnical rules and the local regulations and must be
suitable for damp rooms.
The system is designed for a power supply with a nominal voltage and nominal frequency according to the technical data in
the order confirmation.
Electronic equipment that forms a part of this system may only be installed and connected to the power network or the
control cabinet by trained, sufficiently qualified electricians. The automatic control or other electronic component may not be
opened during installation or at any other time by the user or by other people. They do not contain any parts that can be
repaired by the user. Repairs may only be carried out by the manufacturer of these components. If these components are
opened by unauthorised persons, this shall invalidate any guarantee claim.
Important! The installation of the control panel is to be carried out in such a way that no vibrations or shaking
from the boiler or other devices can be transmitted to the control panel. It shall be erected in areas that protect
the control panel against excess thermal radiation and which allow access safely in dangerous situations.

11 Setting and Adjustment


No particular setting and adjustment work is required during installation.

12 Controls
Note: If the system's controls are not supplied by Loos International, the system must be operated according to
the operating instructions for the controls that are actually used.
Notes on the controls are given in the circuit diagram and the operating instructions for the controls and process technology
in Registers G and/or H.

13 Start-up
Please read the Operating Instructions:

A002 Basic Safety Instructions

13.1 General
For the start-up of the boiler, all the other components of the boiler house (e.g. fuel supply devices, water treatment systems
flue gas systems etc.) must be provided in working order by their suppliers. Equipment that has an influence on the function
of the components supplied by Loos International must be coordinated carefully. Operation without faults and without
damage is only possible if all part components are working perfectly.
All people who are entrusted to carry out the maintenance and supervision of the boiler must be present during the start-up
works, and the immediate superiors of these persons should be present for at least part of the time.

13.2 Start-up preparation


The following points must be carried out before start-up:

The inside of the boiler must be subjected to visual examination before being filled with water for the first time and if
necessary (foreign matter in the inside of the boiler due to transport, storage or assembly) must be rinsed through.

Before start-up or before attachment of the burner, the boiler must be visually examined on the flue gas side (foreign
matter in the inside of the boiler due to transport, storage or assembly).

Page 9 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Closures must be checked before filling to ensure that they are seated centrally, that the clamps are correctly positioned
and for pressure. (See also Operating Instructions K022 Inspection Openings, steam and water side).

All seals (gaskets) must be tested for tightness.

The movement of all shut-off valves must be tested; their seals and packings, if provided, must be tightened if
necessary and tested in accordance with their operating instructions.

The water reservoirs of sensors must be filled with distilled water.

Transport securing devices and protective wrappings, if provided, must be removed.


Important! It is mandatory to open the shut-off valve at the manostat tube. For safeguarding the open state, it is
necessary to lock the hand wheel by screwing in the greasing nipple up to the limit stop (also see Operating
Instructions K007 Shut-off Valve).

13.3 Conditions required on site


For the beginning of the start-up work, the owner of the plant or his agent must meet the following conditions:

The room in which the boiler is erected must be in a tidy condition. Building works and activities that cause dust or
moisture must be completed.

Openings for air intakes and outlets must be provided in sufficient size and must be operable.

The lighting of the room, especially the display devices at the boiler, must be sufficient to allow them to be read off
perfectly.

Emergency exit routes must be kept clear, doors must open outwards (safety doors) and may not be locked.

Access by unauthorised persons must be forbidden by a sign erected by the owner.

In the boiler room, a fire extinguisher suitable for the extinguishing of oil fires in the case of oil-fired boilers must be
provided at an easily accessible point.

The chimney and flue gas outlet routes must be leak-tight. In the case of oil and gas fired boilers and firing systems of a
particular design, devices must be provided which only allow the firing to operate when they are open (limit switches).
Masonry chimneys and flue gas ducts must be sufficiently dried. In cases of doubt, the approval of the manufacturing
company must be obtained.

Brick linings in the boiler must be dried. Possibly existing supporting material for brick linings must be removed before
commissioning.

All necessary operating equipment must be provided with the technical data given in the order confirmation.

The relevant electrical regulations must be noted, especially the protective measures prescribed locally. Emergency
switches to the emergency exit doors must be connected so that they are functioning properly.

Containers and pipelines must be thoroughly cleaned before the commencement of start-up works.

For the start-up and trial run, the owner must allow performance outputs through all the load stages of the boiler in
question or the plant as a whole so that the firing and the control and safety equipment can be set in such a way that
later faults are avoided. In particular, a sufficiently long acceptance process in accordance with the maximum
continuous load is essential for optimum setting.

Depending on the type of system, other points may arise as preconditions. The owner has been made aware of these
preconditions in a suitable form in good time. If these preconditions are not fulfilled or are only partly fulfilled, the start-up
may be delayed or it may be impossible to carry it out in full. Any delays and risks resulting from this shall be the
responsibility of the client for these works.

13.4 Start-up times when commissioning for the first time


The boiler lining contains an amount of residual water due to the manufacturing process. The water is evaporated the first
time the boiler is heated up. The water vapour that is created must escape during the entire heating up process. This may
cause small shrinkage cracks. Minor cracks or spalling will not have any adverse effect on function and are unavoidable.

Page 10 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Note: Because of the cooler ambient air in the boiler house, there will be, in the area of the burner plate, some
condensation of the escaping water vapour from the wall lining (the formation of condensation may continue for
up to a week). This is shown by droplets of water on the burner plate seal.
Caution! If heating up is carried out too quickly, the water vapour created cannot escape via the pores in the
brick lining and spalling of the stones may occur, which may even lead to a total destruction of the brick lining. In
order to prevent the brick lining from being destroyed, it is essential that the specifications for heating times are
followed.
The necessary removal of vapour from the brick lining is guaranteed if the requirements of the following table are met:

Operation of burner at low load


(maximum 50% load)

Operation of burner at full load

Heating up time

10 min.

Downtime

60 min.

Heating up time

20 min.

Downtime

60 min.

Heating up time

30 min.

Downtime

30 min.

Heating up time

30 min.

Downtime

30 min.

Heating up time

60 min.

Downtime

30 min.

Total time

6 hours

Caution! When commissioning for the first time, the complete heating up procedure must be carried out. Under
no circumstances should a brief start-up be tried and then stopped again.

13.5 General instructions on carrying out the start-up


The initial start-up of components supplied by Loos International may only be carried out by employees of the
company Loos International or by people whom Loos International has expressly authorised to carry out such
work.
The following notes on carrying out the initial start-up apply for the boilers supplied by Loos International if the equipment
and control of the boiler were not provided by Loos International:
Warning! Pumps may be filled with anti-freeze preservatives. Empty the pumps via the drainage plugs, rinse
through once and fill with water.

Before pumps are started up, the preconditions given in their operating instructions must have been met.

Fill boiler completely with treated water. The water temperature should be the same as the boiler wall temperature. With
differences of over 50 K, the filling time in continuous filling may not be less than 2 hours (danger of brittle fracture).

Check fuel pipes for leak-tightness.

Rinse suction lines in oil firing systems the part between the filter and the pump with pure heating oil.

Before the start-up of burners, the preconditions given for them in the special operating conditions must be fulfilled, and
in particular the flow of water through the boiler must be ensured by means of circulating pumps. The burner capacity
must be matched to the heat output. The quantity of fuel necessary for this must be defined, unless it is clear from the
order. In the case of oil burners, the nozzles must be checked. Meter readings of oil or gas meters should be noted.

Measurement and control devices must be set according to the individual operating instructions of these components.

Page 11 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Pressure-limiters must react before the pressure safeguard valve. The trigger points of controllers and limiters must be
sufficiently distant from each other and from the limiters.

The trigger points of temperature controllers and limiter must be coordinated to each other.

Tighten up flange connections and screw connections frequently during the heating up process.

Tighten up connections at the boiler's inspection openings and reversing chambers.


Important! Inspection openings are located at the points under the insulation marked by the following sign. For
retightening the connections, carefully remove the insulating strip and the insulation mat below and attach them
again thoroughly after retightening.

Note: During start-up or the subsequent trial operation, if required under regional regulations, the competent
monitoring organisation must carry out the necessary inspections of the boiler system so that the boiler system
can continue seamlessly to be operated as soon as the start-up is completed. The owner or his representative
must ensure that the organisation is notified and the dates agreed in good time.

13.6 Trial run and instruction


The duration of the trial run depends on the times and conditions agreed in the order confirmation.
If no arrangements were made for a trial run in the order confirmation, instruction will be provided for the operating staff
during or immediately after the start-up.
The completion of the trial run (or, if no trial run is carried out, the completion of the start-up) and the associated training of
the operating staff must be confirmed in writing by the owner or his representative, generally by signing the assembly
certificate or corresponding document provided by our service engineer.
Note: In the first few days after completion of the start-up, all filters should be cleaned several times. If the
system continues to be operated, particular attention should be paid to the quality of the boiler water. It is often
found that foreign matter enters the boiler through the water circulation, making drainage and refilling necessary
after just a short time, sometimes only a few days.

14 Operation
Please read the Operating Instructions:

A002 Basic Safety Instructions

14.1 Boiler water


14.1.1 General
The operation of modern, energy-saving boilers assumed that the water will have been pretreated accordingly to avoid heatinsulating deposits especially limescale and corrosion. The values listed in the operating instructions B004 Guideline on
water characteristics must therefore be strictly complied with when designing the water treatment and during boiler
operation. If raw water is not taken from the municipal water network, but is taken, for example, from rivers or the company's
own wells, it is recommended that particularly experienced specialist companies are instructed to supply, set up and
maintain the water treatment plant.
Condensate containing oil or grease may not enter the boiler under any circumstances!

Page 12 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Warning! Severe damage to the system can be caused by insufficiently treated water or unsuitable dosing
agents. Coatings should not be assumed to be harmless. The thickness of the coatings is not an indication of its
heat-blocking effect!
The function of the water treatment, the raw water characteristics, and the associated pipelines and valves must be checked
regularly. The system must be examined regularly for possible entries of foreign matter into the water cycle. Corresponding
entries must be made in the operating log (see Chapter 17.1). The chemical removal of boiler deposits or boiler scale may
only be assigned to experienced specialist firms.

14.1.2 Water samples


The boiler circulating water must be inspected at regular intervals (see Operating Instructions B007/B010 Checklist, hot
water boilers) and the results of the analyses are to be recorded in the operating logbook (see chapter 17.1.
It is essential that a water sample cooler be used to remove the boiler water sample. We recommend the use of the water
sample cooler made by Loos International. If water samples are analysed that are taken incorrectly or via unsuitable water
sample coolers, analytical errors are bound to occur. All water samples may only be taken and analysed in accordance with
the operating instructions B004 Guideline on water characteristics for hot water boilers and E004 Water sample coolers.
Other methods and procedures are not permitted.
Warning! Danger of serious scalding. Removing water samples without suitable water coolers may cause
severe scalding.

14.1.3 Blow-down
Every boiler must be blown down to prevent sludge deposits from forming. These sludge deposits are caused by correcting
chemicals that have loosened or of which a surplus has been added, residues from the attached system, or corrosion
residues or other foreign matter which have entered the boiler via the water.
Warning! Danger of boiler damage through overheating. This is caused by excess sludge deposits.

Generally, corresponding sludge traps are installed in the hot water system, and so a manually operated blow-down device
is therefore sufficiently. This should be operated carefully once a month.
Warning! There is a danger that the system could switch off if the pressure falls too much if automatic quick
shut-off blow-down valves are installed. The installation of automatic quick shut-off blow-down valves is not
permitted.

Note: We would like to point out expressly that leaking waste water or flue gas condensate should not under any
circumstances be disposed of without previously checking the waste water values. If necessary, the waste water
should be treated in such a way (neutralising, cooling, etc.) that it meets the local regulations on the disposal of
waste waters into the sewage system.

14.2 Recurrent start-ups


If system parts are mentioned in the following that are not a part of our delivery, this is done on a non-binding basis. The
operating instructions of the suppliers in question are decisive. The following sequence must be followed precisely:

The conditions given in section "Conditions required on site" must be met.

All necessary system components are ready for operation.

The system is under operating pressure.

If Flue gas heat exchangers are provided, they must comply with the valid operating instructions.

Page 13 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Open air intake and outlet opening, if not automated, and secure against closure.

Open flue gas flaps, if not automated, and secure against closure.

Make sure fuel supply is ready for operation, open shut-off valves.
Note: The following further description assumes that the boiler is fitted either with a boiler circuit pump with a
three-way control valve for return flow temperature control or alternatively with a booster pump.

Open supply flow shut-off device and return flow shut-off device. The network pumps are not yet operating.

Switch on main switch at control cabinet and deal with any fault messages. Unlock boiler and burner control.

In the model "Boiler circuit pump with three-way control valve for return flow temperature control " , the three-way control
valve is to be set by hand to boiler circuit and the return flow temperature control set to manual mode.

Switch on boiler control at control cabinet if a separate switching function is provided.

If necessary, clear any existing fault alarms. Unlock boiler and burner control.

If a return flow temperature monitor is installed has been triggered, it should be deblocked. The task of the return flow
temperature monitor is to switch the system off if the temperature falls below the minimum boiler return flow
temperature. (Basic setting approx. 2 K below the min. permitted return flow temperature). When starting up the boiler,
the return flow temperature monitor should generally be switched in such a way that, on switching on or deblocking, it
remains ineffective until the set temperature a the return flow temperature monitor has been exceeded for the first time.
From this point in time, the monitor is active and reacts as soon as the temperature falls below the set temperature.

Switch output control to manual at control cabinet.

Switch burner control on at control cabinet.


Important! The boiler circuit pump or booster pump must be operating by the time the burner is switched on at
the latest.

Start up burner according to separate operating instructions. Monitor start-up of oil and gas firing to determine any
irregularities and repair them, e.g. hard ignition, uneven burning.

The boiler must be heated up at minimum load to almost supply flow temperature. A sufficient quantity of water must be
passed through the boiler all the time by means of the boiler circuit pump or booster pump.

Once the set average supply flow temperature has been reached, switch performance regulation to automatic mode.

Set control device for ensuring the return flow temperature (control valve e.g. three-way control valve) to automatic, if it
is automated and not already in this position.

Switch in network pumps. Make sure that the temperature does not fall below the minimum boiler return flow
temperature and the maximum temperature difference between the boiler supply and return flow is not exceeded. If
necessary, the volume flow of the network pump(s) should be reduced.

The daily inspections and other maintenance work should only be carried out once the boiler has been fully started up
and is in automatic mode (see chapter on "Care and Maintenance").

If the boiler is not fitted with a boiler circuit pump or booster pump, it must be ensured, depending on the connected hot
water network, that firstly the boiler is heated up to supply flow temperature with a steady through-flow and that the
connected consumer units are only switched on gradually after this. Care should be taken to ensure that the temperature
does not fall below the minimum boiler return flow temperature and that the maximum temperature difference between the
boiler supply and return flow is not exceeded. If necessary, the volume flow of the network pump(s) should be reduced.
Important! As long as the boiler is operated below the minimum permitted boiler supply and return flow
temperatures (information on this is given in the technical data in the order confirmation), the temperature is
below the water dew point in gas operation in particular and flue gas condensate will leak out of the flow gas
hood. This flue gas condensate is highly corrosive and must be removed from the boiler immediately. Closing the
flue gas condensate drainage at the boiler is not permitted.

Page 14 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Note: We would expressly like to point out that leaking waste water must not be disposed of under any
circumstances without the waste water values being checked first. If necessary, the waste should be treated in
such a way (neutralising, cooling, etc.) that it meets the local regulations on the discharge of waste waters.

14.3 Normal operation


Important! Care should also be taken during normal operation that the water through-flow does not fall below
the minimum rate at any time during burner operation. In addition, make sure that the temperatures do not fall
below the permitted minimum boiler supply and return flow temperatures.

14.4 Keeping warm


As an option with multi-boiler systems, there is a facility for keeping warm via network water. For this the firing and if
necessary the boiler circuit pump or booster pump assigned to the boiler are switched off. The return flow shut-off device is
closed, and the supply flow shut-off device is open. Using an additional heat maintenance pump, which is connected on the
suction side at the boiler outlet, network supply flow water is pumped through the boiler to be kept warm into the network
return flow.
Important! Heat maintenance only via the network circulating pump, boiler circuit pump or booster pump is not
sufficient. Because the firing is switched off in heat maintenance mode, there is no boost in the boiler and there
will be a short-circuit flow between the boiler supply and return flow. An even temperature in the boiler is no
longer guaranteed and the base of the boiler cools down. When the boiler, which is assumed to be warm, is
started up again, addition stresses occur which can lead to damage to the boiler.

14.5 Behaviour in the event of operating faults


In the event of a fault that is relevant to safety, the system switches off automatically if the control was supplied and
maintained by Loos International. If provided, an acoustic warning tone will be heard. In the case of boilers with a fault
display device, the fault will also be displayed and saved.
Determine the cause of the fault using the information provided in the chapter Measures in the event of unusual operations
and operating faults and remove it. You should also note the operating instructions and if necessary the visual displays of
the individual additional devices. If the cause of the fault remains unclear or the fault cannot be repaired with the means
available, the nearest Loos Service office should be notified. You will find the Loos Service numbers on the outside of your
boiler's control cabinet.
Important! The system may only be started up again once the cause of the fault has been determined and
repaired.

15 Shutting down
15.1 Recurrent shutting down
If system parts are mentioned in the following that are not a part of our delivery, this is done on a non-binding basis. The
operating instructions of the suppliers in question are decisive. The following sequence must be followed precisely:

Switch burner to minimum load position and then switch off.

Wait while circulating pump (boiler circuit pump or booster pump if provided) runs down.

Switch off pump and close return flow shut-off valve.

The supply flow shut-off valve stays open (unless the boiler is to be completely removed from the network for inspection
works).

If flue gas heat exchangers are provided, they must comply with the valid operating instructions.

Switch off burner and boiler control at control cabinet.

Page 15 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Close flue gas flaps, if not automated.

Close air intake and outlet opening, if not automated.

Switch off fuel supply, close fuel shut-off taps.

Switch off main switch at control cabinet.

Shut down other system components according to their operating instructions.

15.2 Shutting down using the emergency stop switch


In potentially dangerous situations, the firing can be switched off and locked by operating the emergency stop switch or the
main switch in the control cabinet.
Warning! Danger of boiler damage. Before the boiler system can be started up again after an emergency shutdown, the cause for the emergency shut-down must be repaired and the system inspected. Only when all causes
have been safely repaired may the system be started up again.
After unlocking of the emergency stop switch, switching back on should be carried out as described in section 14.2
"Recurrent/daily start-up".

15.3 Corrosion protection in the event of longer down times


Any oxygen in the air which enters has a corrosive effect in the cooled, unpressurised boiler. For this reason, suitable
precautionary steps must be taken. If boilers are idle for longer than 3 days, corresponding protective measures must be
taken Loos International recommends the following:

15.3.1 Water-side preservation through pressure monitoring (independent of time):


If one or more boilers in a boiler system are switched off and if it is ensured that one boiler, or at least the pressuremonitoring unit, remains in operation, no further water-side preservation measures are necessary. Care should merely be
taken to ensure that the boiler stays connected with the network through the opened supply flow shut-off device
(alternatively, the return flow shut-off device can also be opened; the important thing is that both shut-offs are not open in
order to prevent heat losses through undesired circulation), and thus that the network pressure is maintained. This ensures
that no oxygen can get into the boiler due to an overpressure situation.

15.3.2 Wet preservation on the water side for down times of up to approx. 3 months
The boiler is filled completely with water, an excess of oxygen binder added and the boiler water content rotated at defined
intervals.
You will find instructions on wet preservation from Operating Instructions G012 Wet and Dry Preservation.
Carrying out the conservation
In order to ensure an even mixing of the dosing agent (for concentration in boiler water, see Operating Instructions G012
Wet and Dry Preservation) with the boiler water, a regular circulation is essential. For this, a circulating pump should be
installed, which is incorporated on the suction side with a T-piece at the outlet connection after the drain shut-off valve and
on the pressure side into the return flow between the boiler and the return flow shut-off device. Dosing agent can be added
via the dosing station on the pressure side of the circulating pump.
All valves at the boiler should then be shut tightly to prevent the penetration of oxygen from the air during the down time. To
ensure a good mixing through of the preservation solution, the water must be circulated five times at least every three days
using the circulating pump.
Please read the Operating Instructions:

G012 Wet and Dry Conservation

15.3.3 Dry preservation on the water side for down times of more than approx. 3 months:
The system is completely emptied, filled with special drying agents and then sealed again. Rendering the system fully
operational again takes considerably longer than with wet preservation (approx. 1-2 days) and it is recommended that the
Loos International service engineer is consulted for this.

Page 16 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Precise instructions for dry preservation are given in Operating Instructions G012 Wet and Dry Preservation.

15.3.4 Preservation on the flue gas and burner side


To preserve the flue gas side in the case of long down times, sufficient through ventilation must primarily be ensured. For
this, swivel the burners out and open any valves on the flue gas side completely. This generally creates a sufficient through
draught through the pull from the chimney.
Any deposits on the flue gas side in which moisture could be bound must be removed before preservation.
If the system is one that is driven by pressure on the flue gas side, or if it is a multi-boiler system in which several boilers are
connected to one chimney, a separate system-specific preservation on the flue gas and burner side must be defined for
these systems, in agreement with Loos International.
In more difficult conditions, such as:

erection in the immediate vicinity of the sea,

if the air is particularly damp,

in the presence of corrosive media,

dry preservation on the flue gas side is recommended. In this case, please proceed analogously as described in Operating
Instructions G012 Wet and Dry Preservation, Section 6.3 "Dry Preservation" and 6.4 "Restarting after preservation".

16 Measures in the event of unusual observations and operating faults


If anything unusual is observed and/or operating faults are displayed, the following table provides initial information on
repair:

Observation/fault:

Min./Max. pressure limiter/pressure safeguard valve triggered

Cause

Repair

Pressure limiter set incorrectly, moved or faulty

Check pressure limiter

Mean network gauge pressure PM too close to


trigger pressure of the pressure limiter

Adjust mean network gauge pressure PM

Supply and return flow shut-off valve closed during


heating

Open shut-off valves and ensure minimum throughflow

Observation/fault:

By whom?

Temperature limiter triggered

Cause

Repair

Temperature limiter set wrongly, incorrectly


adjusted or faulty

Check temperature limiter

Mean forward flow temperature TM too close to


trigger temperature of temperature limiter

Set mean forward flow temperature TM lower

By whom?

Page 17 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Observation/Fault:

Boiler safety chain triggered (boiler fault)

Cause

Repair

Triggering of one or more boiler safety functions or


limiters

After repairing the fault, release safety fuse chain


using release key on boiler control cabinet

Power supply interrupted

Provide power supply to control cabinet (infeed)


acc. to current regulations

Main switch in OFF position

Switch main switch on

Observation/Fault:

Burner fault

Cause

Repair

Various burner faults

See display for firing manager or burner operating


instructions

Observation/fault:

By whom?

Burner does not start

Cause

Repair

Burner switch in OFF position

Switch burner switch on

Burner faulty

Repair burner fault and unlock with unlocking device


at burner or at boiler control cabinet

Boiler fault

Repair boiler fault and unlock with unlock key in


boiler control cabinet or directly at limiter

Flue gas flap not open

Open flue gas flap

Automated air intake flap not open

Check function of air intake flap

Boiler circulating pump not working

Check function of pump

Observation/fault:

By whom?

By whom?

Burner switches on an off frequently

Cause

Repair

Temperature difference between Burner On and


Burner Off not enough

Increase temperature difference

By whom?

Page 18 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Observation/fault:

Burner only running on low or medium load

Cause

Repair

Performance regulation only released for low or


medium load

Release performance regulation in controller menu

Observation/fault:

Continuous fluctuation of performance regulation

Cause

Repair

Switching points set incorrectly

Check control parameters and switching points

Temperature transmitter faulty

Replace temperature transmitter

Observation/fault:

By whom?

With gas operation, the safety shutoff valve is triggered

Cause

Repair

In a load level, burner switches to down > low load

Check control parameters and switching points

Sudden change in heat emission in the network

Delay reduction in emission of heat

Observation/Fault:

By whom?

By whom?

No control voltage/control fusing tripped

Cause

Repair

Main switch in OFF position

Switch main switch on

One or more control circuit fuses triggered

Check control circuit fuses and electr. system acc.


to current regulations

No power supply to control cabinet

Provide power supply to control cabinet (infeed)


acc. to current regulations

By whom?

Page 19 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

Observation/fault:

Return flow temperature monitoring triggered

Cause

Repair

Return flow temperature too low

Reduce heat removal from network, reset return


flow temperature monitoring

Control device for maintaining return flow


temperature is not working

Check function of control device


Reset return flow temperature monitoring

By whom?

Note: If boiler damage occurs, ore details are given in the operating instructions B006/B009/B011 "Regular
inspections," in the chapter "Measures in the event of unusual observations or operating faults." Further
information is given in the operating instructions for the components in question.

17 Care and Maintenance


17.1 Operating Log
An operating log is to be kept of inspections and maintenance work which must be signed off by the operating staff. The
maintenance work carried out by the competent person must also be entered in this operating log. The forms contained in
Register L (Forms) of these operating instructions should be used for this. Operating logs may be obtained from Loos
International.
The superior of the operating staff must ensure at least once a month that the boiler system is being properly operated and
maintained, and must note this on the back of the sheet in the operating log by signing and giving the date.
Note: Entries must be made in the operating logs at the required intervals. The careful execution of inspections,
proper maintenance and full entries in the operating logs are a precondition for any guarantee claims.

17.2 Entering the boiler


Before the plant is entered, all pipe connections to the boilers still in operation must be safely and visibly disconnected (blind
flange, removal of pipe sections, shut-offs with interim ventilation).
Warning! Danger of personal injury. Merely closing the shut-off valves is not sufficient!
Suitable warning signs must be affixed, which may only be removed by the superiors of the operating and maintenance staff.
Before the boiler is entered, it must have been cooled down sufficiently (< 40C) and sufficient ventilation must be provided.
There may be no dangerous gases, e.g. nitrogen in the boiler any more.
Movement in the boiler must be monitored constantly from outside the boiler by an adult, reliable, trained person. When the
work has been finished, before the boiler is resealed, the superior of the operating and maintenance staff must make sure
that no-one is left in the boiler.
When entering the boiler and the ducts on the burner side, only electrical operating equipment may be used which, including
the cables and wires, complies with the valid regional electrical regulations.
Lights or electrical manual devices may only be operated at a protective low voltage of up to 42 V. Voltage of up to 400 V
are permitted if the supply comes from an isolating transformer. Low-voltage and isolating transformers must be erected
outside the boiler.

Page 20 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

17.3 Repeated, regular inspections and maintenance by the operating and maintenance staff
The works required are given in the Operating Instructions B007/B010 Checklist Hot water boilers, with the necessary
intervals and should be carried out as described there.
9

Warning! Danger of damage to the boiler. If faults cause controllers or limiters or other safety devices to become
ineffective, the system must be constantly supervised if its operation is continued. If safety devices fail, the
system must if necessary be shut down until suitable assistance has been provided. If the situation is dangerous,
the system must be shut down as a matter of urgency.

17.4 Irregular inspections and maintenance by the operating and maintenance staff
Depending on the water conditioning products used, the method of operation, the operating time and the water conditions,
the owner must set the intervals for the following points. The proposed intervals are the minimum requirements laid down by
Loos International:

17.4.1 Boiler valves and boiler parts


In addition to the operating instructions for the individual sensors, valves and actuators, the following applies:

Hydraulic seals (siphon pipes), display, control and limiter devices should be cleaned and filled with distilled water (halfyearly).

Replace seals on inspection openings in the event of leaks and each time the inspection openings are opened.

Replace parts subject to wear (e.g. level display glass) after the times given in the relevant operating instructions.

Tighten packing glands (weekly) and replace if necessary.

Shaft bearings must be maintained according to their design (sliding or roller bearings) and the operating conditions
(e.g. hot rooms) according to the operating instructions. Roller bearings should generally be maintained after a running
time of 2000 operating hours, i.e. to be cleaned and provided with fresh roller bearing grease (do not fill!), unless
otherwise specified in the relevant operating instructions.

17.4.2 Boiler cleaning on the burner and heating gas side


The heating surfaces on the gas side must be cleaned at certain intervals depending on the fuel, the method of operation
and the operating time each day.
For the simple monitoring of the operating conditions on the flue gas side, it is recommended that the boiler is
opened on the flue gas side after the first three months of operating and the state of the heating surfaces
examined. Further inspections should be carried out at least every year.
Heating pipes should be cleaned with a soot coating of approx. 0.5 mm, ideally with a motor-operated suction brush device.
In addition, any rise in the flue gas temperature above the normal level is a suitable way of determining whether the heating
surfaces should be cleaned on both the gas and the water sides.

17.4.3 Boiler cleaning on the water side


Warning! Danger of damage to the boiler. Deposits on the water side of heating surfaces are dangerous. They
reduce the cooling of the material, which may cause dents in the flame tube or tearing of the flame tube. The
pipe area after the flame tube and other loadbearing parts of the boiler are also at risk.
If the water is treated appropriately, the prescribed dosing agents are used and the system operated correctly, overheating
and corrosion damage will not occur.
The heating surfaces and boiler walls must be free from deposits and corrosion.
For the simple monitoring of the operating conditions on the water side, it is recommended that the boiler is
opened on the water side after the first three months of operating and the state of the inside of the boiler
examined. After a further 9 months, we recommend that the same inspection is carried out. If there are no
deposits and no corrosion, and if the operating log has been kept carefully, further inspections can be carried out
every three years.

Page 21 of 22

Operating instructions

Shell Boilers
for the producing of hot water

C014
Version 7 (12/08)

If deposits or corrosion are found, it is recommended that the supplier of the water treatment system or the dosing chemicals
is consulted to determine further measures, e.g. the chemical removal of the deposits. Cleaning on the water side should be
carried out by experienced specialist companies. For chemical cleaning by the owner's operating staff, we recommend
approved boiler scale solvents. If chemical cleaning becomes necessary, this should be noted in the operating log.
Note: Boilers may only be cleaned with boiler scale solvents which are approved under regional regulations. The
regulations on safety and environmental protection must be strictly complied with. These regulations and
instructions are given on the cleaning product containers or in the corresponding safety data sheets. These data
sheets are available from the supplier of the cleaning product.
If corrosion is found, its scope must be determined with the supervisory authority or with the Loos Service engineer. If
necessary, measures to remove the corrosion, or at least to prevent the corrosion continuing, must be taken.

17.5 Repeated, regular inspections and maintenance by experts or competent persons


The scope and the actual work required are listed in the operating instructions B006/B009/B011 Regular inspections with
the necessary time intervals and should be carried out as instructed there. The order-specific overall operating instructions
supplied by Loos International only contain the operating instructions required for the boiler supplied.

18 Replacement Parts
For spare parts orders or spare parts inquiries, please use the special ordering and inquiries form L006 After Sales Services
in Register L (Forms).
Alternatively, you can place your spare parts order or your spare parts offer online at www.loos.de / Kundendienst /
Ersatzteilversorgung (customer service / spare parts supply).

Page 22 of 22

Burner

Operating Instructions

Gas Regulation Module (GRM)


D001
Version 2 (03/04)

Contents
1

Scope of the Operating Instructions ........................................................................................................................ 1

Use in Accordance with Regulations....................................................................................................................... 2

Safety .......................................................................................................................................................................... 2

Operating and Maintenance Staff ............................................................................................................................. 2

General Risks and Accident Prevention .................................................................................................................. 2

Description of Structure and Function / Description of Process .......................................................................... 2

Technical Data (Dimensions, Weight, Operating Conditions) ............................................................................... 3

Transport and Storage .............................................................................................................................................. 3

8.1

General notes on transport .......................................................................................................................................... 3

8.2

Special transport regulations ....................................................................................................................................... 3

8.3

Interim storage............................................................................................................................................................. 3

Assembly.................................................................................................................................................................... 3

9.1

Place of installation ...................................................................................................................................................... 3

9.2

Assembly staff ............................................................................................................................................................. 4

9.3

Installation.................................................................................................................................................................... 4

9.4

Valves and built-in parts............................................................................................................................................... 4

9.5

Feed and discharge pipes............................................................................................................................................ 5

9.6

Supports ...................................................................................................................................................................... 5

10

Setting and Adjustment............................................................................................................................................. 6

10.1

Leakage test of the gas supply line to the gas regulation module................................................................................ 6

10.2

Leakage test of the assembled gas regulation module ................................................................................................ 6

11

Start-up ....................................................................................................................................................................... 7

11.1

General instructions on carrying out the start-up ......................................................................................................... 7

11.2

Checking the gas connection pressure ........................................................................................................................ 7

11.3

Venting......................................................................................................................................................................... 7

11.4

Adjusting the springs in valves..................................................................................................................................... 8

12

Operation.................................................................................................................................................................... 8

13

Shutting down............................................................................................................................................................ 8

14

Measures in the event of unusual observations and operating faults.................................................................. 8

15

Care and Maintenance............................................................................................................................................... 9

16

Replacement Parts .................................................................................................................................................... 9

Scope of the Operating Instructions

These Operating Instructions contain basic information. They apply in combination with the following operating instructions:

A002 Basic Safety Instructions

Operating Instructions for Burner

Operating Instructions for Pressure Regulator

Page 1 of 9

Operating Instructions

Gas Regulation Module (GRM)


D001
Version 2 (03/04)

For the operation of the system as a whole, the operating instructions for the individual components are binding along with
the relevant statutory provisions and official requirements.

Use in Accordance with Regulations

The marginal parameters defined in the technical data of the order confirmation must be complied with. A list of these
parameters is given in Register M. This applies in particular for:

gas characteristics (type of gas, calorific value, gas flow pressure before the shut-off valve at the intake to the gas
regulation module)

ambient parameters: For the gas regulation module, the ambient temperature must be from -10C to +40C. If
necessary, the valves must be protected against radiated heat or temperatures that are too low (risk of embrittlement).
Similar protection must also be provided against moisture, dust and dirt.

Safety

Please read the Operating Instructions:

A002 Basic Safety Instructions


Danger! Gas flowing out uncontrollably can create an explosive mixture of gas and air. This can then explode if
brought into contact with an ignition source.

The gas flow pressure may not exceed the maximum permitted pressure given on the rating plates.

Operating and Maintenance Staff

Please read the Operating Instructions:

A002 Basic Safety Instructions

General Risks and Accident Prevention

Please read the Operating Instructions:

A002 Basic Safety Instructions

Description of Structure and Function / Description of Process

The GRM gas regulation module contains all the valves that are needed for the supply of fuel to the burner on the gas side.
The sequence of the individual valves can be seen in Data Sheet DA038/DA039 in Register M. Using the shut-off valve at
the intake to the gas regulation module, the fuel volume flow can be manually shut off (e.g. for assembly work at the gas
regulation module or for shutting down). The filter valve protects the downstream valves from being soiled by any solids
carried along in the gas. The pressure regulator supplies the burner with the gas flow pressure necessary for safe burner
operation.
A compensator (if necessary) balances out the thermal expansion of the boiler between the cold state and the operating
state. The rear boiler foot (seen from the burner side) is made as the fixed point at the longitudinal support. The front boiler
foot is made as a loose bearing, i.e. the boiler expands forwards when heated up.
In addition, a gas quantity indicator to record the quantity of gas can be integrated into the gas regulating section.
Depending on the gas flow pressure before the shut-off valve at the intake into the gas regulation module, a pressure
safeguard valve (SBV) and a safety shut-off valve (SAV) can be part of the gas regulation module. The pressure safeguard
valve is dimensioned in such a way that if there is a fault in the gas pressure regulator, the flow volume can flow off into the
open without the pressure behind the valve rising impermissibly. The task of the safety shut-off valve is to automatically
shutoff the gas through flow in the gas regulating section if there is any damage to the gas pressure regulator or if the gas
flow pressure at the intake to the gas regulation module is too high, as soon as the pressure in the system to be protected

Page 2 of 9

Operating Instructions

Gas Regulation Module (GRM)


D001
Version 2 (03/04)

reaches an upper trigger pressure (exceeding the pressure). Instructions for setting the two valves are given in separate
Operating Instructions.

Technical Data (Dimensions, Weight, Operating Conditions)

The technical data are fixed in the order confirmation. A copy of the technical data forms part of the delivery documentation
and is generally found in Register M. For further information, please consult the enclosed data sheets.

Transport and Storage

8.1

General notes on transport

When transporting the systems, suitable protective measures should be taken, which will depend on the type of transport
chosen. If necessary, Loos International will advise you on the choice of suitable protective measures. In any case, transport
must be carried out with due caution. Unnecessary loads on the components should be avoided. If required, and for a
charge, the delivery can be packed for transport by Loos International and delivered with the appropriate protection.

8.2

Special transport regulations

The following instructions must be followed under all circumstances:

Avoid wet or damp situations

When transporting insulated systems or system components on open vehicles, suitable packaging should be provided to
protect the equipment from the effects of water and weather.

Avoid vibrations as far as possible

Do not under any circumstances expose the systems or system components to temperatures below -20 C (danger of
embrittlement fractures).

For transport by sea, use suitable packaging (overseas containers). If the system is packed in a wooden crate, it may not
under any circumstances be transported on deck.

Make sure that sufficient suitable corrosion protection is provided whatever form of transport is chosen.

8.3

Interim storage

If the module has to be stored, the following instructions must be followed under all circumstances:

Store in a dry (humidity < 60%), dust-free place.

Temperature change in the store < 10 K/h.

Never expose the module to temperatures below - 20C.

If the module is stored insulated and covered with the protective wrapping provided for transport, the protective wrapping
should be cut open at the base for the full length to prevent condensation and thus oxidation on the insulation surface.

Assembly

When setting up and assembling the module and laying the pipes (supply and removal lines), the regionally valid regulations
must be complied with (e.g. building requirements, clear spaces for operation and maintenance, emergency exit routes,
etc.).

9.1

Place of installation

When choosing the place of installation and assembling the gas regulation module, the following rules must be followed:

The operation and maintenance of the boiler, burner and built-on parts may not be restricted.

Access to the inspection openings on the boiler must not be blocked.

The burner and if necessary the boiler door must still be swivellable.

Page 3 of 9

Operating Instructions

Gas Regulation Module (GRM)


D001
Version 2 (03/04)

In the case of boilers with a swinging front door, a separation point in the connecting line between the burner and the
gas regulation module should be provided in order to allow the door and burner to swing out. If the gas regulation
module is mounted on the door hinge side, an adapter piece must be provided for removal to allow the boiler door and
burner to swing out.

The manual shut-off valve at the intake to the gas regulation module must be freely accessible.

It must be possible to remove and adjust the pressure regulator and, if provided, the safety shut-off valve (SAV) and the
pressure safeguard valve (SBV).

The connecting line between the gas regulation module and the safety shut-off valve at the burner must be made as
short as possible (< 2 m) and in the larger nominal width of the as regulation module and the safety shut-off valve at the
burner in order to keep the pressure losses as low as possible.
Note: If this is not done, it may not be possible for the necessary quantity of gas to flow through and/or there
may be operating problems (unstable operation, "pumping" of the regulator, etc.). If the pipeline between the gas
regulating and burner module cannot be made direct because of the situation on the ground, please contact Loos
International. The gas regulation module and/or the safety shut-off valve must then be made in a larger nominal
width.

If a burner silencer hood is attached (possibly retrofitted), there must be enough space to attach the hood. A straight
piece of pipe must be available to carry out the gas pipe through the hood wall.

9.2

Assembly staff
Assembly of the gas regulation modules may only be carried out by suitably trained specialist personnel who
have the necessary specialist knowledge and who have been authorised by the manufacturer of the system to
carry out this work. Otherwise, the assembly staff must hold the permits required in the regional regulations.

9.3

Installation

To avoid accidents, please follow these instructions on mounting the valves:

Before assembly, remove transport protection or sealing caps.

The supply gas line from the gas transfer station must be connected without tension to the gas regulation module. The
gas regulation module may not serve as a support for the gas supply line.

If assembly welding is required, the valves especially the bellows part of the compensator must be protected against
weld splashing etc. by being covered.
Important: Before starting the work, close the associated shut-off valve in the gas line and secure it to prevent
opening by unauthorised people.

If the gas regulation module was delivered in a dismantled state, for transport reasons, please follow these instructions:

The valves must be arranged in the sequence given in the enclosed Data Sheet (Register M).

The direction of flow for the valves must be noted.


9.4

Valves and built-in parts

Compensator:
When installing the gas regulation module and the connecting pipes to the burner, make sure that the compensator is
handled with care. After assembly, check that the bellows are clean and that the compensator can be shifted.
Important: The compensator is designed for axial forces, and for this reason the compensator may only be
installed parallel to the longitudinal axis of the boiler. Transverse and/or torsional forces must not be allowed to
affect the compensator during assembly or operation.

Page 4 of 9

Operating Instructions

Gas Regulation Module (GRM)


D001
Version 2 (03/04)

Thermally triggered shut-off valve (TAE):


If a thermally triggered shut-off valve is required, it must be installed before the manual shut-off valve at the intake to the gas
regulation module.

9.5

Feed and discharge pipes

For further information, please read the technical information sheet TI024 Requirements for Boiler Installation Rooms (notes
for the installation of boilers and boiler house components).
Low-pressure supply to the gas regulation module
In the case of a low-pressure supply to the gas regulation module, neither a breather line at the pressure regulator nor a
pressure safeguard blowoff line is necessary (see also Data Sheet DA039 for the gas regulation module in Register M).
High-pressure supply to the gas regulation module:
The enclosed Operating Instructions for the pressure regulator can be used to dimension the breather line at the pressure
regulator and at the pressure safeguard blowoff line.
The breather and blowoff lines must be taken safely into the open air. The two lines may not be combined.
Possibility of venting gas pipe
The Client must provide a way of venting before the gas regulation module ( ND 20).
The vent pipe must be taken safely into the open air. It may not be combined with the breather line or the blow-down line.

9.6

Supports

The scope of delivery of the as regulation module also includes all the supports with connecting elements and four screws
for fixing to the floor (express/ segment anchor screws). With a version with a compensator, a transverse rail is also
supplied.

Fig. 1: Supporting the gas regulation module with sleeve version and flange version
The gas regulation module in the sleeve version is fixed to the supports using round steel brackets and screws on the
adapter pieces. With gas regulation modules in the flange version, the supports are fixed to the flange external diameter
using the screws provided.
The compensator must be installed under pre-tension. After pre-assembly of the supports and after assembly of the
connecting pipes from the gas regulation module to the burner, the support with the transverse rail is fixed to the floor using
the express anchor / segment anchor screws M 12 x 110. The pre-tension when the boiler is in the cold state is 5 mm. The
transverse rail must be installed precisely in the longitudinal axis of the gas regulation module so that the loose bearing can
slide without tension.
The support at the outlet of the gas regulation module to the burner is also fixed to the floor using the express anchor /
segment anchor screws M 12 x 110. If necessary, fixing at the side (e.g. support to the boiler base frame) may be necessary
until the gas supply line is connected.

Page 5 of 9

Operating Instructions

Gas Regulation Module (GRM)


D001
Version 2 (03/04)

10 Setting and Adjustment


After completing the assembly work, a leakage text must be carried out on the gas regulating section and the valves.

10.1 Leakage test of the gas supply line to the gas regulation module
The leakage test of the gas pipe to the shut-off valve at the gas regulation module must be carried out by the gas supply
company or the contract installation company. Depending on the height of the intake pressure, the corresponding
regulations must be followed. Local regulations may also be applicable.
Important: To protect against excess pressure at the valves of the gas regulation module or at the burner
system, blanking plates or blanking flanges must be installed in the gas pipe before the shut-off valve of the gas
regulation module. If this is not possible, the shut-off valve (note maximum permitted pressure see rating plate)
at the intake to the gas regulation module must be closed. Suitable measures should be taken to ensure that this
valve cannot be opened during the time when the test pressure is applied. Pressure that is too high can fracture
the membrane of the pressure regulator, the safety shut-off valve or the pressure safeguard valve or cause
damage to other valves.

10.2 Leakage test of the assembled gas regulation module


For the leakage test of the valves and the connecting pipes from the gas regulation module to the burner (9), the shut-off
valve (8) and the double shut-off valve (5) must be closed.

1
2
3
4
5
6
7
8
9

Rubber hose with t-piece


Manual pump
Pressure-measuring device (e.g. U pipe, manometer)
Gas throttle
Double shut-off valve
Gas pressure regulator
Filter valve
Shut-off valve
Burner

Test pressure and carrying out the test for the 1st and 2nd test phase:
Test pressure in the valves:

100 - 150 mbar

Waiting time for pressure/temperature balance: 5 minutes


Test time:

5 minutes

Maximum permitted pressure loss:

1 mbar

1st test phase: Shut-off valve (8) to 1st valve seating at the double shut-off valve (5)
The test device is connected to the measurement point of the filter valve (7) and the intake of the double shut-off valve. In
the pressure test, the measurement connection between the individual valves of the double shut-off valve V1 and V2 must
be open.
2nd test phase: Valve space up to the 2nd valve seating of the double shut-off valve (5)
The test device is connected at the space of the double shut-off valve (5).
3rd test phase: Outlet of double shut-off valve (5) to gas throttle (4)
The 3rd test phase can only be carried out during operation using leakage spray.
After the leakage test, all the measurement points must be closed again. The results of the leakage test must be
documented in the usage report.

Page 6 of 9

Operating Instructions

Gas Regulation Module (GRM)


D001
Version 2 (03/04)

11 Start-up
Please read the Operating Instructions:

A002 Basic Safety Instructions

The following point must be completed before start-up:

Shut-off valves must be checked to see that they move, and their seals and packings, if provided, must be tightened and
checked according to their operating instructions.

At the initial start-up or after work on the valve groups where parts are replaced, a leakage test and venting must be carried
out before the system is started up again.

11.1 General instructions on carrying out the start-up


The initial start-up of components supplied by Loos International may only be carried out by employees of the
company Loos International or by people whom Loos International has expressly authorised to carry out such
work.

Before starting up firings, the conditions given in the special operating regulations must have been met. The firing
capacity must be matched to the boiler steam or heat capacity. The quantity of fuel required for this is given in the Data
Sheet in Register M.

Measurement and control devices must be set according to the individual operating instructions of these components.

Pressure-limiters must react before the pressure safeguard valve. The trigger points of controllers and limiters must be
sufficiently distant from each other and from the limiters.

11.2 Checking the gas connection pressure


The gas connection pressure may not exceed the maximum permitted pressure given on the rating plates of the valves
used.
Before the gas regulation module is vented, the gas connection pressure must be checked. For this, the shut-off valve at the
intake to the gas regulation module is slowly opened and the pressure indicator before the gas pressure regulator is
monitored. Close the shut-off valve immediately if the gas connection pressure exceeds the maximum permitted pressure
for the valves.
Note: If the gas flow pressure does not correspond to the value that is given in the technical data of the order
confirmation in Register M, Loos International must be contacted immediately in any case.

11.3 Venting
Gas must be blown through the pipes and valves in the gas regulation module until the air present or the inert gas has been
pushed out of the lines.
Venting the gas supply line to the gas regulation module:
The gas line as far as the shut-off valve at the intake to the gas regulation module may only be vented by the gas supply
company or by the contract installation company.
Venting the valves of the gas regulation module:
After the pressure test, the valves must be vented. At the measurement point of the double shut-off valve, a hose leading
into the open is attached to remove the air or inert gas. The manual shut-off valve at the intake to the gas regulation module
is opened. The gas in the valves flows through the vent hose into the open. After venting for minutes, the gas regulation
module is guaranteed free of air. After venting, the gas supply should be shut off, the hose removed and the vent connection
closed again immediately.
If the system has a test burner, safe ventilation can also be checked using this burner.

Page 7 of 9

Operating Instructions

Gas Regulation Module (GRM)


D001
Version 2 (03/04)

11.4 Adjusting the springs in valves


The springs in the pressure regulator, safety shut-off valve (SAV) and pressure safeguard valve (SBV) are not set to the
necessary operating conditions. This must be done as part of the start-up procedure in accordance with the relevant
operating instructions.

12 Operation
Please read the operating instructions:

A002 Basic Safety Instructions

C001 Quick steam generators or C003 Shell boilers

The gas supply to the gas regulation module is created by opening the shut-off valve at the intake to the gas regulation
module.

13 Shutting down
Please read the operating instructions:

A002 Basic Safety Instructions

C001 Quick steam generators or C003 Shell boilers

The gas supply must be interrupted by closing the shut-off valve at the intake to the gas regulation module.

14 Measures in the event of unusual observations and operating faults


If anything unusual is observed and/or operating faults are displayed, the following table provides initial information on
repair:

Observation/fault

Vibration of the gas regulation module

Cause

Repair

Insufficient support of the gas regulation module

Check support and use additional support if


necessary

Valve deflected

check valves in use

Pressure regulator has deflected membrane or


valve rod

check valves in use

Observation/fault

By whom?

Vibration (pumping) of pressure regulator when flow is low

Cause

Repair

Pressure regulator has large nozzle and thus high


flow capacity in comparison with its nominal
connection width. With very low flows, the valve
plate only lifts slightly from the nozzle and is thus
not stable in operation.

Use another spring

By whom?

Page 8 of 9

Operating Instructions

Gas Regulation Module (GRM)


D001
Version 2 (03/04)

Observation/fault

Vibration (pumping) of pressure regulator when flow is normal

Cause

Repair

Trigger time of pressure regulator is too short,


leading to vibration of the regulator with normal
flows

Throttle pulse line by reducing the pulse line crosssection

Observation/fault

By whom?

In gas operation, the safety shut-off valve closes

Cause

Repair

Burner switches to a load level > low load

Check regulating parameters and switching points

Closure of quick-close fittings in steam network

Close quick-close fittings with a time delay

By whom?

15 Care and Maintenance


The shut-off valve, the pressure regulating device (including the safety shut-off valve and the pressure safeguard valve if
applicable), the compensator and the gas quantity indicator are maintenance-free.
For general maintenance instructions, please read the operating instructions:

K537 Filter valve

All threaded pipe connections (sleeves) must be sealed in the threads with approved sealing products. Hemp or PTFE
sealing strips are not permitted.
If a connection is undone easily and frequently (separating point), flat-sealing screws with integral sealing must be used.
Only approved sealing products may be used for flange connections too.

16 Replacement Parts
To order or inquire about replacement parts, please use the special Ordering/Inquiries form, L006 After Sales Services
which is to be found in File L (Forms).

Page 9 of 9

manual
Installation and operating instructions

M
X6-03

X6-02

X6-01

X7-03

X7-02

X7-01

PE
N
V1

V3

V2

OIL

GAS

min.

PE

X9-02

X4-01

max.
LT
(CPI)
L

X9-03

GAS
OIL
RESET

X4-03

V1

V2

PV

SV

(START)

X10-03

ION
FSV/QRI
PE
N
L

X10-02

FLAME

ALARM

W-FM 200

MOTOR

L
P

Power QRI
QRB

L
FLANGE

LINE

SAFETY
LOOP

12VAC

L
N
G0

X10-01

X3-01 X3-02 X3-03

X9-01

X4-02

IGNITION

L
PE

X8-01

X5-03

PE

O2
module

INT

X8-02

N
V1

3
2
L

PE

L
ON/OFF

X8-03

PE

PE

PE

Start

PE

L
H0-Start

X5-02

SV

PE
min

PE

Start

X5-01

PE
min

X3-04

PE
L
N

LINE
VOLTAGE

F1/T6,3
IEC 127-2/V

F2/T4
IEC 127-2/V

F3/T4
IEC 127-2/V

info

esc

Weishaupt Combustion Manager W-FM

83054802 - 1/2004

General instructions

Safety instructions

Technical description
3.1 Function
3.2 Display and programmer unit ABE

6
6
7

Installation
4.1 Safety instructions for installation
4.2 Installation of components
4.3 Electrical connection diagram
(principle drawing)

8
8
8

10

Preparation for commissioning


5.1 Safety instructions
5.2 Steps to be taken on burner
and frequency converter
5.3 Preparation steps on
combustion manager

16
16

Commissioning - modulating
6.1 Set fuel and load points on W-FM
6.2 Commission burner
6.2.1 Set mixing pressure for ignition
6.2.2 Burner ignition
6.2.3 Set load point 1
6.2.4 Start full load
6.2.5 Optimise full load
6.2.6 Redefine intermediate load points
6.3 O2 functions - modulating
6.3.1 Set O2 sensor
6.3.2 Set O2 control
6.3.3 Set O2 regulating functions
6.3.4 Check and optimise O2 control
6.3.5 Optimise O2 control
6.4 Concluding work following
commissioning
6.4.1 Set ratings range and flue gas
temperature limit values
6.4.2 Concluding work on the burner

18
18
19
19
20
21
22
23
24
26
26
27
28
28
29

Commissioning multi-stage
7.1 Set fuel and required rating
7.2 Adjust burner
7.2.1 Pre-set curve parameters
7.2.2 Burner ignition
7.2.3 Start full load
7.2.4 Set switch off point(s)
7.2.5 Check operating, switch on
and off points
7.2.6 Check start behaviour
7.2.7 Define full load as required load

16
16

30
30
31

32
32
33
33
34
35
36
36
37
37

Load controller
8.1 Set operating mode
8.2 Configure sensors
8.3 Set point (external)
8.4 Set point (internal)
8.5 Modulating load control
8.5.1 Parameter internal load control
8.5.2 Optimise internal load control
8.6 Multi-stage load control
8.7 Cold start function

38
38
39
40
41
42
42
43
44
45

Parameter and functions


9.1 Menu structure (ABE)
9.2 Operating display
9.3 Operation
9.4 Manual operation
9.5 Burner control
9.5.1 Times
9.5.2 Configuration
9.5.3 Product identification and
software version
9.6 Ratio control
9.6.1 Setting gas/oil
9.6.2 Times
9.6.3 Switch off behaviour
9.6.4 Programme stop
9.7 O2 control and guarding
9.7.1 Setting gas/oil
9.7.2 Process data
9.8 Load controller
9.8.1 Control parameter
9.8.2 Temperature switch
9.8.3 Cold start
9.8.4 Configuration load controller
9.8.5 Adaption
9.8.6 SW version
9.9 AZL (ABE)
9.9.1 Times
9.9.2 Language
9.9.3 Date format
9.9.4 Physical units
9.9.5 eBus
9.9.6 Modbus
9.9.7 Display contrast
9.9.8 Serial number and SW version
9.10 Stepping motors
9.10.1 Addressing
9.10.2 Rotation direction
9.10.3 Serial number and SW version
9.11 FC module
9.11.1 Configuration
9.11.2 Process data
9.11.3 Serial number and SW version
9.12 O2 module
9.12.1 Configuration
9.12.2 Display values
9.12.3 Serial number and SW version
9.13 System configuration
9.14 Operating hours
9.15 Start counter
9.16 Fuel meter
9.17 Updating
9.17.1 Parameter back-up
9.17.2 Load SW from PC
9.18 Password
9.19 TV test
9.20 Sequence of operation diagrams

46
46
54
54
55
56
56
56
56
57
57
61
61
61
62
62
64
65
65
66
67
68
71
71
72
72
72
72
72
72
73
73
73
74
74
74
74
75
75
76
76
77
77
77
77
78
78
79
79
80
80
80
80
80
81

10 O

sensor

86

converter
88
11 Frequency
11.1 Programming and display unit frequency
converter VLT series
11.2 Parametering VLT 2800
11.3 Parametering VLT 5000

12 Cause and rectification of faults


13 Maintenance
13.1 Safety information for maintenance
13.2 Maintenance plan

data
14 Technical
14.1 Combustion manager W-FM

88
90
92

94

105
105
105

14.2 Servomotor SQM45.../48...


14.3 Flame guarding
14.4 Display and operating unit (ABE)

106
106
107
108
109

Appendix
Notes

110

General information

These installation and operating instructions


are an integral part of the equipment and must be
kept permanently on site.

are to be used by qualified personnel only.

contain the relevant information for the safe assembly,


commissioning and servicing of the equipment.

are for the attention of all personnel working with the


equipment.

in addition to this installation and operating manual,


the documentation for the relevant burner and the
type of frequency converter must be observed.

Explanation of notes and symbols


This symbol is used to mark instructions,
which, if not followed, could result in death or
serious injury.
DANGER

Hand-over and operating instructions


The contractor is responsible for passing the operating
instructions to the plant operator prior to hand-over. He
should also inform the plant operator that these instructions should be kept with the heating appliance. The
address and telephone number of the nearest service
centre should be entered on the reverse of the operating
instructions. The plant operator must note that an agent of
the contractor or other suitably qualified person must
inspect the plant at least once a year. To ensure regular
inspections, -weishaupt- recommends a service contract.
The contractor should instruct the plant operator in the use
of the equipment prior to hand-over and inform him as and
when necessary of any further inspections that are required
before the plant can be used.
Guarantee and liability
Weishaupt will not accept liability or meet any guarantee
claims for personal injury or damage to property arising as
a result of one or more of the causes below:

This symbol is used to mark instructions,


which, if not followed, could result in life
threatening electric shock.
DANGER

ATTENTION

This symbol is used to mark instructions,


which, if not followed, could result in damage
to, or the destruction of the equipment and
environmental damage.

This symbol is used to mark procedures,


which you should follow.

1.
2.
3.

Procedures with more than one step are


numbered.

This symbol is used when you are required to


carry out a test.

This symbol is used to list points.

This symbol indicates detailed information

Abbreviations
Tab.
Table
Ch.
Chapter

Failure to use the equipment as intended


Improper assembly, commissioning, operating or
servicing of the equipment.
Operating the appliance with defective safety
equipment, or with non-recommended or nonfunctioning safety and protection devices
Failure to follow the information in the Installation and
Operating Instructions
Alterations made to the construction of the equipment
by the plant operator
Fitting additional components not tested or approved
for use with the equipment.
Alterations made to the equipment by the plant
operator (e.g. motor ratio - rating and speed)
Alterations made to the combustion chamber, which
hinders constructive, predetermined flame formation
Inadequate guarding of parts liable to wear and tear
Improperly executed repairs
Acts of God
Damage caused by continued use despite the
occurrence of a fault
Use of incorrect fuel
Obstruction or damage of the supply lines
Use of non-original -weishaupt- spare parts

2 Safety information
Dangers when using the equipment
Weishaupt products are manufactured in accordance with
the relevant existing standards and guidelines and the
recognised safety laws. However, improper use of the
equipment could endanger life of the user or a third party,
or result in damage to the plant.
To avoid unnecessary danger, the equipment is only to be
used:
for its intended purpose
under ideal safety conditions
with reference to all the information in the installation
and operating instructions
in accordance with inspection and service work.
Faults, which could affect the safe operation of the burner,
should be rectified immediately.
Personnel training
Only competent personnel may work on the appliance.
Competent personnel according to this operating manual
are persons who are familiar with the installation,
mounting, setting and commissioning of the product and
have the necessary qualifications such as: Training, instruction or authorisation to switch electrical
circuits and electrical devices on and off, to earth them
and to mark them in accordance with the safety
standards.
Training, instruction or authorisation to carry out
installation, alteration and maintenance work on gas
installations in buildings and on site.
Organisational measures
Everyone working on the plant should wear the
necessary protective clothing.
All safety devices should be checked regularly.
Informal safety measures
In addition to the installation and operating instructions,
local codes of practice should also be adhered to.
Special attention should be paid to the relevant
installation and safety guidelines given.
All safety and danger notices should be kept in a
legible condition.
Furthermore, all safety documentation and danger
notes covering the frequency converter and burner
must be observed.

2
Electrical safety
Before starting work - isolate plant and protect against
reactivation, check voltage is isolated, the unit is
earthed, and protected from adjacent equipment that
might still be under voltage!
Work on the electrical supply should be carried out by
a qualified electrician
Electrical components should be checked during
servicing. Loose connections and heat damaged
cables should be dealt with immediately.
The control panel should be locked at all times. Access
should be restricted to authorised button holder
personnel.
Should it be necessary to carry out work on live parts,
country specific safety regulations must be observed
and tools to EN 60900 must be used. A second
person should be present to switch off the mains
supply in an emergency.
Maintenance and fault rectification
Necessary installation, service and inspection work
should be carried out at the specified time.
Inform the operator before beginning any service
work.
For all service, inspection and repair work, electrically
isolate the equipment and ensure the mains switch
cannot be accidentally switched back on. Cut off the
fuel supply.
Flame guarding devices, limit controls, correcting
elements and all other safety devices must be
commissioned by, and may only be replaced by, the
manufacturer or an authorised agent.
Following service work, all safety devices should be
tested to ensure they are functioning correctly.
Alterations to the construction of the equipment
No alterations to the equipment are to be made without
the approval of the manufacturer.
All conversions require written confirmation from Max
Weishaupt GmbH.
Any parts not in perfect working order should be
replaced immediately.
No additional components may be fitted, which have
not been tested for use with the equipment.
Use only -weishaupt- replacement and connection
parts. Parts from other manufacturers are not
guaranteed to be suitable to meet the necessary
operational and safety requirements.

Safety measures in normal operation


Only use the equipment when all the safety devices are
fully functional.
The moving parts of the burner should not be touched
during operation.
At least once a year the equipment, including the safety
devices, should be checked for signs of visible damage
and to ensure that the safety devices are operating
correctly.
More frequent safety check may be required
depending on plant conditions.

Technical description

The combustion manager W-FM contains all functions


required for safe and efficient operation of multi-stage or
modulating single fuel and dual fuel burners.
The display and programming unit shows the conditions
and allows programming via dial knob and function
buttons.

Functions
Burner control
Electronic compound regulation for up to a max of
5 1 stepping motors
Speed control
O2 control
Valve proving
True dual fuel operation
Integral load/ratings controller 2
Flame guarding
Separate ABE programmer

3.1 Function
Combustion manager
The combustion manager:
controls the sequence of operation
guards the flame
communicates with the stepping motors
controls and guards the frequency converter
carries out valve proving of the gas valves
has: an integrated load controller 2
Speed control 1
O2 control 1
Operating elements
The system can be controlled by several operating units:
a plug-in programmer ABE
PC module for guard control
Remote main control system (Building Management
System)
Flame sensor
Guards the flame during all phases of operation. If the
flame signal does not correspond to the sequence of
operations, a safety lockout will occur.
Flame sensors used:
QRI for continuous or intermittent operation for oil,
gas and dual fuel burners.
Ionisation electrode only for gas for continuous or
intermittent operation.
Stepping motors
Separate stepping motors (as appropriate) on:
Air damper
Oil controller
Gas butterfly valve
Mixing head
Providing precise, direct control of the correcting elements
in the compound.
Individual setting values are transmitted via CAN BUS from
the combustion manager to the stepping motors, the
stepping motors are electronically adjusted and the
combustion manager constantly guards their position
return signals.

1
2

only W-FM 200


optional on W-FM 100

Load controller 2
The optional, integrated PID load controller can be used as
a temperature or pressure controller for multi-stage or
modulating burners, depending on the connection and
parametering. Furthermore the load controller contains a
control reaction damper which protects the stepping
motors from unnecessary drive impulses, thus protecting
the stepping motors and increases their life span.
The load controller can be operated with one external
setting value or set point input, or with two internal set
points.
The internal set points can be selected using an external,
potential free contact.
Switchover from an external operation to the internal load
controller is via a contact.
A separate start up programme is incorporated for boiler
cold start if required.
Speed control 1
The frequency converter of the fan motor is started by a set
point output (0/4 - 20 mA) and the speed is matched to
the current burner rating required. The speed and the
rotation are determined and guarded using an inductive
proximity switch in conjunction with an asymmetrical
transmitter disc. In compound with the stepping motors
the required combustion air is automatically adjusted and
the electrical consumption is reduced to a minimum.
If the air supply fails or becomes insufficient, an air
pressure switch initiates lockout.
O2 Trim control 1
The residual O2 content in the flue gas is determined by a
sensor, which compares it to the set points calculated
during commissioning. Depending on the control
deviations from the set points, the combustion manager
re-adjusts the air regulating devices and corrects the
burners aeration.
Low gas programme
If the control gas pressure falls below the setting of the low
gas pressure switch during operation, the combustion
manager starts a low gas programme.
If the gas pressure is below the set point prior to start, the
burner start is inhibited.

3
Valve proving (only on gas operation)
Following each controlled shutdown, the combustion
manager carries out a valve proving test of the gas
solenoid valves.
Following lockout or power failure, the valve proving test is
carried out prior to the next burner start.

Sequence diagram valve proving

Function
1st. Test phase:
During a controlled shutdown valve V1 closes
immediately, and valve V2 has a slight delay in closing
which permits the volume between the valve seats to
depressurise. The section between V1 and V2 must
remain depressurised once the second valve has
closed.

Valve V2

1st. Test phase

2nd. Test phase

3 secs.
sek.

3 secs.
sek.

Valve V1
10sek.
secs.
10

10sek.
secs.
10

P between
V1 and V2
Gas press.
switch VP

Setting pressure gas pressure switch


2nd. Test phase:
Valve V1 opens and immediately closes again,
allowing gas pressure build-up between V1 and V2
valve seats. During the test phase, the pressure
between the valve seats must not fall below the
pressure setting of the gas pressure switch XX.

PR +

PV
= setting pressure

2
PR = Control pressure into V1 (reduce impact pressure)
PV = Maximum pressure during pre-purge downstream of V2

3.2 Display and programmer unit ABE


Setting without tools
The advantage of electronic ratio control provided by the
W-FM lies in the simple setting via display menus. The
positioning for fuel, air, and auxiliary actuators is selected
digitally. With only a few input ratings-positions being
entered, the intermediate firing positions are automatically
interpolated.

Display and programmer unit ABE

Display
4 lines with scroll function
ESC button
Cancel or return
Info button
Return to operating display
Enter button
Execution
Scroll knob
Cursor control and value change
RS 232 interface (COM1)
For PC or Laptop connection
CAN Bus
Connection to W-FM
RJ45 interface for eBus/Mod Bus (COM2)

Emergency - Off function


Simultaneous pressing of the ESC and Enter buttons
immediately initiates lockout. The Emergency - Off function
is saved in the lockout history.
Contrast adjustment
To change the contrast of the display, press Enter button
and hold down whilst changing the contrast using the
scroll knob (+/). (Only possible in menu Normal
operation, contrast adjustment with saving see Ch. 9.9.7).
7

Installation

4.1 Safety instructions for installation


Electrically isolate the plant
Prior to installation switch off the mains switch
and the safety switch.
Failure to comply could cause death or
serious injury by electric shock.
DANGER

Note

Due to the frequency converters used it is


possible for some of the electrical
components to continue to be energised
following mains isolation. The waiting time
given must therefore be observed prior to
starting work.

4.2 Installation of components


The electrical connections should be carried out to the
wiring diagram supplied with the burner. All country and
local codes of practice (i.e. EN, DIN, VDE, BS, etc.) must
be observed.
Line length
The line length of the individual components to the W-FM
can be a maximum of 100 m.
When installing the stepping motors and the ABE it is
particularly important that the total line length of all Bus
connections (CAN-Bus) does not exceed 100 m.

Display and programmer unit ABE


The installation of the ABE to the W-FM is carried out with
a special CAN-Bus cable. This cable supplies voltage to
the ABE and transmits the BUS signals.

Stepping motors
The installation is carried out as a serial Bus system.
Air damper
Gas butterfly valve
Oil controller
Mixing head
The voltage supply of the stepping motors and the
communication with the W-FM is carried out via CAN-Bus
cable.

Frequency converter (only W-FM 200)


The electrical connection of the frequency converter has to
be carried out to the wiring diagram supplied with the
burner. When wiring, ensure that the screens of the cable
are connected only once to the W-FM (FE terminal).

Flame sensor
The 1.8 m senor line to the flame sensor can be extended
by up to 100m if installed separately (i.e. for W-FM in a
separate control panel).

Ignition line
The ignition cables should be installed as close as
possible to the ignition electrodes. Ignition cables must
have an adequate spacing away from any other wiring.

Gas valve train


The pre-wired gas valve train should be connected as per
the wiring diagram supplied with the burner. Cable entry is
via the cable entry access on the right of the burner.

External connections
Mains voltage carrying lines (230V; 50 Hz) should be
flexible and have a minimum cross section of 0.75 mm. The
PE terminals on the fixing plate of the W-FM should be
used for earth wire connection.

O2 sensor / O2 module (only W-FM 200)


The electrical connection of the O2 sensor or O2 module
should be carried out to the wiring diagram supplied with
the burner. Please note that the screened sensor line of
the O2 sensor must be connected separately and line
length must not exceed 10 m.
Installation O2 sensor see Ch. 10.

Bus connection
On last component of the Bus line, a Bus connection
should be made using the jumper supplied. On all other
components within the Bus, the Bus termination jumper
must not be connected.
On the ABE the Bus connection is inbuilt.

4
Installation example: W-FM in burner housing
(only W-FM 200)

with Bus
connection

Jumper

O2-Modul

with Bus
connection

SQM4...
no Bus
connection

SQM4...
no Bus
connection

(only W-FM 200)

Burner

Burner
Frequency
converter 2

GND
CANL
CANH
AC2 12V
AC1 12V

SQM4...
no Bus
connection

AC1 12V 4 AT
GND
AC2 12V 4 AT

SQM4...
no Bus
connection

2 AT

SQM4...
no Bus
connection

GND
CANL
CANH
AC2 12V
AC1 12V

SQM4...
no Bus
connection

GND
CANL
CANH
AC2 12V
AC1 12V
4 AT

4 AT

ABE

3
6,3 AT
5

W-FM
GND
CANL
CANH
AC2 12V
AC1 12V

ABE

Jumper

GND
CANL
CANH

O2 module

Installation example: W-FM in a control panel

Netz
4 AT

4 AT
5

6,3 AT

(only W-FM 200)

W-FM
Frequency
converter

Frequency
converter 1
Mains
5

(only W-FM 200)

Frequency converter

Frequency
converter

W-FM fitted into a control panel


A second supply transformer is required for the Bus supply
if distance between W-FM and burner is an extended
distance. The supply transformer 2 is fitted to the burner
and connected to the burner terminal rail. The voltage
supply of all following Bus components is exclusively via
supply transformer 2.
The voltage supply (AC1 and AC2) must not be connected
to the bus line from W-FM to burner terminal rail.
Bus line W-FM to control panel order number: 743 192.

KX

L N

SX

FX

L PE N L

1
X30-01

X3-04

X10-01

X3-01

12V

230V

Safety circuit

1
2

Burner lockout

12V

12V

1
2
3
4

3
2

SX

X52

KX

Additional connections

External connections

PE
230V 1/N/PE 50-60Hz N
L

F10

X3-02

SX

FX

S7

L
L

T1

PE N
L
L
L

(F10)

Y9

L N PE

X36

P<

PE 2

PE
L

1
1

3
3

F36

X35

P>
1
1

3
3

B3

Pt/Ni1000

B3

Pt100

Y7

PE N L

1 3

B3

P20W/P30W

Legend:
A1 Combustion manager
B3 Appliances temperature/ pressure sensor
F10 Air pressure switch
F35 Max. oil return pressure sensor
F36 Min. oil supply pressure sensor
S7 Burner flange limit switch
T1 Ignition unit
T2 Control transformer
Y7 Magnetic coupling
Y9 Solenoid valve on air pressure switch
Y10 Anti siphon fuel valve
FE certified earth

Y10

FE

F35

PE 2

PE

X5-02

X4-01

X30-02

Burner on
ext. controller
contacts

1
2
3
4

Pre-selection Gas
Pre-selection Oil

X5-03

1
2

Burner reset

X3-03
1
2
3
4

X4-02
Start release Oil

1
2

X6-01

X7-03

1
2

1
2
3
4

Residual oil immediate


start

X4-03
1
2

Start release Gas

X6-03

3
2
1

X8-01

2
3
3
2
1

1
2
3
4

Motor start
contactor

X61

1
2

X60

X6-02

5
4
3
2
1

1
2
3
5
4
3
2
1
FE
0
4 - 20mA0
0 - 10V
Power Sensor

W-FM 200
5
4
3
2
1
FE
0
4 - 20mA0
0 - 10V

T2

X63

X5-01

1
2

Gas operation
Oil operation

1
2
3
4

Return signal motor


protection contact

FE 3
0 2
4 - 20mA0
1

10

X30-03

4.3 Electrical connection (principle drawing)


X60/X61 = actual value
X62
= Set point
X63
= Plotter output
Function X60 - X63 only
with internal load controller

Set point switchover or


operating type switchover load controller

X62

On multi stage
Light-oil burners
size 30 - 40

On multi stage
Heavy-oil burners
size 30 - 50

X7-01

X7-01

Y13

PE N L

Y11

Legend:
Y11 Partial load solenoid valve
Y12 Intermediate load solenoid valve
Y13 Full load solenoid valve
Y14 Additional solenoid valve
Y15 Additional solenoid valve

PE N L

1
2
3

X7-02

X7-02

1
2
3

1
2
3

1
2
3

Y12

X8-02

Y12

N PE

1
2
3
4

Y14
(U /2)

Y14

X8-03
X8-03
L

N PE

Y15
(U /2)
On modulating
Light-oil burners
sizes 30 - 70
On modulating
Heavy-oil burners
sizes 30 - 70

1
2
3
4
(Option)

1
2
3
4

Y11
Y12
Y14
Y15

X7-01

Y11

Y11

(UN/2)

Y11

PE N L

N PE

(UN/2)

Y12

Solenoid valve/nozzle solenoid


Solenoid valve (normally open)
Additional solenoid valve
Additional solenoid valve

X8-02

Y14
(U /2)

Y14
(U /2)

X8-03
X8-03

1
2
3
1
2
3
4

1
2
3
4

N PE

1
2
3
4

Y11

(UN/2)

Y15

(UN/2)

Y15

W-FM 200

11

BK

BN
BN

B20

BN

B20

X70

BU

X71
BU

1
2
3
4
5
1
2
3
4

BU

B12

X72
B21

B21

BN

X73

0/4-20
mA out

Connection
frequency converter

+24V
Start frequency converter
Lockout frequency converter

1
2
3
4
BU

12-24V
DC in

1
2
3
4
5
6

12
Set point
Earth
Screen

B12

Legend:
B12 Proximity switch burner motor
B20 Fuel meter Gas (optional)
B21 Fuel meter Oil (optional)

W-FM 200

X10-02.1

BN

P<

X21-01

X22-01

X21-02

braun

F11

P>

F33

P>

F12

9
8
4
3

X10-02.2

L1

4
3
9
8

X23-01

X8A
3

BK

X8B

2
7
7
2

X10-03

X8

1
6
6
1
1
PE

1
2
3
4
5

X22-03

X70
X50
2

blue

PE

3
L1

X9-02
3
L1

X20-02

2
PE

1
10

black

Connection control panel


External signalling pressure switch (optional)

5
4
5
4
4
3

X23-03

2
3
4
5
6

L2

X22-02

PE

2
3
3
2

1
1
1

PE
2

X23-02
L2

X9-03
X20-03
L2

8
4
7
2
3
4

1
2
3
4
5
6

X9-01
X20-01
2

1
1
2

PE N

Y2

X9

X24-01

1
PE

B1

X9A
3

Y20

Terminal box gas valve train

4
L2

QRI

X24-02

X72

1
PE

Bus interface

Y1

2
L1

X51
3
L1
N

1
3
4/6
5
7

X24-03

A2

Y3

B1

QRB

3
N

1
2
3
4
5
6
3

B1

A2
B1
F11
F12
F33
Y1
Y2
Y3
Y17
Y18
Y19
Y20

Only with O2 control (optional)

Connection O2 module

Y18

Display unit/programmer
Flame sensor
Low gas pressure switch
Valve proving pressure switch
High gas pressure switch
Ignition gas solenoid valve
Main gas solenoid valves
Remote solenoid valve
Oil controller stepping motor
Gas butterfly stepping motor
Mixing head stepping motor
Air damper stepping motor

Legend:

W-FM 200

Y19

Y17

13

L N PE

B11
Pt/Ni1000

B10

1
2
3

Pt/Ni1000

X83
X86

X89-01

X88

6
5
4

3
2
1

1
2
3

L N PE

3
2
1
1
2
3

X82
X85

3
2
1

3
2
1

X87

X89-02

QGO20

O2 module

X81

Mains voltage

Connection stepping
motor

X84

Q4
Q5
PE
3
2
1
12VAC1
12VAC2
CANH
CANL
GND
1
2
3
4
5

U3
G2
M
B2
M
B1
6
5
4
3
2
1
12VAC1
12VAC2
CANH
CANL
GND

14
1
2
3
4
5

O2 sensor

B10 Combustion air temperature sensor


B11 Flue gas temperature sensor

Legend:

Usensor

X70
MOTOR SPEED INPUT

X71
X72
FUEL COUNTER INPUT
X5-03

X4-01
X4-02
X4-03
X3-01 X3-02 X3-03

L
N

PE

L
LINE
VOLTAGE

PE
M

F1/T6,3
IEC 127-2/V

Start

L
H0-Start
F2/T4
IEC 127-2/V

X10-01
F3/T4
IEC 127-2/V

12VAC

G0

QRB
LINE

X10-02

SAFETY
LOOP

FLANGE

Power QRI

GND

X51

Shield

12VAC1

12VAC2

CANH

CANL

GND

Shield

12VAC1

12VAC2

CANH

CANL

M
12VAC1

BUS

ALARM

PE

Pt/Ni1000

PE

MOTOR

X10-03

ION

X9-01

FSV/QRI

FE
12VAC2

Pt100

(START)

SV

X60

L
L

PV

V2

FE

0-10V
Power Supply
Sensor

4-20mA

FE

0-10V

4-20mA

FE

TEMP.

PE
V1

PE

max.
LT
(CPI)
L
N

X9-02

RESET

IGNITION

X9-03

PE

FE

GAS

min.

OIL

OIL
GAS

X8-01

0/4-20mA Setpoint OUT

INT

V1

L
PE

0
4-20mA

TEMP./PRES.
INPUT
X61

12-24VDC Alarm in

X5-02

Start-OUT

X5-01

3 Wire-PNP

SV

OIL

V1

PE

X8-02

FE

Pulse-IN

ON/OFF

X7-01

V2

2 Wire

Start

GAS

X7-02

FE

SET POINT
INPUT
X62

Usensor

X7-03

OIL

X6-01
X8-03

FE

PE
min

X6-02

3 Wire-PNP

X6-03

2 Wire

PE
min
N

Pulse-IN

Usensor

2 Wire

3 Wire-PNP

LOAD
OUTPUT
X63

FE

Reserve

Pulse-IN

TRAFO
X52

X50
BUS

PE
FLAME

PE

V3

W-FM

PE
L

X3-04

FREQUENCY CONVERTER

X73

15

Preparation for commissioning

5.1 Safety note


Check installation
All installation work must be completed and
checked prior to commissioning. The burner
must be mounted on the appliance, ready for
operation and all control and safety devices
DANGER must be connected correctly.

Safety notes on initial commissioning


The initial commissioning must only be carried out by the
supplier, manufacturer or their appointed agent. At this
time, all the control and safety equipment must be
checked to ensure correct operation and, if it can be
adjusted, it should be checked that it has been set
correctly.

Burner mounted, including refractory as required


Fuel supply complete
Electrical connections and controls complete

Furthermore the correct fusing of the circuits and the


measures for contact protection of electrical equipment
and of all wiring must be checked

5.2 Preparation on the burner and the frequency converter


Burner
Check setting on burner, vent fuel lines and connect
measuring instruments.
If the burner is fitted with a moving mixing head (with
stepping motor), this should be checked for freedom of
movement.

Additional data relating to the burner and frequency


converter can be found in the relevant installation and
operating instructions.

Frequency converter 1 (only for Danfoss VLT...)


Check parameter settings on frequency converter (see
parameter list Ch. 11).
Carry out automatic motor adaption on frequency
converter using parameter 107 (not possible on all
frequency converters).
Note Due to the automatic motor adaption, the motor-slip
adjustment and the load compensation are set
back. These parameters must be re-set to the weishaupt- data (parameter 134, 136 on VLT 2800
or 113, 114 and 115 on VLT 5000).

5.3 Preparation on the combustion manager


1. Burner OFF
To be able to carry out the following steps it is necessary
to set the burner to OFF in menu Manual Operation.

Burner Off

2. Enter password
By asking for a password it is ensured that only authorised
personnel have access to the configuration and setting
parameter.
Enter digit or number using the dial knob at the flashing
cursor point and confirm with <ENTER>.
Corrections can be made using <ESC>, empty data
spaces should be filled using <ENTER>.

Enter password

16

W-FM 200 only when used with frequency converter

Manual Operation
Auto/Manual/Off
Auto/Manual/ Off
Curr: Automatic
New: Burner Off

Enter PW
Access SERV
Enter
password
:........
-

Ch. 9.4

Ch. 9.18

5
3. Carry out speed control standardisation 1
During speed control standardisation a set point signal of
95% is given. The speed is determined and saved in
parameter Standardised Speed. If, during standardisation
more than 50Hz is displayed, the motor-slip compensation
(=0) on the frequency converter has to be checked.
The rotational direction of the motor should be checked
during speed standardisation.
Note After each speed standardisation, or changes to the
saved values, the combustion quality needs to be
checked.
4. Check configuration of O2 module 1
The following parameter should be check and set for
operation with O2 trim control.

O2-Sensor:
QGO20
Supply air sensor:PT1000 (if fitted)
Flue gas sensor: PT1000 (if fitted)
MaxTempFlueGas: Presetting 400 C

5. Check O2 sensor temperature 1


The O2 sensor requires an internal operating temperature
of 700 C (15C). If the sensor has been connected
incorrectly, this can lead to overheating and thus damage
of the sensor. If the sensor temperature exceeds 750 C,
the sensor should be isolated and the electrical
connection should be checked.

Speed standardisation
Parm + display
FC module
Configuration
Speed control
Standardisation
Standardisation
Curr: deactivated
New: activated

Ch. 9.11.1

O2 module configuration
Parm + display
O2 module
Configuration
O2 sensor
SupAirTempSens
FlueGasTempSens
MaxTempFlGas

Ch. 9.12.1

Check O2 sensor temperature


Param + Display
O2 module
Displayed values
QGOSensorTemp
QGOHeatingLoad

Ch. 9.12.2

Note The QGOSensorTemp and QGOHeatingLoad


should be guarded regularly during the heat up
process.
HeatingLoad: Start heating load to 100 C ___approx. 13%
Heat up process ____________approx. 60%
Operating temperature: __approx. 15 25%
6. Deactivate O2 trim control 1
For commissioning the O2 trim control for the individual
fuels, the O2Ctrl should initially be deactivated.
The O2 controller and the O2 guard have no influence on
the burner operation at this setting.
Note On dual fuel burners the O2 trim control should be
deactivated on both fuels.

7. Enter fuel type


To be able to calculate the combustion efficiency it is
necessary to define the type of fuel used.
If a fuel is used which is not available for selection, its fuel
specific values can be entered under Fuel type def.
Note On dual fuel burners both the oil and gas type must
be entered.

Automatic O2 trim control deactivate


Param + Display
O2Ctrl/GuardDeac
t Setting ...
OperatingMode
OperatingMode
Curr: man deact
New: man deact

Ch. 9.7.1

Enter fuel type


Param + Display
O2Ctrl/Guard
Setting ...
Fuel type
Fuel type def.

Ch. 9.7.1

only W-FM 200 in connection with frequency


converter or O2 module
17

Commissioning - modulating

6.1 Set fuel and load limits on W-FM


Select fuel (only on dual fuel burners)
Select the required fuel using the external fuel selection
switch. If an external fuel selection switch is not available,
fuel selection is made using the ABE or BMS.
Note The external fuel selection switch takes priority. That
means the commissioning can only be carried out
with the fuel set at this switch.

Check load limits


To ensure that the whole ratings range is available for
commissioning, check load points and adjust if necessary.
MinRating: _______________________________ 0,0 %
MaxRating: _______________________________ 100 %
Note On dual fuel burners the load points for oil and gas
should be checked. On single fuel oil and gas
burners only one fuel appears in the display.

18

Select fuel
Operation
Fuel
Fuel selection
Fuel selection
Curr: Oil
New: Gas

Ch.9.3
or:

Fuel selection
switch on Oil

Load limits
Param + Display
RatioControl
GasSettings
LoadLimits
MinLoadGas
MaxLoadGas

Ch. 9.6.1

6
6.2 Commissioning the burner
6.2.1 Set mixing pressure for ignition
Set Program stop 36
Prior to the first ignition trial, the program stop must be set
to 36 IgnitionPos. After burner start the burner runs to the
ignition position without actual ignition occurring.
Note In its delivered condition the program stop has
already been factory pre-set to 36.

Open manual fuel shut off devices and the burner is


ready to start
After the fuel shut off devices have been opened the
burner should be started in manual operation.
Note For burner start all safety devices, pressure and
temperature controllers should be in operating
position.
Ensure sufficient heat requirement for the duration
of the commissioning procedures.
Set ignition position
Set the ignition positions whilst observing the mixing
pressure.
The speed during ignition should not be less than 80% for
oil and 70% for gas (only when using a frequency
converter / W-FM200).
If the measured mixing pressure is too high, this can be
adjusted by reducing the air damper position.
The relevant ignition pre-settings should be taken from the
installation and operating instructions of the burner or its
test data sheet.
Note The auxiliary motor position on 3LN burners
(multiflam) in ignition position and during burner
operation must be a minimum of 18.

Program stop 36: Ignition position without ignition


RatioControl
ProgramStop
ProgramStop
Curr: 36 IgnitionPos
New: 36 IgnitionPos

Ch. 9.6.1

Burner On
RatioControl
Auto/Manual/Off
Auto/Manual/Off
Curr: Burner Off
New: Burner ON

Ch. 9.3

Ignition positions (example gas operation 3LN multiflam)


RatioControl
GasSettings
SpecialPositions
IgnitionPos
IgnitionPosGas
IgnitionPosAir
IgnitionPosAux
IgnitionPosFC

Ch. 9.6.1

IgnitionPosGas
Curr: 10.5
New: 15
IgnitionPosAir
Curr: 13
New: 10
IgnitionPosAux
Curr: 18
New: 19
IgnitionPosFC
Curr: 100%
New: 70%

19

6
6.2.2 Burner ignition
Set program stop 52
To ignite the burner the program stop should be set from
36 to 52. Fuel is released following
pre-ignition. The motors remain in the ignition positions
setting.

Pre-set fuel pressure


On oil and dual fuel burners the oil throughput for full load
has been measured, that means the pump pressure has
been factory pre-set (20-30 bar) and should only be
adjusted if starting problems occur.
The gas setting pressure can be found in the installation
and operating instructions of the burner.
Carry out combustion analysis
Determine CO, O2 values and carry out smoke
measurement. If necessary, optimise combustion by
adjusting the ignition positions.

20

Program stop 52: ignition after safety time


SpecialPositions
ProgramStop
ProgramStop
Curr: 36 IgnitionPos
New: 52 Interv 2

Ch. 9.6.1

6
6.2.3 Set load point 1
Deactivate program stop
To continue with commissioning the program stop has to
be deactivated. If the program stop is not deactivated, the
burner remains in the position set and setting of additional
load points is not possible.

Deactivate program stop

Set load point 1


In setting oil, the first load point has been programmed by
the factory.
If the first load point has been deleted, the ignition load
values will be taken over automatically as the first load
point just as with Setting Gas.
In both cases the values should be matched and a
combustion analysis should be carried out.

Take over Ignition load point as load point 1

Procedure:
1. Drive up the air damper stepping motor until a residual
O2 content in the flue gas of max. 8% has been
achieved (on 3LN burners multiflam max. 7% residual
O2 content in the flue gas).

Note If the burner is fitted with an auxiliary motor and


speed control the value selected by the turn knob is
displayed in the last line.

:70.0

FC

Point
1
O2
4.9

:70.0

:15.0
:15.0
:10.0
:19.0

FC

:70.0

Point
: 1
O2
6.4

Load
Burn
Air
FC

Load :15.0
Burn:15.0
23.6
Air :2
Aux1 :19.0
FC

Point
save>ENTER
delete- >ESC

50.2
:5
esc

:15.0
:15.0
:23.6
:50.2

Minimum speed
Fuel

Load
Burn
Air
Aux1

Ch. 9.6.1

Point Load: 10.5


Point I Point
: 1 C
Change?
Point Load:15.0
1 Burn:15.0
O2
Air :10.0
A
4.9 Aux1 :19.0

3. Carry out combustion analysis and if necessary


optimise combustion by adjusting the air damper
position.

5. Leave programming of point 1 by pressing <ESC>.

Point
: 1
O2
4.9

Change load point 1

2. Reduce speed1 (not below minimum speed). To


achieve minimum speed it may be necessary to repeat
steps 1 and 2.

4. Leave point 1 by pressing <ESC> and save by


pressing <ENTER>.

Ch. 9.6.1

GasSettings
CurveParams
Point Load :15.0
P
Burn:15.0
ManualAir :10.0
Aux1 :19.0
FC

At the first load point the fuel dependent minimum speed1


should be aimed for whilst observing the combustion
quality and flame stability.

Ch. 9.6.1

RatioControl
ProgramStop
ProgramStop
Curr: 52 Interv 2
New: deactivated

Setting
FC

Frequency
at transformer

Oil (pump separate)

60 %

approx. 30 Hz

Oil (pump fitted)

70 %

approx 35 Hz

Gas

50 %

approx 25 Hz

only W-FM 200 with speed control


21

6
6.2.4 Start full load
Drive to full load via intermediate load points
Starting from the first load point, drive to full load via the
intermediate load points.
Procedure:
1. Set cursor to Manual and press <ENTER>.
2. Increase burner rating using the dial knob, whilst
guarding the combustion quality (excess air, flame
stability).
3. Set intermediate point before reaching the combustion
limit by pressing <ENTER> (on 3LN multiflam max. 7%
residual O2 content in the flue gas).
4. Carry out combustion analysis and correct intermediate
load point values.
5. Leave load point by pressing <ESC> and save with
<ENTER>.

Increase load manually


Point Load:15.0
Burn :15.0
Hanual Air :23.6
M
Aux1 :19.0

Ch. 9.6.1

O2
Load :15.0
6.4 Burn :15.0
Manual Air :23.6
. Aux1 :19.0
:15.0

O2
Load:25.0
6.1 Burn :23.8
Manual Air :31.4
:19.8 Aux1 :27.3

Setting intermediate load points, correcting and saving


O2
Load :25.0
6.1 Burn :23.8
Manual Air :31.4
:19.8 Aux1 :27.3

Repeat procedure until full load (Load: 100) has been


reached.

FC
Point
Save- >ENTER
enter->ESC

Point
:5
O2
3.8

22

O2
Load :25.0
L
roint18.7
Punkt Load:25.0
:28.4
: 2uft
2 Burn
:21.9
8O2 Hilfs:60.1
28.8
Air :2
26.0
5.9 Aux1 :2

Load:100
Burn:73.6
Air :67.8
Aux1 :78.5

:56.0
esc

6
6.2.5 Optimising full load
Optimising full load
In the last load point (load = 100%) the exact fuel quantity
throughput for the required full load should be set.
Note Observe load data supplied by the appliance
manufacturer and the capacity graph of the burner.
Procedure:
1. Set fuel throughput
Gas: At 65 to 70 gas butterfly setting, determine
gas throughput and adjust using the setting
screw on the pressure controller.
Oil:

Set pump pressure required, determine oil


throughput and adjust using stepping motor
setting of the oil controller (see burner test data
sheet: Indicator setting oil controller).

2. Determine combustion limit at full load and set excess


air.
The fan speed should be selected as low as possible
whilst observing NOx and flame stability, however it
should not be below 40 Hz / 80% (only when using
frequency converter / W-FM 200).

Optimising full load


Point
5
O2
4.5

Load
Burn
Air
Aux1

Point
5
O2
3.8

Load :100
Burn:68.7
76.2
Air :7
78.0
Aux1 :7
FC

:100
68.7
:6
:67.8
:78.5

Ch. 9.6.1

88.8
:8

3. Re-determine fuel quantity throughput and if necessary


adjust.
Once this step has been completed, the pump and gas
setting pressure must not be altered.
4. Save full load point.

23

6
6.2.6 Re-define intermediate load points
Re-define load point 1
To later allow O2 control across the whole ratings range,
point 1 must be a minimum 30% below the required partial
load (only when using an O2 module / W-FM 200).
Procedure:
1. Select point 1 with dial knob, press <ENTER>, confirm
Change point with <ENTER>, point 1 is started.
2. Check combustion quality, and optimise if necessary.
Drive to combustion limit, note down and set excess air
required for combustion limit.
Excess air: without O2 control approx. 15% to 20%
with O2 control approx. 20% to 25%

Drive to load point 1 and optimise combustion


Point
:5
O2
3.8

Load :100
Burn:68.7
Air:76.2
Aux1 :78.2

Point
:1
O2
6.4

Load :15.0
Burn:15.0
Air :23.6
Aux1 :19.0

Point Point
: 1 c
vhange?
lschen?
Point
Load:15.0
11.9
: 1 Burn:1
22.2
O2
Air :2
6.3 Aux: 18.6

Please observe the minimum speed and the mixing


pressure required.

FC

50.0
:5

3. Determine fuel quantity throughput and carry out


ratings distribution.
4. Save load point 1.

Delete intermediate points


Delete intermediate load points and re-define.
To achieve an even speed reference line, the fan speed at
the newly set intermediate load points should not be
altered (only when using a frequency converter / W-FM
200).
Procedure;
Select Point 2 with dial knob, press <ENTER>, confirm
Delete point with <ENTER>, point 2 is deleted and the
setting values for the next intermediate load point
below point 2 appear automatically.
Repeat procedure, until full load settings appear under
point 2.
Do not delete the full load point (Load: 100) and point
1.
Check
Select point 3 with dial knob. If all intermediate load
points have been deleted, no values are defined in
point 3 and the following display is shown.
Point Load :XXXX
: 3 Burn: XXXX
Manual Air :XXXX
Aux1 :XXXX

24

Delete intermediate load points


Point
: 1
O2
6.3

Load:15.0
Burn:11.9
Air :22.2
Aux :18.6

Point
: 2
O2
5.9

Load:19.8
Burn :19.3
Air :25.5
Aux1 :23.2

Point Point
: 2 change?
lelete?
Manual d
49.6
Point Load :4
: 2 Burn: 35.9
Manual Air: 47.3
44.2
47.1 Aux1 :4

Point
:2
O2
3.8

Load: 100
Burn: 68.7
Air :76.2
Aux1 :78.2

6
Set new intermediate load points and carry out ratings
distribution in percentages
For burner operation 5 load points are required, this means
at least 3 intermediate load points must be set.
depending on the installation, more intermediate load
points may be required (maximum 15 load points).
Note When using O2 trim control, partial load cannot be
set below point 2, this means point 2 should be set
smaller or equal to the eventual partial load.
Procedure
1. Leave load point by pressing <ESC>, select manual
function using the dial knob and confirm with
<ENTER>.

Reduce rating and optimise combustion


Ch. 9.6.1

Point Load: 100


Burn :68.7
Hanual Air :76.2
M
Aux1 :78.2
O2
Load :100
3.8 Burn :68.7
Manual Air :76.2
0 Aux1 :78.2
100

O2
3.9
Hand
.
:90.0

2. Whilst observing the combustion quality, reduce the


burner rating using the dial knob.
Recommendation: 10% steps

FC

4. Determine fuel quantity throughput, calculate rating


and carry out ratings distribution.
5. Leave point using <ESC> and save with <ENTER>.
6. Repeat procedure for all curve points.

Point
: 3
O2
4.0

Load
Burn
air
Aux1

:84.2
esc

Point
Save- >ENTER
Delete->ESC

3. Optimise combustion quality and set excess air


required for the combustion limit
Excess air: without O2 control approx. 15% to 20%
with O2 control approx. 20% to 25%
To maintain an even speed reference line, the speed
should not be adjusted after this process if at all
possible (only when using a frequency converter / WFM 200).

Load :90.0
Burn :62.0
Air :69.7
Aux1 :71.2
Point Load :89.7
: 3 Burn: 62.0
O2
Air: 68..8
70.7
4.0 Aux1 :7

:100
:68.7
:76.2
:78.2

esc

P
Point Load
Burn
HAnd Air
Aux1
FC

:89.7
:62.0
:68.8
:70.7
:84.2

Example ratings distribution


Ch. 9.6.1
Throughput intermediate load point
Rating [%] =
100
Throughput full load
Gas:
Rating [%] =

305 m3/h
340 m3/h

100 = 89.7 %

Oil:
Rating [%] =
Point
: 3
O2
4.0

260 kg/h
290 kg/h

.
Load:90.0
Burn:62.0
Air :68.8
Aux1 :70.7

100 = 89.7 %
Punkt
: 3
O2
4.0

Load
Burn
Air
Aux1

89.7
:8
:62.0
:68.8
:70.7

25

6
6.3 O2 functions modulating
The settings for the O2 trim control must only be carried
out if a W-FM 200 with O2 trim control is to be used.

6.3.1 Set O2 guard


The combustion limit has to be determined for each P
point, and saved in the guard function as the O2 minimum
value. The operating type for O2 control / guard or must be
deactivated during setting.
If the O2 limit values are already known, these can be
entered directly as O2 minimum values.
It is also possible to drive to the combustion limit of each
load point and to copy over the determined O2 set points
as O2 min. values.

O2 guard

Direct entry of known O2 limit values:


1. Select point to be set using the dial knob and confirm
with <ENTER>.

Direct entry O2 min value

2. Select O2 min value using dial knob and confirm with


<ENTER>.
3. Enter the O2 min value using the dial knob and save
with <ENTER>.

Ch. 9.7.1

Param + Display
O2Ctlr/Guard
Setting
O2 Guard

Ch. 9.7.1

Point:1
13.9%
:
100%
Point:9
:9
Point:9
100%
02-Minval: 0.0.
P-Airman : 0.0

Point:9
100%
02-Minval: 0..7
P-Airman:
0.0

4. Enter O2 min value in the O2 graph on the right.

2. Select P air manual using dial knob and confirm with


<ENTER>.
3. Turn dial knob to the right. The air rating is reduced on
the curve flow line in relation to the ratings setting of P
air manual. The fuel quantity throughput remains
unchanged.
Reduce air rating until the combustion limit (CO or
soot) has been reached.
4. Leave setting level with <ESC> and save the O2 value
as min value for the guard function using <ENTER>.
5. Enter O2 min value in the graph on the right.

Determine combustion limit


Ch. 9.7.1

Point:1
13.9%
:
100%
Point:9
:9
Point:9
100%
02-Setpoint: 3.8
P-AirHand: 0.0.

Point:9
100%
02-Setpoint: 0.7
10.4 .
P-AirMan:1

O2 graph
8
7
O2 content [%]

Determine O2 value of combustion limit and note it:


1. Select the point to be set using the dial knob and
confirm with <ENTER>.

6
5
4
3
2
1
0

10

20

30

40

50

60

Burner rating [%]

26

70

80

90

100

6.3.2 Set O2 trim control


For subsequent O2 trim settings, a standardisation has to
be carried out at each point.

O2 trim

Procedure:
1. Select point to be set using the dial knob and confirm
with <ENTER>.

Standardisation

2. As soon as the O2 value is stabilised confirm with


<ENTER>.

Note At point 2 and with 100% the time (Tau) between


the air quantity change and its recognition at the O2
sensor is determined. This results in the controller
parameters for subsequent O2 control.

Ch. 9.7.1
Point
:221.1%
O2 RatioCon: 6.0
O2 SetPoint:3.9
StandardVal:11.3
.

Point:2
21.1%
:
02-Verbund
Point:2
21.1%
: :xxxx
02-Sollwert:xxxx
O2 RatioCon: 6.0
Normierert
:xxxx
If the value
is stable
continue with ENTER

3. Turn dial knob to the right. The air rating is reduced on


the curve flow line in relation to the ratings setting of
standardisation value. The fuel quantity throughput
remains unchanged.
The standardised O2 value should be 1 to 1.5% points
above the combustion limit (O2 min value of guard
function) and minimum of 1 % point below the O2 ratio.
4. Leave setting level with <ESC> and save the O2 value
using <ENTER>.

Ch. 9.7.1

Param Display
O2Ctlr/Guard
Setting ...
O2 trim

esc

Point
save- >ENTER
delete->ESC

delay time is
measured O2 Actual
value: 4.2
Measurem success
ControlParam has
been determined
continiue with ESC

Example: O2 set points

Control limit
At burner ratings in the lower load range, the flue gas
velocity at the O2 sensor may not be sufficient for correct
and problem free control. In this case the O2 control limit
must be increased accordingly.
Flue gas velocity [v]: min. = 1 m/s
max. = 10 m/s or sensor temperature
min. 680C
QB L
v=
QB =
L =
=
T =
d =

T+273
273

d2 0.785 3600

8
7
O2 Content [%]

Following completion of the O2 standardisation the ratio


curve points should not be altered, otherwise the
standardisation for the point altered will be deleted and
O2 control will not be possible. If a curve point is altered,
the standardisation for this point will have to be repeated.

O2

6
5

ratio
Con
trol

O2 S
etP
oint
O2 G
uard

4
3
2
1
0

10

20

30

40

50

60

70

80

90

100

Burner load [%]

O2 control limit
Param + Display
O2Ctrl/Guard
Setting ...
O2CtrlThreshold

Ch. 9.7.1

Fuel throughput (kg/h) (m3/h)


Stoichiometric air requirement (m3/kg) (m3/m3)
Air number
Flue gas temperature C
Flue gas pipe diameter (m2)

General formula: v =

QB 0,0046
2

T+273

273
27

6
6.3.3 Set O2 controlling functions
The O2 trim control function is set using OptgMode.

O2 operating mode

man deact
The O2 control and O2 guard are deactivated. The burner
starts with cold sensor (only for commissioning, not
recommended for normal operation).

Param + Display
O2Ctrl/Guard
Setting ...
OptgMode
OptgMode
Curr: man deact
New: conAutoDeac

O2 guard
Only the O2 guard is active.
Start-up only when the operating temperature of the
sensor has been reached.
If the O2 guard reacts, or if an error is detected during
measuring, lockout occurs, if there is no possibility of
repetition.

Ch. 9.7.1

O2 controller
The O2 controller and O2 guard are active.
Start-up only when the operating temperature of the
sensor has been reached.
If the O2 guard reacts, or if an error is detected during
measuring, lockout occurs, if there is no possibility of
repetition.
conAutoDeact
The O2 controller and O2 guard are active.
Start-up before operating temperature of the sensor has
been reached.
If the O2 guard reacts, or if an error is detected during
measuring the function auto deact is initiated.
auto deact (not recommended)
The O2 controller and the O2 guard have been deactivated
automatically by the function
conAutoDeact.
The burner remains in operation, however without O2
control and O2 guard.
6.3.4 Check and optimise O2 control
Check O2 control
Procedure:
1. Re-start burner in automatic operation. The start
behaviour can be checked again.
2. Change rating with external signal, so that the O2 value
can be checked on the display of the ABE i.e.
connect a 3 pole switch to X5-03 and change over the
LC operating type to ExtLC X5-03.
3. In menu OperationalStat select NormalOperation
and change over to the second display using
<ENTER>.
4. Carry out various load changes across the whole
ratings range whilst observing the O2 controllers
behaviour.

28

If the O2 sensor has reached its operating temperature,


and the controllers damping time (10 x Tau in partial load)
has elapsed, pre-control starts and the O2 value goes
close to the set point. If within the delay time (approx. 2 x
Tau in full load) no load changes occur, control goes to the
O2 set point. The actual O2 value should then be equal to
the O2 set point.
When a load change occurs the O2 controller is locked at
the existing value, and the air motors are re-adjusted with
the pre-control starting from the previous differential value
setting. This means that the O2 set point is almost
maintained even during pre-control.
Note The O2 control can also be guarded using
recording software.

6
6.3.5 Optimise O2 control
Depending on site specific requirements it may be
necessary to adjust the O2 control parameters in the
SERV level.

O2 control parameters
Param + Display
O2Ctlr/Guard
Setting ...
ControllerParams

Ch. 9.7.1

O2 actual value fluctuates


If the control fluctuates parameter I and P should be
optimised.
In the lower ratings range:
I-Partial reduce
increase
or
PP-Partial load
reduce
In the upper ratings range
I-Full load load
increase
or
P-Volllast
P-Full load
O2 control remains locked
If a ratings change occurs prior to the end of the locking
times the controller remains stationary.
LoadCtrlSuspend
FilterTmeLoad

increase
reduce

O2 guard reacts at ratings change


A rapid ratings change will result in lockout by the O2
guard.
LoadCtrlSuspend
O2Offset

increase
increase

29

6
6.4 Concluding work following commissioning
6.4.1 Lower load limit (partial load)
Observing the instructions given in the installation and
operating instructions of the burner and the instructions
given by the appliance manufacturer, partial load and the
control range should be set in menu Load limits. Here,
partial load is defined with parameter MinLoad.

Set lower load limit

Flue gas temperature limit value


If the limit value is exceeded the warning Flue gas
temperature too high is given. A prerequisite for this is a
configured flue gas temperature sensor on the O2 module
(only W-FM 200).
The limit value should be set approx. 20% above the flue
gas temperature at nominal load.

Set flue gas temperature limit values

Ch. 9.6.1

GasSettings
LoadLimits
MinLoadGas
MinLoadGas
Curr: 0.0%
22.8%
New:

Ch. 9.12.1

Param + Display
O2 Module
Configuration
MaxTempFlueGas

Overheating due to flue gas temperatures


above 300C can damage the O2 sensor.
ATTENTION

Select second fuel (only on dual fuel burners)


Select required fuel using the external fuel selection
switch. If an external selection switch is not available fuel
selection is made with the ABE or BMS.
Note The external fuel selection switch has priority, this
means commissioning can only be carried out with
the fuel selected with this switch.

30

Fuel Selection
Operation
Fuel
Curr fuel
Fuel selection
Curr: Oil
New: Gas

Ch. 9.3
or:

Fuel selection
switch set
to oil

6
6.4.2 Concluding work on the burner
Following commissioning the following, concluding work
has to be carried out on the burner.
Set air pressure switch.
Set gas and oil pressure switches.
Remove measuring devices,
etc ...
More detailed information can be obtained from the
installation and operating instruction of the burner.

31

Commissioning multi-stage

Prior to commissioning the preparations necessary for


commissioning (Ch. 5) must be completed.

7.1 Set fuel and required load


Burner OFF
To be able to carry out the following steps the burner has
to be set to OFF in menu Manual Operation.

Burner OFF

Select fuel Oil (only on dual fuel burners)


Select fuel Oil using the external fuel selection switch. If an
external fuel selection switch is not available, fuel is
selected using the ABE or BMS.

Select fuel

Note The external fuel selection switch has priority, this


means commissioning can only be carried out with
the fuel selected with this switch.

Select required rating S1


In menu Manual operation call up the function required
load and set to S1.

32

Ch. 9.4

Manual operation
Auto/Manual/Off
Auto/manual/Off
Curr: Automatic
New:: Burner Off

Operation
Fuel
Curr fuel
Fuel selection
Curr: Gas
New: Oil

Ch. 9.3
or:

Fuel selection
switch is set
to Oil

Select fuel
Manual operation
Required load
Required load
Curr: S3
New: S1

Ch. 9.3

7
7.2 Adjust burner
7.2.1 Preset curve parameter
For commissioning the fan speed1 and air damper setting
of each operating point as well as the On/Off switch points
must be checked and if necessary adjusted.
Procedure;
1. Call up stepping motor positions.
2. Select option Without start
3. Call up operating, the on and off stage switch points
one by one using the dial knob and compare air damper
setting (air stepping motor) and fan speed1 (FC) with
table values. If they deviate, overwrite the parameter
by
calling up operating, on and off switch points with
<ENTER>,
selecting parameter using dial knob and confirming
with <ENTER>,
inputting parameter value (dial knob +/-) and saving
with <ENTER>.
Continue procedure until all parameters are the same
as the table values.

Call up stepping motor positions


Ch. 9.6.1

Param + Display
RatioControl
Oil Settings
CurveParams
Curve Settings
Stepping motor
positions
With start
Without start

Activate option without start


Ch. 9.6.1
Point Air :40.0
::BS1 FC
:80.0
O2
xxxx

Stepping motor
positions
With start
W
Without
start

Call up operating, on and off switch points


two
operating stages

Air damper [<]


Air

Speed [%]
PC

Operating point BS1


Switch on point ES2

40

80

Switch off point AS2


Operating point BS2

70

100

three
operating stages

Point Air
::BS1 FC
O2
xxxx

Ch. 9.6.1
Point Air :40.0
ES2 FC
::E
:90.0
O2
xxxx

:40.0
:80.0

Overwrite parameters
Air damper [<]
Speed [%]1
Air motor
Auxiliary motor

Operating point BS1


Switch on point ES2
Switch off point AS2
Operating point BS2
Switch on point ES2
Switch off point AS3
Operating point BS3

30

80

50

90

70

100

4. Exit level with <ESC>.

Point Air :40.0


ES2 Point
::E
FU ALir
ir0 :40.0
:ES2 FC
:90.0
O2
xxxx
change values with dial knob

Point Air
:ES2 FFC
O2
xxxx

:40.0
:90.0

Point Air
:ES2 FFC
O2
xxxx

:40.0
:80.0

Point Air
:ES2 FC
O2
xxxx

:40.0
80.0
:8

save values

Exit level
Without start
Operating point S3

Air motor: 70.0


AAux motor: 100

esc

SSpecialPositions
CurveParams
LoadLimits

Only W-FM200 in connection with frequency


converter
33

7
7.2.2 Burner ignition
Set programme stop 36
Prior to first ignition the programme stop has to be set to
36 IgnitionPos. After burner start, the burner then drives to
ignition position without igniting (with long pre-ignition,
ignition is carried out without fuel release).
Note In its delivered condition the programme stop has
already been factory pre-set to 36.

Open manual fuel isolation devices and start burner


Once the fuel shut off devices have been opened the
burner should be started in manual operation.
Note For the burner start all safety devices, pressure and
temperature controllers must be in operating
position.
Sufficient heat demand must be ensured for the
duration of commissioning.

Programme stop 36: Ignition position without ignition


Ch. 9.6.1

SpecialPositions
ProgramStop
ProgramStop
Curr: 36 IgnitionPos
New: 36 IgnitionPos

Burner On
Ch. 9.4

RatioControl
Auto/Manual/Off
Auto/Manual/Off
Curr: Burner Off
New: Burner On

Setting ignition position


The fan speed and the ignition position of the air damper
should be set whilst observing the mixing pressure. The
ignition speed1 should not be below 80%. Depending on
the burner, the mixing pressure for ignition should be
between 3 and 5 mbar. The mixing pressure can be
adjusted with the air damper and diffuser positions.
It is recommended to note down the IgnitionPos set
values..

Set air damper fan speed and ignition position

Set programme stop 44


To be able to ignite the burner the programme stop has to
be set from 36 to 44. Once the pre-ignition time has
elapsed fuel is released. The stepping motors remain in the
ignition position setting.

Programme stop 44: ignition position after safety time

RatioControl
OIlSettings
SpecialPositions
IgnitionPos
IgnitionPosOil*
IgnitionPosAir
IgnitionPosAux
IgnitionPosFC

SpecialPositions
ProgramStop
Programmstopp
Curr: 36 IgnitionPos
New: 44 Interv 1

Ch. 9.6.1

* The IgnitionPosOil does


not need to be set for
multi-stage operation, as
no oil throughput regulator valve and thus no
stepping motor is fitted.

Ch. 9.6.1

Check fuel pressure


The atomising pump pressure is factory pre-set and can be
determined from the burner test data sheet.
Deactivate programme stop
The programme stop has to be deactivated to continue
commissioning. If the programme stop is not deactivated,
the burner remains in the existing position, the setting of
new load points is therefore not possible.

34

only W-FM 200 in connection with frequency


converter

Deactivate programme stop


ProgramStop
Curr: 44 Interv 1
New: deactivated

Ch. 9.6.1

7
7.2.3 Start full load
Activate option With start
In stepping motor positions activate the option With start
by pressing <ENTER>.
Note Operation of the switch off points should be
avoided during commissioning, as this can lead to
excessive air deficiency.

Pre-set operating point S1


1. Select operating point S1 using the dial knob and
confirm with <ENTER>.
2. Call up parameter values using the dial knob and
<ENTER> and adjust operating point BS1 whilst
observing the combustion quality.

Activate option With start


CurveParams
Curve Settings
Stepping motor
positions
With start
Without start

Ch. 9.6.1
Point Air
::BS1 FC
O2
xxxx

:40.0
:80.0

Pre-set operating point and set switch on point


Point Air
::BS1 FC
O2
xxxx

:40.0
:80.0

Lir
Point A
:BS1 F C
O2
xxxx

:36.0
:80.0

Ch. 9.6.1

Note The burner motor speed XX should not be selected


below 70% (30 Hz).
3. Exit parametering with <ESC>.

Set switch on point S2


1. Select switch on point S2 using the dial knob and
confirm with <ENTER>.
2. Call up parameter values using the dial knob and
<ENTER> and increase excess air whilst observing the
flame stability.
3. Note down values.
4. Exit parametering with <ESC>.

Point Air
:BS1 FC
O2
xxxx

36.0
:3
74.0
:7

esc

Point Air
::BS1 FC
O2
xxxx

:33.0
:63.0

Start next operating or


switch on point and set
parameter.
Do not operate switch off
point

Note When using a three stage burner the procedure has


to be repeated for operating point BS2 and switch
on point ES3.

Set Full Load


1. Select full load point using the dial knob and confirm
with <ENTER> .
2-stage burner:
operating point BS2
3-stage burner:
operating point BS3
2. Determine fuel throuhput and adjust if necessary.
3. Call up the parameter values using the dial knob and
<ENTER> , and optimise combustion (carry out a
combustion test)
4. After saving with <ENTER> exit parametering with
<ESC> .

only W-FM 200 in connection with frequency


converter

35

7
7.2.4 Set switch off point(s)
Change over to option Without start
Exit option With start in stepping motor positions with
<ESC> and re-enter Curve setting to select option
Without start and activate with <ENTER>.

Activate option Without start

Set switch off point S2


1. Using the dial knob select switch off point AS2 and
confirm with <ENTER>.
2. The air damper and motor speed of switch on point of
ES2 should also be set for the switch off point of AS2.
and save with <ENTER>.
3. Exit parametering with <ESC>.

Set switch off point(s)

Note When using three stage burners repeat procedure


and transfer values from switch on point ES3 to
switch off point AS3.

Curve Settings
Stepping motor
positions
With start
W
Without
start

Point Air
AS2 FC
::A
O2
xxxx

:50.0
:90.0

iir
Point A
:AS2 F C
O2
xxxx

:50.0
:90.0

Ch. 9.6.1
Point Air :33.0
::BS1 FC
:63.0
O2
xxxx

Ch. 9.6.1

Point Air
:AS2 FC
O2
xxxx

42.0
:4
69.0
:6

esc

Point Air
::AS2 FC
O2
xxxx

:42.0
:69.0

On three stage burners:


Call up switch off point AS3
and transfer the values
from switch on point ES3.

7.2.5 Check operation of, on and off switch points


If the pump pressure has been changed during full load
adjustment the operating and switchover points has to be
checked.

Carry out combustion check


activate option With start.

Drive to operating point BS1 and check combustion


quality.

If necessary, optimise combustion quality by changing


the air damper setting and burner motor speed.
During this procedure, the pump pressure must not be
altered.

Check on and off switch points


Drive to operating points several times, whilst checking the
on and off switching behaviour of the second or third
stages and optimise if necessary.

36

Note With 3-stage operation an additional combustion


quality check for stage 2 (operating point BS2) is
required.

7
7.2.6 Check start behaviour
Procedure:
1. Set ProgramStop to phase 44.
2. Re-start burner in manual operation.
3. Check start behaviour and if necessary correct ignition
load setting.

Programme stop
SpecialPositions
ProgramStop
ProgramStop
Curr: deactivated
New: 44 Interv 1

Ch. 9.6.1

Note If the ignition load setting has been altered, the start
behaviour has to be rechecked.
4. Deactivate programme stop.

Restart burner
Auto/Maual/Off
Auto/Manual/Off
Curr: Burner Off
New: Burner Off
Auto/Manual/Off
Curr: Burner On
New: Burner On

Ch. 9.4

7.2.7 Define full load as required load


Call up function required load in menu Manual operation
and set to full load.
two stage operation: BS2
three stage operation: BS3

Set required load


Manual operation
Required load
Required load
Curr: BS1
New: BS3

Ch. 9.4

37

Load controller

The controller has to be configured relevant to the


installation to ensure safe and reliable load control. On the
W-FM100 the load controller is optional.

8.1 Set operating mode


The operating mode determines if and how the internal
load controller is used and if an external load controller is
connected.
If the internal load controller is deactivated in menu
SystemConfig, it can only be reactivated in this menu.
Note As an emergency function switchover from the
external load controller to the Int LC can be carried
out with a switch contact on input X62. The Int LC
must be configured for this and must be equipped
with a process condition (temperature/pressure)
sensor.
ExtLC X5-033 point step input signal of external load
controller to X5-03
.
Int LC
Internal load controller with 2 set points.
Int LC Bus

Digital set point signal from building


management system via eBus or Modbus.
The ABE acts as interface.

Int LC X62

Analogue set point signal from the


building management system on input
X62
(4 to 20 mA or 0 to 10V).
switchover to the internal set point W1 is
possible with an external switch contact
on terminal X62:1/2.

Ext LC X62

Analogue setting signal from the building


management system on input X62 (4 to
20 mA or 0 to 10V).

Ext LC Bus

Load control is carried out by the building


management system.
Signal transfer is carried out with eBus or
Modbus, the ABE acts as interface.

38

Set operating mode


Param + Display
LoadController
Configuration
LC-OptgMode
LC-OptgMode
Curr: Int LC
New: Int LC

Ch. 9.8.4

8
8.2 Configure sensors
Sensors used
Sensor selection has to be configured depending on
whether the actual value is determined by a temperature
sensor (input X60) or a temperature or pressure sensor
(input X61).
PT 100

PT 100 sensor on terminal X60:1/2/4,


temperature limit (TL) function is active.

PT 1000

PT 1000 sensor on terminal X60:3/4,


temperature limit (TL) function is active.

Ni 1000

Ni 1000 sensor on terminal X60:3/4,


temperature limit (TL) function is active.

PT100 PT1000

PT 100 sensor on terminal X60:1/2/4


for temperature controller function.
PT 1000 sensor on terminal X60:3/4
for temperature limit (TL) function.

Configure sensors
Param + Display
LoadController
Configuration
Sensor selection
Sensor selection
Curr: PT 100
New: PT 100

Ch. 9.8.4

PT 100 Ni 1000 PT 100 sensor on terminal X60:1/2/4


for temperature controller function.
Ni 1000 sensor on terminal X60:3/4 for
temperature limit (TL) function.
TempSensor
Temperature sensor on input X61, no
(thermocouple) temperature limit (TL) function.
PressureSens

Pressure sensor on input X61, no limit


(TL) function.

None

No sensor fitted to W-FM.

Sensor measuring range


To allow correct actual value determination the measuring
range of the sensor has to be defined.
MeasR PtNi

: 150C/302F or 400C/752F

MeasR TempSensor : 0 to 2000C


MeasR PressSens : 0 to 99.9 bar

Set measuring range


Param + Display
LoadController
Configuration
MeasureRange PtNi
MRange TempSens
MRange PressSens

Ch. 9.8.4

MeasureRange
Curr: 150C/302F
New: 400C/752C

The measuring range is also the setting range for the


external set point.

Sensor signal
If the actual value is determined by a sensors connection
to input X61, the relevant analogue signal has to be set.
4 to 20 mA : Current signal on terminal X61:3
with load limit (TL)
2 to 10 V

: Voltage signal on terminal X61:2


with load limit (TL)

0 to 10 V

: Voltage signal on terminal X61:2


without load limit.

Set analogue signal at input X61


Param + Display
LoadController
Configuration
Ext Inp X61 U/I
Ext Inp X61 U/I
Curr: 0 ... 10 V
New: 4 ... 20 mA

Ch 9.8.4

39

8
8.3 Set point (external)
External load / set point signal
If a load controller is connected to input X62 (Ext LC X62),
or if the set point signal for the internal load controller (Int
LC X62) is given by this input, the type of analogue signal
must be defined.
Ext LC X62 (load signal)

: 4 to 20 mA or 2 to 10 V

Int LC X62 (set point signal)

: 4 to 20 mA or o to 10 V

Set limit values for external set point


The set point signal for the internal load controller (Int LC
X62) can be limited in parameter Ext MinSetPoint and Ext
MaxSetPoint.
The percentages given for the limit relate to the value set
under MeasureRange PtNi.
Example:
Upper set point limit required = 80C
MeasureRange PtNi = 150C
Calculation

80C
150C

40

100 53,3%

Define analogue signal at input X62


Param + Display
LoadController
Configuration
Ext Inp X62 U/I
Ext Inp X62 U/I
Curr: 4 ... 20 mA
New: 0 ... 10V

Ch. 9.8.4

Set limit values


Param + Display
LoadController
Configuration
Ext MinSetPoint
Ext MinSetPoint
Curr: 0%
New: 33%

Ch. 9.8.4

Ext MaxSetPoint
Ext MaxSetPoint
Curr: 100%
New 5 3%

8
8.4 Set point (internal)
Internal set points (W1 / W2)
Two internal set points can be stipulated.
Switchover is with potential free contact on the terminals
X62:1/2.
The set points cannot be set above the temperature limit
value already entered.

Internal set points (W1 / W2)

Switching differential
The on and off switch point is given in percent relating to
the set point.

Switch differential

Set point70C
Sd_ModOff
Sd_ModOn-

10%
5%

Installation Off
Installation On

70C + 7.0K = 77.0C


70C - 3.5K = 66.5C

(from 70C = + 7.0K)


(from 70C = - 3.5K)

Param + Display
LoadController
ControlParam
ContParamList
Setpoint W1
Setpoint W2
Setpoint W1
Curr: 80C
New: 70C

Param + Display
LoadController
ControlParam
Sd_ModOn
Sd_ModOff

Ch. 9.8.1

Ch. 9.8.1

Sd_ModOn
Curr: 3%
New: - 5%

Note If a positive Sd_ModOn is defined, the switch on


point will be above the set point.

Temperature limit (TL)


If the temperature limit is exceeded, the installation
switches off and the message internal
temperature limit (TL_ThreshOff) has reacted is displayed.
The switch on threshold is given in percent relative to the
set point temperature.
If a thermocouple or pressure sensor has been configured,
the limit function is inactive.
TL Threshold Off
TL SwDiff On

Temperature limit
Param + Display
LC-OptgMode
TempLimiter
TL_ThreshOff
TL_SD On

Ch. 9.8.2

TL_ThreshOff
Curr: 95
New: 90

90C
- 10% (from 80C = 9.0K)

Installation Off
90C
Switch on threshold 90C - 9.0K = 81C

41

8
8.5 Modulating load control
8.5.1 Parametering internal load control
Adaption
During adaption, the internal load controller recognises the
control section and calculates the PID parameter.
Adaption can be started in manual or automatic operation
independent of the operating phase (standby or
operation).
During adaption, the parameter SW-FilterTmeCon should
be between 2 and 4 seconds. If the value selected is too
high, this can stop the adaption or lead to insufficient
control parameters.

Filter time

Adaption rating
If during adaption insufficient heat demand is available, full
load can be limited to up to 40% in parameter
AdaptionLoad.
However, if the AdaptionLoad selected is too low, this can
stop the adaption.

Adaption Load

Start adaption
Select parameter StartAdaption and confirm with
<ENTER>. The respective phases of adaption are
displayed alternately with the actual value and load signal.

Start adaption

Phases of adaption:
Decreasing of temperature (Temp decrease)
Before the adaption can be started, the actual
temperature (or pressure) must be 5% below the set
point temperature (or steam pressure).

Determine actual value (stabilising phase)


The direction of the actual value is determined for 5 min.
During this time the actual value should be constant.
If strong fluctuations occur the time is increased to
maximum 10 min, and anything greater leads to
termination.

Start-up (heating)
The direction of the actual value during the heat up
phase is determined.

calculation of control parameter (Adaption ok)


Using the measured values of the stabilising phase,
the heat input and reaction times and the PID
parameter are calculated.
The values calculated can be called up using the dial
knob.

Standard control parameters


If an adaption is not possible or not necessary, standard
parameters can be used as PID values. Various settings
are available depending on the behaviour of the control
section.

very slow
slow
normal
fast
very fast
42

P (Xp)
30 %
15 %
7%
4%
40 %

I (Tn)
400 s
320 s
90 s
35 s
55 s

D (Tv)
10 s
40 s
50 s
17 s
15 s

Param + Display
LC-OptgMode
Regelparameter
SW-FilterTmeCon
SW-FilterTmeCon
Curr: 3 s
New: 3 s

Param + Display
LC-OptgMode
Adaption
AdaptionLoad
AdaptionLoad
Curr: 100%
New: 80%

Param + Display
LC-OptgMode
Adaption
Start adaption

Ch. 9.8.1

Ch. 9.8.5

Ch. 9.8.5

Start adaption
with ENTER
12
Set point
80C
Actual value 79C

Adaption complete
Adaption ok
P-content (Xp)
11.2%
continue with <>

Adaption ok
P-content (Tu)
53s
continue with <>

Standard control parameters


Param + Display
LC-OptgMode
ControllerParam
ContrlParamList
StandardParam
SW-FilterTmeCon
Curr: XXX
New: Normal

Ch. 9.8.1

8
8.5.2 Optimising internal load control
Control behaviour
Observe load control for some time during operation and if
necessary optimise the PID parameter.

Adapt PID parameters

Setting adjustment stability


With the MinActuatorStep unnecessary drive impulses of
the stepping motors can be reduced and thus their
longevity increased.
However, the MinActuatorStep adjustment affects the
precision control and stability of the load control.

Setting adjustment stability

Erroneous signal filter


Using a filter with time constants (SW_FilterTmeCon),
signals which affect the D-Part can be weakened.
However, a time filter that is too long will have a negative
effect on the control.

Fault signal Filter

Recommendation: 2 to 4 seconds

Param + Display
LC-OptgMode
ControllerParam
ControlParamList
P-Part (Xp)
I-Part (Tn)
D-Part (Tv)

Param + Display
LC-OptgMode
ControllerParam
MinActuatorStep
MinActuatorStep
Curr: 1.0%
New:
2.0%

Param + Display
LC-OptgMode
ControllerParam
SW_FilterTmeCon
SW_FilterTmeCon
Curr: 3 s
New: 4 s

Ch. 9.8.1

Ch. 9.8.1

Ch. 9.8.1

43

8
8.6 Multi-stage load control
Switching differentials
The switching differentials are formed in percentages
depending on the current set point.
SD_S
Stage1On:
At this switching differential the control circuit is closed
and the burner is switched on.
SD_S
Stage1Off:
As this switching differential is exceeded the control circuit
is opened and the burner is switched off.

Switching differentials
Param + Display
LC-OptgMode
ControllerParam
SD_Stage1On
SD_Stage1Off
SD_Stage2Off
SD_Stage3Off

Ch. 9.8.1

SD_Stage1On
Curr: 1.0%
New: 1.0%

SD_S
Stage2Off:
As this switching differential is exceeded the system is
switched from stage 2 to stage 1.
SD_S
Stage3Off:
As this switching differential is exceeded the system is
switched from stage 3 to stage 2.
Switch thresholds
This is the integral (I) from the control devitation multiplied
by the time.
This function monitors the behaviour of the installation.
depending upon demand the next higher load stage is
selected.
The control devitation refers to the set point (W1 or W2).
ThresholdStage2On:
Switch criteria for the release of second stage.
ThresholdStage3On:
Switch criteria for the release of third stage.

Notes for 2 stage operation


If a burner with 3 nozzles is only to be operated in two
stage mode, the ThresholdStage2On should be set to 0.
This means that with the release of the load control the
second nozzle is immediately switched on. The burner is
then in partial load. To ensure correct switch off behaviour,
SD_Stage2Off and SD_Stage1Off should be set to the
same value.

44

Switch thresholds
Param + Display
LC-OptgMode
ControllerParam
ThresholdStage2On
ThresholdStage3On

Ch. 9.8.1

ThresholdStage2On
Curr: 300
New: 300

8
8.7 Cold start function
Activate cold start function
In order to avoid the appliance operating at its maximum
loading before the required minimum appliance
temperature or pressure has been reached, the cold start
function has to be activated.

Activate cold start function

Additional sensor
A separate temperature sensor (terminal X60) for the cold
start function must only be activated if either a temperature
or pressure sensor on terminal X61 is used for the load
control.
The switch thresholds then relate to the set point for the
additional sensor.

Configure additional sensor

Switch thresholds
The thresholds relate to the current set point (W1/W2) or
if an additional sensor is fitted to the Set point add sens.

Switch thresholds

ThresholdOn:
If the actual temperature falls below the switch on
threshold the burner starts in the cold start function.

Param + Display
LC-OptgMode
LC OptgMode

StageSetp_Mod
StageSetp_Mod (stage set point modulating):
If the actual temperature exceeds the next stage set point ,
the cold start load increases by the value set under
StageLoad.
StageSetp_Stage: (stage set point multi-stage):
If the actual temperature exceeds the next stage set point ,
the next stage is released

Time controlled load increase


If the actual temperature does not reach the
StageSetPoint ..., the cold start load (StageLoad) is
increased following the MaxTmeStage...

Cold start On
Curr: deactivated
New: activate

Ch. 9.8.3
Param + Display
LC-OptgMode
ColdStartOn
Additional
Set point add sens
Additional sensor
Set point add sens
Curr: deactivated
Curr: 60C
New: Pt 1000
New: 70C

Param + Display
LC -OptgMode
ColdStartOn
ThresholdOn
ThresholdOff

ThresholdOff:
If the actual temperature exceeds the switch off threshold
the cold start function is deactivated. Set switch
thresholds
Load steps (only with modulating operation)
At parameter, StageLoad the load increase can be set up
to that of the ThresholdOff value.

Ch. 9.8.3

Ch. 9.8.3

ThresholdOn
Curr: 20%
New: 25%

Set StageLoad
Param + Display
LC-OptgMode
ColdStartOn
StageLoad

Ch. 9.8.3

StageLoad
Curr: 15%
New: 15%

Setting StageSetp_Stage
Param + Display
LC-OptgMode
ColdStartOn
StageSetp Mod
StageSetp Stage

Ch. 9.8.3

StageSetp Mod
Curr: 5%
New: 5%

Setting StageSetp_Stage
Param + Display
LC OptgMode
ColdStartOn
MaxTmeMod
MaxTmeStage

Ch. 9.8.3

MaxTmeMod
Curr: 3 min
New: 3 min
45

Parameters and functions

9.1 Menu structure (ABE)


Menu level 1

Menu level 2

OperationalStat
esc

Operation

Menu level 3

Menu level 4

Menu level 5

NornalOperation
Status/Reset
FaultHistory
LockoutHistory
Alarm Act/deact

Boiler setpoint
esc

esc

Setpoint W1
Setpoint W2

esc

CurrentFuel
FuelSelect

Fuel

DisplayClock

Date/TimeOfDay
esc

esc

SetClock
esc

HoursRun
esc

StartCounter
esc

Fuel meter
esc

Date
TimeOfDay
Weekday

Date
TimeOfDay
Weekday

GasFiring
OilStage1/Mod
OiStage2
OilStage3
TotalHoursreset
TotalHours
SystemOnPower

GasStartCount
OilStartCount
TotalStartCountR
TotalstartCount

Curr Flow Rate


Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset Date Gas
Reset Date Oil

LockoutCounter

O2 Module
only W-FM200

esc

Current O2 value
O2 Setpoint
SupplyAirTemp
FlueGasTemp
CombEfficiency

BurnerID

OptgModeSelect
esc

InterfacePC
GatewayBASon
GatewayBASoff
Type of Gateway

O2Ctr Activate
only W-FM200

ManualOperation
esc

SetLoad
Auto/Manual/Off

End user: Access without password


Engineer: Access with SERV password
46

9
Menu level 1

Menu level 2

Param & Display

Menu level 3

BurnerControl
esc

esc

Times

Menu level 4
esc

Times Startup1

TimesStartup2

TimesShutdown

TimesGeneral

Configuration

esc

ProductID
esc

Configuration
General

Menu level 5
esc

esc

esc

FanRunup Tme
Prepurge TmeGas
Prepurge TmeOil

Interval1Gas
Interval1Oil
Interval2Gas
Interval2Oil

MaxTmeLowFire
Postpurge3Gas
Postpurge3Oil

esc

AlarmDelay
DelayStartPrev

esc

AlarmStartprev
ForcedIntermit
ConfigFlameSens

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

SW version

RatioControl
esc

GasSettings

esc

SpecialPositions

esc

HomePos
PrepurgePos
IgnitionPos
PostpurgePos
ProgramStop
ResetignitPos

CurveParams

LoadLimits

OilSettings

esc

SpecialPositions

CurveParams

LoadLimits

esc

esc

esc

esc

MinLoadGas
MaxLoadGas

HomePos
PrepurgePos
IgnitionPos
PostpurgePos
ProgramStop
ResetignitPos

Curve Settings

MinLoadOil
MaxLoadOil

Auto/Manual/Off

Times

esc

OperatRampMod
OperatRampStage
DriveRamp

ShutdownBehav

ProgramStop

End user: Access without password


Engineer: Access with SERV password
47

9
Menu level 1
Param & Display

Menu level 2
esc

O2Contr/Guard
(only W-FM 200)

Menu level 3
esc

GasSettings

Menu level 4
esc

Menu level 5

OptgMode
O2 Control
O2 guard
Control Param

esc

P Low-Fire
I Low-Fire
Tau Low-Fire
P High-Fire
I High-Fire
Tau High-Fire

O2CtrlThreshold
Type of fuel

esc

Fuel user-def

Control param

esc

esc

V_Lnmin
V_afNmin
V_atrNmin
A2
B / 1000

like theory
like P air

OptgMode
O2 Control
O2 Guard

esc

OilSettings

esc

OptgMode
O2 Control
O2 Guard
Control param

esc

P Low-Fire
I Low-Fire
Tau Low-Fire
P High-Fire
I High-Fire
Tau High-Fire

O2CtrlThreshold
Type of fuel

esc

Fuel user-def

Control param

esc

esc

V_Lnmin
V_afNmin
V_atrNmin
A2
B / 1000

like theory
like P air

O2 OffsetOil
LoadCtrlSuspend
Filter TimeLoad

Process Data

esc

CombEfficiency
ManVar O2 Ctrl
State O2 Ctrl
Air-related Load
Diag Reg State

End user: Access without password


Engineer: Access with SERV password
48

9
Menu level 1
Param & Display

Menu level 2
esc

LoadController
(optional on W-FM
100)

Menu level 3

Menu level 4

ControllerParam
esc

Menu level 5

ContrlParamList
esc

esc

StandardParam
P-Part (Xp)
I- Part (Tn)
D-Part (Tv)

MinActuatorStep
SW_FilterTmeCon
SetpointW1
SetpointW2
SD_ModOn
SD_ModOff
SD_Stage1On
SD_Stage1Off
SD_Stage2Off
SD_Stage3Off
ThreshStage2On
ThreshStage3On

TempLimiter

ColdStart

esc

esc

Configuration
esc

Adaption
esc

TL_ThreshOff
TL_SD_On

ColdStartOn
ThresholdOn
StageLoad
StageSetp_Mod
StageSetp_Stage
MaxTmeMod
MaxTmeStage
ThresholdOff
AdditionalSens
Setp AddSensor
Release Stages

LC_OptgMode
Sensor Select
MeasureRangePtNi
Ext Inp X61 U/I
MRange TempSens
MRange PressSens
Ext Inp X62 U/I
Ext MinSetpoint
Ext MaxSetpoint

StartAdaption
AdaptionLoad

SW version

End user: Access without password


Engineer: Access with SERV password
49

9
Menu level 1
Param & Display

Menu level 2
esc

AZL(ABE)

Menu level 3

Menu level 4

Times
esc

esc

Sum/WinterTime
Time EU/US

esc

UnitTemperature
UnitPressure

esc

Address
SendCycleBU

Menu level 5

Language
DateFormat

PhysicalUnits

eBus

ModBus
esc

Address
Baudrate
Parity
Timeout
Local/Remote
Remote Mode
W3

Display Contrast

ProductID
esc

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

SW Version

End user: Access without password


Engineer: Access with SERV password
50

9
Menu level 1

Menu level 2

Menu level 3

Actuators
Param & Display

esc

esc

Addressing

DirectionRot

Menu level 4
esc

esc

ProductID

Menu level 5

1 AirActuator
2 GasActuat(Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2
6 AuxActuator3

Delete curves

1 Air Actuator
esc

esc

2 Gas Actuator
(Oil)

esc

3 Oil Actuator
esc

4 Auxiliary Actuator
esc

5 Auxiliary
Actuator 2
(only on W-FM 200)

5 Auxiliary
Actuator 3
(only on W-FM 200)

SW Version
esc

esc

esc

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

1 AirActuator
2 GasActuat(Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2
6 AuxActuator3

End user: Access without password


Engineer: Access with SERV password
51

9
Menu level 1
Param & Display

Menu level 2
esc

FC Module
(VSD Module)
(optional on
W-FM 100)

Menu level 3
esc

Configuration

Menu level 4
esc

Speed

Fuel meter

Process Data
esc

ProductID
esc

Menu level 5
esc

esc

Num Puls per R


Standardisation
StandardisedSp
Setpoint Output

PulseValueGas
PulseValueOil

Max Stat Dev


Max Dyn Dev
Num Dev >0.3%
Num Dev >0.5%
Absolute Speed

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

SW Version

esc

O2 module
(only W-FM 200)

esc

Configuration

esc

Displayed Values
esc

ProductID
esc

O2 Sensor
SupAirTempSens
FlueGasTempSens
MaxTempFlGasGas
MaxTempFlGasOil

Current O2 Value
O2 Setpoint
SupplyAirTemp
FlueGasTemp
CombEfficiency
QGO SensorTemp
QGO HeatingLoad
QGO Resistance

ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers

SW Version

SystemConfig
esc

LC_OptgMode
Inp3Config..I/U

TempLimiter

esc

TL_Thresh_Off
TL_SD_On
Sensor Select
MeasureRangePtNi

O2Ctrl/LimitrGas
O2Ctrl/LimitrOil

End user: Access without password


Engineer: Access with SERV password
52

9
Menu level 1

Menu level 2

Menu level 3

HoursRun
Param & Display

esc

esc

Menu level 4

GasFiring
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
TotalHours
SystemOnPower

Reset
esc

StartCounter
esc

esc

esc

ParamBackup

Updating
esc

GasFiring
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset

GasStartCount
OilStartCount
TotalStartCountR
TotalStartCount

Reset

Fuel Meter

Menu level 5

GasStartCount
OilStartCount
TotalStartCountR

Curr Flow Rate


Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset DateGas
Reset DateOil

BackupInfo
esc

esc

Date
TimeOfDay
BU included?
AZL(ABE) included?
LC included?
ACT1 included?
ACT2 included?
ACT3 included?
ACT4 included?
ACT5 included?
ACT6 included?
VSD included?
O2 included?

LMV5 -> AZL


AZL
-> LMV5

PW Login
PW Logout

Load_SW_from_PC

SafetyCheckFunct
esc

LossFlameTest
SLT Test

End user: Access without password


Engineer: Access with SERV password
53

9
9.2 Operating display
The operating display is accessible by pressing the Info
button, by pressing ESC you return to the previous menu.

NormalOperation

FaultHistory

Display of:
Phases during start up
Set points and actual values
Current burner rating
Flame signal
by pressing ENTER the stepping motor positions,
speed and the O2 value can be displayed.

Fault memory with the last 21 faults.


Display of:
Fuel at onset of fault
Fault group
Fault and diagnostic codes (C/D) see Ch. 12
Phase, in which the fault occurred
Load position and start No.

Status/Reset

LockoutHistroy

If a lockout is present at display NormalOperation, this


can only be reset using parameter Status/Reset.
The display alternates between displaying fault information
and clear text description of the fault. The display is exited
using ESC and the plant can be reset by pressing ENTER.

Memory of the last 9 faults, which caused lockout.


Display of:
Date and time when lockout occurred
Fault and diagnostic codes (C/D) see Ch. 12
Phase, in which lockout occurred (P)
Load position and fuel

Alarm act/deact
With this function the lockout signal output on terminal
X3-)1:2 can be reactivated or deactivated. Deactivation
of the output remains active until reset, the next start or a
system reset.

9.3 Operation
BoilerSetpoint

Switchover from set point W1 to W2 is carried out with


potential free contact at input X62:1/2

Set point switchover W1/W2

X62

Two set points (W1/W2) can be entered for the internal


load controller. The set points cannot be set using the
current guarding temperature (optional on W-FM 100).

Activation
2nd set point

W2

Fuel

Fuel selection with ABE or eBus (BMS) have equal


preference, this means the option selected last is valid.
Date/TimeOfDay
In this menu the date, time and weekday are shown and
can be adjusted if required.

54

2
1
012

If an external fuel selection switch has been fitted, this has


priority.
If an external fuel selection switch is not fitted, or if this
switch has been set to W-FM internal the current fuel can
be changed with the ABE using FuelSelect.

External fuel selection switch

X4-01

Fuel determination with CurrentFuel (read only)

Pre-selection
Oil
Pre-selection
Gas
W-FM internal

9
HoursRun

BurnerID

HoursRun is read only. Reset of the individual counters is


only possible in level Param & Display in menu HoursRun
(see Ch. 9.14).

Here, the burner specific serial number is saved at the


factory. Using the serial number it is possible to replace a
failed unit with one that has the same factory pre-settings.
BurnerID also acts as copy protection; this means burner
specific data in the memory of the ABE cannot be
transferred to another W-FM.

StartCounter
The burner starts are read only. Reset of the individual start
counters is only possible in level Param & Display in menu
StartCounter (see Ch. 9.15).

OptgModeSelect
Here, the operating mode of ABE for serial interface is set.

Fuel meter
see Ch. 9.16 Param & Display - fuel meter
LockoutCounter
Total number of lockouts since commissioning (cannot be
reset).
CombEfficiency
Display of the current efficiency during burner operation
(see Ch. 9.7.1).

InterfacePC
The ABE acts as PC interface. The W-FM is set using a
PC and software.
GatewayBASon
Access by building management (BMS) to the W-FM
using the ABE. The ABE remains functioning.
GatewayBASoff
Operation without building management. Access to the
W-FM only with ABE.
Type of Gateway
Stipulated by the relevant bus protocol (eBus or Modbus).

9.4 Manual operation


Target rating
0-100%
Load started in manual operation (burner On). if not
specified, partial load is started.
S1-S3
Highest stage which can be started in manual operation
(burner On).
Auto / Manual / Off
Burner operation is set using this parameter.
This menu is also accessible from level RatioControl.
Automatic
The burner is regulated by an external or the internal load
controller to set point. Regulation can be two stage, three
stage or modulating.
Manual On
The burner starts and is switched of by the external or
internal temperature guard. Prerequisite is a closed control
circuit or bridge at input X5-03 terminals 1 and 4.
Manual Off
Burner switches off. Even if the switch on hysteresis is not
reached, the burner remains off.

55

9
9.5 Burner control
Depending on the password entry the relevant parameter
for the operator or the engineer is displayed.

9.5.1 Times
Time start up 1

Time general

Fan run up time


Duration of fan start up to start of stepping motors.

Alarm delay time


This time stipulates how soon the combustion manager
signals lockout. The self-test of the system can take up to
35 seconds. If the fault has been rectified during this test
phase, the installation re-starts.

Pre-purge time gas/oil


Duration after reaching the pre-purge positions up to drive
to ignition positions.

Time start up 2

Delay Start Prevention


This stipulates after how many seconds the display
message is shown if start prevention is active during heat
demand.

The interval times act as stabilisation periods following


flame formation. The interval time 2 is only active with pilot
ignition.
Time shutdown
MaxTime_LowFire
If the burner is shut down, or if fuel change over is initiated,
the shutdown program starts at the latest after completion
of this time. If low fire is reached prior to this time elapsing,
the shutdown program starts when low fire is reached.
Post-purge time 3
Duration of post-purge.

9.5.2 Configuration
Configuration general

ConfigFlame Sensor

Alarm start prevention


Stipulates if start preventions are signalled by the alarm
output (terminal X3-01:2)

Flame signal
Display of the current signal at the flame sensor.

ForcedIntermit
With ForcedIntermit active, a controlled shutdown with
immediate restart is carried out after 23 h 50 mins.

9.5.3 Product ID and software version


Product ID

SW version

The ProductID gives information about:


Type description (LMV...)
Production date
Serial number
Parameter set codes
Parameter set version

The SW Version gives information about the software


version of the burner control.

56

9
9.6 Ratio control
The setting parameters in menu RatioControl can only be
accessed with the password for the engineer.

9.6.1 Settings gas/oil


SpecialPositions
The special positions are fuel specific and can be entered
individually for oil and gas.
Home positions
This parameter is used to set the stepping motor positions
or speed control in Standby.
HomePosFC = 0
Frequency converter deactivated
HomePosFC > 0
Start release frequency converter
Fan motor starts with relevant
speed set (in %).

Ignition positions
This parameter is used to set the stepping motor positions
and speed for ignition. Ignition (phase 38) is only carried
out when all motors have reached their ignition positions.
IIgnPosGas

: Ignition must be carried out with excess


air. The gas pressure has to be set to the
instructions given in the installation and
operating instructions of the burner.
Gas butterfly opening during ignition:
with ignition pilot 10 to 20<)
without ignition pilot approx. 10<)

IgnPosOil

: Position of the oil controller. The ignition


position for oil can be found on the burner
test data sheet. The indicator position
given is the same as the data given for the
degree of angle. If an oil controller is not
fitted (multi-stage) the ignition position of
oil has no influence.

IgnPosAir

: When the fuel is ignited a pressure


increase occurs in the combustion
chamber. The burner must create a
resistance against this to avoid a back
flow of flue gases. Therefore ignition with
open air damper and matching of the
mixing pressure by speed only is not
possible. A setting of approx. 30<) for the
air damper is recommended. The actual
air damper opening will be determined
later by the mixing pressure measurement.

IgnPosAux

: The position of the adjustable mixing head


can be found in the installation and
operating instructions of the burner. If an
adjustable mixing head is not fitted, the
fixed sleeve or the adjustable flame head
must be pre-set to the operating points in
the capacity graph.

Reset ignition position


The values of ignition position for oil, air and auxiliary motor
are deleted, existing programming points remain.
The burner without ignition position data can no longer
start.

IgnPosAux2
IgnPosAux3

: Auxiliary motors for special applications.


: For example: Second fuel Kerosene or
Liquid Petroleum Gas, flue gas damper
etc.
(only W-FM 200)

Note: In its delivered condition a provisional ignition


position has been set, for fuel oil also the program
point P1 (these values are needed for burner
testing).
To ensure that the burner does not start at the
installation, a program has been set in phase 36.

IgnPosFC

: The ignition speed depends on the fuel


and should not be below 70% for gas and
80% for oil. If the mixing pressure for
ignition is outside of the limit, correction
must be made using the air damper or
mixing head position (only in connection
with a frequency converter / W-FM 200).

Pre-purge positions
This parameter is used to set the air determining stepping
motor positions or the motor speed for pre-purge.
Pre-purge only starts once all motors have reached their
pre-purge positions.
Post-purge positions
The parameter PostpurgePos allows separate setting of
the individual stepping motors.
Pre-set values have been entered at the factory. Generally,
setting values are required, which ensure sufficient cooling
of the mixing head whilst still maintaining adequate heat in
the heat exchanger.
The speed of the frequency converter must not be set
below 10%.
Program stop
In menu, ProgramStop the start of the burner can be
stopped at 7 defined positions and adjustments to the
burner settings can be made.
24 PrePurgPos
32 PreP FGR
36 IgnitPos
44 Interv 1
52 Interv 2
72 PostPPos
76 PostPFGR

: Nominal load pre-purge position


: Nominal load pre-purge for FGR
: Ignition position without ignition
: End of first safety time
: End of second safety time
: Air damper in post-purge position
(shutdown)
: Air damper in post-purge position
for FGR

57

9
Curve parameters (modulating)

90

100

80

90

Speed %

Starting at the first load point reference lines for the


maximum stepping motor position are created up to full
load (100%), if no other load point is defined.

Manual load increase starting from point P1


Motor positions <)

Increase load manually


Due to burner testing load point 1 (P1) has been factory
pre-programmed for fuel oil. If P1 has been deleted the
W-FM suggests the ignition position as load point 1.

80

70

70

60

60

If the load is now increased in menu curve


parameter/manual, the stepping motors and the frequency
converter are driven by the predetermined reference lines.

50

Set intermediate load points


When nearing the combustion limit, a further load point has
to be set and combustion optimisation has to be carried out.

30

Once the new load point has been saved, a new reference
line is created. The reference lines are drawn between the
previous and the new load point and are further extrapolated. in manual load increase, the stepping motors are
now driven on the basis of the new reference lines.

10

50
40
40

Gas: Due to the control characteristic of the gas butterfly


this should be set to 65 to 70. The gas throughput
has to be determined and adjusted using the setting
screw on the pressure controller.

P2

20
10

P1
0

10

20

30

40

50

60

70

80

90

100

Rating %

Curve lines after saving P2


90

100

80

90

Speed %

Optimising full load


The required nominal load in full load has to be set with the
fuel throughput.

20

Motor positions <)

This procedure is repeated until full load has been


reached.

30

80

70

70

60

60
50
50
40
40

Oil: Set required pump pressure in accordance with the


information given in the installation and operating
instructions or the burner test data sheet. Determine
oil throughput and adjust using the setting of the oil
controllers stepping motor.

20

30
20
P2

10

10

P1
0

10

20

30

40

50

60

70

80

90

100

Rating %

90

100

80

90
80

70

70

60

P5
60

Due to the changes made to the mixing pressure and the


speed the fuel quantity throughput should be checked and
adjusted if required.
The pump or gas setting pressure must not be alter once
this process has been completed.

50
50

P4
40

40
30

20

30

P3

20
P2

10

10

P1
0

10

20

30

40

50

60

70

80

90

100

Rating %

58

Speed %

Drive to full load and optimise


Motor positions <)

For the air quantity setting this means, that the speed is set
to a minimum, depending on the load and the emissions,
however not below 40Hz (80%). If at all possible, the
position of the mixing head should be set for maximum
mixing energy and the air damper should be set to the
effective point. With additional O2 control, this will ensure
an effective involvement of the air damper.

Determine combustion limit at full load and set excess air.


Excess air:
without O2 control approx. 15 to 20%
with O2 control approx. 20 to 25%

30

9
100

80

90
80

70

70

60

P4
P5 60

50
50

P3
P4

40

40
30

3
2

20

30

P2
P3

20
P2

10

10

P1

When saving the intermediate load point, an automatic resorting of the load points is carried out according to the
load.
This means: The new point 8 now becomes point 7,
point 7 becomes point 8.

Note: If O2 control is used, point P2 forms the minimum


O2 control load.
For loads below P2, the O2 control is deactivated
and the burner runs on the normal ratio control
curve.
Point P1 is important for the air ratings reduction of
the O2 control. This must have sufficient distance
to P2.
Recommendation: P1 minimum 30% below P2

10

20

30

40

50

Example;
Current throughput at point 7 (70%):
Throughput full load:

250m /h
340 m3/h

80

90

100

90

100

80

90
80

70

70

60

P7
P8 60

50
50
40
40

P8
P7
P6

Load assignment
Once the curve points have been saved, they automatically
sort themselves according to the load assigned to them.
The percentage load assignment depends on the current
and full load fuel throughput.

If the calculated load deviates too much from the load


point, the fuel throughput can be matched by adjusting the
stepping motor position.

70

Enter intermediate load points

30

Current throughput
Load [%] = x 100%
Full load throughput

60

Rating %

Motor positions <)

It is possible to optimise ratio control with up to 15 points.

Speed %

90

Speed %

Insert load points


If a new load point is inserted, its number is always the
number of existing load points plus one. In setting
Manual the load is set with the burner in operation to the
value at which the load point is required (recommendation:
all 10%).
Carry out combustion optimisation and once the fuel
throughput has been determined, carry out load
apportionment. To achieve an even speed curve line, the
speed should not be adjusted during combustion
optimisation.

Delete intermediate load points


Motor positions <)

Deleting points
If a curve point is deleted, the numbering is automatically
changed to the next point. The reference line will then run
linear with the neighbouring points.

30

P5
20

2
1

10
P1
0

10

P4

20

P3

P2

20

10

30

40

50

60

70

80

90

100

Rating %

1
2
3
4

Air damper
Fuel
Mixing head
Speed
manually started load points
Saved load points
Deleted load points

250 m3/h
Load [%] = x 73,5%
340 m3/h
In this case the fuel throughput (P7) can be reduced with
the fuel motor, the combustion optimisation now has to be
repeated.

59

9
Curve parameter (multi-stage)
The operating mode multi-stage is only possible in oil
operation. Depending on burner version two or three stage
operation is available. A three stage burner can also
operate in two stage mode with low impact start.

On and off switch point - 2 stage operation


BS2

Set operating and switch points


The setting of the operating and switch points can be
carried out with or without starting up. By turning the dial
knob the positions of all operating and switch points
entered can be viewed. This does not have any effect on
the system. Even if with start up is selected the stepping
motors do not follow!

AS2
ES2

Without start-up
The stepping motor positions can be set without the
motors following; they remain in the required load set
under manual operation.

BS1

With start-up
By pressing the ENTER button the point called up is
started and the motors follow the current settings made
with the dial knob.
The on and off switch points are also started, however the
valve does not yet switched at the on and off switch point.
This procedure is required to optimise the air quantity to
the fuel quantity.
If the burner is set to Off in manual operation, only the
stepping motors follow, the solenoid valves of the
individual stages, however, are not operated.
Operating points
BS1: Stipulates the air quantity for fuel quantity for
stage 1 (excess air approx. 20 to 25%).
BS2:

Stipulates the air quantity for fuel quantity for


stage 2 (excess air approx. 15 to 20%).

BS3:

Stipulates the air quantity for fuel quantity for


stage 3 (excess air approx. 15 to 20%).

Switch on point
Only once the switch on point has been exceeded will the
solenoid valve for the next stage open. This means the
solenoid valve of the next stage remains closed at the
direct start of the point. This allows the flame stability can
be checked prior to switching to the next stage.
Switch off point
If the burner is reset by one stage, the relevant solenoid
valve will close when the switch off point has been
exceeded (stage 3 or stage 2).
A direct start of the switch off point is not recommended,
as the solenoid valve of the higher stage will remain open,
which leads to soot due to insufficient air.

60

Solenoid valve
stage 2 opens
Solenoid valve
stage 2 closes

9
Load limits
Using the parameter min and max load, the burner can be
limited fuel specific in its load range within the
programmed curve lines.

MinLoad_Gas/Oil
Limits the load range downwards (low fire).
The min load cannot be set below point 1 and if used with
O2 control not below point 2.
MaxLoad_Gas/Oil
Limits the load range upwards (full load).

9.6.2 Times
The duration of the slowest motor across a setting section
of 90 is important for parametering the drive times.

OptgRampMod

DriveRamp

Gives the run time of the motors in modulating operation.

Gives the run time of the motors during the operating


phase without flame.

OptgRampStage
Gives the run time of the motors in multi-stage operation.

9.6.3 Switch off behaviour


Using the parameter Switch off behaviour it is stipulated,
how the ratio control behaves during lockout.
SM stopped

HomePos

The stepping motors remain in the position at the time of


lockout.

At lockout the motors drive to the given home positions.

Post purge
If lockout occurs the combustion manager carries out a
post purge.
9.6.4 Programme stops
In menu programme stop the commissioning of the burner
can be interrupted at 7 pre-defined positions and the
burner setting adjustments can be made.
24 PrePurgP
32 PreP FGR
36 IgnitPos
44 Interv 1
52 Interv 2
72 PostPPos
76 PostPFGR

: Nominal load pre-pre purge position


: Nominal load pre-purge for FGR
: Ignition position without ignition
: End first safety time
: End second safety time
: Air damper in post purge position
(shutdown)
: Air damper in post purge position for
FGR
61

9
9.7 O2 control and guarding
Here, the relevant parameters for the operator or the
engineer are displayed depending on the password
entered (only W-FM 200).

9.7.1 Setting Gas/Oil


The following parameters are fuel specific and can be
entered separately for oil and gas.
Operating mode
auto deact
Is activated automatically, if the O2 control is switched off
in operating mode RegAuto deact.
O2 controller and guard are deactivated and ratio control
drives on the curve lines programmed. At the same time a
warning message appears in the display. Manual activation
of operating mode is not recommended.
man deact
O2 controller and guard are deactivated. The systems
drives on the parametered ration control curve lines. The
burner starts with cold sensor (only for commissioning, not
recommended for normal operation).
O2 guard
Only the O2 guard is active.
If the O2 sensor has not reached operating temperature,
start is prevented.
If the O2 guard reacts, or if a fault occurs in connection
with the O2 measurement, the O2 module or the O2 sensor,
a safety shutdown is initiated. If repetition is not possible
lockout occurs.

O2 control
Using this parameter an O2 set point standardisation has
to be carried out at each point.
The air determining stepping motors are driven down on
the programmed ration control curve lines in line with the
standard values given. The air load this reduced, but the
fuel quantity remains unchanged.
During standardisation of point 2 and the last load point
(full load) the PI control parameters are determined. In
these two points the O2 ratio control value is started after
the standardised value has been saved and the
reactivation time (Tau) is determined. This means the delay
time between changes to the air stepping motor positions
and the actual value at the O2 sensor are determined.

62

O2 controller
The O2 controller and guard are active. The same data
applies as for O2 guard.
conAutodeact
The O2 controller and guard are active. Start-up is carried
out prior to the operating temperature of the O2 sensor
being reached. Activation of the O2 control in operation is
only carried out once the operating temperature has been
reached and the sensor test has been successful.
If the O2 guard reacts, or if a fault occurs in connection
with the O2 measurement, the O2 module, the O2 sensor
or the sensor test, the O2 controller and O2 guard are
deactivated automatically.
The system drives to the O2 ratio control setting. The
operating mode is set to auto deact. The ABE displays
the note about the automatic deactivation. The fault code
remains until the operating mode is changed.

9
O2 Guard

The O2 min limit can be entered directly if the combustion


limit has already be determined, or it can be determined by
reducing the air load.
Direct input:
If the O2 values on the combustion limit are already known
these can be assigned as O2 min value for the Guard
function.

O2 min limit
3,0
2,5
O2 content [%]

Using this parameter, an O2 limit value has to be set for


each point (CO/soot).
If during operation, the O2 min limit is not reached for
3 secs. this leads to either a safety shutdown or an
automatic deactivation of the O2 control / guarding
function, depending on the operating mode selected.

2,0
1,5
1,0
0,5
0

Determination:
Using P-Air manual reduce air load until the combustion
limit (CO/soot) has been reached and save the O2 actual
value displayed as limit value.

10

20

30

40 50 60
Burner rating [%]

70

80

90

100

O2 min limit for guard function


Increased O2 min value with steep CO increase at the
combustion limit (+0.2 to 0.3 % points)

Note If the CO increases sharply at the combustion limit,


the O2 min value for the guard function can be
selected 0.2 to 0.3% points higher.

Control parameter
O2 control behaviour

Pre-control becomes active at entry into the load control


after 10 x Tau low fire. If during the delay time full load no
load changes occur, the O2 control becomes active.

Using the control parameter the behaviour of the O2


control can be influenced.

4
1

Load [%]

At each load change the actual load is calculated. If the


difference of the reference line exceeds the LoadContLock
value the O2 control is stopped.
If the load signal remains constant and the difference is not
exceeded, the O2 control becomes active again once the
delay time full load has elapsed.

O2 Currual value
O2 set point

O2 content [%]

The O2 control is supported by the pre-control function.


If equal ambient conditions are present, the pre-control
calculates the air load reduction for the total load range. If
the load signal changes, a setting size alteration (air) of the
ratio control is carried out by the pre-control. This means,
the O2 control only has to adjust deviations in ambient
conditions (temperature, air pressure, ...).

1
2
1
2
3
4
5

parameter LoadContLock
locked range
Delay time full load ( 2 x Tau full load)
Burner load
Following actual load

P Low/high fire
Proportional part of O2 control.

Tau high fire


Reaction time at 100% determined during standardisation.

I Low/high fire
Integral part of O2 control.

LoadContLock
Limit value of the load difference from which the O2 control
is locked.

Tau low fire


Reaction time in point 2 determined during
standardisation.

FilterTimeLoad
Lock time after which a load change in the size of the
LoadContLock can be made.
O2 Offset Gas/Oil
Increase of O2 content before a load increase is carried
out.
63

9
O2 control limit
For burner ratings below the set value, the O2 control is
deactivated and the system drives on the programmed
curve lines of the ratio control. If the burner rating
increases to 5% points above the control limit, the O2
control is reactivated.
Type of Fuel
To calculate the combustion efficiency the fuel currently
used must be set.
If the fuel is not available, its fuel values can be entered
under FuelUseDef.
In parameter FuelUseDef the calculation values for the
combustion efficiency will be displayed.

The values
V_Lnmin = Air volume under normal conditions at 1
V_afNmin = Flue gas volume wet under normal cond. 1
V_atrNmin = Flue gas volume dry under normal cond. 1
are required for converting O2 wet to O2 dry
A2
= Adjustable constancies for F
B/1000
= Adjustable constancies for F
are constancies depending on the fuel.

Type air change


Influences the calculation procedure for pre-control.
As P Air:
A change in air density (temperature pressure) will affect
the fuel throughput.
Recommended setting for fuel Gas.
LoadContLock
Limit value of the load difference from which the O2 control
is locked.
FilterTimeLoad
Lock time after which a load change in the size of the
LoadContLock can be made.
O2 Offset gas/Oil
Increase of O2 content before a load increase is carried
out.
9.7.2 Process data
The menu process data is read only:
about the current combustion efficiency
about the setting size of the O2 controller
release of O2 controller (activated/deactivated)
current load of the air determining motors
diagnostic codes if the controller is locked

64

In theory:
A change in air density (temperature pressure) will not
affect the fuel throughput.
Recommended setting for fuel Oil.

9
9.8 LoadController
Here, the relevant parameters for the operator or the
engineer are displayed depending on the password
entered.
On W-FM 100 the load controller is optional.
Note: To set the internal load controller this must be
activated in SystemConfig (Ch. 9.13).

9.8.1 ControlParam Select


ReglerParam Wahl
Under (StandardParam) 5 standard parameter sets and
the adaption PID values can be accessed. Each one of
these parameter sets can be copied direct into the PID
memory, the existing values will be overwritten.

StandardParam
very slow
slow
normal
fast
very fast
Adaption

P (Xp)
I (Tn)
D (Tv)
30 %
400 s
10 s
15 %
320 s
40 s
7%
90 s
50 s
4%
35 s
17 s
40 %
55 s
15 s
values determined during adaption

Adapt control parameters


Xp too small

Xp too large

Tn, Tv too small

Tn, Tv too large

The control parameters can also be entered manually:


P-Part (Xp):
I-Part (Tn):
D-Part (Xv):

Proportional band
Integral action
Derivative action

MinActuatorStep
The smallest possible correcting element step is used for
setting value damping.
If the difference between the new calculated setting size
and the current setting size is smaller than
MinActuatorStep, the current setting size is maintained.
SW FilterTmeCon
Using the filter time actual value fault signals, which
predominantly affect the D content, can be weakened.
However, if the filter time is too long this influences the
actual value determination and has a negative effect on the
control accuracy.
A filter time of 2 to 4 seconds should be set for automatic
adaption. If the time selected is too long this can lead to
automatic adaption being stopped.
Set points W1/W2

Switchover from set point W1 to W2 is by potential free


contact at input X62:1/2

Set point switchover W1/W2

X62

Two set points (W1/W2) can be set for the internal load
controller. The set points can not be set above the current
limit temperature.

Activation
2. set point

2
1

W2
65

9
SD_M
ModOn/Off
Switch difference in percent for modulating operation.
With positive SD_ ModOn the switch difference is above
the set point, with negative below.
SD_S
Stage On/Off
Switch difference in percent for modulating operation.
With positive SD_Stage1On the switch difference is
above the set point, with negative below.
ThresholdStage... On
If control deviations occur an integral is created over the
time.
If the integral drops below the ThresholdStage...On the
next stage is switched. This can influence the switching
frequency of the individual stages.

Switch ThresholdStage... On
Actual
value
Set point
SD_Stage
1 On

Stage 2
Stage 3

Q2

Q2
Q3

O2 = switch threshold stage 2 (ThresholdStage2On)


O2 = switch threshold stage 3 (ThresholdStage3On)

9.8.2 Temperature switch


The temperature switch is only active in connection with
the relevant sensors (see Ch. 9.8.4).
The TL_ThresholdOff stipulates the temperature at which
the installation is switched off. Once the switch on
hysteresis TL_SD_On is reached, the installation is
released again.

66

9
9.8.3 Cold start
ColdStartOn
Activates/deactivates the cold start function. The cold start
function ensures that the boiler is not operated at its
maximum loading if the preset minimum boiler temperature
has not been reached.
This operating mode protects the material of the boiler.
Threshold On
Switch on threshold in percent relating to the set point
(W1/W2) or Setpoint AddSens.
The cold start function is started if the boiler temperature is
below this switch on threshold at heat demand.

Cold start function

Set point

Threshold
Off
StepSetpoint
Threshold
On
Actual
value
appliance

Step Load (modulating)

Cold start load modulating

The cold start load increases by this value, when the boiler
temperature has reached the next set point step. If the set
point step is not reached, the cold start load is increased
after completion of the parametered MaxTmeMod.

Step load

Step Setpoint m/s


Stipulates the cold start set point increase.
If the boiler temperature reaches the current cold start set
point, this is increased by the given value.

Low fire
MaxTmeMod
Cold start load multistage

MaxTime
MaxTimeMod:
Time after which a load increase is carried out (modulating
operation).
MaxTimeStage:
Time after which the next stage is released. Pre-requisite is
that Release Stages is activated.

ThresholdOff
Switch off threshold in percent relating to the set point
(W1/W2) or Setpoint AddSens. Once the switch off
threshold has been reached the installation switches to
control operation.

Stage 3

Stage 2

Stage 1

MaxTmeStage

Release Stages

Additional sensor

Not released:
Cold start only in the first burner stage. Stage 2 and stage
3 are locked during the cold start.

Activates the temperature sensor on terminal X60.


The additional sensor is required if a pressure sensor has
been fitted to terminal X61 and if start-up is to be carried
out with media temperatures below 100 C.

Released:
Cold start is carried out in the first burner stage. Once the
boiler temperature reaches the current cold start set point,
the next stage is released.

Setpoint AddSens
If the additional sensor has been activated this set point is
the reference size for the on and off switch threshold of the
cold function.

67

9
9.8.4 Configuration load controller
LC operating mode
The load controller setting (internal/external) in
SystemConfig has priority. This means that if an external
load controller has been activated in SystemConfig,
operating mode selection is not possible.

int LC Bus
The building management system stipulates the set point
for the internal load controller. Signal switchover is carried
out by the ABE and an additional eBus interface. For this
the gateway has to be activated in menu Operation,
parameter Select operating mode (Ch. 9.3) and the Bus
protocol (Gateway type) has to be entered. If the Gateway
type ModBus has been selected, the ModBus must be set
to local in menu AZL(ABE) (Ch. 9.9.6).

X5-03

int LC
Activates the internal load controller. Set point (W1/W2)
are set using the ABE.
If a different operating mode is selected, the int LC
operating mode can be activated using one of the switch
contacts on terminal X62:1/2. In this case, control is to set
point W1.
The internal load controller must be configured and
optimised to carry out this function.

External LC on input X5-03

Stage 1

Stage 3

Closed

Stage 2

Open

On
C

4
3
2

BMS

420 mA
010 V
ext. switch contact

Int LC

External set point / load input via Bus

BMS

int LC X62
The building management system stipulates an analogue
signal as set point for the internal load controller. The
setting range automatically matches itself to the
parametered measuring range of the sensor
(MeasureRange PtNI). Additionally, it is possible to limit
the set point range both up and down (Ext SetPoint ...).
ext LC X62
The building management system stipulates an analogue
load signal (tab. External load input). The W-FM converts
the signal and starts the relevant motors or the frequency
converter.

LC

Ext. analogue signals and switchover to int. LC

X62

extLC X5-3
Load control is via three-point step signal of an external
controller at input X5-03. The input must not be switched
with radio interference suppressors.

eBus
Interface
W-FM 200

Load signal output - only with internal load controller -

Modulating
Multistage
Analogue
signal
Low fire High fire Stage 1 Stage 2 Stage 3

X63

External load input

2
1

I (mA)

20

10

15

U (V)

10

2,5

7,5

Ext LC Bus
Load control is carried out by the building management
system. Start-up is carried out by the ABE and an
additional eBus interface. For this the gateway has to be
activated in menu Operation, parameter Select operating
mode (Ch. 9.3) and the Bus protocol (Gateway type) has
to be entered. If the Gateway type ModBus has been
selected, ModBus must be set to remote in menu AZL
(ABE) (Ch. 9.9.6).
68

0
420 mA

For the operating modes with internal load controller a load


signal of 4 to 20 mA is given to output X63:1/2.
4 mA 0% load
20 mA 100% load

9
Senor selection
PT100
PT 100 sensor on terminal X60:1/2/4 (three core switching)
temperature limiting function is active.

Sensor connection

PT1000
PT 1000 sensor on terminal X60:3/4
temperature limiting function is active.

X60

Pt 100

Pt/Ni 1000

4
3
2
1

Ni 1000
Ni 1000 sensor on terminal X60:3/4
temperature switch function is active.
PT100 PT1000
PT 100 sensor on terminal X60:1/2/4 (three core switching)
for temperature switch function.
PT1000 sensor on terminal X60:3/4 for temperature
limitng function.
PT100 Ni 1000
PT 100 sensor on terminal X60:1/2/4 (three core switching)
for temperature switch function.
Ni 1000 sensor on terminal X60:3/4 for temperature
limiting function.

PressSens
Pressure sensor at input X61
no limiting function.

Sensor connection
P/
X61

TempSensor
temperature sensor at input X61
no temperature limiting function.

420 mA

2
1

010 V
20V DC

none
No sensor connected to W-FM (i.e. external ratings input
without temperature guarding function).
Measuring range PtNi
The start of the measuring range is fixed at 0 C or 32 F
and cannot be altered.
The end of the measuring range can be configured.
Two possibilities are available:
150 C/302 F or 400 C/752 F
Valid for Pt100:
Load balancing of the three core switching is not required,
if the resistance of the connecting lines are equa
Ext Input X61 U/I
Input X61 has to be configured depending on the sensor
used.
4...20 mA : Current signal to terminal X61:3
with line guarding
2...10 V : Voltage signal to terminal X61:2
with line guarding
0...10 V : Voltage signal to terminal X61:2
without line guarding
The supply voltage (20V DC) on terminal X61:1 cannot be
altered.
69

9
MeasureRange TempSens / PressSens
The measuring range of the temperature or pressure sensor
can be parametered freely within the preset limits.
MeasureRange TempSens: 0 to 2000 C or 32 to 3632 F
MeasureRange PressSens: 0 to 99.9 bar or 0 to 1450 psi
Values 105 outside of the measuring range are interpreted as
sensor short circuit or as line break.
Ext Input X62 U/I
If an external load or set point signal is switched at terminal
X62, the analogue signal has to be defined.
4...20 mA : Current signal on X62-/4
Load or set point signal with line monitoring
2...10 V : Voltage signal on X62:2/4
Load input with line monitoring
0...10 V : Voltage signal on X62:2/4
Set point input without line monitoring

Ext Setpoint min/max


The external analogue set point signal is applied as a
percentage in the internal load controller to the
temperature range set under MeasureRange PtNi.
Temperature inputs outside of this limit will not be included
into the control by the load controller, even if the external
input does not reach or exceeds these values.

Set point input

Measure Range

PtNi

Current signal

Voltage signal

4 mA

20 mA

0V

10 V

0150C

0C

150C

0C

150C

0400C

0C

400C

0C

400C

Example 1 (set point signal in mA):

Example 2 (set point signal in Volt):

Upper set point limit required = 80 C

Lower set point limit required = 50 C

MeasureRange PtNi
150 C

MeasureRange PtNi
400 C

ExtInput X62 U/I


40 to 20 mA; corresponds to analogue range of 16 mA

ExtInput X62 U/I


0 to 10 V; corresponds to analogue range of 10 volt

Calculation

Calculation:

80C
150C

50C

100 53,3%

400C

Corresponds to a set point signal of


16 mA
150C

70

80C

+ 4mAOffset

100 = 12,5%

Corresponds to a set point signal of


12,53 mA

10 V
400C

50C

1,25 V

9
9.8.5 Adaption
Start adaption
The adaption allows the load controller to automatically
identify the control section and to create the PID
parameter from the data determined. Adaption is available
for both temperature and pressure control. The adaption
can be started in manual or automatic operation; the
installation can be in operation or standby.
Adaption is not possible in multi-stage operation.

Adaption Load
With this parameter, the adaption load can be reduced by
up to 40%. This could be necessary, if the heat demand
during adaption for full load (100%) is insufficient and the
installation switches off during the adaption process.
If the adaption load is selected so low that the set
temperature is not reached this leads to interruption of the
adaption.

9.8.6 SW version
The SW Version supplies details about the software
version of the load controller.

71

9
9.9 ABE
9.9.1 Times
Sum/Winter time

Time EU/US

Manual or automatic changeover from Summer to Winter


time can be selected.

European or American Summer / Winter times can be


selected.

9.9.2 Language
Six languages are available for selection.
If the required language is not available the language
group can be overwritten with PC software. A total of 4
language groups, each with 6 languages, are available in
the software.

9.9.3 Date format


Available for selection are the European format: DD, MM,
YY or the international format: MM, DD, YY.

9.9.4 Physical units


Temperature can be selected as degrees Celsius or
degrees Fahrenheit, pressure in bar or psi.

9.9.5 eBus
Adress

Send Cycle

Here the eBus address of the W-FM is set, which the


building management uses to communicate with the
combustion manager.

Here the cycle time for sending operating data of the


combustion manager to the BMS is set.

72

9
9.9.6 Modbus
Adress

Local / Remote

Here the Modbus address of the W-FM is set, which the


building management uses to communicate with the
combustion manager.

In Local setting the internal load controller of the


combustion manager becomes active.
In remote setting, the building management system is
active.

Baudrate

Remote Modus

The baudrate stipulates the transfer speed.


The baudrate of the combustion manager and the BMS
must be identical.

The parameter is read only, input is by BMS.

Parity
Parity is a safety feature for data words during transfer.
The parity of the combustion manager and the BMS must
be identical.

Remote Auto : Set point input W3 by BMS


Remote on
: Set degree input by BSM
Remote off
: The internal load controller is active

W3
Set point input press or temperature by BMS.

Timeout
This time stipulates, after what time the ABE automatically
switches from remote to local if Modbus communication
fails.
This means the building management system is
deactivated and the internal load controller of the W-FM
takes over control.

9.9.7 Display contact


With this selection the dial knob is active and the required
contrast can be set and saved.
The display contrast can also be altered without saving it.
To do this turn the dial knob left or right whilst holding
down the ENTER button (only possible in the operating
display normal operation).

9.9.8 Product ID and SW Version


Product ID

SW Version

The Product ID gives information about:


Type description (ABE)
Production date
Serial number
Parameter set code
parameter set version

The SW Version gives information about the software


version of the display and operating unit (ABE).

73

9
9.10 Stepping motors (Actuators)
9.10.1 Addressing
If only one stepping motor is changed the addressing and
the rotational direction will remain the same. If more than
one stepping motor is changed, a new address has to be
entered for each new motor.

Addressing stepping motor

Bus connection
If the stepping motor is the last unit in the bus line,
a bus connection has to be made using a jumper. The bus
connection on all other units must be deactivated (the ABE
has a fixed bus connection).
Addressing stepping motors
Select relevant motor in the menu and confirm with Enter.
Then start the address assignment by pressing Enter and
press the address button on the stepping motor to be
addressed.
Following addressing the LED shows the flashing code
and the display shows a confirmation message.

Address button
LED
Jumper

Delete address
If a wrong address has been entered, this can be deleted
by pressing the push button on the stepping motor for 10
seconds, if necessary disconnect the mains voltage whilst
holding down the button. The LED will return to continuous
illumination.
Flashing codes
Air stepping motor
Gas stepping motor (Oil)
Oil stepping motor
Auxiliary motor
Auxiliary motor 2
Auxiliary motor 3

1 impulse
2 impulses
3 impulses
4 impulses
5 impulses
6 impulses

without bus
connection

with bus
connection

LED continuous illumination = no address


LED continuous flashing = addressing in progress
LED flashing codes = addressed

9.10.2 Rotation direction


DeleteCurves
Deletes curve lines of all stepping motors, only required to
change the rotation direction in menu level OEM.

9.10.3 Product ID and SW Version


Product ID

SW Version

The Product ID gives information about:


Type description (stepping motor)
Production date
Serial number
Parameter set code
Parameter set version

The SW Version gives information about the software


version of the stepping motor.

74

9
9.11 FC-Modul
Depending on the password entered this displays the
parameters for the operator or the engineer (only WFM200).

9.11.1 Configuration
Speed

Standardisation
During standardisation a set point signal of 95% is given
at open air or auxiliary stepping motor. This means that
there is a shortfall of 5% of the max. frequency set at the
transformer (52.5 Hz x 0.95 = 50 Hz). The speed reached
at the standardised 50 Hz is saved in parameter
Standardised Speed as 100% value for the speed control.
If more than 50 Hz is shown during standardisation, the
motor slip adjustment (=0) on the frequency converter has
to be checked.
If the standardised speed is not reached during operation
at 100%, a reserve of 5% is available to the system.
Note Following speed standardisation or changes to the
speed saved, the combustion values should be
checked.

Set point output


The output signal (0/4 to 20 mA) at terminal X73 of the
W-FM and the input signal of the frequency converter must
have been matched to one another.
To guard the signal line, the setting 4 to 20 mA should be
selected on the W-FM and frequency converter.

Speed determination
180
10 V DC
Pulse
GND
Reserve
Screen

1
X70

Number of impulses per rotation


Speed determination is carried out with an asymmetrical
transmitter (3 impulses per rotation) at input X70. The
asymmetrical transmitter construction (60, 120, 180) is
used for recognising the rotation direction, motor start with
the wrong direction is therefore not possible.

2
3
4
5

60
2 core
3 core PNP
120
Pulse sequence: 60, 120, 180

Connection Frequency converter

X73

Standardised speed
The speed determined during standardisation is saved in
this parameter and can be altered if necessary (not
recommended).

FC

24 V
Start FC
1224 V DC in (Alarm)
0/420 mA out (Setpoint)
GND
Screen

1
3
4
5
6

Fuel meter
Fuel meters with Namur or Reed output and Open
Collector (pnp) can be used.
The system continually calculates the current fuel
throughput for the fuel selected. Calculation time
is dynamic and is between 1 and 10 seconds.
If the meter does not supply an impulse for 10 seconds,
throughput Zero is displayed. This means that the
transmitter should have a minimum impulse frequency of
0.1 Hz at minimum throughput.
At maximum throughput the maximum frequency is 300 Hz.

Impulse value Gas


Depending on the type of gas meter, m3 or ft3 can be
selected.
Impulse value Oil
Depending on the type of oil meter, l or gal can be
selected.
Fuel meters
Gas

1
X71

Example:
Data on gas meter: 250 impulses per m3
Throughput full load:
20 m3/h ^
= 5000 Imp./h ^
= 1,388Hz
Throughput partial load: 4 m3/h ^
= 1000 Imp./h ^
= 0,277Hz

2
3
4

Oil
X72

1
2
3
4

10 V DC
Pulse
GND
Screen

10 V DC
Pulse
GND
Screen

2 core
3 core PNP

2 core
3 core PNP

Fuel meter
Oil

Fuel meter
Oil

75

9
9.11.2 Process data
The process data is located in the volatile memory and is
reset automatically following lockout.

Max Stat Dev

Num Dev>...

The maximum static deviation shows the largest speed


deviation at the end of value input alteration.

Shows the frequency of static deviations at the end of a


value input alteration, which were > 0.3% or > 0.5%.

Max Dyn Dev

Absolute Speed

The maximum dynamic deviation shows the largest


speed deviation between actual speed and set speed in
multistage operation.

Shows the actual speed.

9.11.3 Product ID and SW Version


Product ID

SW Version

The Product ID gives information about:


Type description (FC module)
Production data
Serial number
Parameter set code
Parameter set version

The SW Version gives information about the software


version of the FC module.

76

9
9.12 O2-Module
Depending on the password entered this displays
the parameters for the operator or the engineer (only
W-FM200).

9.12.1 Configuration
O2 sensor

MaxTempFlueGas ...

To determine O2 the O2 sensor QGO20 has to be


activated.

If the flue gas temperature set is exceeded a warning


message is given. The set limit can be set individual for oil
and gas and indicates increased appliance losses. The set
value should be approx. 20% above the nominal flue gas
temperature of the appliance manufacturer.

Supply air sensor / flue gas sensor


To be able to determine the combustion efficiency the
supply air sensor and the flue gas sensor must be
connected and configured.

9.12.2 Display values


Current O2 value

QGO Heating Load

Current O2 value measured by the sensor QGO20.

Display of the actual heat rating in %.


The heat rating is in the range of 0 to 60%. The percentage
displayed corresponds to an impulse/pause ratio relating
to 2 seconds and 230 V.
60% heat rating corresponds to 1.2 seconds impulse and
0.8 seconds pause.
After approx. 15 minutes the sensor has reached the set
point of 700 C (pre-requisite for release of the O2 control).

Supply air temperature


Air intake temperature measured by the Pt/Ni sensor.
Used to determine combustion efficiency.

Flue gas temperature


Flue gas temperature measured by the Pt/Ni sensor. Used
to determine combustion efficiency.

Heating Load:
Start heat load up to 100 C ______________approx. 13%
Heat up process
approx. 60%
Operating temperature ______________approx. 15 to 25%
QGO Resistance

QGO SensorTemp
Current operating temperature of the O2 sensor.

The internal resistance is a measure for the function ability


of the sensor. It changes during the operating time.
If the internal resistance is < 5 or > 150 the sensor is
ageing.

9.12.3 Product ID and SW version


Product ID

SW Version

The Product ID gives information about:


Type description (O2 module)
production date
Serial number
Parameter set code
Parameter set version

The SW Version gives details about the software version


of the O2 module.

77

9
9.13 SystemConfig
LC operating mode

TempLimit

The configuration of the load controller operating mode is


identical to that in menu LoadController (Ch. 9.8.4).
However, the setting in SystemConfig has priority.
This means that if an external load controller is selected in
menu SystemConfig you cannot change over to internal
operating mode in menu LoadController.

The configuration of the TL_ThresholdOff and TL_SD_Off


is identical to that in menu LoadController (Ch. 9.8.2).
The configuration for SensSelect and for MeasureRange
is identical to that in menu LoadController (Ch. 9.8.4).

Ext Input X62 U / I


The configuration of the external input X62 is identical to
that in menu LoadController (Ch. 9.8.4).

O2Ctrl/Guard.....
The configuration is identical with that in menu
O2Ctrl/Guard (Ch. 9.7.1).

9.14 Operating hours


Gas operation

TotalOperHoursR

Operating hours for fuel Gas since last reset.

Total operating hours oil and gas since last reset.

Stage 1 / Mod

TotalOperHours

Operating hours of stage 1 or modulating (oil) since last


reset.

Total operating hours oil and gas.


This value cannot be reset.

Stage 2

Unit under voltage

Operating hours of stage 2 (oil) since last reset.

Total hours the W-FM has been connected to mains


voltage.
This value cannot be reset.

Stage 3

Reset

Operating hours of stage 3 (oil) since last reset.

Here all parameters, which can be reset, can be set to


Zero.

78

9
9.15 Start counter
Start counter Gas

TotalStartCounterR

Burner starts with fuel gas since last reset.

Total burner starts with fuel oil and gas since last reset.

Start counter Oil

TotalStartCounter

Burner starts with fuel oil since last reset.

Total burner starts with fuel oil and gas.


This value cannot be reset.
Reset
Here all parameters, which can be reset, can be set to
Zero.

9.16 Fuel meters


If an oil or gas meter is installed and configured (Ch.
9.11.10), the fuel quantities determined can be called up
and reset here.
Current throughput

Volume Gas R

Displays the current throughput for gas in m3/h or oil in l/h.

Fuel throughput for gas in m3 since last reset. Reset by


pressing the ENTER button.

Volume Gas
Reset date gas

Total gas throughput in m3.


This value cannot be reset.

Date of last reset for fuel gas.

Volume Oil

Reset date oil

Total oil throughput in litres.


This value cannot be reset.

Date of last reset for fuel oil.

Volume Gas R
Fuel throughput for oil in litres since last reset. Reset by
pressing ENTER button.

79

9
9.17 Updating
9.17.1 Parameter backup
Backup-Info

ABE -> LMV5...

Displays information about the date and time of the last


parameter backup as well as their system components.

Loads the data from the display and operating unit (ABE)
to the base unit (W-FM). Pre-requisite is that the burner
identification of the ABE and the W-FM are identical or
that burner identification of the W-FM is still in its delivery
condition.
The data in the W-FM are overwritten and can no longer
be reproduced.

LMV5... -> ABE


Loads the data from the base unit (W-FM) to the display
and operating unit (ABE).
Any data in the ABE is overwritten and can no longer be
reproduced.

9.17.2 Load SW from PC


Updates the software of the display and operating unit
(ABE) with PC-Tool using a serial interface.

9.18 Password
PW login

Deactivate PW (PW Logout)

After entering the engineers password additional access


to the engineers level is available. The password is
deactivated 120 minutes after the last input.

Using this parameter the password protected level can be


protected at an earlier stage.

9.19 TV test
LossFlameTest

SLT Test

The flame failure test interrupts the flame sensor signal and
it can be checked if the W-FM will go to lockout.

During the SLT Test the control circuit as well as the


temperature guard are bridged and the burner is operated
at maximum load, allowing the response of the safety
temperature limiters to be checked.

80

Gas + Oil

Times

Inputs

Gas

Gas + Oil

Output

Gas

X10-02: 6 q
X3-02: 1 1
X4-01: 3
X4-01: 3
X9-03: 2
X9-03: 4 3t
X7-03: 1 3w
X9-03: 3 3
Gas pressure switch GPSVP X9-03: 2
Burner motor / Fan
X3-01: 1
9/0
Ignition
X4-02
u
3-way solenoid
X4-03
Alarm
X3-01: 2 i N
Safety relay internal
X3-04: 1/2
Safety relay Gas
X9-01: 1
Valve pilot ignition Gas
X9-01: 2
Fuel valve 1 Gas
X9-01: 4
Fuel valve 2 Gas
X9-01: 3

90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position

Home run

N
N

N
N

49 4
N
N

A
B
B

C
C
C
A
B
B

c
A
G
G

N
N

B
B
B
B
i
A
A
A
A
B
B

N
N

tmx1
B
B
B
B
i
A
A
A
A
B
B

N
N

B
B
B
B
i
A
A
A
A
B
B

N
N

tmx1
B
B
B
B
i
A
A
A
A
B
B

N
N

N
N
4

A
A
A
A
B
B

B
B
B
B

N
N

N
N

N
N
4

D
D
A

A
A
A

D
F

Ignition position
Flame signal ON

N
N

N
N

D
D
A

A
A
A

D
F

N
N

N
N

D
D
A

F
D
F
F
L
A
A
A

t42 t44

44

N
N

N
N

D
D
A

F
D
F
F
L
A
A
A

50

Flame stabilisation

TSA

Ignition OFF
42

N
N

N
N

F
D
F
F
L
A
A
A
a
D
D
A

t52

52

Interval time 2

t38

Fuel valve
ON
40

N
N

N
N

tmx1
F
D
F
F
L
A
A
A
a
D
D
A

54

Low fire position

tmx1
B
B
B
B

Pre-ignition
38

N
N

N
N

D
D
A

G
D
F
G
L
A
A
A

60

Operating phase 1

B
B
B
B

Stepping motor in
ignition position
36

N
N

N
N

D
D
A

L
A
A
A

D
F

A
A

k
A
A

tmx1 tmx1 tmx1

62 70 72
or and
t62 t70

Operating phase 2

t34

34

After burner time

tmx2
B
B
B
B

Pre-purge
32

Air stepping motor in


post purge position

t30
tv

30

k
A
A

t74

74

tn1

t01 tmx1 tmx1


C
B
C
B
C
B
C
B
c
k
A/c A/c
e A/c A/c 9
A/c A/c
C
A

Air stepping motor in


pre-purge position
24

k
A
A
A
A

tmx1

76

Post purge

Fan = ON

21 22
und
t21 t22

Safety fuel
valve = ON
Safety
relay = ON
20

E
E
m
k
A
A
A
A

t78

78

tn3 5

90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position

Standby

10 12
und
t10

N
N

c
A
H
H

k
c

w
w

tmx2
B
B w
B

79

t0

Safety phase

01

TSA2

Shutdown

Direct start

X4-01: 1
X3-04: 1

Lockout phase

00

TSA1

Operation

Valve proving

81

82

83

N
N

N
N

N
N

A
N
N

i
A
A
A

D
D

7
i
A
A
A

D
D

D
D

i
A
A
A

N
N

a
N

D
D

i
A
A
A

t80 t81 t82 t83

80

Press test
V1 = Closed, V2 = Closed
Fill valve train
V1 = Open, V2 = Closed
Test no press
V1 = Closed, V2 = Closed
Empty valve train
V1 = Closed, V2 = Open

Operating phase
Timer-Event- Link
Timer 1
Timer 2
Timer 3 = Phase max. time
Fuel switch GAS
Safety circuit
Temperature guard internal
Controller ON
Flame signal
Air press. switch APS
BrnFan motor aux-contact
or FGR- Fan-PS
CPI or VP-PS
Low gas press.sw. LGPS
Release Gas
Lockout HGPS.

Gas direct ignition

tv

Start up

9.20 Sequence of operation diagrams

Sequence diagram gas with direct ignition

Fuel

Air

Actuators

81

82

Times

Gas + Oil

Inputs

Gas

Gas + Oil

Output

Gas

90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position

Home run

X10-02: 6 q
X3-02: 1 1
X4-01: 3
X4-01: 3
X9-03: 2
X9-03: 4 3t
X7-03: 1 3w
X9-03: 3 3
X9-03: 2
X3-01: 1
9/0
X4-02
u
X4-03
X3-01: 2 i N
X3-04: 1/2
X9-01: 1
X9-01: 2
X9-01: 4
X9-01: 3

9
8

N
N

N
N

49 4
N
N

A
B
B

C
C
C
A
B
B

c
A
H
H

Air stepping motors in


pre-purge position
tmx1
B
B
B
B

N
N

B
B
B
B
i
A
A
A
A
B
B

N
N

tmx1
B
B
B
B
i
A
A
A
A
B
B

N
N

B
B
B
B
i
A
A
A
A
B
B

N
N

tmx1
B
B
B
B
i
A
A
A
A
B
B

N
N

N
N
4

A
A
A
A
B
B

B
B
B
B

N
N
N
N

N
N
4

D
D
A

A
A
A

D
F

Ignition position
Flame signal ON

N
N
N
N

D
D
A

A
A
A

D
F

N
N
N
N

D
D
A

F
D
F
F
L
A
A
A

t42 t44

44

N
N
N
N
N

D
D
A

F
D
F
F
L
A
A
A

50

Flame stabilisation

TSA

Ignition OFF
42

N
N

N
N

F
D
F
F
L
A
A
A
a
D
D
A

t52

52

Pilot ignition valve OFF

t38

Fuel valve
ON
40

N
N

N
N

tmx1
F
D
F
F
L
A
A
A
a
D
D
A

54

Low fire position

B
B
B
B

Pre-ignition
38

N
N

N
N

D
D
A

G
D
F
G
L
A
A
A

60

Operating phase 1

tmx2
B
B
B
B

Stepping motors in
ignition position
36

N
N

N
N

D
D
A

L
A
A
A

D
F

A
A

k
A
A

tmx1 tmx1 tmx1

62 70 72
or and
t62 t70

Operating phase 2

t34

34

After burner time

t01 tmx1 tmx1


C
B
C
B
C
B
C
B
c
k
A/c A/c
e A/c A/c 9
A/c A/c
C
A

Pre-purge
32

Air stepping motor in


post purge position

t30
tv

30

k
A
A

t74

74

tn1

24

k
A
A
A
A

tmx1

76

Post purge

Fan = ON

21 22
und
t21 t22

Safety fuel
valve = ON
Safety
relay = ON
20

E
E
m
k
A
A
A
A

t78

78

tn3 5

90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position

Standby

10 12
und
t10

N
N

c
A
H
H

k
c

w
w

tmx2
B
B w
B

79

t0

Safety phase

01

TSA2

Shutdown

Direct start

X4-01: 1
X3-04: 1

Lockout phase

00

TSA1

Operation

Valve proving

81

82

83

N
N

N
N

N
N

A
N
N

i
A
A
A

D
D

7
i
A
A
A

D
D

D
D

i
A
A
A

N
N

a
N

D
D

i
A
A
A

t80 t81 t82 t83

80

Press test
V1 = Closed, V2 = Closed
Fill valve train
V1 = Open, V2 = Closed
Test no press
V1 = Closed, V2 = Closed
Empty valve train
V1 = Closed, V2 = Open

Operating phase
Timer-Event- Link
Timer 1
Timer 2
Timer 3 = Phase max. time
Fuel switch GAS
Safety circuit
Temperature limit internal
Controller ON
Flame signal
Air press. switch APS
BrnFan motor aux-contact
Or FGR-Fan-PS
CPI or VP-PS
Low gas press. sw. LGPS
Release Gas
Lockout HGPS.
Gas press. switch GPSVP
Burner fan motor
Ignition
3-way solenoid valve
Alarm
Safety relay internal
Safety relay Gas
Valve pilot ignition Gas
Fuel valve 1 Gas
Fuel valve 2 Gas

Gas pilot ignition

tv

Start up

Sequence diagram gas with pilot ignition

Fuel

Actuators

Air

Times

Gas + Oil

Inputs

Oil

Gas + Oil

Output

90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position

Oil

90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position

Home run

8
N

Stepping motors in
ignition position

u
i

Pre-ignition

N
N

N
N

N
N

N
N

N
N

N
N

2
N
N

N
N

N
N
N

N
N
N

A
A
A
A
A
A
D
N

D
D

N
N
N

D
D
D
D
L
A
A
A
A
A
A
D
N

t42 t44

Flame stabilisation
N

N
N
N

D
D
D
D
L
A
A
A
A
A
A
D
N

50

N
N
N

D
D
D
D
L
A
A
A
A
A
A
D
N

t52

52

Interval time 2

Ignition position
Flame signal ON
44

N
N
N

tmx1
D
D
D
D
L
A
A
A
A
A
A
D
N

54

Low fire position

Ignition OFF
42

N
N
N

G
D
D
G
L
A
A
A
A
A
A
D
N

60

Operating phase 1

34

N
N
N

N
N
N

L
A
A
A
A
A
A
D
N

D
D

N
N

A
A

k
A
A

tmx1 tmx1 tmx1

62 70 72
or and
t62 t70

Operating phase 2

9/0

Pre-purge
32

After burner time

t01 tmx1 tmx1


C
B
C
B
C
B
C
B
c
k
A/c A/c
e A/c A/c 9
A/c A/c
C
A

30

Air stepping motor in


post purge position

Air stepping motors in


pre-purge position
24

Fuel valve
ON

36 38 40
und und
t30
t34 t36 t38
tv
TSA1
tmx2
tmx1
tmx1
tmx1 tmx3
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
D
D
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
i
i
i
i
c
C
A
A
A
A
A
A
C
A
A
A
A
A
A
c
C
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
r
C
A
A
C
A
A
A
A
A
A
A
B
B
B
B
B
B
B
H
D
9
N
N
N
N
N
N
N
N
2 2 2 2 2 2
N
N
49 4 4 4 4 4 4 4 4

Fan = ON

21 22
und
t21 t22

Safety fuel
valve = ON
Safety
relay = ON
20

k
A
A

t74

74

tn1

3
3
3

Standby

10 12
und
t10

k
A
A
A
A

tmx1

76

Post purge

q
1

Safety phase
01

E
E
m
k
A
A
A
A

t78

78

tn3 5

X10-02: 6
X3-02: 1
X4-01: 3
X4-01: 3
X9-03: 2
X5-02: 1
X5-02: 2
X6-01: 1
X3-01: 1
X4-02
X4-03
X3-01.2
X3-01: 1/2
X6-03: 3
X8-02/-03
X7-01
X7-02
X6-02: 3

Lockout phase
00

TSA2

Shutdown

N
N

H
N

c
A

k
c

tmx2
B
B
B

tmx1

79

X4-01: 2
X3-04: 1

Oil direct ignition

TSA1

Operation

Direct start

Operating phase
Timer-Event-Link
Timer 1
Timer 2
Timer-Event- Link
Fuel switch OIL
Safety circuit
Temperature limit internal
Controller ON
Flame signal
Air press. switch APS
BrnFan motor aux-contact
or FGR-Fan-PS
CPI or VP-PS
Low oil press. sw. LOPS
High oil press. sw. HOPS
Start release Oil
Burner fan motor
Ignition
3-way solenoid on APS
Alarm
Safety relay internal
Safety relay Oil
Fuel valve 1 Oil
Fuel valve 2 Oil
Fuel valve 3 Oil
Magnetic clutch/sep. Pump

tv

Start up

Sequence diagram oil with direct ignition

Fuel

Actuators

Air

83

9
Legend for the sequence diagrams
Signal ON
A

Signal OFF

Reaction if relevant signal to sequence diagram is not given


Jump to operating phase 01, with repetition counter = 0 on to phase 00 otherwise in Ph 12

Jump to operating phase 10

B
C

Stop until completion of Phase max. time (tmx...), then jump to phase 01

Jump to operating phase 70

With heat demand from controller and parametered direct start jump to phase 79,
otherwise to phase 10

Without valve proving jump to operating phase 70, otherwise to phase 80

Jump to operating phase 62

Stop until completion of Phase max. time (tmx...), then jump to phase 10

03 s

Jump to operating phase 01, with repetition counter = 0 on to phase 00 otherwise in Ph 12

030 s

Jump to operating phase 01, with repetition counter = 0 on to phase 00 otherwise in Ph 12

03 s

Jump to operating phase 01, with repetition counter = 0 on to phase 00 otherwise in Ph 12


i

With parametered direct start jump to phase 79, otherwise to phase 10

Output: ON
Output: OFF
Input: no influence

1 Depending on parametering with or without LP


2 Depending on parametering short or long pre-ignition time and pump on time
3 Delayed shutdown in TSA1 + TSA2
4 Depending on parametering output as start signal or PS relief valve
5 Depending on parametering Normal/Direct start
6 Follow on phase 24
7 Only with valve proving during commissioning
8 Depending on parametering with or without alarm at start inhibition
9 With parametered continuous running fan
0 Fan remains driven as before
q Depending on parametering with or without extraneous light test in standby
w With deviation during start up follow on phase 10
e With normal venting: Check for ON in phase 10, stop until completion of phase max. time, then jump to phase 01
With continuous running fan: Check for ON in phase 10 and 12, stop until completion of phase max. time, then jump to
phase 01
r If the min. oil pressure switch input has been parametered to Act from ts no check is carried out prior to completion of
TSA 1 time
t If the low gas pressure switch input has been parametered to deactOgp no check is carried out with oil with gas pilot
ignition
z If the output is parametered to DirectCoupl, the safety valve Oil has to be connected. The output is driven together
with the fan and stops 15 s after the fan in time delay.
u If the output is parametered to PS relief, this (output PS relief valve) is inverted logically
i The alarm output can be temporarily deactivated for the current fault

84

9
Assignment times:
Time

Description

t0
t01
t10
t21
t22
t30
t34
t36
t38
t42
t44
t52
t62
t70
t74
t78
t80
t81
t82
t83
tmx1
tmx2
tmx3
TSA1
TSA2
tv

Post-purge lockout setting


MaxTime_SiPhase
MinTimeHomerun
MinTimeStartrelease
FanRunupTime
Prepurgetime part 1
Prepurgetime part 3
MinOnTimeOilPump
PreIgnTime_Gas / Oil
PreIgnTime_Off
IntervalTime 1 Gas / Oil
IntervalTime 2 Gas / Oil
MaxTime low fire
Afterburn time
PostpurgeTime 1 Gas / Oil (tn1)
PostpurgeTime 3 Gas / Oil (tn3)
Valve proving empty time
Leakage test test time atm. pressure
Leakage test filling test
Leakage test test time gas pressure
Max. damper run time
MaxTime start release
MaxTime venting HO Oil
Safety time 1 Gas / Oil
Safety time 2 Gas / Oil
Prepurge time_Gas / Oil

Actuators
In Standby:
The SA can be moved within the permitted
position range, will however, always be driven
to the standby position, and must be in
standby for phase change.

Abbreviations
FGR
CPI
PS
VP
BrnFan
PL or LF
AD
APS
PP
S
SR
STB
TL
PV
Z

Flue gas recirculation


Closed position indicator
Pressure switch
Valve proving
Auxiliary contact burner fan contactor
Low fire position
Air damper
Air pressure switch
Post-purge position / post-purge
Standby
Safety relay
Safety temperature limiter
Temperature guard
Pre-purge position / pre-purge
Ignition position

85

10 O2 sensor
Installing the O2 sensor

DANGER

Electrically isolate the plant


Prior to installation, switch off the mains
switch and the safety switch.
Failure to comply could cause death or
serious injury by electric shock.

The O2 sensor must only be fitted with the relevant


flanges and to the enclosed drawing.

No infiltrated air must enter before, and at least 2 x


diameters of the flue gas ducting after the sensor.

The sensor should be fitted as close as possible after


the flue gas outlet terminal of the appliance, but no
closer than 1 diameter of the flue gas pipe.

During operation, the sensor is heated to


approx. 700C.
DANGER

Sensor position

min.
1x

The sensor must not be fitted vertically from below,


pointing upwards.

The favourable fitting position is vertically from above


or up to 45 angle either side of vertical.

The minimum distance between the inner wall of flue


gas duct and the flue gas sampling outlet hole on the
flange is 10 mm.

1020

Air

up to 45

Installation instruction

Gas tight (sealed)


welding

do not insulate

86

min. 10 mm

10
Electrical connection
The 6 core connection line between the terminal rail X1 of
the O2 module and the sensor is fitted with a screened line
twisted in pairs (3 x 2 x 0.25 mm2).
One side of the screening should be attached to the
mounting plate of the O2 module. There must be no
connection between GND and earth.
The sensor heating L (Q4), N (Q5), PE should be fitted to
the O2 module terminal rail X10 Pin 1, 2, 3 with a minimum
3 x 0.75 mm2.
The line of the sensor heating must be a separate cables.
Outside diameter of the cable = Max. 8 mm.

Connection to O2 module

X10

Mains

O2 module

L (Q4)
N (Q5)
PE

Q5
Q4

GND

U3
G2
M
B2
M
B1

U3

B2
M
B1

L, N, PE:

Supply voltage sensor heating 230V pulsed


(N switching)

U3 :

Temperature compensation 1 A/K relating to


absolute zero, i.e. 273 A corresponds to a
sensor temperature of 0 C

G2 :

Feeder voltage temperature compensation 2


to 10V

B3 / M :

Thermo element 0 to 33 mV
29.1 mV corresponds to approx. 700 C

B1 / M :

Nernst voltage (0 to 700 mV)

Nernst voltage at 700 C sensor temperature


700C

120
100
Nernst voltage [mV]

X1

G2

80
60
40
20
0
0,05

0,1

0,2

0,5

10

20

O2 content [%]
87

11 Frequency converter
If the W-FM 200 is used in connection with a frequency
converter VLT 2800 or VLT 5000 (Danfoss),the
parametering of the frequency converter has to be
checked and if necessary adjusted.

Further information and details relating to the frequency


converter can be found in the manufacturers
documentation.

If a frequency converter (Siemens) fitted directly to the


burner motor is used, parametering of the FC is not
required or indeed possible.

11.1 Programming and display unit frequency converter Series VLT


The programming and display unit allows manual access to
the frequency converter during burner operation or
commissioning.
Furthermore the programming and display unit shows
operating values and is used to program the frequency
converter.
Programming the frequency converter with the W-FM or its
ABE is not possible.
Note Please observe the manufactures installation and
operating instruction for the frequency converter.

Programming and display unit VLT 2800

Six digit LCD display


+/- Buttons
Selection of parameters and value changes
Quick-Menu
Call up menu or return without changes
Change Data
Confirm value changes
LED display of operating conditions

Stop/Reset
Stop motor / reset lockout
Start
Starts the frequency converter

88

11
Programme and display unit VLT 5000

4 line LCD display

24,3% 30,2% 13,8A

50.0 Hz
Menu
Call up of menus for all parameters

Operation

Quick-Menu
Call up of all parameters in the quick menu
Display/Status
Selection of display/change to display mode
OK
Confirmation of value changes

DISPLAY
STATUS

MENU

Cancel
Cancel value changes
Change Data
Changes the parameter selected

CANCEL

OK

+/- Buttons
Selection of parameters and value changes
Arrow buttons
Selection of parameter groups and value changes

LED display of operating conditions

Stop/Reset
Stop motor/reset lockout
JOG
Activate fixed speed / deactivating (parameter 15)

STOP
RESET

JOG

FWD.
REV.

START

FWD./REV.
Change of rotation direction (parameter 16)
Start
Starts the frequency converter

89

11
11.2 parametering the VLT 2800
In connection with the W-FM 200, certain parameters on
the frequency converter have to be checked and set if
necessary.
No.

Description

Value

Unit

019 Mains-On-Mode

automatic restart at mains activation

100 Configuration

speed control with motor slip adjustment

101 Torque reference line

constant torque

xx.yy

kW

to name plate

103 Motor voltage

xx

to name plate

104 Motor frequency

xx

Hz

to name plate

105 Motor current

xx.yy

to name plate

106 Motor speed

xxxx

kW

to name plate

123 Frequency stop function

Hz

activation motor free run if not reached

126 Direct current brake time

sec.

127 Frequency DC brake

Hz

activation of DC brake if exceeded

132 Voltage DC brake

50

brake voltage

133 Voltage increase

no voltage increase

134 Load compensation

80

load reference line

136 Slippage adjustment

0.0

no motor slip adjustment

144 Increase AC brake

1.0

202 Max. frequency

52.5

Hz

upper limit value output frequency

204 Min set point

0.0

Hz

minimum set point input

205 Max. set point

52.5

Hz

maximum set point input

207 Ramp time Open 1

81/152/283

sec.

acceleration time from 0 Hz to nominal frequency

208 Ramp time From 1

81/152/283

sec.

delay time from nominal frequency to 0 Hz

211 Ramp time Jog

81/152/283

sec.

acceleration/delay time fixed speed

212 Ramp time From Quick Stop

81/152/283

sec.

delay time quick stop

Hz

52.5

Hz

102 Motor rating

Meaning

duration for DC brake

128 Thermal motor protection

213 Frequency Jog


226 Warning fmax limit
1 up to size 50
2 on sizes 60 to 70
3 WK burners

90

alternating current brake deactivated

frequency for fixed speed

11
No.

Description

Value

Unit

Meaning

302 Input 18 digital

Start signal from W-FM200 contact X73:1/2

303 Input 19 digital

No function, input deactivated

304 Input 27 digital

Direct current brake

305 Input 29 digital

No function, input deactivated

307 Input 33 digital

Recording, reset with W-FM 200

308 Input 53 analogue

0-

314 Input 60 analogue

set point signal from W-FM200 terminal X73:4

314 Input 60 min. scaling

4.0

Alower set point signal min.

315 Input 60 max. scaling

20

Aupper set point signal max.

318 Function after set point fault

off, function deactivated

319 Output 42 analogue

recorder output 0-20 mA

323 Relay output

38-contacts are switched at alarm

341 Output 46 digital

output reacts at alarm or warning

349 Delay speed comp.

ssystem delay time

400 Brake function

with alternating current brake

405 Type of recording

10

10 automatic restart trials after termination

445 Motor hold switching

Holding the motor

no function, input deactivated

91

11
11.3 Parametriering VLT 5000
In connection with the W-FM 200 certain parameters on
the frequency converter have to be checked and set if
necessary.

No.

Display

Data

Meaning

002 Operating mode

REMOTE

013 Setp. Local Mode

BLOCKED

019 Mains ON mode

AUTO RESTART

Automatic restart when mains switch on

100 Configuration

WITH SLIP COMP.

Speed control with slippage adjustment

101 Torque ref. line

N-CONST-TORQUE

Constant torque

Set nominal rating

as per name plate

Set nominal voltage

as per name plate

Set nominal frequency

as per name plate

105 Motor current

Set nominal current

as per name plate

106 Motor nom. speed

Set nominal speed

as per name plate

102 Motor rating


103 Motor voltage
104 Motor frequency

Remote control
Set point input only with digital inputs from W-FM

113 Load adjust. low

80%

Load compensation in lower speed range

114 Load adjust. high

80%

Load compensation in upper speed range

115 Slip. adjustment

0.0%

no slippage adjustment

122 Stop function

DC BRAKE

active at shutdown

123 Freq. stop function

2Hz

activates motor free run if not reached

124 DC Hold current

0.0%

Off

125 DC Brake current

50%

corresponds to half motor nominal current

126 DC Brake time

2 sec.

Duration DC braking

127 DC br. start freq.

2Hz

activates motor free run brake if exceeded

128 Therm. motor protection


202 Max. frequency

52.5 Hz

Upper limit value output frequency

204 Min set point

0.0 Hz

Minimum set point input

205 Max set point

52.5 Hz

Maximum set point input

207 Ramp Open

181/152/283 sec

Acceleration time 0 Hz to nominal speed

208 Ramp From

181/152/283 sec

Delay time nominal speed to 0 Hz

212 Ramp Q Stop

181/152/283 sec

Delay time quick stop

213 Frequency Jog

0.0 Hz

Frequency for fixed speed

216 f-max limit

52.5 Hz

Warning at speed limit

1 up to size 50
2 on sizes 60 to 70
3 WK burners

92

11
No.

Display

Data

Meaning

300 Input 16 digital

NO FUNCTION

no function, input deactivated

301 Input 17 digital

NO FUNCTION

no function, input deactivated

302 Input 18 digital

STARTS

303 Input 19 digital

NO FUNCTION

304 Input 27 digital

DC BRAKE

305 Input 29 digital

NO FUNCTION

no function, input deactivated

306 Input 32 digital

NO FUNCTION

no function, input deactivated

307 Input 33 digital

RECORDING

tart signal from W-FM 200 contact X73:1/2


no function, input deactivated
Direct current brake

Rest by W-FM 200

314 Input 60 analogue

SETPOINT

315 Input 60 scale min

4.0 m

Alower set point signal min.

316 Input 60 scale max

20.0 m

Aupper set point signal max.

OFF

no function, input deactivated

318 Funct. foll. setp. fault

Set point signal from W-FM 200

319 Output 42 d or a

0-I MAX = 0-20 m

321 Output 45 d or a

ALARM

output reacts at alarm

323 Output 1-3 relay

ALARM

Contacts switched at alarm

400 Brake function


405 Recording
445 Hold switching

OFF
10 x AUTOMATIC
ACTIVE

Aanalogue recorder output 0-20 mA

no brake resistance
10 automatic restarts after termination
Holding the motor

93

12 Cause and rectification of faults (fault list)


Faults are displayed alternating as codes and clear text
information. The following fault possibilities are listed in
order of fault code and diagnostic code.
Fault rectification:
Call up fault history - analyse last fault
Determine cause, determine reason
Rectify fault
If necessary, record fault

Display - Fault history


Operating mode
Fault history
1 18.06.99
C:15 D:1
Start No:
Load:25.0

10:35
P:81
123456
Gas

Stepping motor
fault from ECR

C: = Fault code
D: = Diagnostic code
P: = Phase

Fault list
Fault
list

Fault
code

Cause

Recommended measures

01
02
03
04
05

01
0107
0144

01,02

ROM Fault
RAM Fault
Fault at internal data comparison
Synchronisation fault
Fault flame signal booster test

0104
011B

Fault internal hardware test


Fault inputs / outputs

1)
1)
1)
1)
1)
Replace flame sensor
1)
The number of the diagnostic codes shows
which input is faulty.
Neutral conductor may be missing, (or not zero V)

06
10

01
02
03
04
05
06
07
08
09
0A
0B
0C
0D
0E
0F
10
11
12
13
14
15
16
17
18
19
1A
1B

Load controller on/off


Fan contact
Oil operation selection
Gas operation selection
Reset
Pressure switch Oil maximum
Pressure switch Oil minimum
Pressure switch valve proving
Safety valve Oil return signal
Fuel valve 1 Oil return signal
Fuel valve 2 Oil return signal
Fuel valve 3 Oil return signal
Safety valve Gas return signal
Fuel valve 1 Gas return signal
Fuel valve 2 Gas return signal
Fuel valve 3 Gas return signal
Safety circuit burner flange
Safety relay return signal
Pressure switch Gas minimum
Pressure switch Gas maximum
Ignition transformer return signal
Fan pressure switch
Start release Oil
Residual oil immediate start
Load controller open
Load controller closed
Start release Gas

The fault could be caused by capacitance loads,


causing longer than 10 ms to reduce the voltage
to 0 Volts before the relay switches off.

Check control wiring

1)

1) If it occurs sporadically improve EMC measures.


If it occurs permanently replace W-FM

94

12
Fault
list

Fault
code

11
15

01
013F

16

17

18

01
02
04
08
10
20
0023
00
01
02
03
04
05
0A
0B
0C
0D

Cause

Recommended measures

Short circuit contact return signal network


Stepping motor position or
speed not reached

1)
The diagnostic value is made up of the
faults listed or their combination.
The individual diagnostic codes are added
hexadecimal.
With sporadic occurrences improve EMC measures.

Positioning fault air stepping motor


Positioning fault fuel stepping motor
Positioning fault auxiliary stepping motor 1
Positioning fault auxiliary stepping motor 2
Speed not reached
Positioning fault auxiliary stepping motor 3
Plausibility fault in ECR
Fault ratio curve air stepping motor
Fault ratio curve fuel stepping motor
Fault ratio curve auxiliary stepping motor 1
Fault ratio curve auxiliary stepping motor 2
Fault ratio curve auxiliary stepping motor 3
Fault ratio curve frequency converter
P-content outside of permissible range
I-content outside of permissible range
Tau outside of permissible range
Calculated O2 set point outside
of permissible range
0E
Calculated O2 min value outside
of permissible range
0F
Calculated O2 ratio value outside
of permissible range
13
Load /point number input of the
ABE outside of permissible range
14
Calculated standardisation
value outside of permissible range
20
With hysteresis compensation, exceeding
the permissible adjustment range
21
Load /point number input of the ABE
outside of permissible range
22
At switch command none
of the def. cases was met
23
At switch command no defined
ECR phase was recognised
0103, 3F Internal communication fault ECR
01
TimeOut at programme run
synchronisation of data transfer
02
TimeOut at data transmission
03
CRC fault at data transfer
3F
Different values detected at
data synchronisation

Invalid curve data

With permanent occurrence, replace relevant


stepping motors (see diagnostic code).
Check if motor is overloaded
The diagnostic code describes the cause
Check ratio curve of relevant motor or FC module
and parameter if necessary.

Check O2 control parameter and adjust if necessary

Check if the values entered are valid.


If necessary repeat setting for O2 control

1)

1)

Check curve data for invalid entries.


For initial commissioning of the unit:
Correct to the valid value range
If previously operating correctly:
Replace defective base unit
1) With sporadic occurrences improve EMC measures.
With permanent occurrence replace W-FM

95

12
Fault
code
19

Diagnostic Cause
code
012F

01
02
04
08
20
1A

01

1B

1C

013F

01
02

1D

04
08
10
20
013F

1E

01
02
04
08
10
20
013F

01
02
04
08
10
20

96

Fault at comparison pot channel A to B.


The diagnostic code shows which motor
is faulty.
Air stepping motor faulty at comparison
pot channel A to B
Active fuel stepping motor faulty
at comparison pot channel A to B
Auxiliary stepping motor 1 faulty
at comparison pot channel A to B
Auxiliary stepping motor 2 faulty
at comparison pot channel A to B
Auxiliary stepping motor 3 faulty
at comparison pot channel A to B
The curve gradient of a partial
curve section is too high

The programming mode remains active


in phase 62 and the set positions
(normal operation) have not been
reached

Recommended measures
The diagnostic value is made up of the faults listed
or their combination. The individual diagnostic codes
are added hexadecimal.
With sporadic occurrences, improve EMC
measures.
With permanent occurrence, replace relevant
steppingmotors (see diagnostic code).

Max. gradient between two support points:


- 3.6 per 0.1 % (30s ramp)
- 1.8 per 0.1 % (60s ramp)
- 0.9 per 0.1 % (120s ramp)
Alter load matching of the support point until
the conditions are met.
Curve parametering should be carried out in manual
operation to avoid shutting down the load controller.
However, if the TL reacts this can lead to shutdown.
The value (curve point) currently being changed
can however be locked in Standby or lockout

The relevant ignition positions


have not been parametered.

The diagnostic value is made up of the faults listed


or their combination. The individual diagnostic
codes are added hexadecimal.
Ignition pos. air stepping motor not param. Set ignition position
Ignition pos. of active fuel stepping motor
not parametered
Ign. pos. auxiliary stepping motor 1 not param.
Ign. pos. auxiliary stepping motor 2 not param.

Ignition pos. FC not parametered


Ign. pos. auxiliary stepping motor 3 not param.

Run time fault stepping motors /


frequency converter

The diagnostic value is made up of the faults listed


or their combination. The individual diagnostic
codes are added hexadecimal.
Run time fault air stepping motor
Check motor for mechanical overload.
Run time fault current fuel stepping motor Check supply voltage and fuses.
Run time fault auxiliary stepping motor 1 Drive ramp of the stepping motor must be
Run time fault auxiliary stepping motor 2
parametered ramp.
Run time fault frequency converter
Ramp of the frequency converter must be smaller than the
Run time fault auxiliary stepping motor 3
ramp parameter in the WM-F. Recommendation 20%.
The base unit has detected, that one
The diagnostic value is made up of the faults listed
or more stepping motors (incl. FC) have
or their combination. The individual diagnostic
not reached the special position
codes are added hexadecimal.
required for the phase.
Special pos. air stepping motor not reached
Check motor for mechanical overload.
Special pos. current fuel stepping motor Check supply voltage and fuses.
not reached
Spec. pos. auxiliary stepping motor 1 not reached
Spec. pos. auxiliary stepping motor 2 not reached

Spec. pos. FC (speed) not reached


Spec. pos. auxiliary stepping motor 3 not reached

12
Fault
code
1F

Diagnostic Cause
code
0106

Fault detected with FC module

01
02

Fault internal test in FC module


Wrong rotation direction of fan

03

Impulse sequence and length at speed


input different than expected
Nominal speed not reached stable

04
05

21
22
23
24
25
26
27
28
29

06

2A

2B

2C

2D

00, 01

2E

00, 01

2F
30
31
32
33
34
35
36
37
38
39

3A
3B
40

0103
01
02
03

41

Air stepping motor(s) did not reach open


position for standardisation
Fault internal speed test FC module
Safety circuit opened
Temperature guard value exceeded
Extraneous light during start up
Extraneous light during shutdown
No flame end of safety time ts1
Flame failure during operation
Impermissible air pressure signal On
Impermissible air pressure signal Off
Impermissible message On
from fan relay contact
Impermissible message Off
from fan relay contact
Impermissible air pressure signal On
flue gas recirculation
Impermissible air pressure signal Off
flue gas recirculation
Impermissible message On
from valve closing contact
Impermissible message Off
from valve closing contact
Low gas pressure switch has reacted
High gas pressure switch has reacted
Gas pressure switch VP has reacted
Gas pressure switch VP not reacted
Unexpected oil pressure present
Low oil pressure switch has reacted
High oil pressure switch has reacted
No start release oil
No release residual oil immediate start
Low gas programme active
Parameter of safety time faulty
Internal fault at timer1
Internal fault at timer2
Internal fault at timer3
No burner ID defined
No engineers password defined
Setting internal safety relay

Internal ignition contact setting

Recommended measures
With sporadic occurrences:
Check CAN Bus wiring or improve EMC measures.
With permanent occurrence, replace W-FM

Check rotational direction of motor and transmitter disc.


Check rotational direction on FC, correct if necessary
Check installation of transmitter disc and transmitter.
Check distance and connection inductive transmitter.
Check motor is running
Check distance and connection inductive transmitter.
Check motor(s) for mechanical overload.
Check voltage supply to stepping motors

Check gas supply pressure


Check setting gas pressure switch
V1 leaking
V2 leaking
Min. permissible oil pressure not reached
Max. permissible oil pressure exceeded

Check gas supply pressure

Parameter burner ID
Enter engineers password
With sporadic occurrences, improve EMC
measures.
With permanent occurrence, replace W-FM
Check wiring of output

97

12
Fault
code
42

43

44

45
46

47
48

98

Diagnostic Cause
code

Recommended measures

01FF

Contact setting fault of internal


fuel valve relays

01
02
04
08
10
20
40
80
010D
01
02
03
04
05
06
07
08
09
0A
0B
0C
0D
010A
01
02
03
04
05
06
07
08
09
0A

Safety valve - Oil


Fuel valve V1 - Oil
Fuel valve V2 - Oil
Fuel valve V3 - Oil
Safety valve - Gas
Fuel valve V1 - Gas
Fuel valve V2 - Gas
Fuel valve V3 - Gas
Fault during plausibility check
No fuel selected
No def. fuel train parametered
Variable train not defined
Variable fuel not defined
Undefined mode of operation with LC
Pre-purge time gas too short
Pre-purge time oil too short
Oil Safety time 1 too long
Gas Safety time 1 too long
Ignition - Off - Time > ts1 Gas
Ignition - Off - Time > ts1 Oil
Oil Safety time 2 too long
Gas Safety time 2 too long
Deactivated inputs connected
Controller input to X62
Activate input or connect nothing
Air pressure switch input X3-02
Brn Fan / FGR air pressure switch X4-01:3
Low gas pressure switch terminal X9-03:4
High gas pressure switch terminal X9-03:3
Low oil pressure switch terminal X5-01
High oil pressure switch terminal X5-02
Start signal Oil input X6-01:1/2

0107
01
02
03
04
05
06
07

The diagnostic value is made up of the faults listed


or their combination. The individual diagnostic codes
are added hexadecimal.
Check wiring of output

Residual Oil immediate start input X6-01:3/4

Start signal Gas input X7-03


At STB test activated a controlled
shutdown was carried out
A programme stop has been activated
Phase 24: Pre-purge
Phase 32: Pre-purge for FGR
Phase 36: Ignition positions
Phase 44: End first safety time
Phase 52: End second safety time
Phase 72: Post-purge position
Phase 76: Post-purge position FGR
Start release Gas = Off
1 sensor operation parametered,
but 2 flame signals present

If the programme stop (see Ch. 9.6.1) is no longer


required, deactivate it.

12
Fault
code

Diagnostic Cause
code

50
51
52
53
58
59
5A
5B
5C
5D
5E
5F
60
61
70

0007
0007
0103
01

0123
0104

71

72
80
81
82
83
84
85
86
87

0104
0103
0103
0103
0103
0103
0103
0103
0103

88

90
91
92
93
94
95
96
97
98

0105
01
02
03
04
01

99
9A
9B

01, 02

Fault in button value check


Time block overrun
Stack fault
Faulty reset condition
Parameter setting is incorrect
Parameter setting is incorrect
Parameter setting is incorrect
Parameter setting is incorrect
Backup restore was carried out
Internal fault
Internal fault
Parameter setting is incorrect
Internal fault
Internal fault
Fault at rectification of
lockout information
Manual lockout with contact

Recommended measures
1)

Reset unit
If this fault occurred during parametering:
check parameter last changed for plausibility.
If reset does not achieve faultless condition:
Restore parameters from ABE
Otherwise replace defective base unit.

1)

The lockout by the external contact


is cancelled by re-activating.
Plausibility fault at fault entry
1)
Impermissible cond. auxiliary stepping motor3 With sporadic occurrences, improve EMC measures.
Impermissible condition air stepping motor
Impermissible con. gas stepping motor (Oil)
With permanent occurrence, replace relevant motor.
Impermissible condition oil stepping motor
Impermissible cond. auxiliary stepping motor1
Impermissible cond. auxiliary stepping motor2

Impermissible condition of internal LC


Impermissible condition of ABE

Plausibility fault
Non defined fault stepping motors
Non defined fault load controller
Non defined fault ABE
Non defined fault FC module
Non defined fault O2 module
ROM-CRC fault auxiliary stepping motor3
ROM-CRC fault air stepping motor
ROM-CRC fault gas stepping motor (oil)
ROM-CRC fault oil stepping motor
ROM-CRC fault auxiliary stepping motor1
ROM-CRC fault auxiliary stepping motor2
ROM-CRC fault load controller
ROM-CRC fault ABE
Multiple components with the same
address on the CAN Bus
CAN is in BusOff
CAN Warning Level
CAN Queue overrun

1)
With sporadic occurrences,
improve EMC measures.
With permanent occurrence, replace ABE
With sporadic occurrences,
improve EMC measures.
With permanent occurrence replace defective unit
(see diagnostic code) or base unit.

Check addressing of connected components


and correct if necessary.
Check CAN wiring
1)
1) With sporadic occurrences,
improve EMC measures.
With permanent occurrence, replace W-FM

99

12
Fault
code
A0
A1
A2
A3
A4
A5

Diagnostic Cause
code
011F
011F
011F
011F
011F
011F
01
02
04
05
07
08
09
0C
0D
0E
10
11
12
13
15
16
17
18
19
1B

A6

1E
1F
10FF
10
12
13
14
15
16
17
18
22
3032
33
343B
40

4143

Auxiliary stepping motor3 has signalled fault


Air stepping motor has signalled fault
Gas stepping motor has signalled fault
Oil stepping motor has signalled fault
Auxiliary stepping motor1 has signalled fault
Auxiliary stepping motor2 has signalled fault
CRC fault at ROM test
CRC fault at RAM test
Fault in button value test
Time block overrun
Sync fault or CRC fault
Revolution counter
Fault at stack test
Temperature warning and shutdown
Wrong rotation direction
Ramp time for stretch too small
Timeout at AD change
Fault at ADC test
Fault at AD change
Stepping motor is outside of the valid
degree of angle (0-90)
CAN fault
CRC fault of one parameter section
Section was opened too long
Section is damaged
Invalid access to parameter
Fault at copying parameter section

Invalid setting in drive order


Plausibility fault internal
Internal LC has signalled fault
No actual value increase
Invalid XP identified
Invalid TN identified
TV larger than identification time
Invalid TV identified
Timeout during observation time

Recommended measures
With sporadic occurrences,
improve EMC measures.
With permanent occurrence,
replace the relevant motor.

Check housing temperature (max. 60 C)

Match ramp time to slowest motor


Reduce spanning between special positions

Check setting range (0-90)


Check CAN wiring
Reset unit
If this fault occurred during parametering:
check parameter last changed for plausibility.
If reset does not achieve faultless condition:
Restore parameters from ABE
Otherwise, replace defective base unit.
Check special positions are within valid range
Type of fault: see diagnostic code
1)

Cold start thermal shock protection is active

Timeout during adaption load


Temp controller Set point larger limit value
Internal fault load controller
Invalid CRC when reading a section
Reset unit, poss. repeat Backup Restore
Internal fault load controller
1)
Section open too long
Reset unit. If this fault occurred during parametering:
check parameter last changed for plausibility.
If reset does not achieve faultless condition:
Restore parameters from ABE.
Otherwise, replace defective base unit.
Internal fault load controller
1)
1) With sporadic occurrences, improve EMC measures.
With permanent occurrence, replace W-FM

100

12
Fault
code

Diagnostic Cause
code
44
45
46

Section was set to ABORT


Section was set to RESTO
Section has invalid status

4A4E
50

CAN fault
PT 100 sensor short circuit
on input X60:1/4
PT 100 sensor break
on input X60:1/4
Break in compensation line
on input X60:2/4
PT 1000 sensor short circuit
on input X60:3/4
PT 1000 sensor break
on input X60:3/4
Ni 1000 sensor short circuit
on input X60:3/4
Ni 1000 sensor break
on input X60:3/4
Over voltage on input X61
Break or short circuit
on input X61
Over voltage on input X62
Break or short circuit
on input X62
Internal fault load controller

51
52
53
54
55
56
57
58
59
5A
606F
70
71
72
73
74
75
76
77
78
79
7A
7B
7C
7D
7E
7F
80A6
A7
B0FF

Recommended measures
Reset unit
If this fault occurred during parametering: check parameter last changed for plausibility. If reset does not
achieve faultless condition: Restore parameters from ABE
Otherwise, replace defective base unit.
1)
Check wiring and sensor

1)
Measurement value variation, PT 100 sensor Check wiring of input
Measurement value variation, PT 100 line
Measurement value variation, PT 1000
Measurement value variation, PWM
1)
Measurement value variation, U input X61 Check wiring of input
Measurement value variation, I input X61 Check signal for ripple voltage
Measurement value variation, U input X62
Measurement value variation, I input X62
Over voltage or wrong polarity
Check wiring of input
PT 100 sensor, input X60
Over voltage or wrong polarity
PT 100 sensor, input X60
Over voltage or wrong polarity
PT 1000 sensor, input X60
Over voltage or wrong polarity PWM
1)
Over voltage or wrong polarity
Check wiring of input
U measurement input X61
Check input voltage or current
Over voltage or wrong polarity
I measurement input X61
Over voltage or wrong polarity
U measurement input X62
Over voltage or wrong polarity
I measurement input X62
Internal fault load controller
1)
Impermissible selection for the additional A pressure or temperature sensor must
sensor
be fitted to X61 (see Ch. 9.8.3 and 9.8.4)
Internal fault load controller
1)
1) With sporadic occurrences, improve EMC measures.
With permanent occurrence replace W-FM
101

12
Fault
code
A7

Diagnotic Cause
code
018A

The ABE signals faults.


Type of fault, see diagnostic code

Recommended measures
With sporadic occurrences, improve EMC measures.
With permanent occurrence, replace ABE

A9

01 08
09
0A
0B
0C
0D
0E
15 1A
1B
1C28
30
38
40
888A
011F
0109
0A
0C
0D

0E
15 F

16
17
18
19
1B

AB

1E
1F
013F
010A
10
12
13
15
16
171B
20
21
22
23

Internal fault ABE


Fault signal Emergency-Off Function ABE
Internal fault ABE
Service message through burner starts
Fault parameter backup
Fuel changeover from oil to gas
Fuel change over from gas to oil
Internal fault ABE
Fault during copying parameter section
Interner Fehler ABE
Fault during eBus communication
Interface mode could not be stopped
Parameter fault PC Tool
Internal fault ABE
FC module has signalled a fault
Internal fault FC module
Poss. fault on line to speed
transmitter
Frequency converter has initiated fault
FC module could not control speed
difference within its control limit

Fault during speed calculation test


Interrupted CAN Bus transmission

CRC fault of a parameter section


Section was open too long
Section has been destroyed
Invalid access to parameter
Fault during copying parameter section
Invalid entries in drive order
Plausibility fault internal
O2 module has signalled a fault
Internal fault O2 module
Nernst voltage QGO sensor (B1/M)
Voltage thermo element (B2/M)
Voltage compensation element (G2/U3)
Supply air sensor out of range
Flue gas sensor out of range
Internal fault O2 module during test phase
Temperature of O2 sensor too low
Temperature of O2 sensor too high
Fault during calculation test
Internal resistance of sensor is smaller
5 Ohm or larger 150 Ohm

1) With sporadic occurrences, improve EMC measures.


With permanent occurrence, replace W-FM
102

Carry out service, reset start counter


Change to menu Settings Gas
Change to menu Settings Oil
Reset unit, if necessary repeat parameter backup

1)
Check cabling, use screened
1)
Read fault codes of frequency converter
Check if current interfaces on frequency converter
and FC module are set the same (0/4 to 20 mA).
Carry out speed standardisation incl.
burner adjustment (fuel / air ratio)
1)
With sporadic occurrence check CAN Bus wiring,
improve EMC measures
Check closed resistance, correct if necessary
Reset unit
If this fault occurred during parametering:
check parameter last changed for plausibility.
If reset does not achieve faultless condition:
Restore parameters from ABE
Otherwise, replace defective base unit.
Check special positions for valid range
1)
2)
Check connection (poling, short circuit, break)

Check connection (short circuit, break)


Check ambient temperature (-20 C to +400 C)
2)
Check heating start up O2 sensor (Q4/Q5)
Check QGO temperature
2)
Check connection (poling, short circuit)
Replace O2 sensor
2) With sporadic occurrences, improve EMC measures.
With permanent occurrence, replace W-FM

12
Fault
code

Diagnostic Cause
code
24

25
24

B0
B1
B5

25
31
32
33
34
38
3E
3F
01, 02
01
01
01
02
03
04
05
06

BA
BF

07
01

C5

012F

D1
D3
E1
E3
F0
F1

01
02
04
08
10
20
0103
0103

0107

Recommended measures

Reaction time O2 sensor more than 5 s

Check position of O2 sensor


Check soiling of O2 sensor
O2 sensor
Faulty O2 sensor test
Check variation of O2 value
Reaction time of O2 sensor more than 5 s Check position of O2 sensor
Check soiling of O2 sensor
O2 sensor
Faulty O2 sensor test
Check variation of O2 value
CRC fault of a parameter section
Reset unit
Section was open too long
If this fault occurred during parametering:
Section has been corrupted
check parameter last changed for plausibility.
Invalid access to parameter
If reset does not achieve faultless condition:
Fault during copying parameter section
Restore parameters from ABE
Invalid external entry
Otherwise, replace defective base unit.
Plausibility internal fault
2)
Fault during testing port outputs
1)
Fault during short circuit testing
1)
from inputs to outputs
Fault during O2 guarding
1)
O2 min value not reached
Check settings of ratio curve
Increase differential O2 set point to O2 min value
Invalid O2 min value
Define all O2 min values
Invalid O2 set point
Define all O2 set points
Adaption fault point 2 or at 100%
Repeat standardisation at this point (Ch. 9.7.1)
No valid O2 actual value > = 3 s
Check connection O2 module and O2 sensor
Air oxygen content at pre-purge
Increase pre-purge time
not achieved
Replace O2 sensor
O2 value during operation above 15%
Check installation and connection O2 sensor
Test O2 sensor not successful
1)
Fault in connection with O2 control
In the fault history immediately prior to fault BF
or O2 guard
the reason for switch off can be read
ABE has detected old versions during the The diagnostic value is made up of the faults
version comparison of individual units
listed or their combination. The individual diagnostic
codes are added hexadecimal.
Software version of LC not current
Prior to replacing, any units switch on the system
Software version of ABE not current
and wait for approx. 1 min. (until the display parameters
Software version of stepping motor(s) not current are being updated disappears when entering the
Software version of FC module not current parameter level). Then reset. If the fault still persists,
Software version of O2 module not current replace the relevant unit.
Software version of O2 module not current
Impermissible condition frequency converter 1)
Impermissible condition O2 module
1)
ROM - CRC fault in FC module
1)
ROM - CRC fault in O2 module
1)
Plausibility at interpolation calculation
1)
Fault during pre-control calculation
Check curve setting
Check setting of fuel parameter depending
on the fuel selected

1) With sporadic occurrences, improve EMC measures.


With permanent occurrence, replace W-FM

2) With sporadic occurrences, improve EMC measures.


With permanent occurrence, replace W-FM
103

12
Fault
code
F2

Diagnostic Cause
code
070A

07
08
0A
F3

104

01

Wrong temperature values from


O2 module during calculation of
air load change
O2 module transmitted invalid
value
Flue gas temperature outside of
permitted value range
QGO sensor not heated
sufficiently
The control algorithm is missing
the PID parameters

Recommended measures

Increase permitted flue gas temperature


Wait until sensor reaches operating temperature
Check control parameters

13 Maintenance

13

13.1 Safety information for maintenance

DANGER

Failure to carry out maintenance and service


work properly can have severe consequences, including the loss of life. Pay close
attention to the following safety notes.

Detailed information and instructions for maintenance can


be found in the installation and operating instructions of
the burner.
Qualified personnel
Only qualified and experienced personnel must carry out
maintenance and service work.

Endangering operational safety


Maintenance work on the following parts may only be
carried out by the manufacturer or their appointed agent
on the individual components.
Combustion manager
Stepping motors
Flame sensor
Gas pressure switch
Air pressure switch
Oil pressure switch
Solenoid valves

Prior to all maintenance and service work:


1. Electrically isolate the equipment
2. Close all fuel shut off devices
After all maintenance and service work:
1. Function test.
2. Check flue gas analysis i.e. CO2 / O2 / CO values,
smoke No.
3. Complete a test sheet.

13.2 Maintenance plan


The operator should ensure that combustion plant is
serviced at least
once a year by an agent of the supplier or other suitably
qualified person.
During this service all system components with high wear
and tear, or components with a specific life span should be
replaced. Notes to be made of such exchanges.

105

14 Technical data
14.1 Combustion manager W-FM
Mains voltage

AC 230V -15% / +10%

Transformer AGG5,220 - primary


- secondary
Mains frequency

AC 230 V
2 x AC 12V

Ambient conditions for all components:

Transport
- climatic conditions
- temperature ranges
- humidity

DIN EN 60 721-3-2
Class 2K2
-20 to + 70 C
< 95 % r. h.

Operation
- climatic conditions
- temperature ranges
- humidity

DIN EN 60 721-3-3
Class 3K5
-20 to + 60 C
< 95 % r. h.

Mechanical requirements

50...60 Hz 6%

Consumption

< 30W

Type of protection housing


Protection class I

IP00, IEC 529


with parts according
to II and III to DIN EN 60 730-1

Mains pre-fusing (external)max. 16 AT


Unit fusing (internal)
6.3 AT (IEC 127 2 / 5)

Dew point, freezing, water ingress not permitted


CE Conformity

To the guidelines of the EU


Electromagnetic compatibility
EMC 89 / 336 EU incl. 92 / 31 EU

Mains supply input currentinstallation specific


Individual contact loading:
Nominal voltage
AC 230V + 10% / - 15%, 50-60 Hz
- Fan motor contactor
max. 1 A
- Ignition transformer
2A
- Fuel valves Gas
2A
- Fuel valves oil
1A
- Oil pump / solenoid valve
max. 2 A
- LP test valve
max. 0.5 A
- Alarm output
1A
- Ratings factor
cos > 0.4

Interference transmission
Interference fastness

To EN 55022
To IEC 1000-4-3

Housing dimension

Input currents/input voltages

200

UeMaxUmains + 10%
UeMinUmains - 15%
leMax 1.5 mA peak
leMin 0.7 mA peak

182

Signal inputs

Class 2M2

Total contact loading (Safety circuit)


Nominal load
Unit input current

AC 230V + 10% / - 15%, 50-60 Hz


max. 5 A

Cable lengths
CAN Bus total length
CAN Bus special cable
Cable diameters

max. 100 m (100pF/m)


max. 100 m
Weishaupt No. 743 192
min. 0.75 mm2
(multi-core to VDE 0100)

The cable diameters of the mains supply (L, N, PE) and the
safety circuit (STB, low water, etc.) must be selected for
the nominal currents relative to the selected external prefusing.
The cable diameters of the remaining conductors should
be dimensioned in relative to the internal unit fusing (max.
6.3 AT).
Internal fusing: F1
F
F3

6.3 AT (IEC 127 2 / 5)


24 AT(IEC 127 2 / 5)
4 AT(IEC 127 2 / 5)

Low-voltage transformer
When the W-FM is fitted into a control panel, the burner
must also be fitted with a low-volt transformer for the
control voltage to the stepping motors.

106

232
250

82,3

14
14.2 Stepping motors SQM45.../48...
Supply voltage

AC 2 x 12 V

Protection class

Install low voltage cables with safe


separation from mains voltages

Consumption - SQM45...
- SQM48...

9...15VA
26...34 VA

Angular adjustment

max. 90 <

Installation

optional

Degree of protection to EN 60529 IP54 with relevant


version of cable entry
Torque: - SQM45...
- SQM48...

up to 3 Nm
up to 20 Nm

Repeat accuracy

0.2

Rotation direction

Cable connection
The connection of the screened Bus cable is via plug
screw terminal Rast 3.5. The two connection sockets
(x1, X2) on the stepping motor have the same value.
Cable and cable screening
Only special cable (Weishaupt No. 743 192) may be used.
Cable screening must be connected to the circuit board
with the flat plug provided.
Housing cover
The housing cover must only be removed for the short
period during wiring and addressing. Ensure dirt particles
cannot enter the internals of the stepping motor.
The stepping motor contains a printed circuit board with
static sensitive components. Its surface is protected
against direct contact by a protective cover. Contact with
the underside of the circuit board should be avoided.
The protective cover must not be removed!

Can be set in W-FM

Run times: - SQM45...


- SQM48...

10 to 120 s
30 to 120 s

Weight: - SQM45...
- SQM48...

approx. 1.0 kg
approx. 1.6 kg

Dimensions
90

,4

76

116

15
2
12
,0

3N9

122

Groove for
Woodruff key
3 x 3.7 DIN 6888

87

137

25

10 h8

16

SQM 45

41

+0

33

+0,1

2,5 0

50

7814m01

Prepared for
self tapping screws
M5, 10mm deep,
to DIN 7500

+0,1
0

P9

+0,1
0

25,5

2 x M16x1,5

1,9

47

18

Groove for parallel


key 5 x 28
36

SQM 48

39
28

14 h8

107

14
14.3 Flame supervision
QRI
The infrared flame sensor QRI... has the following
characteristics:
Infrared flame sensor with IR sensitive sensor for gas
and oil flames
Integrated flame signal amplifier
Self checking of flame signal for continuous run
For front or side (90) viewing
Fitted to burner body with flange and clamp
Supply voltage: - Operation
- TestDC 21 V + 5%
Signal voltage:
Range
minimum

DC 14 V + 5%

DC 0...5V
DC 3.5 V; Display flame approx. 50%

Consumption

< 0.5 W

Type of protection
Protection class

IP54
II

Length of sensor connection cable


Length of additional sensor line
Installation optional
Vibration to IEC 68-2-6
Weight with cable

max. 1.8 m
max. 100 m
max. 1g / 10...500 Hz
approx. 0.175 kg

Ionisation electrode
Flame supervision with ionisation electrode for gas
operation is suitable for continuous run.
Idle voltage
approx. Umains
Short circuit voltage
max. 0.5mA (AC)
Sensor current
minimum
6 A (DC); display flame approx. 50%
maximum
85 A (DC); display flame approx. 100%
Sensor line length

max. 100m
(core-ground 100 pF (/m)

Note: With increased sensor line (length) the current at


the sensor electrode decreases. For longer line
lengths where very high Ohmic values are
probable, the use of a low capacity sensor line (i.e.
low-loss ignition cable) may be necessary.

108

QRI flame sensor

bl blue wire = reference


br brown wire = supply conductor
sw black wire = signal conductor
Z Additional conductor

14
14.4 Display and operating unit (ABE)
Supply voltage via Bus cable

AC 12 V

Installation

optional

Type of protection to EN 60529


(Viewing side in installed condition)
Ambient conditions

Dimensions

IP54

see basic unit (Ch. 14.1)

Door cut-out for panel mounting


Height 12,5 1 mm
Width90.5 1 mm
Depth (within panel)
Free space for connection cable (below the unit)
Cable - line length
Only original -weishaupt- CAN-BUS cable
(order No. 743 192) must be used.

25 mm
50 mm

max. 100 m

109

110

Notizen

111

Weishaupt products
and service

Max Weishaupt GmbH


D-88475 Schwendi
Find Weishaupt adresses
and telephone numbers
on www.weishaupt.de
Print No.. 83054802, June 2004
Printed in Germany
All rights reserved

Oil, gas and dual fuel burners types W and WG/WGL


up to 570 kW
They are used mainly in houses and small buildings.
Advantages: fully automatic, reliable operation, individual
components easily accessible, easy to service, quiet operation.

Oil, gas and dual fuel burners types Monarch


R, G, GL, RGL up to 10.900 kW
These are used on all types and sizes of central heating
plant. The basic model which has proved successful over
many years is the basis for a variety of versions. These
burners have founded the outstanding reputation of
Weishaupt products.

Oil, gas and dual fuel burners types WK


up to 17.500 kW
WK types are decidedly industrial burners.
Advantages: Built to the modular system, load dependent
variable combustion head, sliding two stage or modulating
operation, easy to service.

Weishaupt control panels, the proven complement to


Weishaupt burners
Weishaupt burners and Weishaupt control panels form
the ideal unit, a combination which has already proved
successful in hundreds of thousands of combustion
installations. The advantages: Cost saving during planning,
installation, servicing and guarantee work. The responsibility
belongs to one manufacturer.

Product and service are the complete


Weishaupt achievement
An extensive service organisation guarantees Weishaupt
customers the greatest possible reliability. In addition
our customers are looked after by heating firms who have
been working with Weishaupt for many years.

info
Information on regulators

Regulators for gas and dual fuel burners with gas supply pressures up to 4 bar

Description

General
The gas pressure regulators fitted to all gas and dual
fuel burners are subject to very high dynamic
demands, owing to the speed of switching of the
burners gas valves and the small volumes of gas
between the gas regulator and the burners safety
shut off valve.

Pressure regulators with safety assemblies are also


tested and this technical manual forms part of the
test report. If other units are used the burner can not
be appended with the CE mark.

Excess pressure increase is possible if the gas


pressure regulator supplies an excess outlet
pressure due to faulty operation, or if an SAV does
not close its seat and leakage via the seat occurs.

The pressure regulators must be fitted to the burner


as part of the gas valve train.

The gas pressure regulators in this manual are direct


acting units and are in accordance with EN 676
Forced Draught Gas Burners

Capacity, operation and safety can only be ensured if


the correct units for the burners are used.

If the set pressure is exceeded the valve opens


against the closing spring. Once the excess pressure
has decreased the SBV closes automatically. A vent
line to atmosphere should be provided to ensure that
any internal gas leakage can be vented safely. By
setting the vent pressure of the SBV below the
tripping set point of the SAV, it is possible to make
the SBV respond first, and only with a further
pressure increase will the SAV then trip.

The opening and closing times of the burners safety


valves are short, so the gas pressure regulators need
to react quickly to this, as well as burner load
changes during operation. They must also react to an
emergency shut off of the burner from full load
operation. In these cases the safety shut off valve is
usually activated.
The correct installation of the pressure regulators and
safety equipment with their associated impulse lines
ensures trouble free operation. The impulse lines are
fitted and dimensioned to ensure correct function,
and thus ensure the required reaction speed of the
units.
Only the breather and blow off lines have to be fitted
to the installation. Relevant guidelines can be found
in the Installation notes section.
This group of regulators is made to suit the DVGW
regulations, however, some of the regulations do not
apply to burner installations. Here, the problem with
back pressure does not exist. On burner installations,
the outlet pressure for operating and shut down
mode  Pa is permitted, and is equal to the required
pressure of the plant.

The units described in this brochure are designed


with maximum inlet pressures: see table.
Refer to DVGW work sheets for partially pre-adjusted
high gas pressure regulators. Gas pressures in
excess of 4 bar make particular demands on space,
installation and equipment, such that their use in
boiler rooms is possible only in very limited
circumstances. Consequently, boiler rooms do not
generally have supply pressures greater than 4 bar.

The entire Weishaupt burner programme is covered,


and the connections to the burner valve trains are of
the correct size.

Purpose of the SAV safety shut off valve


Safety shut off valves serve as a primary safeguard
against excess pressure and gas throughput. The
SAV shuts off the gas supply if its set pressure has
been reached. During normal operation this is open.
The safety shut off valve must not reopen
automatically. Resetting must be carried out
manually.

Contrary to some instructions, which suggest that


installations having a main service pressure regulator
fitted do not then need each appliance to have its
own individual regulator, each burner must in fact be
fitted with one of the regulators detailed here. Mains
supply gas pressure regulators have specific
functions, which are different to those required for
burner operation. Besides which, ratings related
pressure deviations will occur. For example, the gas
throughput changes between partial and full load.
The commissioning engineer familiar with the burner
regulators has immediate access to setting gas
pressures required for each individual burners
requirements.
Burner components and type testing
The standard for forced draught gas burners
stipulaes that the burner must be treated as a single
unit. This operational unit includes all gas side and air
side equipment, and the burners are tested as such.

With types 06/1 to 09/1 and 1-5/1 (type 133...,


233..., 244...) the SAV and the SBV form one unit in
the gas pressure regulating assembly.

With gas inlet pressures above 0.3 bar, the gas


pressure is further safeguarded with SAV and SBV
safety assemblies. These also protect the rest of the
gas valve train from pressures in excess of the
permitted maxima.
Purpose of the gas pressure regulator
Gas pressure regulators have the purpose of
maintaining the outlet gas pressure for every burner
load point, irrespective of the gas inlet pressure and
throughput.

The regulators are designed for burner operation and


should not be used as a main service pressure
regulating station. On installations which operate
more than one burner, each burner should be fitted
with its own regulator.

The SBV is fitted downstream of the gas pressure


regulator.

Safeguard against excess gas throughput


The gas pressure regulator ensures a virtually
constant gas pressure to the burner across all load
points.

Matched to the Weishaupt burner programme


The gas pressure regulators and safety assemblies
covered in this brochure are specially matched to
Weishaupt gas burners. Outlet gas pressures of 200,
140, 100, 50 and 20 mbar are catered for. Operating
pressures above and below these can be set by
spring adjustment. The safety assemblies are factory
preset, for the values see Technical Data.

The pre-assembled sets have been individually tested


for soundness and operation. These tests must be
repeated during commissioning and servicing.

Maximum inlet pressures


Supply pressures of up 0.3 bar are classed as a low
pressure supplies, whereas supply pressures above
0.3 bar are classed as a medium or high pressure
supplies.

The gas regulator closes tightly if the outlet pressure


exceeds the set value, or under zero flow conditions.

The safety shut off valve forms part of the relevant


gas pressure regulator. Via an impulse-line
the SAV senses the outlet pressure from the
pressure regulator section, and if this pressure
exceeds the set value of the SAV, the SAV shuts off
the flow of gas entering the gas-train.
Setting and operations checks form part of the
commissioning. This includes checking the closing
procedure, i.e. if it functions correctly.

Contents

Page

Description

Construction

High gas supply pressure diagram

Weishaupt gas filter and ball valve


pressure loss chart

Weishaupt pressure regulators


types 06/1 to 9/1 and 1/1 to 5/1
with safety assemblies

Selection chart

The set point is determined on site and depends on


the pressure at which the gas pressure regulator
shuts off. The set point must not be higher than the
maximum inlet pressure of the valve trains.

Weishaupt pressure regulators


types 5/1 to 9/1
with safety assemblies

Please note the setting advice given at the end of this


document.

Example of a high pressure gas supply

12

Connection parts

13

Purpose of the SBV safety relief valve


Safety relief valves are incorporated as an additional
safety device. If internal gas leakage (pressure-creep)
is detected, e.g. if the gas pressure regulator does
not close its seat, the safety relief valve vents the
excess pressure to atmosphere.

10

Installation examples and notes

14

Notes on adjustment

15

Dimensions

16

Construction

Pressure regulator, types 06/1 to 09/1

Pressure regulator, type 5/1 25/50

Types 1/1 to 4/1

Type 5/1

Type 8/1 80/80

Pressure regulator, type 9 100/100

High gas pressure supply:


Two burners, each with a pressure
regulator with safety assemblies

Pressure regulator with


safety assemblies
Supply
line

Pressure regulator with


safety assemblies

The burners are each supplied with a pressure


regulator set , which is in accordance with DVGW
worksheet G 490.
In many cases a mains regulator station is connected
upstream, to reduce a supply pressure of between 4
and 100 bar to below 4 bar, at which the regulators
described here can be used on the burners.

Legend
1 Ball vlave
2 Gas filter
3 Pressure gauge with push button valve
4 Safety shut off valve(SAV)
5 Pressure regulator
6 Safety relief valve (SBV)
7 Gas pressure switch
8 Valve proving
9 Double solenoid valve (DMV, up to DN 125)
10 Ignition gas solenoid valve
11 Gas butterfly valve

8 10 11

8 10 11

Burner 1

Burner 2

Weishaupt gas filter and ball valve


pressure loss chart

Pressure loss p [mbar] at inlet pressure of (see below)


50

20

10
9
8
7
6

1.5
1,5

2
2

1.5
1,5

1.5
1,5
0.5
0,5

1.5
1,5

1
1

mb

50

30

mb
0
50

r
0
1,

ba

r
0
2,

ba

r
ba
0
3,

ar

ar

0,5
0.5

25

125
DN
15
0

DN

100

1.5
1,5

DN

10
9
8
7
6
65
DN
80

5
3
2

15

50

10
9
8
7
6

20

15

DN

15

30

DN

40

20

10
9
8
7
6

50

40
30

15

10
9
8
7
6

50

30

20

DN

15

40

40

20

DN

30

Inlet pressure pe

60

70

90
80 100

150 200

Flow rate Vn [m3/h]

300

400 500 700 900


600 800 1000

1500 2000

3000 4000
5000

Natural Gas E, Hu,n = 10.35 kWh/m3, d = 0.606


Natural Gas LL, Hu,n = 8.83 kWh/m3, d = 0.641

Please note:
Gas filter and ball valve must be selected to not
exceed a pressure loss of approx. 50 mbar.

Conversion of LPG, Towns Gas etc. to equivalent Natural Gas throughputs:

Up to this value the admissible flow velocity is not


exceeded and the filtration will be satisfactory. The
nominal diameter selected should be the same or
larger than the inlet nominal diameter of the high
pressure regulator.

VGas

= QBr /Hu,Gas

= 
dGas /dNat Gas

Note:
The pressure loss of the gas filter and ball valve has
been included in the graph.

Examples:

VNat Gas = VGas x f

= 
dGas /0.641

Gas type

Cal. value Hu
kWh/m3n

Density
kg/m3

Relative
density d

Correction
factor f

Propane
Butane
Towns Gas 1
Towns Gas 2
Towns Gas 3
Towns Gas 4

25.89
34.39
4.89
4.30
6.40
4.20

2.011
2.708
0.513
0.624
1.060
0.801

1.555
2.094
0.397
0.483
0.820
0.620

1.557
1.807
0.787
0.868
1.131
0.967

Application:
Burner rating

Value on Natural Gas axis

QBr

1500 kW, Propane

VPropane =

1500 / 25.89 = 57.9 m3n /h

VNat Gas =

57.9 x 1.557 = 90.1 m3n /h


5

Weishaupt pressure regulators


Types 06/1 to 09/1 and 1/1 to 5/1
with safety assemblies

Technical Data
Weishaupt
type

Pressure
regulator
type

DN

06/1
07/1

133-5-72
133-5-72

25
25

Orifice
mm

inch

3.0
4.7

/8
/16

max. inlet
pressure
bar

Outlet
pressure
mbar

SAV
spring
colour

SAV
setting
range mbar

Product
ID number

Approx
weight
kg

Order No.

4.0
4.0

30 70
30 70

green
green

140 450
140 450

CE-0085 AQ 1090
CE-0085 AQ 1090

15
15

151 336 2666/0


151 336 2667/0

3.0
1.5

30 70
30 70

green
green

140 450
140 450

CE-0085 AQ 1090
CE-0085 AQ 1090

15
15

151 336 2646/0


151 336 2647/0

4.0
4.0

70 140
70 140

green
green

140 450
140 450

CE-0085 AQ 1092
CE-0085 AQ 1092

27
27

151 336 2648/0


151 336 2649/0

08/1
09/1

133-5-72
133-5-72

25
25

6.3
12.5

1/1
2/1

233-12-5-72
233-12-5-72

50
50

10
12.5

3/1
4/1

233-12-5-72
233-12-5-72

50
50

20
25

/4
1

2.5
1.0

70 140
70 140

green
green

140 450
140 450

CE-0085 AQ 1092
CE-0085 AQ 1092

27
27

151 336 2650/0


151 336 2651/0

5/1

244-12-5-72

50

27.5

4.0

70 140

green

140 450

CE-0085 AQ 1094

31

151 336 2652/0

/4
/2

/8
/2

See Print No. 1727 for regulators with safety diaphragms for connection without breather and vent lines

Outlet pressure springs and labels


Type

Outlet pressure
mbar

Colour

Order No.

Label
Order No.

06/1 to 09/1
06/1 to 09/1
06/1 to 09/1
06/1 to 09/1
06/1 to 09/1

12 20
15 35
30 70
50 140
100 210

blue
green
orange
black/white
silver

490 031
490 032
490 033
490 030
490 029

201 000 0810/7


201 000 0811/7
201 000 0812/7
201 000 0813/7
201 000 0815/7

1/1-5/1
1/1-5/1
1/1-5/1
1/1 -5/1

15 35
30 70
70 140
100 210

green
orange
black
silver

490 085
490 086
490 087
490 088

201 000 0811/7


201 000 0812/7
201 000 0814/7
201 000 0815/7

Legend to page 7
1 Cover screw
2 Pressure regulator
3 Regulator spring
4 Adjusting screw
5 Sealing cap
6 Diaphragm
7 Breather port
8 Breather line connection
9 Connection section
10 Inlet and outlet pressure gauge
with push button valve

11 Control orifice
11a Impulse line (SAV)
12 SAV spring
13 SAV measuring mechanism
14 Valve adjusting rod
15 Cover cap
16 Diaphragm casing
16a Impulse line
(pressure regulator)
17 SBV safety relief valve
18 Diaphragm support
19 Lever system

20 Valve stem
21 Flange connection
22 Cotter pin
23 Valve disc
24 Orifice
25 SAV valve disc
26 Flange connection
27 Blocking spring
28 SAV safety shut off valve
29 Operating stem

Function of the pressure regulator


The diaphragm (6) of the pressure regulator is
loaded with a spring (3) and transfers its movements
via a lever system (19) to the valve disc (23). The
level of outlet pressure is achieved by an appropriate
spring load.

Function of the SAV safety shut off valve


If damage occurs to the orifice (24), or if the lever
rods (19) jam, the pressure in the diaphragm area
(16) and behind the orifice (24) can rise only until the
safety shut off valve responds, thus interrupting the
gas supply.

Without gas pressure the regulator is open, i.e. the


spring tension presses the diaphragm (6) and the
lever system (19) downwards so that the valve disc
(23) is raised from the orifice (24). As the gas flow is
released, the gas flows through the orifice (24). This
allows the pressure to increase and produces a force
on the diaphragm (6) counter acting the spring
tension. If the resulting force of gas pressure
exceeds the adjusted spring loading, the lever
system (19) is raised by the diaphragm (6) and the
valve disc (23) starts to constrict the orifice (24),
thus throttling the gas flow and terminating the
pressure increase. If, due to gas reduction the gas
pressure behind the orifice and consequently in the
diaphragm casing (16) drops, the valve disc (23) is
opened by the force of the spring.

The SAVs measuring mechanism (13) is connected


to a spring loaded operating stem (29) and transfers
its movement to the valve disc (25). The switching
pressure is taken via an impulse line from the outlet
pressure area of the regulating section and is
temporarily delayed by the throttle effect of the
control orifice (11), so that even with a sudden
reduction of capacity and momentary pressure
increase resulting therefrom, no closure of the safety
shut off valve will be effected.

This alternating process repeats itself until a balance


prevails between the force of the spring and the
force of the gas pressure on the diaphragm (6),
depending on the throughput.

The measuring mechanism is separated from the


inlet pressure space by an O ring seal.

When the pressure rises above the value set with the
spring (12) the diaphragm (13) overcomes the
resistance of the operating stem (29). The blocking
spring (27) presses the valve disc (25) against the
valve seat thus closing the gas supply.

Function of the SBV safety relief valve


The safety relief valve (17) is sized so that if the
regulator fails, then the flow capacity of the orifice
(24) can be vented without any inadmissible rise in
outlet pressure. The venting pressure is approx. 30
mbar above the outlet pressure, 10%. The excess
pressure is released to the vent connection (8) via
the SBV and thence safely to open atmosphere.

Note:
06/1 to 09/1 pressure regulators are supplied as
standard with orange springs (30 to 70 mbar). Types
1 to 5 are fitted black springs (70 to 140 mbar).
The actual outlet pressure has to be determined for
each individual installation. This outlet pressure
should be quoted when ordering, as well as the
spring required. The pressure regulator will then be
supplied with the correct spring and label.
Scope of delivery:
1 Pressure regulating unit, comprising:
pressure regulator, SAV safety shut off valve and
SBV safety relief valve
1 Inlet pressure gauge with push button valve
1 Outlet pressure gauge with push button valve
Connection pieces, screws, nuts, gaskets, zustzlich
and additionally with type 5/1:
Stabilising section with connections and control line
for pressure regulator and SAV
The unit is tested for soundness.

Installation
In order to avoid damage and operational faults,
care must be taken that the connection line and
the regulator are free from contamination.
Jointing rings must be in place.
The pressure regulator is installed in such a way
that the directional arrow on the casing points in
the direction of the gas flow. Due to the spring
load, the installation of the pressure regulator is
independent of its position. Due to the flange
connection (21) between valve body and the
casing of the diaphragm on the one hand and the
valve body and the casing of the SAV on the other
hand, various installation possibilities are
available. In standard execution, regulator, SAV
and gas flow are horizontal. The assembly may
however be installed in any position, but care
must be taken that the outlet pressure is
re-adjusted accordingly.
A line leading into safe open atmosphere is
connected to the breather port (7) .
(For installation instructions see page 14).
Once the pressure regulating assembly has been
installed in the burners gas valve train, a
soundness test must be carried out in accordance
with the burner operating instructions.
Prior to commissioning, the pressure regulating
assembly must be tested for correct function,
including the closing of the SAV.
All local legislation and directives must be
observed.

Commissioning
Function test of the burner with ball valve closed
(see the burners installation and operating
instructions).
Setting pressure to be set according to the
burners installation and operating instructions.
The ball valve can be opened slowly.
It is usually necessary to re-adjust the outlet
pressure. To do this the sealing cap (5) must be
removed. By turning the adjusting screw (4), the
pressure can be set to the required value.
Pressure increases when turning clockwise.
Adjustments should only be made under gas flow
conditions. This can be done during operation, as
all gas carrying areas of the regulator are sealed.
Should a fault on the pressure regulator result in a
closure of the SAV (28), the valve can be reset
manually once the cause of the fault has been
eliminated. In order to open the SAV valve disc
(25), first the cover cap (15) is removed and then
the valve adjusting rod (14) is set to the point
where the operating stem (29) will re-engage. It
should be noted that a small quantity of gas is
discharged via the valve adjusting rod after the
cover cap (15) has been removed. It is necessary
for the plant working pressure to be below the set
response limit of the valve.
Afterwards the cover cap (15) with the sealing
gasket has to be replaced. The SAV (28) is ready
for operation. Check the cover cap (15) for leaks
(by using Nekal or soap solution).

Types 06/1 to 09/1 and 1/1 to 4/1

Atmosphere
Inlet pressure
Outlet pressure

SBV safety relief valve

Adjustment and operational check of the SAV


Once burner settings have been completed, a
controlled shut down is carried out.

SAV responds:
Increase shut off pressure by clockwise rotation of
the adjusting screw SAV (12) until there is no
further response on controlled shut down.

SAV does not respond:


Reduce shut off pressure by anti-clockwise
rotation of the adjusting screw, until SAV
responds on controlled shut down.
After determining the shut off pressure, turn the
setting screw 1/2 to 1 turn clockwise.
Check by means of further controlled shut downs
whether the SAV remains in the open position.

SAV cannot be reset


The blow off pressure of the SBV is always
approx. 30 mbar above the outlet pressure. If the
shut off pressure of the SAV is less than this
figure, reset is not possible.

SAV does not engage


Decrease pressure on the outlet side.

Type 5/1

Atmosphere
Inlet pressure
Outlet pressure

SBV safety relief valve

Visual test
A visual test is carried out during annual
maintenance, when the condition and operation of
the units are checked for deviations in the desired
conditions (gas throughput, gas pressure, set
points).
Sequence test
After the visual test, the setting and operation of the
pressure regulator, SAV and SBV are checked.
Please pay attention to the notes on page 15.
Maintenance
The pressure regulators require practically no
maintenance. Damage to the orifice (24), due to
contaminants in the gas is however possible.
Therefore a gas filter should be fitted upstream of the
pressure regulator.

Selection chart for outlet pressure pa:


200 mbar, 140 mbar, 100 mbar, 50 mbar

6/
1

Ty
pe
07
/1

4.0

Ty
pe
0

Example 2

8/
1

3.0

Ty
pe
0

3.5

2.5

2.0

 Inlet pressure p [bar] before the regulator

Ty
pe
0

9/
1

1.5

1.0
0.9
0.8

0.7
0.6
0.5

Example 1

0.4

0.35
0.3
3

10

15

20

25

30

35

40

50

60

70

80 90 100
Q1req.

Flow rate Vn [m3/h] Natural Gas H, Hu,n = 10.35 kWh/m3, d = 0.606


Natural Gas L, Hu,n = 8.83 kWh/m3, d = 0.641

The type of regulator required can be selected using


the chart. The followingmust be known:
Gas type (calorific value, density)
Burner rating
Inlet pressure [bar]
Required outlet pressure pa.

Selection example 1
Gas type:
Natural Gas
Hu,n = 10.35 kWh/m3n , d = 0.606
Gas throughput:
90 m3n /h
Inlet pressure pe: 480 mbar
Outlet pressure pa: 100 mbar (valve train selection)

The type is determined by referring to the


intersection point of the flow rate and inlet pressure,
and selecting the regulator shown to the right.

1. Pressure loss p from DN 50 filter and ball valve


(see pressure loss chart, page 5) approx.. 1 mbar.
2. Selection chart gives type 3/1.

If a gas filter and ball valve are installed upstream, the


pressure loss of these components must be
deducted form the inlet pressure (see example).

Selection example 2
Gas type:
LPG, Propane
Hu = 25.89 kWh/m3n , d = 1.555
Burner rating:
4,556 kW
Gas throput VGas: 176 m3n /h
Gas throput, rel.
to Natural Gas:
275 m3n /h (see page 9)
Inlet pressure pe: 2.9 bar
1. Pressure loss p from DN 50 filter and ball valve
approx. 1 mbar.
2. Selection chart gives 5/1 (permitted operating
pressure of regulator type 3/1 is exceeded).
3. Check: partial load turndown 1,500 kW
Q2max = 520 m3n /h (Natural Gas) = 520/1,557 =
333 m3n /h; Propane Qmin = 1,500/25.89 =
58 m3n /h G turndown1:5.7 < 1:20.
The selection is therefore OK.

DN 80
outlet

DN 100
outlet

DN 150
outlet

6/
1a

Typ
e6
/1

3.0

Ty
pe

2.5

80
/1
5

50
/1
00

1.5

Ty
pe
8/
1

Ty
pe
7/
1

Ty
pe

25
/5
0

6/
1a

0/
80

2.0

1.0
0.9

pe
Ty

1a
6/

1
7/
e
p
Ty

00
/1
5
1

0.8
0.7

Ty
pe
9

8/
1

Ty
pe

0
/5
50

Ty
pe

7/
1

80
/1
00

50
/8
0

50
/5
0
Ty
pe
6/
1

Ty
pe
5/
1

Ty
pe
4/
1

3.5

0/
10
0

50
/8
0

25
/8
0
Typ
e5
/1

Typ
e3
/1

Typ
e1
/1

Typ
e2
/1

Typ
e5
/1

4.0

0.6
0.5

0
/5
50

e
Typ

8/1

/80
80

9
pe
y
T

0
10
0/
0
1

0.4
0.35
0.3

150

200

250
300 350 400
Q2req.

500
600 700 800 9001000
Q2max

The stabilising section at the outlet must be enlarged


in accordance with the gas flow rate, so that the
permissible velocity is not exceeded.
Note:
The flow rate curves comply to regulator standard
RG10. The maximum regulation deviation is 10%
of the desired outlet value. At the minimum
throughput qmin, the outlet pressure pa rises by 10%,
at the maximum throughput qmax, the outlet pressure
pa drops by 10%.
The gas pressure regulators are direct operating
regulators and have a turndown ratio of 20:1, which
means that the smallest adjustable flow quantity is
5% of the maximum flow rate. The max. flow rate can
be read off the flow rate curve for the appropriate
inlet pressure (see example 2).

1250 1500 1750 2000

2500 3000 3500 4000

5000

Conversion of LPG, Towns Gas etc. to equivalent Natural Gas throughputs:


VNat Gas = VGas x f
Examples:
Gas type
Propane
Butane
Towns Gas 1
Towns Gas 2
Towns Gas 3
Towns Gas 4
Application:

VGas = QBr /Hu,Gas

f = 
dGas /dNat Gas = 
dGas /0.641

Calorific value
Hu kWh/m3n

Density
kg/m3

Relative
density d

Correction
factor f

25.89
34.39
4.89
4.30
6.40
4.20

2.011
2.708
0.513
0.624
1.060
0.801

1.555
2.094
0.397
0.483
0.820
0.620

1.557
1.807
0.787
0.868
1.131
0.967

Burner rating
Value on Natural Gas axis

QBr
= 1500 kW, propane
VPropane = 1500 / 25.89 = 57.9 m3n /h
VNat Gas = 57.9 x 1.557 = 90.1 m3n /h

700 m3/h _________ DN 50

from1750 to 2700 m3/h ________ DN 100

from 700 to 1750 m3/h _________ DN 80

from 2700 m3/h _______________ DN 150

up to

Weishaupt pressure regulators


Types 5/1 to 9
with safety assemblies

Technical Data:
Weishaupt
type

Connection
DN
Inlet
Outlet

Approx.
weight
kg

Order No.

Gas pressure regulator


Type
DN

Orifice

mm

max. inlet
pressure
bar

Outlet
pressure
mbar

Spring
colour

Product
ID number

5/1-25/50
5/1-25/80

25
25

50
80

46
58

151 336 2637/0


151 336 2653/0

RR 16-25-31-8N-033
RR 16-25-31-8N-033

25
25

31
31

4.0
4.0

100 210
100 210

green/white CE-0085 AQ 1103


green/white CE-0085 AQ 1103

6/1-50/50
6/1-50/80

50
50

50
80

44
57

151 336 2638/0


151 336 2639/0

RR 16-50-31-8N-033
RR 16-50-31-8N-033

50
50

31
31

4.0
4.0

100 210
100 210

green/white CE-0085 AQ 1103


green/white CE-0085 AQ 1103

6/1a-50/50
6/1a-50/80
6/1a-50/100

50
50
50

50
80
100

44
57
62

151 336 2663/0


151 336 2664/0
151 336 2665/0

RR 16-50-42-8N-033
RR 16-50-42-8N-033
RR 16-50-42-8N-033

50
50
50

42
42
42

4.0
4.0
4.0

100 210
100 210
100 210

green/white CE-0085 AQ 1103


green/white CE-0085 AQ 1103
green/white CE-0085 AQ 1103

7/1-50/50
7/1-50/80
7/1-50/100

50
50
50

50
80
100

54
68
73

151 336 2640/0


151 336 2641/0
151 336 2642/0

RR 16-50-54-12N-033
RR 16-50-54-12N-033
RR 16-50-54-12N-033

50
50
50

54
54
54

4.0
4.0
4.0

100 210
100 210
100 210

black
black
black

CE-0085 AQ 1103
CE-0085 AQ 1103
CE-0085 AQ 1103

8/1-80/80
8/1-80/100
8/1-80/150

80
80
80

80
100
100

86
100
120

151 336 2643/0


151 336 2644/0
151 336 2645/0

RR 16-80-82-12N-033
RR 16-80-82-12N-033
RR 16-80-82-12N-033

80
80
80

82
82
82

4.0
4.0
4.0

100 210
100 210
100 210

black
black
black

CE-0085 AQ 1103
CE-0085 AQ 1103
CE-0085 AQ 1103

100
100

100
150

122
149

151 336 2620/0


151 336 2627/0

12-4-12
12-4-12

100
100

107
107

2.0
2.0

100 210
100 210

silver
silver

CE-0085 AQ 1095
CE-0085 AQ 1095

9-100/100
9-100/150

The RR 16... regulator has an integral SAV with safety diaphragm, green spring, setting range 140 - 400 mbar (unit supplied set to 350 mbar)
Scope of delivery:
1 Pressure regulator
1 SAV safety shut off valve
1 SBV safety relief valve
1 Inlet pressure gauge with push button valve
1 Outlet pressure gauge with push button valve
1 Bypass line with ball valve
1 Impulse line (pressure regulator)

1 Impulse line (SAV)


1 Stabilising piece with connections
1 Key for resetting SAV, with screw and gaskets
Unit supplied fully assembled and pressure tested.

Legend:
1 Inlet pressure gauge with push button valve
2 Gas pressure regulator
3 Setting screw (pressure regulator)
4 Cover
5 Spring (pressure regulator)
6 Diaphragm (pressure regulator)
7 Breather connection, 1
8 Impulse line connection (pressure regulator)
9 Setting screw (SBV)
10 Spring (SBV)
11 SBV safety relief valve
12 Vent line connection , 3/4
13 Diaphragm
14 Outlet pressure gauge with push button
15 Stabilising line
16 Impulse line (SAV)
17 Impulse line (pressure regulator)
18 Intermediate piece
19 Orifice (pressure regulator)
20 Valve body
21 Base plate
22 Valve disc
23 Valve stem
24 SAV seat
25 Impulse line (SAV)
26 Diaphragm (SAV)
27 Spring (SAV)
28 Setting screw (SAV)
29 SAV safety shut off valve
30 Latch lever
31 SAV valve
32 Reset shaft

Atmosphere
Inlet pressure
Outlet pressure

10

Types 9-100/100 and 9-100/150 only

Types 5 to 9

SAV
type

DN

Spring
colour

Setting
range
mbar

Pemax.
bar

Product
ID Number

SH-I

100

green

140 310

CE-0085 AQ 1096

SBV
type

275 D

DN

Spring
colour

Setting
range
mbar

Product
ID Number

black

150 500

CE-0085 AQ 1102

/4

Outlet pressure springs and labels


Outlet
pressure
mbar

Colour

Order No.

Label
Order No.

For use with type


5/1-25/50
6/1-50/50
5/1-25/80
6/1-50/80

15 35
15 35
15 35

orange/grey
yellow/black
green

490 190
490 191
490 085

2010000811/7
2010000811/7
2010000811/7

30 70
30 70
30 70

yellow/black
red/blue
orange

490 191
490 192
490 086

2010000812/7
2010000812/7
2010000812/7

70 140
70 140
70 140

red/blue
blue/green
black

490 192
490 193
490 087

2010000814/7
2010000814/7
2010000814/7

100 210
100 210
100 210

green/white
black
silver

490 194
490 195
490 088

2010000815/7
2010000815/7
2010000815/7

Note:
The pressure regulators are fitted as standard with
springs for the highest outlet pressure (see table
technical data). The actual outlet pressure must be
determined for the individual installation. This outlet
pressure and the required spring must be shown on
the order. The pressure regulators will then be
supplied with the relevant spring and adhesive plate.

7/1-50/50
7/1-50/80
7/1-50/100

8/1-80/80
8/1-80/100
8/1-80/150

9-100/100
9-100/150

Function of the pressure regulator


The pressure regulators diaphragm (6) transfers
movement via the valve stem (23) to the valve disc
(22). The outlet pressure is transferred via the
impulse line (17) into the space below the
diaphragms (6). This pressure is set with the setting
screw (3) and can be varied by adjsuted the spring
(5) loading. At zero gas flow the pressure regulator
(2) is closed. The valve disc (22) tightly closes the
orifice (19). Without gas pressure the pressure
regulator (2) is open. The spring tension presses the
diaphragm (6) and the valve stem (23) downward.
The valve disc (22) is thus lifted off the orifice (19).
When gas flows through the orifice (19), pressure
can build up via the impulse line (17) below the
diaphragm (6). If the gas pressure exceeds the set
spring tension, the valve stem (23) and valve disc
(22) are lifted and the orifice (19) is constricted. The
gas flow is thus reduced and the pressure rise
terminated. If the gas pressure behind the orifice (19)
drops due to gas reduction, the valve cross section
is again enlarged by the increased spring tension.
Function of the SAV safety shut off valve
During normal operation the SAV is open. It
automatically shuts off the gas flow if the pressure
rises above the set amount. After responding it
remains shut and can only be re-opened manually.
The shut off valve disc, coated with vulcanised
synthetic rubber, is spring loaded and is retained by
the latch lever (30) in the open position. Once the
trip pressure downstream of the valve has been
reached, the shut off valve is tripped and shut by the
spring tension.

As the gas flow presses the valve tightly onto the


valve seat, a tight seal is achieved. The SAV is reset
by the reset shaft (32).The shut off point of the SAV
is set via the setting screw (27). The SAV must not
be set above the maximum pe of the downstream
solenoid valves

Direction
of flow

Release principle

Function of the SBV safety relief valve


During normal operation the SBV is closed. The SBV
(11) is adjusted in such a manner that that this valve
will be the first to respond to an excess outlet
pressure. Only then will the SAV (29) become
operative. The gas is vented into safe open
atmosphere via the vent line (12). With a pressure
rise the diaphragm (13) is raised by the valve disc
and gas can thus flow through the valve. When the
diaphragm drops again following a reduction in
pressure, the valve is closed.
The appropriate venting pressure level is set via the
setting screw (9).

11

Installation
In order to avoid damage and operational faults,
care must be taken that the connection line and
the regulator are free from contamination.

Install horizontally, with the spring housing of the


gas pressure regulator vertically upwards.

The assembly must be installed in such a manner


that the directional arrows on the regulator and on
the SAV point in the direction of the gas flow.

When installing, particular care must be taken to


ensure the impulse lines (16 & 17) are not
damaged.

The vent line connection (12) should be connected


to the 3/4 breather port and led into a safe, open
atmosphere.

Once the pressure regulating assembly has been


installed in the burners gas valve train, a
soundness test must be carried out in accordance
with the burner operating instructions.

Prior to commissioning, the pressure regulating


assembly must be tested for correct function,
including the closing of the SAV.

All local legislation and directives must be


observed.

Commissioning
Slowly open the shut off assembly on the inlet
pressure side.

The outlet pressure of the pressure regulator (8),


the shut off pressure of the SAV (2) and the shut
off pressure of the SBV (17) are factory preset as
follows:
Pressure regulator ___________ approx. 140 mbar
SAV _______________________ approx. 350 mbar
SBV_______________________ approx. 300 mbar
If a different outlet pressure is required, this can be
achieved by adjusting the setting screw (3). For
instructions on pressure adjustment see page 15.

Should an operational fault on the pressure


regulator effect a closure of the SAV (2) it can be
reopened manually at the reset shaft (32), after
previously opening the ball valve in the bypass line
(equalisation of pressure).

Visual test
A visual test is carried out during annual
maintenance, when the condition and operation of
the units are checked for deviations in the desired
conditions (gas throughput, gas pressure, set
points).
Sequence test
After the visual test, the setting and operation of the
pressure regulator, SAV and SBV are checked.
Please pay attention to the notes on page 15.
Maintenance
The pressure regulators require practically no
maintenance. A gas filter must be fitted upstream of
the pressure regulator.

12

Faults
Vibration: The regulator is frequently held responsible
for pulsations, whereas in reality pulsations originate
mainly in the pipe line. A close check should therefore
be made first, as to whether the pipe line is well
supported and does not have any points causing
vibrations (half opened valves, pipework with many
changes in direction etc.).
Pulsation in the regulator can only be caused by a
distorted diaphragm or valve rods, which happens
very rarely.
Fluctuations (surges): The regulator has a large orifice
and consequently a very large throughput in
comparison to its connection size. At very low
throughputs the valve disc barely lifts from the orifice.
When this happens the regulator may become
unstable. To overcome this proceed as follows:
If the regulator surges at normal throughput the fault
can be rectified by throttling the impulse line.
Generally, a reduction in the cross section of the
impulse line effects an attenuation and consequently a
slower response period for the pressure regulator.
Surging of the regulator can often be eliminated by
reducing the breather cross section (see rubber
washer, page 13).
Where operating conditions permit, a different spring
may also be used.
No zero cut off: The cause may be a damaged valve
seat, or a non-tight orificie.
Note:
All SAV impulse connections are fitted as standard
with a 1.6 mm orifice. All RR16 regulators are
fitted as standard with a 3 mm orifice. This should
be checked if the equipment does not function
correctliy.

Connections / Accessories

Weldable flange Flange table: DIN 2633 PN 16


DN

Approx. kg

Order No.

20/ 26.9
25/ 33.7
40/ 48.3

38
38
42

0,9
1,1
1,8

452 940
452 941
452 942

50/ 60.3
65/ 76.1
80/ 88.9

45
45
50

2,5
3,0
3,7

452 936
452 910
452 911

100/114.3
125/139.7
150/168.3

52
55
55

4,6
6,3
7,7

452 913
452 914
452 918

Flanged eccentric reducer; aluminium


(Max. operating pressure 3 bar, flange table: DIN 2633 PN 16.
not for installation upstream of the high pressure regulator).
DN1

DN2

25
25
25
25

40
50
65
80

144
159
172
177

7.5
12.5
20.0
27.5

Approx. kg*
2.6
2.7
3.3
3.7

Order No.
151 329 2630/2
151 329 2631/2
151 329 2632/2
151 329 2683/2

40
40
40
40

50
65
80
100

163
177
181
195

5.0
12.5
20.0
31.0

3.7
4.1
4.4
6.0

151 329 2634/2


151 329 2635/2
151 329 2684/2
151 329 2637/2

50
50
50

65
80
100

180
185
197

7.5
15.0
26.0

4.4
5.1
6.3

151 329 2638/2


151 329 2685/2
151 329 2640/2

65
65
65

80
100
125

185
197
227

7.5
18.5
31.0

5.1
6.6
7.7

151 329 2686/2


151 329 2642/2
151 329 2643/2

80
80

100
125

207
232

11.0
23.5

7.0
8.2

151 329 2687/2


151 329 2688/2

100
100
125

125
150
150

234
247
250

12.5
26.5
14.0

9.4
12.0
12.8

151 329 2646/2


151 329 2647/2
151 329 2648/2

Includes nuts, bolts and gaskets for two break points.


Flanged concentric reducer; steel, grey cast iron or ductile cast iron
(Max. operating pressure 16 bar, flange table DIN 2633 PN 16).
DN1

DN2

Material

25
25
25
25

40
50
65
80

150
165
173
182

Steel
Steel
Steel
Steel

4.5
5.3
6.0
7.0

151 327 2671/2


151 327 2680/2
151 330 2620/2
151 330 2621/2

40
50
50
50

50
65
80
100

200
200
200
200

Grey cast iron


Grey cast iron
Ductile cast iron
Ductile cast iron

7.0
9.0
7.2
8.1

151 330 2625/2


151 327 2682/2
151 329 2689/2
151 327 2644/2

65
80
80
80

80
100
125
150

200
200
200
200

Ductile cast iron


Ductile cast iron
Ductile cast iron
Ductile cast iron

8.2
9.3
10.5
12.0

151 330 2608/2


151 329 2690/2
151 329 2691/2
151 330 2622/2

100
100
125

125
150
150

200
200
200

Ductile cast iron


Ductile cast iron
Ductile cast iron

11.4
12.8
14.1

151 327 2689/2


151 328 2626/2
151 330 2623/2

Approx. kg*

Order No.

Includes nuts, bolts and gaskets for two break points.


Rubber washer
Dimensions

Order No.

44 mm, 2 mm thick

151 336 2616/7

See page 10 for notes and installation.

* the weights given include nuts, bolts and gaskets.


Dimensions are approximate. We reserve the right t make changes in the light of future developments.

13

Installation examples and notes

1
2
3
4
5
6
7
8
9
10

Ball valve
Gas filter
SAV safety shut off valve
Pressure regulator
SBV safety relief valve
Compensator
Reducing flange
Pressure gauge with push button valve
SBV vent line
Pressure regulator breather line

Installation instructions
In many cases the pressure regulators inlet and
outlet sizes are smaller than those of the gas
valve trains other components, particularly with
high gas pressures. A range of flanged reducers
in all the necessary sizes is available to enable
installation to be carried out quickly and correctly
(see page 13).

The distance between the solenoid valves and


the pressure regulator can be short, or several
meters long. With large distances the gas flow
can stabilise and a buffer volume is obtained.

There must be an ambient temperature of - 15C


to + 60C for the pressure regulators and the
safety assemblies. If necessary, the regulators
should be shielded from heat radiation or
excessively low temperatures. Protection is also
necessary against damp, dust and dirt.

Example: installation with pressure regulator types 08/1 to 09/1 and 1/1 to 4/1

The breather line (10) is the line between the


space above the diaphragm of the pressure
regulator or safety shut off valve and free
atmosphere. Correct operation can only be
guaranteed if the air column above the
diaphragm can move quickly without undue
resistance. The line diameters below must be
provided for the various lengths of line as shown.
mm

length m

15
20
25

3
5
>5

For longer lengths up to 30 m, 25 mm is


sufficient.

Due to the SAV shut off cap ,which is fitted with a


diaphragm, it is not necessary to fit a breather
line from the SAV diaphragm housing to
atmosphere.

Multiple breather lines from the gas pressure


regulator can be manifolded together or
separately over the roof. The common line must
be laid with a larger diameter. It should be noted
that no mutual interference is caused by this.

The vent line (9) is the line between the safety


relief valve and free atmosphere. This line must
be installed separately

Example: installation with pressure regulator types 5/1 to 8/1

Connection for types 5/1 to 9 ____________ 3/4

There is a common breather and vent line (9/10)


on pressure regulator types 08/1 and 09/1 and
types 1/1 to 5/1. This line must be installed
separately. For the nominal diameter, the same
instructions as for the breather line apply.
Connection for:
Types 08/1 and 09/1 ___________________ 3/4
Types 1/1 to 5/1 ________________________ 1

14

The termination of the lines must be an adequate


distance from sources of ignition (at least 3
metres) and and installed so that any outflowing
gas cannot enter buildings. The line must also be
protected against the entry of rainwater and
against blockages.

Attention must be paid to installation expansion


and movement. Compensators can be used for
this.

The gaskets supplied should be inserted


between the flanges.

The complete assembly must be tested for


soundness before commissioning. The outlet
side is tested according to the instructions given
in the burner installation and operating manual.
For valve proving of the inlet side see page 15.

Prior to commissioning, check for correct


function, including the closed position test of the
safety shut off valve. The installation must be
purged carefully and the pressure increased by
slowly filling with gas.

Notes on adjustment

Fig. 1

Fig. 2

Fig. 3

Adjusting the outlet pressure (Fig. 1)


When reading the pressure gauge, the push
button valve must be depressed.

Adjusting the SBV (Fig. 2)


The SBV is factory preset to 300 mbar

The SAV is factory preset to 350 mbar

This setting does not normally require an

This setting does not normally require an

The outlet pressure of the regulator can be

decreased by turning the setting screw (item 3,


page 10) anticlockwise, and increased by turning
the screw clockwise.

adjustment
The setting pressure of the SBV can be

decreased by turning the setting screw (item 9,


page 10) anticlockwise and increased by turning
the screw clockwise.
The relief pressure must be lower than the max.

permitted inlet pressure of the solenoid valve.

Adjusting the SAV (Fig. 3)

adjustment
The setting pressure of the SAV can be

decreased by turning the setting screw (item 8,


page 10) anticlockwise and increased by turning
the screw clockwise.
The setting pressure may only be as high as the

max. permitted setting pressure of the solenoid


valves.
The SAV cannot be reset
This occurs if the SBVs vent pressure is set higher
than the tripping pressure of the SAV.

Fig. 4

Fig. 5

Fig. 6

Reseting the SAV


Equalise the pressure by opening the bypass
valve (Fig. 4).

Unscrew sealing cap and pull back valve rod until

Turn reset shaft anticlockwise until the valve disc

it engages (Fig. 5, only possible if the outlet


pressure is less than the SAV release pressure).

arm in the release arm engages (Fig. 6).


Screw on sealing cap.
Manual bypass valve must be closed.

Soundness test:
Once installed and prior to commissioning, the
complete regulator assembly has to be tested for
soundness, in accordance with the instructions given
in the burners installation and operating manual (the
connection of a filter is possible during the 1st test
phase of the soundness test).

SAV soundness test:

Checking the regulators zero shutdown:

Activate the SAV by increasing the pressure

Open the ball valve and wait until the outlet

downstream of the regulator.


Release pressure in the regulator section by

opening the test point downstream of the


regulator. (ball valve closed).
Connect a pressure gauge to the test point and

check if the pressure increases when the ball


valve is opened.

pressure of the regulator is constant.


Note: SBV must be closed!
Close ball valve
Check if the pressure difference between the

regulators inlet and outlet remains constant.

15

Dimensions

Max Weishaupt GmbH


D-88475 Schwendi
Tel (0 73 53) 8 30, Fax (0 73 53) 8 33 58
www.weishaupt.de
Print No. 83001202, October 2006
Printed in Germany. All rights reserved.
Neachells Lane, Willenhall, WV13 3RG
Tel (01902) 609841, Fax (01902) 633343
www.weishaupt.co.uk

Fig. 1 Types 06/1 to 09/1 and 1/1 to 4/1

Types

d1/d2

06/1 to 09/1
1/1 to 4/1

25
50

d3

d4

h1

h1*

h2

h3

190
350

/4
1

155
250

345
445

100
100

380
490

l4

l5

l6

160
260

100
150

Types

l1

l2

l3

06/1 to 09/1
1/1 to 4/1

160
200

250
290

100
110

60
60

* Dimension for disassembling spring

Flange
DIN 2633

Fig. 2 Type 5/1 (compact)

Dimensions in mm are approximate


(Counterflange not included in delivery, for exact scope of delivery see page 6)
Type

d2

d1

5/1

50

50

l1

l2

h1

h2

h2*

200

750

490

250

445

* Dimension for disassembling spring

Flange
DIN 2633

All other dimensions as per types 1/1 to 4/1.

Fig. 3 Types 5/1 to 8/1

d31)

d4

d6

h1

h1*

h2

5/1-25/50
5/1-25/80

25
25

50
80

310
310

1
1

190
190

470
470

660
660

195
195

6/1-50/50
6/1-50/80

50
50

50
80

310
310

1
1

190
190

485
485

680
680

195
195

6/1a-50/50
6/1a-50/80
6/1a-50/100

50
50
50

50
80
100

310
310
310

1
1
1

190
190
190

485
485
485

680
680
680

195
195
195

7/1-50/50
7/1-50/80
7/1-50/100

50
50
50

50
80
100

405
405
405

1
1
1

190
190
190

485
485
485

680
680
680

195
195
195

8/1-80/80
8/1-80/100
8/1-80/150

80
80
80

80
100
150

405
405
405

1
1
1

190
190
190

545
545
545

735
735
735

240
240
240
l5

Types
3

G /4 reverse
Pressure regulator
RR 16

Flange
DIN 2633

1) Diaphragm and largest width

* Dimension for disassembling spring

Fig. 4 Type 9

Flange DIN 2633

d1

d2

Types

h3

h4

h5

l1

l2

l3

l4

5/1-25/50
5/1-25/80

430
430

350
360

280
280

133
133

180
180

847
1016

250
250

95
95

6/1-50/50
6/1-50/80

430
430

350
350

295
295

179
179

250
250

752
1104

250
250

95
95

6/1a-50/50 430
6/1a-50/80 430
6/1a-50/100 460

350
350
370

295
295
295

179
179
179

250
250
250

752
1104
1204

250
250
250

95
95
95

7/1-50/50
7/1-50/80
7/1-50/100

430
450
460

350
360
370

295
295
295

179
179
179

250
250
250

752
1104
1204

250
250
250

95
95
95

8/1-80/80
450
8/1-80/100 460
8/1-80/150 480

360
370
400

355
355
355

210
210
210

300
300
300

952
1254
1254

250
250
250

95
95
95

Types

d1

d2

d31)

d4

d5

9-100/100
9-100/150

100
100

100
150

360
360

1
1

Types

h2

h3

h4

l1

9-100/100
9-100/150

365
365

455
480

375
400

350
350

1)
*

Diaphragm and largest width


Dimension for disassembling spring

d6

h1

h1*

190
190

425
425

620
620

l2

l3

l4

350
350

1455
1655

250
250

/2
1
/2

VLTAutomationDrive FC 300 Produkthandbuch

Inhaltsverzeichnis

Inhaltsverzeichnis
1. Lesen des Produkthandbuchs

Zulassungen

Symbole

Abkrzungen

2. Sicherheitshinweise und Allgemeine Warnung

Hochspannung

Vermeiden des unerwarteten Anlaufs

Sicherer Stopp des FC 300

Installation Sicherer Stopp (nur FC 302 und FC 301 mit A1-Gehuse)

11

IT-Netz

11

3. Installieren

13

Mechanische Installation

16

Elektrische Installation

21

Netzanschluss und Erdung

22

Motoranschluss

25

Sicherungen

28

Elektrische Installation, Steueranschlsse

32

Anschlussbeispiele

33

Start/Stopp

33

Puls Start/Stopp

33

Drehzahl auf/ab

34

Potentiometer-Sollwert

34

Elektrische Installation, Steuerkabel

35

Schalter S201, S202 und S801

36

Zustzliche Verbindungen

40

Mechanische Bremssteuerung

40

Thermischer Motorschutz

40

4. Programmieren

41

Die grafische und numerische Bedieneinheit

41

Programmieren an der grafischen LCP-Bedieneinheit

41

Programmieren an der numerischen LCP-Bedieneinheit

42

Inbetriebnahme-Men

44

Parameterlisten

48

5. Allgemeine technische Daten

77

6. Fehlersuche und -behebung

83

Warnungen/Alarmmeldungen

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

83

Inhaltsverzeichnis

VLTAutomationDrive FC 300 Produkthandbuch

Index

91

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

1. Lesen des Produkthandbuchs

1. Lesen des Produkthandbuchs

1.1.1. Lesen des Produkthandbuchs


VLT AutomationDrive FC 300 dient zur Regelung der Drehzahl bzw. des Drehmoments an der Welle von elektrischen Motoren. Lesen Sie dieses Handbuch
sorgfltig durch. Eine unsachgeme Verwendung des Frequenzumrichters kann zu Fehlfunktionen des Umrichters und der angeschlossenen Gerte, zu
einer Verkrzung der Lebensdauer oder zu anderen Problemen fhren.

Mithilfe dieses Produkthandbuchs knnen Sie den VLT AutomationDrive FC 300 installieren und programmieren und gegebenenfalls Fehler beheben.
Der VLT AutomationDrive FC 300 ist in zwei Wellenleistungsniveaus lieferbar. Der VLT AutomationDrive FC 300 ist in zwei Wellenleistungsniveaus
lieferbar. Der FC 301 reicht von skalar (U/f) bis WC+ und kann nur mit Asynchronmotoren eingesetzt werden. Der FC 302 ist ein Hochleistungs-Frequenzumrichter fr Asynchron- und permanenterregte Motoren, der verschiedene Motorsteuerverfahren wie Skalar (U/f), VVC+ und Flux-Vektor
untersttzt.
Diese Bedienungsanweisungen gelten fr FC 301 und FC 302. Wenn Informationen fr beide Typen gelten, verwenden wir die Bezeichnung FC 300.
Andernfalls wird speziell auf FC 301 bzw. FC 302 verwiesen.

Kapitel 1, Lesen des Produkthandbuchs, gibt eine Einfhrung zum Handbuch und informiert ber Zulassungen, Symbole und Abkrzungen, die in
diesem Handbuch verwendet werden.

Kapitel 2, Sicherheitsanweisungen und allgemeine Warnungen, enthlt Anweisungen zur korrekten Handhabung des FC 300.

Kapitel 3, Installieren, fhrt Sie durch das mechanische und elektrische Installationsverfahren.

Kapitel 4, Programmieren, erklrt, wie Sie den FC 300 ber die LCP-Bedieneinheit bedienen und programmieren.

Kapitel 5, Allgemeine technische Daten , enthlt die technischen Daten zum FC 300.

Kapitel 6, Fehlersuche, hilft Ihnen, die Ursachen von Problemen, die beim Arbeiten mit dem FC 300 vorkommen knnen, ausfindig zu machen und zu
beheben.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

1. Lesen des Produkthandbuchs


Verfgbare Literatur fr FC 300
-

Die VLT AutomationDrive FC 300 Bedienungsanweisungen liefern die erforderlichen Informationen fr die Inbetriebnahme und den Betrieb
des Frequenzumrichters.

Das Projektierungshandbuch zum VLT AutomationDrive FC 300 enthlt alle technischen Informationen zum Frequenzumrichter sowie Informationen zur kundenspezifischen Anpassung und Anwendung.

Das Produkthandbuch zum VLT AutomationDrive FC 300 Profibus enthlt Informationen zum Steuern, berwachen und Programmieren des
Frequenzumrichters ber einen Profibus-Feldbus.

Das Produkthandbuch zu VLT AutomationDrive FC 300 DeviceNet enthlt Informationen zum Steuern, berwachen und Programmieren des
Frequenzumrichters ber die DeviceNet-Schnittstelle.

Das Produkthandbuch zu VLT AutomationDrive FC 300MCT 10 enthlt Informationen zur Installation und Verwendung der Software auf einem
PC.

Das Handbuch zu VLT AutomationDrive FC 300 IP21 / Typ 1 enthlt Informationen zur Installation der Option IP21/Typ 1.

Das Handbuch zu VLT AutomationDrive FC 300 24 V DC Backup enthlt Informationen zur Installation der Option fr die 24 V DC-Notstromversorgung.

Technische Literatur von Danfoss Drives ist ebenfalls verfgbar unter www.danfoss.com/drives.

1.1.2. Zulassungen

1.1.3. Symbole
In diesem Produkthandbuch verwendete Symbole.

ACHTUNG!
Kennzeichnet einen wichtigen Hinweis.

Kennzeichnet eine allgemeine Warnung.

Kennzeichnet eine Warnung vor Hochspannung.

Markiert in der Auswahl die Werkseinstellung.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

1. Lesen des Produkthandbuchs

1.1.4. Abkrzungen
Wechselstrom
American Wire Gauge = Amerikanisches Drahtma
Ampere
Automatische Motoranpassung
Stromgrenze
Grad Celsius
Gleichstrom
Abhngig von Frequenzumrichter
Elektromagnetische Vertrglichkeit
Elektronisch-thermisches Relais
Frequenzumrichter
Gramm
Grssenabhngig
Hertz
Kilohertz
LCP-Bedieneinheit
Meter
Induktivitt in Millihenry
Milliampere
Millisekunde
Minute
Motion Control Tool
Nanofarad
Newtonmeter
Nennmotorstrom
Motornennfrequenz
Nennmotorleistung
Nennmotorspannung
Parameter
Schutzkleinspannung
Platine (engl. Printed Circuit Board)
Wechselrichter-Ausgangsnennstrom
Umdrehungen pro Minute
Sekunde
Drehmomentgrenze
Volt

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

AC
AWG
A
AMA
ILIM
C
DC
D-TYPE
EMV
ETR
FC
g
SR
Hz
kHz
LCP
m
mH
mA
ms
min.
MCT
nF
Nm
IM,N
fM,N
PM,N
UM,N
Par.
PELV
PCB
IINV
UPM
s
TLIM
V

2. Sicherheitshinweise und Allgemeine Warnung

VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

2. Sicherheitshinweise und Allgemeine Warnung

2. Sicherheitshinweise und Allgemeine Warnung

2
Gerte mit elektronischen Bauteilen drfen nicht im normalen Hausmll entsorgt werden.
Sie mssen separat mit Elektro- und Elektronikaltgerten gem rtlicher und geltender Gesetzgebung gesammelt werden.

Die Zwischenkreiskondensatoren bleiben auch nach Abschalten der Netzversorgung eine gewisse Zeit geladen. Zum Schutz vor elektrischem Schlag ist der Frequenzumrichter vor allen Wartungsarbeiten vom Netz zu trennen. Bei Verwendung eines PM-Motors
sicherstellen, dass dieser getrennt ist. Vor der Durchfhrung von Wartungsarbeiten mssen unbedingt die folgenden Wartezeiten
eingehalten werden:

380 - 500 V

525 - 690 V

0,25 - 7,5 kW
11 - 75 kW
90 - 200 kW
250 - 400 kW
37 - 250 kW
315 - 560 kW

4 Minuten
15 Minuten
20 Minuten
40 Minuten
20 Minuten
30 Minuten

FC 300
Betriebsanleitung
Softwareversion: 4.8x

Dieses Produkthandbuch gilt fr smtliche FC 300-Frequenzumrichter mit Softwareversion 4.8x.


Die Softwareversion kann ber Parameter 15-43 aufgerufen werden.

2.1.1. Hochspannung
Der Frequenzumrichter steht bei Netzanschluss unter lebensgefhrlicher Spannung. Unsachgeme Installation des Motors oder des
Frequenzumrichters knnen Schden am Gert sowie schwere Personenschden oder sogar tdliche Verletzungen verursachen. Halten
Sie daher unbedingt die Anweisungen in diesem Handbuch sowie die lokalen und nationalen Sicherheitsvorschriften ein.

Installation in groen Hhenlagen


380 - 500 V: Bei Hhen ber 3 km ber NN ziehen Sie bitte Danfoss Drives zu PELV (Schutzkleinspannung) zurate.
525 - 690 V: Bei Hhen ber 2 km ber NN ziehen Sie bitte Danfoss Drives zu PELV (Schutzkleinspannung) zurate.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

2. Sicherheitshinweise und Allgemeine Warnung

VLTAutomationDrive FC 300 Produkthandbuch

Der Frequenzumrichter steht bei Netzanschluss unter lebensgefhrlicher Spannung. Unsachgeme Installation des Motors, Frequenzumrichters oder Feldbus kann Schden am Gert sowie schwere Personenschden oder sogar tdliche Verletzungen verursachen.
Befolgen Sie daher stets die Anweisungen in diesem Handbuch sowie die rtlichen und nationalen Vorschriften und Sicherheitsbestimmungen.

Sicherheitsvorschriften
1.

Bei Reparaturen muss die Stromversorgung des Frequenzumrichters abgeschaltet werden. Vergewissern Sie sich, dass die Netzversorgung
unterbrochen und die erforderliche Zeit verstrichen ist, bevor Sie die Motor- und Netzstecker entfernen.

2.

Die [OFF]-Taste auf dem Bedienfeld des Frequenzumrichters unterbricht nicht die Netzspannung und darf deshalb nicht als Sicherheitsschalter
benutzt werden .

3.

Es ist dafr Sorge zu tragen, dass gem den rtlichen und nationalen Vorschriften eine ordnungsgeme Schutzerdung des Gertes erfolgt,
der Benutzer gegen Versorgungsspannung geschtzt und der Motor gegen berlast abgesichert wird.

4.

Der Erdableitstrom bersteigt 3,5 mA.

5.

Ein berlastungsschutz des Motors ist in der Werkseinstellung nicht enthalten. Wenn diese Funktion erforderlich ist, stellen Sie Par. 1-90 auf
Datenwert ETR Alarm 1 [4] oder Datenwert ETR Warnung 1 [3] ein.

6.

Die Stecker fr die Motor- und Netzversorgung drfen nicht entfernt werden, wenn der Frequenzumrichter an die Netzspannung angeschlossen
ist. Vergewissern Sie sich, dass die Netzversorgung unterbrochen und die erforderliche Zeit verstrichen ist, bevor Sie die Motor- und Netzstecker
entfernen.

7.

Der VLT-Frequenzumrichter hat auer den Spannungseingngen L1, L2 und L3 noch weitere Spannungseingnge, wenn DC-Zwischenkreiskopplung bzw. externe 24 V DC-Versorgung installiert sind. Kontrollieren Sie, dass vor Beginn der Reparaturarbeiten alle Spannungseingnge
abgeschaltet sind und die erforderliche Zeit verstrichen ist.

2.1.2. Allgemeine Warnung


Warnung:
Das Berhren spannungsfhrender Teile auch nach der Trennung vom Netz ist lebensgefhrlich.
Achten Sie darauf, dass alle Spannungseingnge, wie z. B. die Zwischenkreiskopplung (Zusammenschalten von Gleichstrom-Zwischenkreisen) sowie der Motoranschluss (z. B. bei kinetischem Speicher), abgeklemmt wurden.
Verwendung des VLT AutomationDrive FC 300: mindestens 15 Minuten warten.
Eine krzere Wartezeit ist nur mglich, wenn dies auf dem Typenschild des jeweiligen Gerts entsprechend vermerkt ist.

Ableitstrom
Der Ableitstrom des FC 300 bersteigt 3,5 mA. Um einen guten mechanischen Anschluss des Erdungskabels an Erde (Klemme 95)
sicherzustellen, muss z. B. der Kabelquerschnitt mindestens 10 mm2 betragen, oder es mssen 2 getrennt verlegte Erdungskabel
verwendet werden.
Fehlerstrom-Schutzeinrichtungen
Dieses Gert kann einen Fehler-Gleichstrom im Schutzleiter verursachen. Als Fehlerstromschutzschalter (FI-Schutzschalter) darf netzseitig nur Typ B (allstromsensitiv) verwendet werden. Siehe auch die FI-Anwendungshinweise MN.90.GX.02.
Die Schutzerdung des FC 300 und die Verwendung von FI-Schutzschaltern mssen stets in bereinstimmung mit den nationalen und
lokalen Vorschriften erfolgen.

2.1.3. Bevor Sie Reparaturarbeiten ausfhren

1.

Trennen Sie den Frequenzumrichter vom Netz.

2.

Trennen Sie die DC-Zwischenkreisklemmen 88 und 89 von Lastteilungsanwendungen.

3.

Warten Sie, bis keine Spannung mehr an der Klemme anliegt. Die Wartezeiten sind auf dem Warnschild vermerkt.

4.

Entfernen Sie das Motorkabel.

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2. Sicherheitshinweise und Allgemeine Warnung

2.1.4. Vermeiden des unerwarteten Anlaufs


Solange der FC 300 an die Netzversorgung angeschlossen ist, kann der Motor ber digitale Befehle, Busbefehle, Sollwerte oder ber die LCP-Bedieneinheit
gestartet bzw. gestoppt werden.

Trennen Sie den FC 300 vom Stromnetz, wenn ein ungewollter Start aus Grnden des Personenschutzes verhindert werden soll.

Um einen ungewollten Start zu vermeiden, bettigen Sie stets die [OFF]-Taste, bevor Sie Parameter ndern.

Ein elektronischer Fehler, eine vorbergehende berlast, ein Fehler in der Netzversorgung oder ein Verlust des Motoranschlusses kann bewirken,
dass ein gestoppter Motor anluft. Die Funktion des Sicheren Stopps beim FC 300 (d. h. FC 301 mit A1-Gehuse und FC 302) schtzt vor einem
unerwarteten Anlauf, wenn an Klemme 37 nur eine geringe Spannung anliegt oder die Klemme von der Stromversorgung getrennt ist.

2.1.5. Sicherer Stopp des FC 300


Der FC 302 und der FC 301 mit A1-Gehuse sind fr Installationen mit der Sicherheitsfunktion Sichere Abschaltung Motormoment (nach IEC 61800-5-2)
oder Stoppkategorie 0 (nach EN 60204-1) geeignet.

FC 301 mit A1-Gehuse: Wenn der Frequenzumrichter mit der Funktion Sicherer Stopp ausgestattet ist, muss Position 18 des Typencodes T oder U
lauten. Lautet Position 18 B oder X, ist sicherer Stopp ber Klemme 37 nicht vorgesehen!
Beispiel:
Typencode fr FC 301 A1 mit Sicherem Stopp: FC-301PK75T4Z20H4TGCXXXSXXXXA0BXCXXXXD0

Er ist fr die Anforderungen der Sicherheitskategorie 3 in EN 954-1 ausgelegt und als dafr geeignet zugelassen. Diese Funktion wird als Sicherer Stopp
bezeichnet. Vor der Integration und Benutzung der Funktion Sicherer Stopp des Frequenzumrichters in einer Anlage muss eine grndliche Risikoanalyse
der Anlage erfolgen, um zu ermitteln, ob die Funktion Sicherer Stopp und die Sicherheitskategorie des Frequenzumrichters angemessen und ausreichend
sind. Zur Installation und zum Gebrauch der Funktion Sicherer Stopp gem den Anforderungen von Sicherheitskategorie 3 in EN 954-1 mssen die
zugehrigen Informationen und Anweisungen des FC 300-Projektierungshandbuchs MG.33.BX.YY befolgt werden! Die Informationen und Anweisungen
des Produkthandbuchs reichen zum richtigen und sicheren Gebrauch der Funktion Sicherer Stopp nicht aus!

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2. Sicherheitshinweise und Allgemeine Warnung

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10

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2. Sicherheitshinweise und Allgemeine Warnung

2.1.6. Installation Sicherer Stopp (nur FC 302 und FC 301 mit A1-Gehuse)
Die Installation der Stoppkategorie 0 (EN 60204) gem Sicherheitskategorie 3 (EN 954-1) ist folgendermaen auszufhren:
1.

Entfernen Sie die werksseitig angebrachte Kabelbrcke zwischen Klemme 37 und Klemme 12 (24 V DC). Es reicht nicht aus,
das Kabel nur durchzuschneiden oder zu unterbrechen. Es muss
vollstndig entfernt werden, um Fehlkontaktierung zu vermeiden. Siehe Kabelbrcke in Abbildung.

2.

Schlieen Sie Klemme 37 mit einem gegen Kurzschluss geschtzten Kabel (verstrkte Isolation) ber eine Sicherheitsvorrichtung gem EN 954-1 Kategorie 3 an die 24-V-DCVersorgung an. Sind die Sicherheitsvorrichtung und der
Frequenzumrichter im selben Schaltschrank untergebracht, darf
auch ein normales Kabel verwendet werden.

3.

Sofern der FC 302 nicht Schutzart IP54 oder hher hat, muss er
in ein IP54-Gehuse eingesetzt werden. Daher muss ein FC 301
A1 immer in ein IP54-Gehuse gesetzt werden.

Abbildung 2.1: Kabelbrcke (Jumper) zwischen Klemme 37 und Klemme 12 (24 V DC)

Die folgende Abbildung zeigt als Beispiel eine Anwendung mit Stoppkategorie 0 (EN 60204-1) gem Sicherheitskategorie 3 (EN 954-1). Klemme 37 wird
ber einen Sicherheitsbaustein (der auch Kategorie 3 nach EN 954-1 erfllen muss) geschaltet. Der zustzliche abgebildete Freilaufkontakt ist nicht
sicherheitsbezogen und erfllt nicht Kategorie 3 nach EN 954-1.

Abbildung 2.2: Abbildung der wesentlichen Aspekte einer Installation zum Erzielen der Stoppkategorie 0 (EN 60204-1) mit Sicherheitskategorie 3 (EN
954-1).

2.1.7. IT-Netz
Par. 14-50 EMV 1 kann benutzt werden, um in Frequenzumrichtern mit einem Spannungsbereich von 380 - 500 V die internen Funkenstrkondensatoren
vom EMV-Filter an Erde zu trennen. Wenn dies geschieht, wird die EMV-Leistung auf das Niveau A2 reduziert. Bei 525 - 690 V-Frequenzumrichtern hat
Par. 14-50 keine Funktion. Der EMV-Schalter kann nicht geffnet werden.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

11

3. Installieren

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12

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3. Installieren

3. Installieren
3.1.1. Vorgehensweise bei der Installation
In diesem Kapitel wird die mechanische und elektrische Installation an den Leistungsklemmen und Steuerkartenklemmen beschrieben.
Die elektrische Installation von Optionen ist im entsprechenden Profihandbuch und Projektierungshandbuch beschrieben.

3.1.2. Erste Schritte


Fhren Sie die unten beschriebenen Schritt-fr-Schritt-Anweisungen aus, um den FC 300 schnell und EMV-gerecht zu installieren.

Lesen Sie die Sicherheitshinweise, bevor Sie das Gert


installieren.

Mechanische Installation

Mechanische Installation

Elektrische Installation

Netzanschluss und Erdung

Motoranschluss und Verkabelung

Sicherungen und Trennschalter

Steuerklemmen - Kabel

Inbetriebnahme-Men

Lokale Bedieneinheit (LCP)

Automatische Motoranpassung, AMA

Programmierung
Abbildung 3.1: Die Grafik zeigt die grundlegende Installationskonfiguration, einschlielich Stromnetz, Motor, Start/Stopp-Taste und Potentiometer fr die Drehzahleinstellung.

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13

VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren

Die Gehusegre hngt vom Gehusetyp, der Leistung und der Netzspannung ab.
Gehusetyp
A1
A2
A3

A5

3
Gehuse
IP
20/21
Gehuse/Typ 1
Absicherung NEMA
Nenn0,25-1,5 kW (200-240 V)
Leistung
0,37-1,5 kW (380-480 V)

20/21
Chassis/Typ 1
0,25-3 kW (200-240 V)
0,37-4,0 kW (380-480/ 500V)
0,75-4 kW (525-600 V)
B2

20/21
55/66
Chassis/Typ 1
Typ 12/Typ 4X
3,7 kW (200-240 V)
0,25-3,7 kW (200-240 V)
5,5-7,5 kW (380-480/ 500 V) 0,37-7,5 kW (380-480/500 V)
5,5-7,5 kW (525-600 V )
0,75 -7,5 kW (525-600 V)
B3
B4

Gehuse
IP
21/55/66
Typ 1/Typ 12
Absicherung NEMA
Nenn5,5-7,5 kW (200-240 V)
Leistung
11-15 kW (380-480/ 500V)
11-15 kW (525-600 V)
Gehusetyp
C1

21/55/66
Typ 1/Typ 12
11 kW (200-250 V)
18,5-22 kW (380-480/ 500V)
18,5-22 kW (525-600 V)
C2

20
Chassis
5,5-7,5 kW (200-240 V)
11-15 kW (380-480/500 V)
11-15 kW (525-600 V)
C3

20
Chassis
11-15 kW (200-240 V)
18,5-30 kW (380-480/ 500 V)
18,5-30 kW (525-600 V)
C4

Gehuse
IP
21/55/66
Absicherung NEMA
Typ 1/Typ 12
Nenn15-22 kW (200-240 V)
Leistung
30-45 kW (380-480/ 500V)
30-45 kW (525-600 V)

21/55/66
Typ 1/Typ 12
30-37 kW (200-240 V)
55-75 kW (380-480/ 500V)
55-90 kW (525-600 V)

20
Chassis
18,5-22 kW (200-240 V)
37-45 kW (380-480/500 V)
37-45 kW (525-600 V)

20
Chassis
30-37 kW (200-240 V)
55-75 kW (380-480/ 500 V)
55-90 kW (525-600 V)

Gehusetyp

14

B1

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3. Installieren

Montagezubehr: Der Frequenzumrichter wird mit folgendem Montagezubehr geliefert:

Gehusegren A1, A2 und A3, IP20/Chassis

Gehusegre A5, IP55/Typ 12

Gehusegre B1 und B2
IP21/IP55/Typ 1/Typ 12

Gehusegre B3, IP20/Chassis

Gehusegre B4, IP20/Chassis

Gehusegre C1 und C2, IP55/66/Typ 1/Typ


Gehusegre C3, IP20/Chassis
Gehusegre C4, IP20/Chassis
12
1 + 2 nur bei Gerten mit Bremschopper. Es gibt fr den FC 301 nur einen Relaisanschluss. Fr die DC-Zwischenkreiskopplung kann Steckanschluss
1 separat bestellt werden (Bestellnummer 130B1064).
Fr den FC 201 ohne sicheren Stopp enthlt das Montagezubehr einen achtpoligen Stecker.

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3. Installieren

3.2. Mechanische Installation


3.2.1. Mechanische Installation
Alle IP20-Gehusegren sowie die IP21/IP55-Gehusegren mit Ausnahme von A1*, A2 und A3 eignen sich zur Installation nebeneinander.

Beim IP21-Gehuse (130B1122 bzw. 130B1123) muss zwischen den Frequenzumrichtern ein Abstand von mindestens 50 mm eingehalten werden.

Fr optimale Khlbedingungen muss ber und unter dem Frequenzumrichter freier Luftdurchlass gewhrleistet sein. Siehe nachstehende Tabelle.

Luftdurchlass fr verschiedene Gehuse


Gehuse:

A1*

A2

A3

A5

B1

B2

B3

B4

C1

C2

C3

C4

a
(mm):

100

100

100

100

100

100

200

200

200

225

200

225

b
(mm):

100

100

100

100

100

100

200

200

200

225

200

225

Tabelle 3.1: * Nur FC 301.


1.

Sehen Sie die Befestigung gem den Angaben zu den Montagelchern vor.

2.

Verwenden Sie geeignete Schrauben fr die Oberflche, auf der der Frequenzumrichter montiert wird. Achten Sie auf ebene Auflage des Khlkrpers, und ziehen Sie alle vier Schrauben gut an.

Tabelle 3.2: Bei der Montage von Gren A5, B1, B2, B3, B4, C1, C2, C3 und C4 auf einer nicht stabilen Wand muss der Frequenzumrichter wegen
unzureichender Khlluft ber dem Khlkrper mit einer Rckwand A versehen werden.

16

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3. Installieren

Abbildung 3.2: Bei schwereren Frequenzumrichtern ist eine Hebevorrichtung zu verwenden. Befestigen Sie zunchst die unteren beiden Schrauben an
der Wand. Heben Sie den Frequenzumrichter auf die unteren beiden Schrauben, und fixieren Sie ihn mit den oberen beiden Schrauben an der Wand.
Abmessungen, A-Gehuse
A1

A2/ A3

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A5

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3. Installieren

Gehusegre

IP
NEMA
Hhe
Hhe der Rckplatte
Hhe des Abschirmblechs
Abstand zwischen Montagelchern
Breite

20
Chassis

A2
0,25-3 kW
(200-240 V)
0,37-4,0 kW
(380-480/ 500 V)
0,75-4 kW
(525-600 V)
20
21
Chassis
Typ 1

A3
3,7 kW
(200-240 V)
5,5-7,5 kW
(380-480/ 500 V)
5,5-7,5 kW
(525-600 V)
20
21
Chassis
Typ 1

A5
0,25-3,7 kW
(200-240 V)
0,37-7,5 kW
(380-480/ 500 V)
0,75-7,5 kW
(525-600 V)
55/66
Typ 12

A
A

200 mm
316 mm

268 mm
374 mm

375 mm

268 mm
374 mm

375 mm
-

420 mm
-

190 mm

257 mm

350 mm

257 mm

350 mm

402 mm

75 mm

Breite der Rckplatte


Breite der Rckplatte mit einer
C-Option
Breite der Rckplatte mit zwei
C-Optionen
Abstand zwischen Montagelchern
Tiefe

90 mm

90 mm

130 mm

130 mm

242 mm

130 mm

130 mm

170 mm

170 mm

242 mm

150 mm

150 mm

190 mm

190 mm

242 mm

60 mm

70 mm

70 mm

110 mm

110 mm

215 mm

Tiefe ohne Option A/B

207 mm

205 mm

207 mm

205 mm

207 mm

195 mm

Mit Option A/B


Bohrungen

222 mm

220 mm

222 mm

220 mm

222 mm

195 mm

c
d
e
f

6,0 mm
8 mm
5 mm
5 mm
2,7 kg

8,0 mm
11 mm
5,5 mm
9 mm
4,9 kg

8,0 mm
11 mm
5,5 mm
9 mm
5,3 kg

8,0 mm
11 mm
5,5 mm
9 mm
6,6 kg

8,0 mm
11 mm
5,5 mm
9 mm
7,0 kg

8,25 mm
12 mm
6,5 mm
9 mm
13,5/14,2 kg

Max. Gewicht

18

A1
0,25-1,5 kW
(200-240 V)
0,37-1,5 kW
(380-480 V)

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3. Installieren

Abmessungen, B-Gehuse
B1/ B2

B3

B4

Gehusegre

IP
NEMA
Hhe
Hhe der Rckplatte
Hhe des Abschirmblechs
Abstand zwischen
Montagelchern
Breite
Breite der Rckplatte
Breite der Rckplatte mit einer COption
Breite der Rckplatte mit zwei COptionen
Abstand zwischen
Montagelchern
Tiefe
Tiefe ohne Option
A/B
Mit Option A/B
Bohrungen

Max. Gewicht

B1
5,5-7,5 kW
(200-240 V)
11-15 kW
(380-480/500 V)
11-15 kW
(525-600 V)
21/ 55/66
Typ 1/Typ 12

B2
11 kW
(200-240 V)
18,5-22 kW
(380-480/ 500 V)
18,5-22 kW
(525-600 V)
21/55/66
Typ 1/Typ 12

B3
5,5-7,5 kW
(200-240 V)
11-15 kW
(380-480/500 V)
11-15 kW
(525-600 V)
20
Chassis

B4
11-15 kW
(200-240 V)
18,5-30 kW
(380-480/ 500 V)
18,5-30 kW
(525-600 V)
20
Chassis

480 mm

650 mm

399 mm

520 mm

420 mm

595 mm

454 mm

624 mm

380 mm

495 mm

242 mm

242 mm

165 mm

230 mm

242 mm

242 mm

205 mm

230 mm

242 mm

242 mm

225 mm

230 mm

210 mm

210 mm

140 mm

200 mm

260 mm

260 mm

249 mm

242 mm

260 mm

260 mm

262 mm

242 mm

c
d
e
f

12 mm
19 mm
9 mm
9 mm
23 kg

12 mm
19 mm
9 mm
9 mm
27 kg

8 mm
12 mm
6,8 mm
7,9 mm

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8,5 mm
15 mm
23,5 kg

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3. Installieren
Abmessungen, C-Gehuse
C1/ C2

C3/ C4

20

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Gehusegre

IP
NEMA
Hhe
Hhe der Rckplatte
Hhe
des
Abschirmblechs
Abstand zwischen
Montagelchern
Breite
Breite der Rckplatte
Breite der Rckplatte mit einer COption
Breite der Rckplatte mit zwei COptionen
Abstand zwischen
Montagelchern
Tiefe
Tiefe ohne Option
A/B
Mit Option A/B
Bohrungen

Max. Gewicht

3. Installieren

C1
15-22 kW
(200-240 V)
30-45 kW
(380-480/ 500 V)
30-45 kW
(525-600 V)
21/55/66
Typ 1/Typ 12

C2
30-37 kW
(200-240 V)
55-75 kW
(380-480/ 500 V)
55-90
kW (525-600 V)
21/55/66
Typ 1/Typ 12

C3
18,5-22 kW
(200-240 V)
37-45 kW
(380-480/ 500 V)
37-45 kW
(525-600 V)
20
Chassis

C4
30-37 kW
(200-240 V)
55-75 kW
(380-480/ 500 V)
55-90 kW
(525-600 V)
20
Chassis

680 mm

770 mm

550 mm

660 mm

630 mm

800 mm

A
a

648 mm

739 mm

521 mm

631 mm

308 mm

370 mm

308 mm

370 mm

308 mm

370 mm

308 mm

370 mm

308 mm

370 mm

308 mm

370 mm

272 mm

334 mm

270 mm

330 mm

310 mm

335 mm

333 mm

333 mm

310 mm

335 mm

333 mm

333 mm

c
d
e
f

12 mm
19 mm
9,8 mm
17,6 mm
43 kg

12 mm
19 mm
9,8 mm
18 mm
61 kg

8,5 mm
17 mm
35 kg

8,5 mm
17 mm
50 kg

3.3. Elektrische Installation


ACHTUNG!
Allgemeiner Hinweis zu Kabeln
Befolgen Sie stets die nationalen und rtlichen Vorschriften zum Kabelquerschnitt und zur Umgebungstemperatur. Verwenden Sie nach
Mglichkeit Kupferleiter (60/75C).

Aluminiumleiter
Klemmen knnen zwar Aluminiumleiter aufnehmen, aber die Leiteroberflche muss sauber sein, und die Oxidation muss vor Anschluss des Leiters durch
neutrales, surefreies Vaselinefett beseitigt und die Verbindung abgedichtet werden.
Auerdem muss die Klemmenschraube nach zwei Tagen angezogen werden. Der Anschluss muss unbedingt gasdicht gehalten werden, um ein erneutes
Oxidieren der Aluminiumoberflche zu verhindern.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

21

VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren

Anzugsdrehmoment
Gehuse
200 - 240 V
A1
0,25-1,5 kW
A2
0,25-2,2 kW
A3
3-3,7 kW
A5
3-3,7 kW
B1
5,5-7,5 kW

B2

B3

B4

C1

C2

C3

C4

11 kW

5,5-7,5 kW

11-15 kW

15-22 kW

30-37 kW

18,5-22 kW

37-45 kW

380 - 500 V
0,37-1,5 kW
0,37-4 kW
5,5-7,5 kW
5,5-7,5 kW
11-15 kW

525 - 690 V
0,75-4 kW
5,5-7,5 kW
0,75-7,5 kW
-

18,5-22 kW

11-15 kW

18,5-30 kW

30-45 kW

55-75 kW

30-37 kW

55-75 kW

Kabel fr:
Anzugsdrehmoment
Netz, Bremswiderstand, Zwischenkreiskopp- 0,5-0,6 Nm
lung, Motorkabel

Netz, Bremswiderstand, Zwischenkreiskopplung, Motorkabel


Relais
Erde
Netz, Bremswiderstand, Zwischenkreiskopplung
Motorkabel
Relais
Erde
Netz, Bremswiderstand, Zwischenkreiskopplung, Motorkabel
Relais
Erde
Netz, Bremswiderstand, Zwischenkreiskopplung, Motorkabel
Relais
Erde
Netz, Bremswiderstand, Zwischenkreiskopplung
Motorkabel
Relais
Erde

1,8 Nm

Netz, Bremswiderstand, Zwischenkreiskopplung


Motorkabel
Relais
Erde
Netz, Bremswiderstand, Zwischenkreiskopplung, Motorkabel
Relais
Erde
Netz, Motorkabel

14 Nm

Zwischenkreiskopplung, Bremskabel
Relais
Erde

0,5-0,6 Nm
2-3 Nm
4,5 Nm
4,5 Nm
0,5-0,6 Nm
2-3 Nm
1,8 Nm
0,5-0,6 Nm
2-3 Nm
4,5 Nm
0,5-0,6 Nm
2-3 Nm
10 Nm
10 Nm
0,5-0,6 Nm
2-3 Nm

10 Nm
0,5-0,6 Nm
2-3 Nm
10 Nm
0,5-0,6 Nm
2-3 Nm
14 Nm (bis 95 mm2)
24 Nm (ber 95 mm2)
14 Nm
0,5-0,6 Nm
2-3 Nm

3.3.1. Ausbrechen von zustzlichen ffnungen fr Kabeldurchfhrungen


1.

Entfernen Sie die Kabeleinfhrung vom Frequenzumrichter (es drfen beim ffnen der Aussparungen keine Fremdkrper in den Frequenzum-

2.

Die Kabeleinfhrung muss rund um die zu ffnende Aussparung abgesttzt werden.

3.

Die Aussparung kann nun mit einem starken Dorn und Hammer ausgeschlagen werden.

4.

Das Loch entgraten.

5.

Kabeldurchfhrung wieder am Frequenzumrichter befestigen.

richter gelangen).

3.3.2. Netzanschluss und Erdung

ACHTUNG!
Der Netzanschluss ist steckbar und an Frequenzumrichtern fr eine Leistung von bis zu 7,5 kW ausgelegt.

22

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren

1.

Befestigen Sie zuerst die beiden Schrauben am Abschirmblech, schieben Sie dieses auf, und ziehen Sie die Schrauben fest.

2.

Stellen Sie sicher, dass der Frequenzumrichter korrekt geerdet ist. Schlieen Sie den Frequenzumrichter an den Erdanschluss an (Klemme 95).
Verwenden Sie hierzu die mitgelieferte Schraube.

3.

Stecken Sie den Netzanschlussstecker (91 (L1), 92 (L2) und 93 (L3)) auf die Klemmen mit der Bezeichnung MAINS unten am Frequenzumrichter.

4.

Schlieen Sie die Netzphasen an den mitgelieferten Netzanschlussstecker an.

5.

Befestigen Sie das Kabel mit den mitgelieferten Halterungen.

ACHTUNG!
Stellen Sie sicher, dass die Netzspannung der auf dem Typenschild angegebenen Nennspannung entspricht.

IT-Netz
Schlieen Sie 400-V-Frequenzumrichter mit EMV-Filtern nicht an ein Stromnetz mit einer Spannung zwischen Phase und Erde von mehr
als 440 V an.

Der Querschnitt des Erdungskabels muss mindestens 10 mm2 betragen, oder es mssen zwei getrennt verlegte und gem EN 50178
angeschlossene Erdleitungen verwendet werden.

Bei Varianten mit Hauptschalter ist dieser auf der Netzseite vorverdrahtet.

Netzanschluss fr Gehuse A1, A2 und A3:

Netzanschluss fr A5-Gehuse (IP 55/66)

Bei Verwendung eines Trennschalters (A5-Gehuse) muss der Erdungsanschluss links im Frequenzumrichter erfolgen.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

23

VLTAutomationDrive FC 300 Produkthandbuch

130BA725.10

3. Installieren

3
Abbildung 3.3: Netzanschluss bei B1- und B2-Gehusen (IP21/NEMA
Typ 1 und IP55/66/NEMA Typ 12).

130BA714.10

Abbildung 3.4: Netzanschluss B3-Gehuse (IP20).

Abbildung 3.5: Netzanschluss B4-Gehuse (IP20).

Abbildung 3.6: Netzanschluss C1- und C2-Gehuse (IP 21/ NEMA Typ

Abbildung 3.7: Netzanschluss C3-Gehuse (IP20).

130BA719.10

130BA718.10

1 und IP 55/66/ NEMA Typ 12).

Abbildung 3.8: Netzanschluss C4-Gehuse (IP20).

In der Regel werden ungeschirmte Kabel als Leistungskabel verwendet.

24

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren

3.3.3. Motoranschluss
ACHTUNG!
Das Motorkabel muss abgeschirmt sein. Bei Verwendung eines nicht abgeschirmten Kabels werden einige EMV-Anforderungen nicht
erfllt. Verwenden Sie ein abgeschirmtes Motorkabel, um die Anforderungen der EMV-Richtlinie einzuhalten. Nhere Informationen
finden Sie unter EMV-Prfergebnisse.

Hinweise zu korrekten Maen von Motorkabelquerschnitt und -lnge finden Sie im Kapitel Allgemeine technische Daten.

Abschirmung von Kabeln: Vermeiden Sie verdrillte Schirmenden (Pigtails), die hochfrequent nicht ausreichend wirksam sind. Wenn der Kabelschirm
unterbrochen werden muss (z. B. um ein Motorschtz oder einen Reparaturschalter zu installieren), muss die Abschirmung an der Unterbrechung mit der
geringstmglichen HF-Impedanz fortgefhrt werden (groflchige Schirmauflage).
Schlieen Sie den Motorkabelschirm am Schirmblech des Frequenzumrichters und am Metallgehuse des Motors an.
Stellen Sie die Schirmungsverbindungen mit einer mglichst groen Kontaktflche (Schirmbgel) her. Dies kann unter Verwendung des im Lieferumfang
des Frequenzumrichters enthaltenen Zubehrs erfolgen.
Wenn der Kabelschirm unterbrochen werden muss (z. B. um ein Motorschtz oder ein Motorrelais zu installieren), muss die Abschirmung hinter der
Unterbrechung mit der geringstmglichen HF-Impedanz fortgefhrt werden.

Kabellnge und -querschnitt: Der Frequenzumrichter ist mit einer bestimmten Kabellnge und einem bestimmten Kabelquerschnitt getestet worden.
Wird der Kabelquerschnitt erhht, so erhht sich auch der kapazitive Widerstand des Kabels und damit der Ableitstrom , sodass die Kabellnge dann
entsprechend verringert werden muss. Das Motorkabel muss mglichst kurz sein, um Rauschen und Ableitstrme auf ein Minimum zu beschrnken.

Taktfrequenz: Wenn der Frequenzumrichter zusammen mit einem Sinusfilter verwendet wird, um z. B. die Strgerusche des Motors zu reduzieren,
muss die Taktfrequenz in Parameter 14-01 entsprechend der Angabe zu dem verwendeten Sinusfilter eingestellt werden.

1.

Montieren Sie das Abschirmblech unten am Frequenzumrichter mit den Schrauben und Unterlegscheiben aus dem Montagezubehr.

2.

Schlieen Sie die drei Phasen des Motorkabels an den Klemmen 96 (U), 97 (V), 98 (W) an.

3.

Schlieen Sie den PE-Leiter mit der passenden Schraube aus dem Zubehr an Klemme 99 auf dem Abschirmblech an.

4.

Stecken Sie die Motor-Anschlussstecker mit den Klemmen 96 (U), 97 (V) und 98 (W) auf die Klemmen mit der Bezeichnung MOTOR (bis 7,5
kW).

5.

Befestigen Sie das abgeschirmte Kabel mit Schrauben und Unterlegscheiben aus dem Montagezubehr am Abschirmblech.

Alle dreiphasigen Standard-Asynchronmotoren knnen an den Frequenzumrichter angeschlossen werden. Normalerweise wird fr kleine Motoren Sternschaltung verwendet (230/400 V, Y), Grere Motoren sind in der Regel mit Dreieckschaltung angeschlossen (400/690 V, ). Schaltungsart (Stern/
Dreieck) und Anschlussspannung sind auf dem Motortypenschild angegeben.

Abbildung 3.10: Motoranschluss fr A5-Gehuse (IP 55/66/NEMA Typ


Abbildung 3.9: Motoranschluss fr A1, A2 und A3

12)

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

25

VLTAutomationDrive FC 300 Produkthandbuch

130BA726.10

3. Installieren

3
Abbildung 3.11: Motoranschluss fr B1- und B2-Gehuse (IP 21/NEMA
Typ 1, IP 55/NEMA Typ 12 und IP66/NEMA Typ 4X)

130BA721.10

Abbildung 3.12: Motoranschluss fr Gehuse B3.

130BA740.10

Abbildung 3.13: Motoranschluss fr Gehuse B4.

Abbildung 3.15: Motoranschluss fr Gehuse C3 und C4.

Abbildung 3.14: Motoranschluss fr C1 und C2-Gehuse (IP 21/NEMA


Typ 1 und IP 55/66/NEMA Typ 12)

26

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren

Abbildung 3.18: Kabeleinfhrungsffnungen fr Gehuse C1. Die vorAbbildung 3.16: Kabeleinfhrungsffnungen fr Gehuse B1. Die vor-

geschlagene Verwendung der Lcher ist eine reine Empfehlung, und es

geschlagene Verwendung der Lcher ist eine reine Empfehlung, und es

sind andere Lsungen mglich.

sind andere Lsungen mglich.

Abbildung 3.19: Kabeleinfhrungsffnungen fr Gehuse C2. Die vorAbbildung 3.17: Kabeleinfhrungsffnungen fr Gehuse B2. Die vor-

geschlagene Verwendung der Lcher ist eine reine Empfehlung, und es

geschlagene Verwendung der Lcher ist eine reine Empfehlung, und es

sind andere Lsungen mglich.

sind andere Lsungen mglich.

Klemme Nr.

96
U

97
V

98
W

U1
W2
U1

V1
U2
V1

W1
V2
W1

99
PE1)
PE1)
PE1)

Motorspannung 0-100 % der Netzspannung


(Anschlussklemmen am FC 300)
Dreieckschaltung
Anschlussklemmen am Motor
Sternschaltung (U2, V2, W2)
U2, V2, W2 sind miteinander zu verbinden.

1)Schutzleiteranschluss

ACHTUNG!
Bei Motoren ohne Phasentrennpapier oder eine geeignete Isolation, welche fr den Betrieb an einem Zwischenkreisumrichter bentigt wird, muss ein LC-Filter
am Ausgang des Frequenzumrichters vorgesehen werden.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

27

VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren
3.3.4. Sicherungen
Abzweigschutz:

Zum Schutz der Anlage vor elektrischen Gefahren und Brnden mssen alle Abzweige in einer Installation, Schaltvorrichtungen, Maschinen usw. in
bereinstimmung mit den nationalen/internationalen Vorschriften mit einem Kurzschluss- und berstromschutz versehen sein.

Kurzschluss-Schutz:

Der Frequenzumrichter muss gegen Kurzschluss abgesichert werden, um elektrische Gefahren und ein Brandrisiko zu vermeiden. Danfoss empfiehlt die
im Folgenden aufgefhrten Sicherungen, um das Bedienpersonal und die Installation im Fall einer internen Funktionsstrung im Frequenzumrichter zu
schtzen. Der FC 300 selbst gewhrleistet einen vollstndigen Kurzschluss-Schutz am Motorausgang.

berstromschutz:
Fr einen berlastschutz ist zu sorgen, um eine Brandgefahr wegen berhitzung der Kabel in der Anlage auszuschlieen. Der Frequenzumrichter verfgt
ber einen internen berstromschutz, der als berlastschutz zwischen FC 300 und Motor verwendet werden kann (nicht UL/cUL-zugelassen). Siehe Par.
4-18. Auerdem knnen Sicherungen oder Trennschalter als berstromschutz in der Anlage verwendet werden. berstromschutz muss stets gem den
nationalen Vorschriften ausgefhrt werden.

Die Sicherungen mssen fr einen Kurzschlussstrom von max. 100.000 Arms (symmetrisch) bei 500 V ausgelegt sein.

Keine UL-Konformitt

Wenn keine bereinstimmung mit UL/cUL-Zulassung bestehen muss, knnen die nebenstehenden Sicherungen in bereinstimmung mit EN50178 verwendet werden.
Die Nichtbeachtung dieser Empfehlung kann im Fall einer Fehlfunktion zu unntiger Beschdigung des Frequenzumrichters fhren.

FC 300
K25-K75
1K1-2K2
3K0-3K7
5K5-7K5
11K

Max. Sicherungsgre1)
10A
20A
32A
63A
80A

15K-18K5
22K
30K
37K

125A
160A
200A
250A

Spannung
200-240 V
200-240 V
200-240 V
380-500 V
380-500 V

Typ
Typ gG
Typ gG
Typ gG
Typ gG
Typ gG

380-500
380-500
380-500
380-500

Typ gG
Typ aR
Typ aR
Typ aR

V
V
V
V

1) Max. Sicherungen siehe nationale/internationale Vorschriften zur Auswahl einer geeigneten Sicherungsgre.
FC 300
K37-1K5
2K2-4K0
5K5-7K5
11K-18K
22K
30K
37K
45K
55K-75K

28

Max. Sicherungsgre1)
10A
20A
32A
63A
80A
100A
125A
160A
250A

Spannung
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Typ
Typ gG
Typ gG
Typ gG
Typ gG
Typ gG
Typ gG
Typ gG
Typ aR
Typ aR

VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren

UL-Konformitt
200-240 V
FC 300
kW
K25-K37
K55-1K1
1K5
2K2
3K0
3K7
5K5
7K5
11K
15K-18K5

Bussmann
Typ RK1
KTN-R05
KTN-R10
KTN-R15
KTN-R20
KTN-R25
KTN-R30
KTN-R50
KTN-R60
KTN-R80
KTN-R125

FC 300
kW
K25-K37
K55-1K1
1K5
2K2
3K0
3K7
5K5
7K5
11K
15K-18K5

FC 300
kW
22K
30K
37K

Bussmann
Typ J
JKS-05
JKS-10
JKS-15
JKS-20
JKS-25
JKS-30
KS-50
JKS-60
JKS-80
JKS-150

Bussmann
Typ T
JJN-06
JJN-10
JJN-15
JJN-20
JJN-25
JJN-30
JJN-50
JJN-60
JJN-80
JJN-125

SIBA

Littelfuse

Typ RK1
5017906-005
5017906-010
5017906-016
5017906-020
5017906-025
5012406-032
5014006-050
5014006-063
5014006-080
2028220-125

Typ RK1
KLN-R05
KLN-R10
KLN-R15
KLN-R20
KLN-R25
KLN-R30
KLN-R50
KLN-R60
KLN-R80
KLN-R125

Bussmann
Typ CC
FNQ-R-5
FNQ-R-10
FNQ-R-15
FNQ-R-20
FNQ-R-25
FNQ-R-30
-

Bussmann
Typ CC
KTK-R-5
KTK-R-10
KTK-R-15
KTK-R-20
KTK-R-25
KTK-R-30
-

FerrazShawmut
Typ CC
ATM-R05
ATM-R10
ATM-R15
ATM-R20
ATM-R25
ATM-R30
-

Bussmann

SIBA

Littelfuse

Type JFHR2
FWX-150
FWX-200
FWX-250

Typ RK1
2028220-150
2028220-200
2028220-250

JFHR2
L25S-150
L25S-200
L25S-250

Bussmann
Typ CC
LP-CC-5
LP-CC-10
LP-CC-15
LP-CC-20
LP-CC-25
LP-CC-30
-

FerrazShawmut
Typ RK1
A2K-05R
A2K-10R
A2K-15R
A2K-20R
A2K-25R
A2K-30R
A2K-50R
A2K-60R
A2K-80R
A2K-125R

FerrazShawmut
JFHR2
A25X-150
A25X-200
A25X-250

KTS-Sicherungen von Bussmann knnen KTN-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.


FWH-Sicherungen von Bussmann knnen FWX-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
KLSR-Sicherungen von LITTELFUSE knnen KLNR-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
L50S-Sicherungen von LITTELFUSE knnen L50S-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
A6KR-Sicherungen von FERRAZ-SHAWMUT knnen A2KR-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
A50X-Sicherungen von FERRAZ-SHAWMUT knnen A25X-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
380-500 V
FC 300
kW
K37-1K1
1K5-2K2
3K0
4K0
5K5
7K5
11K
15K
18K
22K
30K
37K
45K

Bussmann
Typ RK1
KTS-R6
KTS-R10
KTS-R15
KTS-R20
KTS-R25
KTS-R30
KTS-R40
KTS-R50
KTS-R60
KTS-R80
KTS-R100
KTS-R125
KTS-R150

Bussmann
Typ J
JKS-6
JKS-10
JKS-15
JKS-20
JKS-25
JKS-30
JKS-40
JKS-50
JKS-60
JKS-80
JKS-100
JKS-150
JKS-150

Bussmann
Typ T
JJS-6
JJS-10
JJS-15
JJS-20
JJS-25
JJS-30
JJS-40
JJS-50
JJS-60
JJS-80
JJS-100
JJS-150
JJS-150

Bussmann
Typ CC
FNQ-R-6
FNQ-R-10
FNQ-R-15
FNQ-R-20
FNQ-R-25
FNQ-R-30
-

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Bussmann
Typ CC
KTK-R-6
KTK-R-10
KTK-R-15
KTK-R-20
KTK-R-25
KTK-R-30
-

Bussmann
Typ CC
LP-CC-6
LP-CC-10
LP-CC-15
LP-CC-20
LP-CC-25
LP-CC-30
-

29

VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren

FC 300
kW
K37-1K1
1K5-2K2
3K0
4K0
5K5
7K5
11K
15K
18K
22K
30K
37K
45K

FC 300
kW
55K
75K

SIBA

Littelfuse

Typ RK1
5017906-006
5017906-010
5017906-016
5017906-020
5017906-025
5012406-032
5014006-040
5014006-050
5014006-063
2028220-100
2028220-125
2028220-125
2028220-160

Typ RK1
KLS-R6
KLS-R10
KLS-R15
KLS-R20
KLS-R25
KLS-R30
KLS-R40
KLS-R50
KLS-R60
KLS-R80
KLS-R100
KLS-R125
KLS-R150

Bussmann
JFHR2
FWH-200
FWH-250

FC 300
kW
55K
75K

Bussmann
Typ H
-

SIBA

Littelfuse

Typ RK1
2028220-200
2028220-250

JFHR2
L50S-225
L50S-250

FerrazShawmut
Typ CC
ATM-R6
ATM-R10
ATM-R15
ATM-R20
ATM-R25
ATM-R30
-

FerrazShawmut
Typ RK1
A6K-6R
A6K-10R
A6K-15R
A6K-20R
A6K-25R
A6K-30R
A6K-40R
A6K-50R
A6K-60R
A6K-80R
A6K-100R
A6K-125R
A6K-150R

Bussmann
Typ T
-

Bussmann
JFHR2
-

FerrazShawmut
JFHR2
-

FerrazShawmut
JFHR2
A50-P225
A50-P250

A50QS-Sicherungen von Ferraz-Shawmut knnen durch A50P-Sicherungen ausgetauscht werden.


Abgebildete 170M-Sicherungen von Bussman verwenden den optischen Kernmelder -/80. Sicherungen TN/80 Typ T, -/110 oder TN/110 Typ
T mit Kernmelder der gleichen Gre und Amperezahl knnen ausgetauscht werden.
550 - 600V
FC 300
kW
K75-1K5
2K2-4K0
5K5-7K5

FC 300

Bussmann
Typ RK1
KTS-R-5
KTS-R10
KTS-R20

Bussmann
Typ J
JKS-5
JKS-10
JKS-20

Bussmann
Typ T
JJS-6
JJS-10
JJS-20

Bussmann
Typ CC
FNQ-R-5
FNQ-R-10
FNQ-R-20

SIBA

Littelfuse

kW
K75-1K5
2K2-4K0
5K5-7K5

Typ RK1
5017906-005
5017906-010
5017906-020

Typ RK1
KLSR005
KLSR010
KLSR020

FC 300

Bussmann

SIBA

kW
P37K
P45K
P55K
P75K

JFHR2
170M3013
170M3014
170M3015
170M3015

Typ RK1
2061032.125
2061032.160
2061032.200
2061032.200

Bussmann
Typ CC
KTK-R-5
KTK-R-10
KTK-R-20

Bussmann
Typ CC
LP-CC-5
LP-CC-10
LP-CC-20

FerrazShawmut
Typ RK1
A6K-5R
A6K-10R
A6K-20R

FerrazShawmut
Typ RK1
6.6URD30D08A0125
6.6URD30D08A0160
6.6URD30D08A0200
6.6URD30D08A0200

Abgebildete 170M-Sicherungen von Bussman verwenden den optischen Kernmelder -/80. Sicherungen TN/80 Typ T, -/110 oder TN/110 Typ
T mit Kernmelder der gleichen Gre und Amperezahl knnen ausgetauscht werden.
Bei 170M-Sicherungen von Bussmann in den Frequenzumrichtern 525-600/690 V FC-302 P37K-P75K, FC-102 P75K oder FC-202 P45K-P90K
handelt es sich um Sicherungen des Typs 170M3015.
Bei 170M-Sicherungen von Bussmann in den Frequenzumrichtern 525-600/690V FC-302 P90K-P132, FC-102 P90K-P132 oder FC-202 P110-P160
handelt es sich um Sicherungen des Typs 170M3018.
Bei 170M-Sicherungen von Bussmann in den Frequenzumrichtern 525-600/690V FC302 P160-P315, FC-102 P160-P315 oder FC-202 P200-P400
handelt es sich um Sicherungen des Typs 170M5011.

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3. Installieren

3.3.5. Zugang zu den Steuerklemmen


Alle Klemmen zu den Steuerkabeln befinden sich unter der Klemmenabdeckung vorn auf dem Frequenzumrichter. Entfernen sie diese Klemmenabdeckung mit Hilfe eines Schraubendrehers.

Abbildung 3.20: Zugriff auf Steuerklemmen in den Gehusen A2, A3,


B3, B4, C3 und C4.
Nehmen Sie die vordere Abdeckung ab. Achten Sie beim Wiederanbringen der Abdeckung auf die richtige Befestigung mit einem Drehmoment
von 2 Nm.

Abbildung 3.21: Zugriff auf Steuerklemmen in den Gehusen A5, B1,B2,


C1 und C2.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

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3. Installieren
3.3.6. Elektrische Installation, Steueranschlsse
Befestigen des Kabels in der Federzugklemme:

1.

Kabel 9-10 mm abisolieren.

2.

Fhren Sie einen Schraubendreher1) in die rechteckige ffnung ein, und ffnen Sie die Klemmfeder.

3.

Kabel in die runde Klemmffnung einfhren.

4.

Schraubendreher herausziehen. Das Kabel ist nun an der Klemme befestigt.

Entfernen des Kabels aus der Federzugklemme:

1)

1.

Fhren Sie einen Schraubendreher1) in die rechteckige ffnung ein, und ffnen Sie die Klemmfeder.

2.

Kabel herausziehen.

Max. 0,4 x 2,5 mm

1.

2.

32

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3.

VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren

3.4. Anschlussbeispiele
3.4.1. Start/Stopp
Klemme 18 = Par. 5-10 [8] Start
Klemme 27 = Par. 5-12 [0] Ohne Funktion (Standardeinstellung Motor-

freilauf (inv.))

Klemme 37 = Sicherer Stopp (wenn verfgbar!)

3.4.2. Puls Start/Stopp


Klemme 18 = Par. 5-10 [9] Puls-Start
Klemme 27= Par. 5-12 [6] Stopp (invers)
Klemme 37 = Sicherer Stopp (wenn verfgbar!)

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3. Installieren
3.4.3. Drehzahl auf/ab
Klemmen 29/32 = Drehzahlkorrektur auf/ab:
Klemme 18 = Par. 5-10 [9] Start (Standard)
Klemme 27 = Par. 5-12 [19] Sollw. speich.
Klemme 29 = Par. 5-13 [21] Drehzahl auf

Klemme 32 = Par. 5-14 [22] Drehzahl ab


Hinweis: Klemme 29 nur bei FC x02 (x=Serie).

3.4.4. Potentiometer-Sollwert
Spannungssollwert ber Potentiometer:
Variabler Sollwert 1 = [1] Analogeingang 53 (Standard)
Klemme 53 Skal. Min. Spannung = 0 Volt
Klemme 53 Skal. Max. Spannung = 10 Volt
Klemme 53, Skal. Min.-Soll/Istwert = 0 UPM
Klemme 53, Skal. Max.-Soll/Istwert = 1500 UPM
Schalter S201 = AUS (U)

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3. Installieren

3.5.1. Elektrische Installation, Steuerkabel

Abbildung 3.22: bersicht ber smtliche Klemmen (ohne Optionen).


Klemme 37 ist der Eingang, der fr die Funktion Sicherer Stopp verwendet wird. Der Abschnitt Sicheren Stopp installieren im Projektierungshandbuch
enthlt Anweisungen zu dieser Installation.
* Klemme 37 ist beim FC 301 nicht verfgbar (Ausnahme: FC 301 A1).
Klemme 29 und Relais 2 sind im Lieferumfang des FC 301 nicht enthalten.
Sehr lange Steuerkabel und Analogsignale knnen in seltenen Fllen und je nach Installation infolge von Rauschen von den Netzstromkabeln zu 50/60
Hz-Brummschleifen fhren.

In diesem Fall sollte getestet werden, ob durch einseitiges Auflegen des Kabelschirms bzw. durch Verbinden des Kabelschirms ber einen 100-nF-Kondensator mit Masse eine Besserung herbeigefhrt werden kann.

Die Digital- und Analogein- und -ausgnge mssen getrennt an die Gleichtakteingnge des Frequenzumrichters (Klemme 20, 55, 39) angeschlossen
werden, damit Erdstrme von beiden Gruppen die anderen Gruppen nicht beeintrchtigen. Beispielsweise kann Einschalten des Digitaleingangs das
analoge Eingangssignal stren.

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VLTAutomationDrive FC 300 Produkthandbuch

3. Installieren
Eingangspolaritt der Steuerklemmen

130BA681.10

ACHTUNG!
Steuerkabel mssen abgeschirmt sein.

Hinweise zur richtigen Terminierung von Steuerkabeln finden Sie im Abschnitt Erdung abgeschirmter Steuerkabel.

130BA681.10

3.5.2. Schalter S201, S202 und S801


Die Schalter S201 (A53) und S202 (A54) dienen dazu, die Betriebsart fr Strom (0-20 mA) oder Spannung (-10 bis 10 V) fr die Analogeingnge 53 bzw.
54 auszuwhlen.

Schalter S801 (BUS TER.) kann benutzt werden, um fr die serielle RS-485-Schnittstelle (Klemmen 68 und 69) die integrierten Busabschlusswiderstnde
zu aktivieren.
Siehe auch das Diagramm mit allen elektrischen Anschlssen im Abschnitt Elektrische Installation.

Werkseinstellung:
S201 (A53) = AUS (Spannungseingang)
S202 (A54) = AUS (Spannungseingang)
S801 (Busterminierung) = AUS

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3. Installieren

Beim ndern der Funktion der Schalter S201, S202 und


S801 darf ein Umschalten nicht mit Gewalt herbeigefhrt werden. Nehmen Sie beim Bedienen der Schalter
vorsichtshalber die LCP-Bedieneinheit ab. Die Schalter
drfen nur bettigt werden, wenn der Frequenzumrichter spannungsfrei geschaltet ist.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

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3. Installieren
3.6.1. Erste Inbetriebnahme und Test

Um die Konfiguration zu testen und sicherzustellen, dass der Frequenzumrichter funktioniert, kann folgendermaen vorgegangen werden:

Schritt 1. berprfen Sie das Motor-Typenschild.


ACHTUNG!
Der Motor hat entweder Sternschaltung (Y) oder Dreieckschaltung (). Diese Informationen befinden sich

auf dem Typenschild.

Schritt 2. Geben Sie die Motor-Typenschilddaten in der folgenden Reihenfolge in die entsprechenden Parameter ein.
Um diese Liste aufzurufen, drcken Sie erst die Taste [QUICK MENU] und
whlen Sie dann Q2 Quick Setup (Inbetriebnahme-Men).

1.
2.
3.
4.
5.

Motornennleistung [kW]
oder Motornennleistung [PS]
Motornennspannung
Motornennfrequenz
Motornennstrom
Motornenndrehzahl

Par.
Par.
Par.
Par.
Par.
Par.

1-20
1-21
1-22
1-23
1-24
1-25

Schritt 3. Aktivieren Sie die Automatische Motoranpassung


(AMA).
Die Ausfhrung einer AMA stellt die optimale Motorleistung sicher. Bei der AMA werden exakt die elektrischen Ersatzschaltbilddaten
des Motors gemessen und die interne Regelung optimiert.
1.

Schlieen Sie Klemme 37 an Klemme 12 an (falls Klemme 37 verfgbar ist).

2.

Schlieen Sie Klemme 27 an Klemme 12 an, oder setzen Sie Par. 5-12 auf Ohne Funktion (Par. 5-12 [0]).

3.

Aktivieren Sie die AMA in Par. 1-29

4.

Aktivieren Sie die AMA. Ist ein Sinusfilter vorhanden, darf nur die reduzierte AMA ausgefhrt werden. Andernfalls ist das Sinusfilter whrend der
AMA zu entfernen.

5.

Drcken Sie die [OK]-Taste. Im Display wird AMA mit [Hand on]-Taste starten angezeigt.

6.

Drcken Sie die [Hand on]-Taste. Ein Statusbalken stellt den Verlauf der AMA dar.

AMA-Ausfhrung vorzeitig abbrechen


1.

Drcken Sie die [OFF]-Taste: der Frequenzumrichter zeigt einen Alarm an, und am Display wird gemeldet, dass die AMA durch den Benutzer
abgebrochen wurde.

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3. Installieren

Erfolgreiche AMA
1.

Im Display wird AMA mit [OK]-Taste beenden angezeigt.

2.

Drcken Sie die [OK]-Taste, um die automatische Motoranpassung abzuschlieen.

Fehlgeschlagene AMA
1.

Der Frequenzumrichter zeigt einen Alarm an. Eine Beschreibung des Alarms finden Sie im Abschnitt Warnungen und Alarme.

2.

Wert im Fehlerspeicher ([Alarm Log]-Taste) zeigt die zuletzt vor dem Alarm von der AMA ausgefhrte Messsequenz. Diese Nummer zusammen
mit der Beschreibung des Alarms hilft Ihnen bei der Fehlersuche. Geben Sie die Nummer und die Beschreibung des Alarms bei eventuellen

Anrufen beim Danfoss-Service an.


ACHTUNG!
Hufige Ursache fr eine fehlgeschlagene AMA sind falsch registrierte Motor-Typenschilddaten oder auch eine zu groe Differenz
zwischen Umrichter-/Motor-Nennleistung.

Schritt 4. Drehzahlgrenze und Rampenzeit einstellen


Minimaler Sollwert
Max. Sollwert

Par. 3-02
Par. 3-03

Tabelle 3.3: Stellen Sie die Grenzwerte fr Drehzahl und Rampenzeit


gem den Anforderungen ein.

Min. Drehzahl
Max. Drehzahl

Par. 4-11 bzw. 4-12


Par. 4-13 bzw. 4-14

Rampenzeit Auf 1
Rampenzeit Ab 1

Par. 3-41
Par. 3-42

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3. Installieren

3.7. Zustzliche Verbindungen


3.7.1. Mechanische Bremssteuerung
In Hub- und Vertikalfrderanwendungen muss in der Regel eine elektromechanische Bremse gesteuert werden:

Verwenden Sie zum Steuern der Bremse einen Relais- oder Digitalausgang (Klemme 27 und 29).

Halten Sie den Ausgang geschlossen (spannungsfrei), so lange der Frequenzumrichter den Motor nicht halten kann, da z. B. die Last zu schwer
ist.

Whlen Sie Mechanische Bremse [32] in Par. 5-4* fr Anwendungen mit einer elektromechanischen Bremse.

Die Bremse wird gelst, wenn der Motorstrom den in Par. 2-20 eingestellten Wert berschreitet.

Die Bremse wird bettigt, wenn die Ausgangsfrequenz niedriger ist als die in Par. 2-21 bzw. 2-22 eingestellte Frequenz und ein Stoppbefehl
anliegt.

Beim Auftreten eines Alarms fllt die mechanische Bremse sofort ein. Siehe auch Abschnitt Ansteuerung der mechanischen Bremse im Kapitel Einfhrung
zum FC 300.

3.7.2. Parallelschaltung von Motoren


Der Frequenzumrichter kann mehrere parallel geschaltete Motoren steuern. Der Gesamtstrom der Motoren darf den maximalen Ausgangsnennstrom IM,N des Frequenzumrichters nicht bersteigen.

ACHTUNG!
Installationen mit gemeinsamem Anschluss wie in der
Abbildung unten werden nur bei kurzen Kabeln empfohlen.

ACHTUNG!
Bei parallel geschalteten Motoren kann Par. 1-29 Au-

tomatische Motoranpassung (AMA) nicht benutzt werden.

ACHTUNG!
Das elektronisch thermische Relais (ETR) des Frequenzumrichters kann bei parallel geschalteten Motoren
nicht als Motor-berlastschutz fr die einzelnen Motoren des Systems verwendet werden. Ein zustzlicher
Motorschutz, z. B. Thermistoren oder Thermorelais
sind deshalb vorzusehen (Motorschutzschalter sind als
Schutz nicht geeignet).

Beim Start und bei niedrigen Drehzahlen knnen mglicherweise Probleme auftreten, wenn die Motorgren sehr unterschiedlich sind, da bei kleinen
Motoren der relativ hohe ohmsche Widerstand im Stator eine hhere Spannung beim Start und bei niedrigen Drehzahlen erfordert.

3.7.3. Thermischer Motorschutz


Das elektronisch thermische Relais im Frequenzumrichter hat die UL-Zulassung fr Einzelmotorschutz, wenn Par. 1-90 Thermischer Motorschutz auf ETR-

Alarm und Par. 1-24 Motorstrom, IM,N auf Motornennstrom (siehe Motor-Typenschild) eingestellt ist.
Als thermischer Motorschutz kann ebenfalls die PTC-Thermistorkartenoption MCB 112 verwendet werden. Diese Karte ist ATEX-zertifiziert fr den Schutz
von Motoren in explosionsgefhrdeten Bereichen, Zone 1/21 und Zone 2/22. Weitere Informationen siehe Projektierungshandbuch.

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4. Programmieren

4. Programmieren
4.1. Die grafische und numerische Bedieneinheit
Am einfachsten lsst sich der Frequenzumrichter ber die grafische Bedieneinheit (LCP 102) programmieren. Bei Verwendung der numerischen Bedieneinheit (LCP 101) bentigen Sie das Projektierungshandbuch des Frequenzumrichters als Referenz.

4.1.1. Programmieren an der grafischen LCP-Bedieneinheit

Die folgenden Anweisungen gelten fr das grafische LCP (LCP 102):

Die Bedieneinheit ist in vier funktionelle Gruppen unterteilt:


1.

Grafikdisplay mit Statuszeilen.

2.

Mentasten und Anzeige-LEDs zum ndern der Parameter und


zum Umschalten zwischen Displayfunktionen.

3.

Navigationstasten und Kontroll-Anzeigen (LEDs).

4.

Bedientasten mit Kontrollanzeigen (LEDs).

Alle Daten werden auf einem LCP-Grafikdisplay wiedergegeben (maximal


fnf Betriebsvariablen) [Status].

Anzeigezeilen:
a.

Statuszeile: Zustandsmeldungen in der Form von Symbolen


und Grafiken.1

b.

Zeile 1-2: Je nach Displayanzeigeart Anzeigebereich fr Betriebsvariablen oder fr Parameternavigation bzw. -nderung.
Durch Drcken der Taste [Status] kann eine zustzliche Zeile
eingefgt werden.1

c.

Statuszeile: Zustandsmeldungen in Textform.1

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4. Programmieren

4.1.2. Programmieren an der numerischen LCP-Bedieneinheit


In den folgenden Anleitungen wird davon ausgegangen, dass eine numerische LCP-Bedieneinheit (LCP 101) angeschlossen ist:

Die Bedieneinheit ist in vier funktionelle Gruppen unterteilt:


1.

Numerisches Display.

2.

Mentasten mit Anzeige-LEDs Parameter ndern und zwischen Displayfunktionen umschalten.

42

3.

Navigationstasten und Kontroll-Anzeigen (LEDs).

4.

Bedientasten mit Kontroll-Anzeigen (LEDs).

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4. Programmieren

4.1.3. Erste Inbetriebnahme


Am einfachsten lsst sich die Anlage in Betrieb nehmen, indem Sie auf die Taste [Quick Menu] drcken und die Anweisungen der grafischen Bedieneinheit
befolgen (lesen Sie die Tabelle von links nach rechts):

Drcken Sie
Q2 Quick Menu/Inbetriebnahme-Men

0-01 Language/Sprache

Legen Sie die Sprache fest.

1-20 Motornennleistung

Stellen Sie die auf dem Typenschild des Motors angegebene


Nennleistung ein.

1-22 Motornennspannung

Stellen Sie die auf dem Typenschild des Motors angegebene


Motornennspannung ein.

1-23 Motornennfrequenz

Stellen Sie die auf dem Typenschild des Motors angegebene


Motornennfrequenz ein.

1-24 Motornennstrom

Stellen Sie den auf dem Typenschild des Motors angegebenen


Motornennstrom ein.

1-25 Motornenndrehzahl

Stellen Sie die auf dem Typenschild des Motors angegebene


Nenndrehzahl ein.

5-12 Klemme 27 Digitaleingang

Sie knnen die Standardeinstellung fr die Klemme, Motorfreilauf (inv.), in Ohne Funktion ndern. In diesem Fall ist fr die
AMA kein Anschluss an Klemme 27 erforderlich.

1-29 Automatische Motoranpassung

Whlen Sie die gewnschte AMA-Funktion aus. Whlen Sie nach


Mglichkeit Komplette AMA.

3-02 Minimaler Sollwert

Legen Sie die Mindestdrehzahl der Motorwelle fest.

3-03 Max. Sollwert

Legen Sie die maximale Drehzahl der Motorwelle fest.

3-41 Rampenzeit Auf 1

Legen Sie die Rampenzeit Auf im Hinblick auf die Motornenndrehzahl aus Par. 1-25 fest.

3-42 Rampenzeit Ab 1

Legen Sie die Rampenzeit Ab im Hinblick auf die Motornenndrehzahl aus Par. 1-25 fest.

3-13 Sollwertvorgabe

Legen Sie fest, welcher Sollwert aktiv ist.

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4. Programmieren

4.2. Inbetriebnahme-Men
0-01 Sprache
Option:

Funktion:
Bestimmt die im Display zu verwendende Sprache.
Der Frequenzumrichter kann mit 4 verschiedenen Sprachpaketen geliefert werden. Englisch und Deutsch sind
in allen Paketen enthalten. Englisch kann nicht gelscht oder gendert werden.

Englisch

Teil der Sprachpakete 1 - 4

[1]

Deutsch

Teil der Sprachpakete 1 - 4

[2]

Franzsisch

Teil des Sprachpakets 1

[3]

Dnisch

Teil des Sprachpakets 1

[4]

Spanisch

Teil des Sprachpakets 1

[5]

Italienisch

Teil des Sprachpakets 1

[6]

Schwedisch

Teil des Sprachpakets 1

[7]

Niederlndisch

Teil des Sprachpakets 1

[10]

Chinesisch

Sprachpaket 2

[20]

Finnisch

Teil des Sprachpakets 1

[22]

Englisch US

Teil des Sprachpakets 4

[27]

Griechisch

Teil des Sprachpakets 4

[28]

Portugiesisch

Teil des Sprachpakets 4

[36]

Slowenisch

Teil des Sprachpakets 3

[39]

Koreanisch

Teil des Sprachpakets 2

[40]

Japanisch

Teil des Sprachpakets 2

[41]

Trkisch

Teil des Sprachpakets 4

[42]

Chinesisch traditionell

Teil des Sprachpakets 2

[43]

Bulgarisch

Teil des Sprachpakets 3

[44]

Serbisch

Teil des Sprachpakets 3

[45]

Rumnisch

Teil des Sprachpakets 3

[46]

Ungarisch

Teil des Sprachpakets 3

[47]

Tschechisch

Teil des Sprachpakets 3

[0]

[48]

Polnisch

Teil des Sprachpakets 4

[49]

Russisch

Teil des Sprachpakets 3

[50]

Thailndisch

Teil des Sprachpakets 2

[51]

Indonesisch

Teil des Sprachpakets 2

1-20 Motornennleistung
Range:
grenabhngig*

Funktion:
[0,09 - 1200 kW] Der Wert der Motornennleistung in kW muss den Angaben auf dem Typenschild des angeschlossenen Motors
entsprechen. Die Werkseinstellung entspricht der Typenleistung des Frequenzumrichters.
Dieser Parameter kann nicht bei laufendem Motor gendert werden. Dieser Par. ist im LCP sichtbar, wenn Par.
0-03 International [0] ist.
ACHTUNG!
Vier Leistungsgren ber, eine Gre unter der VLT-Nennleistung.

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4. Programmieren

1-22 Motornennspannung
Range:

Funktion:

Grenabhngig* [10 - 1000 V]

Der Wert muss den Angaben auf dem Typenschild des angeschlossenen Motors entsprechen. Die Werkseinstellung entspricht der Nennleistung des Frequenzumrichters.
Dieser Parameter kann nicht bei laufendem Motor gendert werden.

1-23 Motornennfrequenz
Option:

Funktion:
Min. - max. Motorfrequenz: 20 - 1000 Hz
Stellen Sie einen Wert ein, der den Angaben auf dem Typenschild des angeschlossenen Motors entspricht. Auerdem besteht die Mglichkeit einer stufenlosen Einstellung der Motorfrequenz. Wird ein Wert abweichend von

50 Hz oder 60 Hz eingestellt, so ist eine Korrektur der Parameter 1-50 bis 1-53 erforderlich. Fr 87-Hz-Betrieb
bei 230/400-V-Motoren die Typenschilddaten fr 230 V/50 Hz einstellen. Parameter 4-13 Max. Drehzahl [UPM]
und Parameter 3-03 Maximaler Sollwert mssen bei der 87-Hz-Anwendung angepasst werden.
[50]

50 Hz, wenn Par. 0-03


= International

[60]

60 Hz, wenn Par. 0-03


= US

1-24 Motornennstrom
Range:

Funktion:

Grenabhngig* [0,1 - 10000 A]

Der Wert muss den Angaben auf dem Typenschild des angeschlossenen Motors entsprechen. Diese Daten dienen
der Berechnung von Drehmoment, Motorschutz usw.

Dieser Parameter kann nicht bei laufendem Motor gendert werden.

1-25 Motornenndrehzahl
Range:

Funktion:

Grenabhngig* [100 - 60.000

Der Wert muss den Angaben auf dem Typenschild des angeschlossenen Motors entsprechen. Dieser Wert dient

UPM]

zur Berechnung des optimalen Schlupfausgleichs.

Dieser Parameter kann nicht bei laufendem Motor gendert werden.

5-12 Klemme 27 Digitaleingang


Option:

Funktion:
Whlen Sie die Funktion aus dem verfgbaren Digitaleingangsbereich aus.
Ohne Funktion
Reset
Motorfreilauf (inv.)
Mot.freil./Res. inv.
Schnellst.rampe (inv)
DC Bremse (invers)
Stopp (invers)
Start
Puls-Start
Reversierung
Start + Reversierung
Start nur Rechts
Start nur Links
Festdrz. (JOG)
Festsollwert Bit 0
Festsollwert Bit 1
Festsollwert Bit 2
Sollw. speich.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

[0]
[1]
[2]
[3]
[4]
[5]
[6]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[16]
[17]
[18]
[19]

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4. Programmieren
5-12 - fortgesetzt
Option:

Funktion:
Drehz. speich.
Drehzahl auf
Drehzahl ab
Satzanwahl Bit 0
Satzanwahl Bit 1
Freq.korr. Auf
Freq.korr. Ab
Pulseingabe
Rampe Bit 0
Rampe Bit 1
Netzausfall (invers)
DigiPot Auf
DigiPot Ab
DigiPot lschen
Reset Zhler A
Reset Zhler B

[20]
[21]
[22]
[23]
[24]
[28]
[29]
[32]
[34]
[35]
[36]
[55]
[56]
[57]
[62]
[65]

1-29 Autom. Motoranpassung


Option:

Funktion:
Die AMA-Funktion optimiert die dynamische Motorleistung durch automatisches Optimieren der erweiterten Motorparameter (Par. 1-30 bis Par. 1-35) im Stillstand.
Aktivieren Sie die AMA-Funktion durch Drcken von [Hand-on] nach Auswahl von [1] oder [2]. Siehe auch
Abschnitt Automatische Motoranpassung. Verluft die Motoranpassung normal, wird zum Abschluss folgende
Meldung im Display angezeigt: AMA mit [OK]-Taste beenden. Nach Drcken der [OK]-Taste ist der Frequenzumrichter wieder betriebsbereit.
Dieser Parameter kann nicht bei laufendem Motor gendert werden.

[0]

Anpassung aus

[1]

Komplette Anpassung

Eine automatische Motoranpassung des Statorwiderstands RS, des Rotorwiderstands Rr, der Statorstreureaktanz X1, der Rotorstreureaktanz X2 und der Hauptreaktanz Xh wird vorgenommen.
FC 301: Die Komplette AMA umfasst beim FC 301 keine Xh-Messung, der Xh-Wert wird jedoch aus der Motordatenbank ermittelt. Par. 1-35 Hauptreaktanz (Xh) kann bei Bedarf manuell angepasst werden, um optimale
Leistung zu erreichen.

[2]

Reduz. Anpassung

Ein reduzierter Test wird durchgefhrt, bei dem nur der Statorwiderstand Rs im System ermittelt wird. Whlen
Sie diese Option, wenn ein LC-Filter zwischen Frequenzumrichter und Motor eingesetzt wird.

Hinweis:

Die AMA sollte an einem kalten Motor durchgefhrt werden.

Die AMA kann nicht durchgefhrt werden, whrend der Motor luft.

Die AMA kann nicht bei permanenterregten Motoren durchgefhrt werden.

ACHTUNG!
Zuvor mssen die Motornenndaten 1-2* vom Typenschild korrekt eingegeben werden, da sie in den AMA-Algorithmus einflieen. Fr
eine optimale dynamische Motorleistung ist eine AMA notwendig. Je nach Nennleistung des Motors kann die Motoranpassung bis zu
10 Minuten dauern.

ACHTUNG!
Whrend der AMA darf die Motorwelle nicht angetrieben werden.

ACHTUNG!
ndert sich eine der Einstellungen in Par. 1-2*, dann werden die Werkseinstellungen fr Par. 1-30 bis 1-39 wiederhergestellt. Gegebenenfalls ist eine erneute AMA notwendig.

46

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

4. Programmieren

3-02 Minimaler Sollwert


Range:

Funktion:

0,000 Einheit* [-100000,000 Par. Der minimale Sollwert bestimmt den Mindestwert der Summe aller Sollwerte. Der minimale Sollwert ist nur aktiv,
wenn in Parameter 3-00 die Option Min. bis Max. [0] gewhlt wurde.

3-03]

3-03 Max. Sollwert


Range:

Funktion:

1500.000* [Par. 3-02 - 100000,000] Geben Sie den maximalen Sollwert ein. Der maximale Sollwert definiert den maximalen Wert, den die Summe
aller Sollwerte annehmen kann.
Die Einheit des max. Sollwerts richtet sich nach:

der Auswahl in Par. 1-00 Regelverfahren: Mit Drehgeber [1]: UPM, Drehmomentregler [2], Nm.

der in Par. 3-01 Soll-/Istwerteinheit gewhlten Einheit.

3-41 Rampenzeit Auf 1


Range:

Funktion:

s* [0,01 - 3600,00 s]

Die Rampenzeit Auf ist die Beschleunigungszeit von 0 UPM bis zur Motornenndrehzahl nM,N (Par. 1-25), vorausgesetzt, der Ausgangsstrom erreicht nicht die Stromgrenze (eingestellt in Par. 4-18). Der Wert 0,00 entspricht
0,01 s im Drehzahlmodus. Siehe Rampenzeit Ab in Par. 3-42.

Par.. 3 41 =

tBeschl s n M , N ( Par.. 1 25) UPM


Sollw. UPM

3-42 Rampenzeit Ab 1
Range:

Funktion:

grenabhngig [0,01 - 3600,00 s]

Die Rampenzeit Ab ist die Verzgerungszeit von der Motornenndrehzahl nM,N (Par. 1-25) bis 0 UPM, vorausgesetzt, es tritt keine berspannung aufgrund von generatorischem Betrieb des Motors auf bzw. es wird nicht die
Drehmomentgrenze erreicht (eingestellt in Par. 4-18). Der Wert 0,00 entspricht 0,01 s im Drehzahlmodus. Siehe
Rampenzeit Auf in Par. 3-41.

Par.. 3 42 =

tBeschl s x nM , N ( Par.. 1 25) UPM


Sollw. UPM

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

47

VLTAutomationDrive FC 300 Produkthandbuch

4. Programmieren

4.3. Parameterlisten
nderungen whrend des Betriebs
TRUE (WAHR) bedeutet, dass der Parameter whrend des Betriebs des Frequenzumrichters gendert werden kann; FALSE (FALSCH) bedeutet, dass der
Frequenzumrichter gestoppt werden muss, um nderungen vorzunehmen.

4-Setup (4-Par. Stze)


'Gesamter Parametersatz': der Parameter kann einzeln in jedem der vier Parameterstze eingestellt werden, d. h., ein einzelner Parameter kann vier
verschiedene Datenwerte haben.

1-Setup (1 Parametersatz): Datenwert ist derselbe in allen Parameterstzen.

Umrechnungsindex
Diese Zahl bezieht sich auf eine Umrechnungszahl, die beim Schreiben oder Lesen mit einem Frequenzumrichter verwendet wird.

Umrechnungsindex
Umrechnungsfaktor

Datentyp
2
3
4
5
6
7
9
33
35
54

100

67

1/60

1000000 100000

-1

-2

10000

1000

100

10

0.1

0.01

Beschreibung
Integer (Ganzzahl) 8 Bit
Integer (Ganzzahl) 16 Bit
Integer (Ganzzahl) 32 Bit
Ohne Vorzeichen 8
Ohne Vorzeichen 16 Bit
Ohne Vorzeichen 32 Bit
Sichtbarer String
Nennwert 2 Byte
Bitsequenz von 16 booleschen Variablen
Zeitdifferenz ohne Datum

Nhere Informationen zu den Datentypen 33, 35 und 54 finden Sie im Projektierungshandbuch.

48

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

-3

-4

0.001 0.0001

-5

-6

0.0000
1

0.000001

Typ
Int8
Int16
Int32
Uint8
Uint16
Uint32
VisStr
N2
V2
TimD

VLTAutomationDrive FC 300 Produkthandbuch

4. Programmieren

Alle Parameter fr den Frequenzumrichter sind zur einfachen Auffindung und Auswahl in verschiedenen Parametergruppen organisiert.

0-xx: Betrieb/Display (Parameter zum Einstellen der allgemeinen Grundfunktionen)

1-xx Motor/Last (enthlt alle last- und motorbezogenen Parameter)

2-xx Bremsfunktionen

3-xx Sollwert/Rampen (enthlt die DigitalPoti-Funktion)

4-xx Grenzen/Warnungen

5-xx Digit. Ein-/Ausgnge (inklusive Relaissteuerungen)

6-xx Analoge Ein-/Ausg.

7-xx PID-Regler (Einstellparameter fr Drehzahl- und Prozessregelungen)

8-xx Opt./Schnittstellen (Einstellung von FC RS485- und FC USB-Schnittstellenparametern)

9-xx Profibus DP

10-xx CAN/DeviceNet

13-xx Smart Logic

14-xx Sonderfunktionen

15-xx Info/Wartung

16-xx Datenanzeigen

17-xx Drehgeber Opt.

32-xx MCO-Grundeinstellungen (MCO 305)

33-xx MCO Erw. Einstell. (MCO 305)

34-xx MCO-Datenanzeigen

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

49

50

0-0* Grundeinstellungen
0-01
Sprache
0-02
Hz/UPM Umschaltung
0-03
Lndereinstellungen
0-04
Netz-Ein Modus (Hand)
0-1* Parameterstze
0-10
Aktiver Satz
0-11
Programm Satz
0-12
Satz verknpfen mit
0-13
Anzeige: Verknpfte Parameterstze
0-14
Anzeige: Par.stze/Kanal bearbeiten
0-2* LCP-Display
0-20
Displayzeile 1.1
0-21
Displayzeile 1.2
0-22
Displayzeile 1.3
0-23
Displayzeile 2
0-24
Displayzeile 3
0-25
Benutzer-Men
0-3* LCP-Benutzerdef
0-30
Einheit fr benutzerdefinierte Anzeige
0-31
Min. Wert benutzerdef. Anzeige
0-32
Max. Wert benutzerdef. Anzeige
0-4* LCP-Tasten
0-40
[Hand On]-LCP Taste
0-41
[Off]-LCP Taste
0-42
[Auto On]-LCP Taste
0-43
[Reset]-LCP Taste
0-5* Kopie/Speichern
0-50
LCP-Kopie
0-51
Parametersatz-Kopie
0-6* Passwort
0-60
Hauptmen Passwort
0-61
Hauptmen Zugriff ohne PW
0-65
Quick-Men Passwort
0-66
Quickmen Zugriff ohne PW
0-67
Bus Password Access

Parameterbeschreibung

All set-ups
All set-ups
1 set-up
1 set-up
1 set-up
1 set-up
All set-ups

[0] Keine Kopie


[0] Keine Kopie
100 N/A
[0] Vollstndig
200 N/A
[0] Vollstndig
0 N/A

set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups
All set-ups

[0] Ohne
0.00 CustomReadoutUnit
100.00 CustomReadoutUnit
All
All
All
All

All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
1 set-up

1617
1614
1610
1613
1602
SR

Aktiviert
Aktiviert
Aktiviert
Aktiviert

1 set-up
All set-ups
All set-ups
All set-ups
All set-ups

[1] Satz 1
[1] Satz 1
[0] Nicht verknpft
0 N/A
0 N/A

[1]
[1]
[1]
[1]

1 set-up
2 set-ups
2 set-ups
All set-ups

4-Setup (4-Par. Stze)

[0] English
[0] U/min [UPM]
[0] International
[1] LCP Stop,Letz.Soll.

Werkseinstellung

nur
FC 302

TRUE
TRUE
TRUE
TRUE
TRUE

FALSE
FALSE

TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
FALSE
FALSE
TRUE

TRUE
FALSE
FALSE
TRUE

ndern whrend
des Betriebs

Par.-Nr.

4.3.1. 0-** Betrieb/Display

0
0
0

-2
-2

0
0

Konvertierungsindex

Int16
Uint8
Int16
Uint8
Uint16

Uint8
Uint8

Uint8
Uint8
Uint8
Uint8

Uint8
Int32
Int32

Uint16
Uint16
Uint16
Uint16
Uint16
Uint16

Uint8
Uint8
Uint8
Uint16
Int32

Uint8
Uint8
Uint8
Uint8

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

1-0* Grundeinstellungen
1-00
Regelverfahren
1-01
Steuerprinzip
1-02
Drehgeber Anschluss
1-03
Drehmomentverhalten der Last
1-04
berlastmodus
1-05
Hand/Ort-Betrieb Konfiguration
1-1* Motorauswahl
1-10
Motorart
1-2* Motordaten
1-20
Motornennleistung [kW]
1-21
Motornennleistung [PS]
1-22
Motornennspannung
1-23
Motornennfrequenz
1-24
Motornennstrom
1-25
Motornenndrehzahl
1-26
Dauer-Nenndrehmoment
1-29
Autom. Motoranpassung
1-3* Erw. Motordaten
1-30
Statorwiderstand (Rs)
1-31
Rotorwiderstand (Rr)
1-33
Statorstreureaktanz (X1)
1-34
Rotorstreureaktanz (X2)
1-35
Hauptreaktanz (Xh)
1-36
Eisenverlustwiderstand (Rfe)
1-37
Indukt. D-Achse (Ld)
1-39
Motorpolzahl
1-40
Gegen-EMK bei 1000 UPM
1-41
Geber-Offset
1-5* Lastunabh. Einst.
1-50
Motormagnetisierung bei 0 UPM.
1-51
Min. Drehzahl norm. Magnetis. [UPM]
1-52
Min. Drehzahl norm. Magnetis. [Hz]
1-53
Steuerprinzip Umschaltpunkt
1-55
U/f-Kennlinie - U [V]
1-56
U/f-Kennlinie - f [Hz]

Par.-Nr.

4.3.2. 1-** Motor/Last

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All

SR
SR
SR
SR
SR
SR
SR
SR
SR
0 N/A
100 %
SR
SR
SR
SR
SR

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups

All
All
All
All
All
All

4-Setup (4-Par. Stze)

SR
SR
SR
SR
SR
SR
SR
[0] Anpassung aus

[0] Asynchron

null
null
[1] 24V/HTL-Drehgeber
[0] Konstant. Drehmom.
[0] Hohes bermoment
[2] Wie Par. 1-00

Werkseinstellung

nur
FC 302

Konvertierungsindex
1
-2
0
0
-2
67
-1
-4
-4
-4
-4
-4
-3
-4
0
0
0
0
67
-1
-1
-1
-1

ndern whrend
des Betriebs
TRUE
FALSE
FALSE
TRUE
FALSE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE

Uint16
Uint16
Uint16
Uint16
Uint16
Uint16

Uint32
Uint32
Uint32
Uint32
Uint32
Uint32
Int32
Uint8
Uint16
Int16

Uint32
Uint32
Uint16
Uint16
Uint32
Uint16
Uint32
Uint8

Uint8

Uint8
Uint8
Uint8
Uint8
Uint8
Uint8

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

51

52

1-6* Lastabh. Einstellung


1-60
Lastausgleich tief
1-61
Lastausgleich hoch
1-62
Schlupfausgleich
1-63
Schlupfausgleich Zeitkonstante
1-64
Resonanzdmpfung
1-65
Resonanzdmpfung Zeitkonstante
1-66
Min. Strom bei niedr. Drz.
1-67
Lasttyp
1-68
Massentrgheit Min.
1-69
Massentrgheit Max.
1-7* Startfunktion
1-71
Startverzg.
1-72
Startfunktion
1-73
Motorfangschaltung
1-74
Startdrehzahl [UPM]
1-75
Startdrehzahl [Hz]
Startstrom
1-76
1-8* Stoppfunktion
1-80
Funktion bei Stopp
1-81
Ein.-Drehzahl fr Stoppfunktion [UPM]
1-82
Ein.-Frequenz fr Stoppfunktion [Hz]
1-83
Prziser Stopp-Funktion
1-84
Prziser Stopp-Wert
1-85
Verzgerung Drehzahlkompensation
1-9* Motortemperatur
1-90
Thermischer Motorschutz
1-91
Fremdbelftung
1-93
Thermistoranschluss
1-95
KTY-Sensortyp
1-96
KTY-Sensoranschluss
1-97
KTY-Schwellwert

Parameterbeschreibung

All
All
All
All
All
All
All
All
All
All
All
All
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
1 set-up

0.0 s
[2] Freilauf/Verz.zeit
[0] Deaktiviert
SR
SR
0.00 A
[0] Motorfreilauf
SR
SR
[0] Prz. Rampenstopp
100000 N/A
10 ms
[0] Kein Motorschutz
[0] Nein
[0] Ohne
[0] KTY-Sensor 1
[0] Ohne
80 C

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All
All
All
All
All
All
All
All
All
All

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

4-Setup (4-Par. Stze)

100 %
100 %
SR
SR
100 %
5 ms
100 %
[0] Passiv
SR
SR

Werkseinstellung

x
x
x

x
x
x
x

nur
FC 302

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
FALSE
TRUE
TRUE

TRUE
TRUE
FALSE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE

ndern whrend
des Betriebs

Par.-Nr.

100

67
-1
0
-3

-1
67
-1
-2

0
0
0
-2
0
-3
0
-4
-4

Konvertierungsindex

Uint8
Uint16
Uint8
Uint8
Uint8
Int16

Uint8
Uint16
Uint16
Uint8
Uint32
Uint8

Uint8
Uint8
Uint8
Uint16
Uint16
Uint32

Int16
Int16
Int16
Uint16
Uint16
Uint8
Uint8
Uint8
Uint32
Uint32

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

2-0* DC Halt/DC Bremse


2-00
DC-Haltestrom
2-01
DC-Bremsstrom
2-02
DC-Bremszeit
2-03
DC-Bremse Ein [UPM]
2-04
DC-Bremse Ein [Hz]
2-1* Generator. Bremsen
2-10
Bremsfunktion
2-11
Bremswiderstand (Ohm)
2-12
Bremswiderstand Leistung (kW)
2-13
Bremswiderst. Leistungsberwachung
2-15
Bremswiderstand Test
2-16
AC-Bremse max. Strom
2-17
berspannungssteuerung
2-2* Mech. Bremse
2-20
Bremse ffnen bei Motorstrom
2-21
Bremse schliessen bei Motordrehzahl
2-22
Bremse schlieen bei Motorfrequenz
2-23
Mech. Bremse Verzgerungszeit
2-24
Stop Delay
2-25
Brake Release Time
2-26
Torque Ref
2-27
Torque Ramp Time
2-28
Gain Boost Factor

Par.-Nr.

4.3.3. 2-** Bremsfunktionen

All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All

null
SR
SR
[0] Deaktiviert
[0] Deaktiviert
100.0 %
[0] Deaktiviert
ImaxVLT (P1637)
SR
SR
0.0 s
0.0 s
0.20 s
0.00 %
0.2 s
1.00 N/A

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups

4-Setup (4-Par. Stze)

50 %
50 %
10.0 s
SR
SR

Werkseinstellung

nur
FC 302

Konvertierungsindex
0
0
-1
67
-1
0
0
-1
-2
67
-1
-1
-1
-2
-2
-1
-2

ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

Uint32
Uint16
Uint16
Uint8
Uint8
Uint16
Int16
Uint8
Uint16

Uint8
Uint16
Uint32
Uint8
Uint8
Uint32
Uint8

Uint8
Uint16
Uint16
Uint16
Uint16

Typ

VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

4. Programmieren

53

54

3-0* Sollwertgrenzen
3-00
Sollwertbereich
3-01
Soll-/Istwerteinheit
3-02
Minimaler Sollwert
3-03
Max. Sollwert
3-04
Sollwertfunktion
3-1* Sollwerteinstellung
3-10
Festsollwert
3-11
Festdrehzahl Jog [Hz]
3-12
Frequenzkorrektur Auf/Ab
3-13
Sollwertvorgabe
3-14
Relativer Festsollwert
3-15
Variabler Sollwert 1
3-16
Variabler Sollwert 2
3-17
Variabler Sollwert 3
3-18
Relativ. Skalierungssollw. Ressource
3-19
Festdrehzahl Jog [UPM]
3-4* Rampe 1
3-40
Rampentyp 1
3-41
Rampenzeit Auf 1
3-42
Rampenzeit Ab 1
3-45
SS-Form Anfang (Rampe Auf 1)
3-46
S-Form Ende (Rampe Auf 1)
3-47
S-Form Anfang (Rampe Ab 1)
3-48
S-Form Ende (Rampe Ab 1)
3-5* Rampe 2
3-50
Rampentyp 2
3-51
Rampenzeit Auf 2
3-52
Rampenzeit Ab 2
3-55
S-Form Anfang (Rampe Auf 2)
3-56
S-Form Ende (Rampe Auf 2)
3-57
S-Form Anfang (Rampe Ab 2)
3-58
S-Form Ende (Rampe Ab 2)

Parameterbeschreibung

All
All
All
All
All
All
All
All
All
All
All
All
All
All

[0] Linear
SR
SR
50 %
50 %
50 %
50 %

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups

0.00 %
SR
0.00 %
[0] Umschalt. Hand/Auto
0.00 %
null
null
null
[0] Deaktiviert
SR
[0] Linear
SR
SR
50 %
50 %
50 %
50 %

All
All
All
All
All

set-ups
set-ups
set-ups
set-ups
set-ups

4-Setup (4-Par. Stze)

null
null
0 ReferenceFeedbackUnit
SR
[0] Addierend

Werkseinstellung

nur
FC 302

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE

ndern whrend
des Betriebs

Par.-Nr.

4.3.4. 3-** Sollwert/Rampen

-2
-2
0
0
0
0

-2
-2
0
0
0
0

-2
-1
-2
-2
67

-3
-3
-

Konvertierungsindex

Uint8
Uint32
Uint32
Uint8
Uint8
Uint8
Uint8

Uint8
Uint32
Uint32
Uint8
Uint8
Uint8
Uint8

Int16
Uint16
Int16
Uint8
Int32
Uint8
Uint8
Uint8
Uint8
Uint16

Uint8
Uint8
Int32
Int32
Uint8

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

3-6* Rampe 3
3-60
Rampentyp 3
3-61
Rampenzeit Auf 3
3-62
Rampenzeit Ab 3
3-65
S-Form Anfang (Rampe Auf 3)
3-66
S-Form Ende (Rampe Auf 3)
3-67
S-Form Anfang (Rampe Ab 3)
3-68
S-Form Ende (Rampe Ab 3)
3-7* Rampe 4
3-70
Rampentyp 4
3-71
Rampenzeit Auf 4
3-72
Rampenzeit Ab 4
3-75
S-Form Anfang (Rampe Auf 4)
3-76
S-Form Ende (Rampe Auf 4)
3-77
S-Form Anfang (Rampe Ab 4)
S-Form Ende (Rampe Ab 4)
3-78
3-8* Weitere Rampen
3-80
Rampenzeit JOG
3-81
Rampenzeit Schnellstopp
3-9* Digitalpoti
3-90
Digitalpoti Einzelschritt
3-91
Digitalpoti Rampenzeit
3-92
Digitalpoti speichern bei Netz-Aus
3-93
Digitalpoti Max. Grenze
3-94
Digitalpoti Min. Grenze
3-95
Rampenverzgerung

Par.-Nr.

0.10 %
1.00 s
[0] Aus
100 %
-100 %
1.000 N/A

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All
All
All
All
All
All

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups
2 set-ups

All
All
All
All
All
All
All

[0] Linear
SR
SR
50 %
50 %
50 %
50 %
SR
SR

All
All
All
All
All
All
All

4-Setup (4-Par. Stze)

[0] Linear
SR
SR
50 %
50 %
50 %
50 %

Werkseinstellung

nur
FC 302

Konvertierungsindex
-2
-2
0
0
0
0
-2
-2
0
0
0
0
-2
-2
-2
-2
0
0
-3

ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

Uint16
Uint32
Uint8
Int16
Int16
TimD

Uint32
Uint32

Uint8
Uint32
Uint32
Uint8
Uint8
Uint8
Uint8

Uint8
Uint32
Uint32
Uint8
Uint8
Uint8
Uint8

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

55

56

4-1* Motor Grenzen


4-10
Motor Drehrichtung
4-11
Min. Drehzahl [UPM]
4-12
Min. Frequenz [Hz]
4-13
Max. Drehzahl [UPM]
4-14
Max Frequenz [Hz]
4-16
Momentengrenze motorisch
4-17
Momentengrenze generatorisch
4-18
Stromgrenze
Max. Ausgangsfrequenz
4-19
4-2* Variable Grenzen
4-20
Variable Drehmomentgrenze
4-21
Variable Drehzahlgrenze
4-3* Drehg. berw.
4-30
Drehgeberberwachung Funktion
4-31
Drehgeber max. Fehlabweichung
4-32
Drehgeber Timeout-Zeit
4-5* Warnungen Grenzen
4-50
Warnung Strom niedrig
4-51
Warnung Strom hoch
4-52
Warnung Drehz. niedrig
4-53
Warnung Drehz. hoch
4-54
Warnung Sollwert niedr.
4-55
Warnung Sollwert hoch
4-56
Warnung Istwert niedr.
4-57
Warnung Istwert hoch
4-58
Motorphasen berwachung
4-6* Drehz.ausblendung
4-60
Ausbl. Drehzahl von [UPM]
4-61
Ausbl. Drehzahl von [Hz]
4-62
Ausbl. Drehzahl bis [UPM]
4-63
Ausbl. Drehzahl bis [Hz]

Parameterbeschreibung

All
All
All
All
All
All
All
All
All
All
All
All
All

0.00 A
ImaxVLT (P1637)
0 RPM
outputSpeedHighLimit (P413)
-999999.999 N/A
999999.999 N/A
-999999.999 ReferenceFeedbackUnit
999999.999 ReferenceFeedbackUnit
[1] Ein
SR
SR
SR
SR

set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups
All set-ups

[2] Alarm
300 RPM
0.05 s

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups

All
All
All
All
All
All
All
All
All

4-Setup (4-Par. Stze)

[0] Ohne Funktion


[0] Ohne Funktion

null
SR
SR
SR
SR
SR
100.0 %
SR
132.0 Hz

Werkseinstellung

nur
FC 302

TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE

TRUE
TRUE

FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE

ndern whrend
des Betriebs

Par.-Nr.

4.3.5. 4-** Grenzen/Warnungen

67
-1
67
-1

-2
-2
67
67
-3
-3
-3
-3
-

67
-2

67
-1
67
-1
-1
-1
-1
-1

Konvertierungsindex

Uint16
Uint16
Uint16
Uint16

Uint32
Uint32
Uint16
Uint16
Int32
Int32
Int32
Int32
Uint8

Uint8
Uint16
Uint16

Uint8
Uint8

Uint8
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint32
Uint16

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

5-0* Grundeinstellungen
5-00
Schaltlogik
5-01
Klemme 27 Funktion
5-02
Klemme 29 Funktion
5-1* Digitaleingnge
5-10
Klemme 18 Digitaleingang
5-11
Klemme 19 Digitaleingang
5-12
Klemme 27 Digitaleingang
5-13
Klemme 29 Digitaleingang
5-14
Klemme 32 Digitaleingang
5-15
Klemme 33 Digitaleingang
5-16
Klemme X30/2 Digitaleingang
5-17
Klemme X30/3 Digitaleingang
5-18
Klemme X30/4 Digitaleingang
5-19
Terminal 37 Safe Stop
5-20
Terminal X46/1 Digital Input
5-21
Terminal X46/3 Digital Input
5-22
Terminal X46/5 Digital Input
5-23
Terminal X46/7 Digital Input
5-24
Terminal X46/9 Digital Input
5-25
Terminal X46/11 Digital Input
5-26
Terminal X46/13 Digital Input
5-3* Digitalausgnge
5-30
Klemme 27 Digitalausgang
5-31
Klemme 29 Digitalausgang
5-32
Klemme X30/6 Digitalausgang
5-33
Klemme X30/7 Digitalausgang
5-4* Relais
5-40
Relaisfunktion
5-41
Ein Verzg., Relais
5-42
Aus Verzg., Relais
5-5* Pulseingnge
5-50
Klemme 29 Min. Frequenz
5-51
Klemme 29 Max. Frequenz
5-52
Klemme 29 Min. Soll-/Istwert
5-53
Klemme 29 Max. Soll-/Istwert
5-54
Pulseingang 29 Filterzeit
5-55
Klemme 33 Min. Frequenz
5-56
Klemme 33 Max. Frequenz
5-57
Klemme 33 Min. Soll-/Istwert
5-58
Klemme 33 Max. Soll-/Istwert
5-59
Pulseingang 33 Filterzeit

Par.-Nr.

4.3.6. 5-** Digit. Ein-/Ausgnge

100 Hz
100 Hz
0.000 ReferenceFeedbackUnit
SR
100 ms
100 Hz
100 Hz
0.000 ReferenceFeedbackUnit
SR
100 ms

null
0.01 s
0.01 s

set-ups
set-ups
set-ups
set-ups

All
All
All
All
All
All
All
All
All
All

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups
All set-ups

All
All
All
All

All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
1 set-up
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups

null
null
null
null
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[1] Safe Stop Alarm
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
null
null
null
null

All set-ups
All set-ups
All set-ups

4-Setup (4-Par. Stze)

[0] PNP
[0] Eingang
[0] Eingang

Werkseinstellung

x
x
x
x
x

nur
FC 302

Konvertierungsindex
-2
-2
0
0
-3
-3
-3
0
0
-3
-3
-3

ndern whrend
des Betriebs
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
FALSE

Uint32
Uint32
Int32
Int32
Uint16
Uint32
Uint32
Int32
Int32
Uint16

Uint8
Uint16
Uint16

Uint8
Uint8
Uint8
Uint8

Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8

Uint8
Uint8
Uint8

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

57

58

5-6* Pulsausgnge
5-60
Klemme 27 Pulsausgang
5-62
Ausgang 27 Max. Frequenz
5-63
Klemme 29 Pulsausgang
5-65
Ausgang 29 Max. Frequenz
5-66
Klemme X30/6 Pulsausgang
5-68
Ausgang X30/6 Max. Frequenz
5-7* 24V Drehgeber
5-70
Kl. 32/33 Drehgeber Aufl. [Pulse/U]
5-71
Kl. 32/33 Drehgeber Richtung
5-9* Bussteuerung
5-90
Dig./Relais Ausg. Bussteuerung
5-93
Klemme 27, Wert bei Bussteuerung
5-94
Klemme 27, Wert bei Bus-Timeout
5-95
Klemme 29, Wert bei Bussteuerung
5-96
Klemme 29, Wert bei Bus-Timeout

Parameterbeschreibung

All set-ups
All set-ups
1 set-up
All set-ups
1 set-up

0 N/A
0.00 %
0.00 %
0.00 %
0.00 %

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups

All
All
All
All
All
All

4-Setup (4-Par. Stze)

1024 N/A
[0] Rechtslauf

null
SR
null
SR
null
SR

Werkseinstellung

x
x

x
x

nur
FC 302

TRUE
TRUE
TRUE
TRUE
TRUE

FALSE
FALSE

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

ndern whrend
des Betriebs

Par.-Nr.

0
-2
-2
-2
-2

0
-

0
0
0

Konvertierungsindex

Uint32
N2
Uint16
N2
Uint16

Uint16
Uint8

Uint8
Uint32
Uint8
Uint32
Uint8
Uint32

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

6-0* Grundeinstellungen
6-00
Signalausfall Zeit
6-01
Signalausfall Funktion
6-1* Analogeingang 1
6-10
Klemme 53 Skal. Min.Spannung
6-11
Klemme 53 Skal. Max.Spannung
6-12
Klemme 53 Skal. Min.Strom
6-13
Klemme 53 Skal. Max.Strom
6-14
Klemme 53 Skal. Min.-Soll/Istwert
6-15
Klemme 53 Skal. Max.-Soll/Istwert
6-16
Klemme 53 Filterzeit
6-2* Analogeingang 2
6-20
Klemme 54 Skal. Min.Spannung
6-21
Klemme 54 Skal. Max.Spannung
6-22
Klemme 54 Skal. Min.Strom
6-23
Klemme 54 Skal. Max.Strom
6-24
Klemme 54 Skal. Min.-Soll/Istwert
6-25
Klemme 54 Skal. Max.-Soll/Istwert
6-26
Klemme 54 Filterzeit
6-3* Analogeingang 3
6-30
Kl.X30/11 Skal. Min. Spannung
6-31
Kl.X30/11 Skal. Max.Spannung
6-34
Kl.X30/11 Skal. Min.-Soll/Istw
6-35
Kl.X30/11 Skal. Max.-Soll/Istw
6-36
Klemme X30/11 Filterzeit
6-4* Analogeingang 4
6-40
Klemme X30/12 Skal. Min.Spannung
6-41
Klemme X30/12 Skal. Max.Spannung
6-44
Kl.X30/12 Skal. Min.-Soll/Istw
6-45
Kl.X30/12 Skal. Max.-Soll/Istw
6-46
Klemme X30/12 Filterzeit
6-5* Analogausgang 1
6-50
Klemme 42 Analogausgang
6-51
Kl. 42, Ausgang min. Skalierung
6-52
Kl. 42, Ausgang max. Skalierung
6-53
Kl. 42, Wert bei Bussteuerung
6-54
Kl. 42, Wert bei Bus-Timeout
6-6* Analogausgang 2
6-60
Klemme X30/8 Analogausgang
6-61
Kl. X30/8, Ausgang min. Skalierung
6-62
Kl. X30/8, Ausgang max. Skalierung
6-7* Analog Output 3
6-70
Terminal X45/1 Output
6-71
Terminal X45/1 Min. Scale
6-72
Terminal X45/1 Max. Scale
6-8* Analog Output 4
6-80
Terminal X45/3 Output
6-81
Terminal X45/3 Min. Scale
6-82
Terminal X45/3 Max. Scale

Par.-Nr.

4.3.7. 6-** Analoge Ein-/Ausg.

All
All
All
All
All
All
All
All
All
All

0.07 V
10.00 V
0 ReferenceFeedbackUnit
SR
0.001 s
0.07 V
10.00 V
0 ReferenceFeedbackUnit
SR
0.001 s

All set-ups
All set-ups
All set-ups
All set-ups
1 set-up
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups

null
0.00 %
100.00 %
0.00 %
0.00 %
null
0.00 %
100.00 %
null
0.00 %
100.00 %
null
0.00 %
100.00 %

set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups

All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups

0.07 V
10.00 V
0.14 mA
20.00 mA
0 ReferenceFeedbackUnit
SR
0.001 s
0.07 V
10.00 V
0.14 mA
20.00 mA
0 ReferenceFeedbackUnit
SR
0.001 s

All set-ups
All set-ups

4-Setup (4-Par. Stze)

10 s
[0] Aus

Werkseinstellung

nur
FC 302

Konvertierungsindex
0
-2
-2
-5
-5
-3
-3
-3
-2
-2
-5
-5
-3
-3
-3
-2
-2
-3
-3
-3
-2
-2
-3
-3
-3
-2
-2
-2
-2
-2
-2
-2
-2
-2
-2

ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

Uint8
Int16
Int16

Uint8
Int16
Int16

Uint8
Int16
Int16

Uint8
Int16
Int16
N2
Uint16

Int16
Int16
Int32
Int32
Uint16

Int16
Int16
Int32
Int32
Uint16

Int16
Int16
Int16
Int16
Int32
Int32
Uint16

Int16
Int16
Int16
Int16
Int32
Int32
Uint16

Uint8
Uint8

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

59

60

7-0* PID Drehzahlregler


7-00
Drehgeberrckfhrung
7-02
Drehzahlregler P-Verstrkung
7-03
Drehzahlregler I-Zeit
7-04
Drehzahlregler D-Zeit
7-05
Drehzahlregler D-Verstrk./Grenze
7-06
Drehzahlregler Tiefpassfilterzeit
7-08
Drehzahlregler Vorsteuerung
7-2* PID-Prozess Istw.
7-20
PID-Prozess Istwert 1
7-22
PID-Prozess Istwert 2
7-3* PID-Prozessregler
7-30
Auswahl Normal-/Invers-Regelung
7-31
PID-Prozess Anti-Windup
7-32
PID-Prozess Reglerstart bei
7-33
PID-Prozess P-Verstrkung
7-34
PID-Prozess I-Zeit
7-35
PID-Prozess D-Zeit
7-36
PID-Prozess D-Verstrkung/Grenze
7-38
PID-Prozess Vorsteuerung
7-39
Bandbreite Ist=Sollwert

Parameterbeschreibung

[0] Normal
[1] Ein
0 RPM
0.01 N/A
10000.00 s
0.00 s
5.0 N/A
0%
5%

[0] Keine Funktion


[0] Keine Funktion

null
SR
SR
SR
5.0 N/A
10.0 ms
0%

Werkseinstellung
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All
All
All
All
All
All
All
All
All

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups

All
All
All
All
All
All
All

4-Setup (4-Par. Stze)

nur
FC 302

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE

FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE

ndern whrend
des Betriebs

Par.-Nr.

4.3.8. 7-** PID-Regler

67
-2
-2
-2
-1
0
0

-3
-4
-4
-1
-4
0

Konvertierungsindex

Uint8
Uint8
Uint16
Uint16
Uint32
Uint16
Uint16
Uint16
Uint8

Uint8
Uint8

Uint8
Uint16
Uint32
Uint16
Uint16
Uint16
Uint16

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

8-0* Grundeinstellungen
8-01
Fhrungshoheit
8-02
Aktives Steuerwort
8-03
Steuerwort Timeout-Zeit
8-04
Steuerwort Timeout-Funktion
8-05
Steuerwort Timeout-Ende
8-06
Timeout Steuerwort quittieren
Diagnose Trigger
8-07
8-1* Steuerwort
8-10
Steuerwortprofil
8-13
Zustandswort Konfiguration
8-3* Ser. FC-Schnittst.
8-30
FC-Protokoll
8-31
Adresse
8-32
FC-Baudrate
8-35
FC-Antwortzeit Min.-Delay
8-36
FC-Antwortzeit Max.-Delay
8-37
FC Interchar. Max.-Delay
8-4* FC/MC-Protokoll
8-40
Telegrammtyp
8-5* Betr. Bus/Klemme
8-50
Motorfreilauf
8-51
Schnellstopp
8-52
DC Bremse
8-53
Start
8-54
Reversierung
8-55
Satzanwahl
8-56
Festsollwertanwahl
8-9* Bus-Festdrehzahl
8-90
Bus-Festdrehzahl 1
8-91
Bus-Festdrehzahl 2

Par.-Nr.

4.3.9. 8-** Opt./Schnittstellen

100 RPM
200 RPM

All set-ups
All set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All
All
All
All
All
All
All

Klemme
Klemme
Klemme
Klemme
Klemme
Klemme
Klemme

[3]
[3]
[3]
[3]
[3]
[3]
[3]

ODER
ODER
ODER
ODER
ODER
ODER
ODER

2 set-ups

[1] Standardtelegr. 1
Bus
Bus
Bus
Bus
Bus
Bus
Bus

1 set-up
1 set-up
1 set-up
All set-ups
1 set-up
1 set-up

All set-ups
All set-ups

[0] FC-Profil
[1] Standardprofil
[0] FC-Profil
1 N/A
[2] 9600 Baud
10 ms
5000 ms
25 ms

All set-ups
All set-ups
1 set-up
1 set-up
1 set-up
All set-ups
2 set-ups

4-Setup (4-Par. Stze)

[0] Klemme und Steuerw.


null
1.0 s
[0] Aus
[1] Par.satz fortsetzen
[0] Kein Reset
[0] Deaktiviert

Werkseinstellung

nur
FC 302

Konvertierungsindex
-1
0
-3
-3
-3
67
67

ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

Uint16
Uint16

Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8

Uint8

Uint8
Uint8
Uint8
Uint16
Uint16
Uint16

Uint8
Uint8

Uint8
Uint8
Uint32
Uint8
Uint8
Uint8
Uint8

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

61

62

Parameterbeschreibung

Sollwert
Istwert
PCD-Konfiguration Schreiben
PCD-Konfiguration Lesen
Teilnehmeradresse
Telegrammtyp
Signal-Parameter
Parameter bearbeiten
Profibus Steuerung deaktivieren
Safe Address
Zhler: Fehler im Speicher
Speicher: Alarmworte
Speicher: Fehlercode
Zhler: Fehler Gesamt
Profibus-Warnwort
Aktive Baudrate
Bus-ID
Profilnummer
Steuerwort 1
Zustandswort 1
Datenwerte speichern
Freq.umr. Reset
Definierte Parameter (1)
Definierte Parameter (2)
Definierte Parameter (3)
Definierte Parameter (4)
Definierte Parameter (5)
Genderte Parameter (1)
Genderte Parameter (2)
Genderte Parameter (3)
Genderte Parameter (4)
Genderte Parameter (5)
Profibus Revision Counter

9-00
9-07
9-15
9-16
9-18
9-22
9-23
9-27
9-28
9-31
9-44
9-45
9-47
9-52
9-53
9-63
9-64
9-65
9-67
9-68
9-71
9-72
9-80
9-81
9-82
9-83
9-84
9-90
9-91
9-92
9-93
9-94
9-99

0 N/A
0 N/A
SR
SR
126 N/A
[108] PPO 8
0
[1] Aktiviert
[1] Bussteuerung aktiv.
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
[255] Baudrate unbekannt
0 N/A
0 N/A
0 N/A
0 N/A
[0] Aus
[0] Normal Betrieb
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A

Werkseinstellung
All set-ups
All set-ups
2 set-ups
2 set-ups
1 set-up
1 set-up
All set-ups
2 set-ups
2 set-ups
1 set-up
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
1 set-up
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups

4-Setup (4-Par. Stze)

nur
FC 302

ndern whrend
des Betriebs
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE

Par.-Nr.

4.3.10. 9-** Profibus DP


Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Uint16
Uint16
Uint16
Uint16
Uint8
Uint8
Uint16
Uint16
Uint8
Uint16
Uint16
Uint16
Uint16
Uint16
V2
Uint8
Uint16
OctStr[2]
V2
V2
Uint8
Uint8
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

10-0* Grundeinstellungen
10-00
Protokoll
10-01
Baudratenauswahl
10-02
MAC-ID Adresse
10-05
Zhler bertragungsfehler
10-06
Zhler Empfangsfehler
10-07
Zhler Bus-Off
10-1* DeviceNet
10-10
Prozessdatentyp
10-11
Prozessdaten Schreiben Konfiguration
10-12
Prozessdaten Lesen Konfiguration
10-13
Warnparameter
10-14
DeviceNet Sollwert
10-15
DeviceNet Steuerung
10-2* COS-Filter
10-20
COS-Filter 1
10-21
COS-Filter 2
10-22
COS-Filter 3
10-23
COS-Filter 4
10-3* Parameterzugriff
10-30
Array Index
10-31
Datenwerte speichern
10-32
DeviceNet Revision
10-33
EEPROM speichern
10-34
DeviceNet-Produktcode
DeviceNet F-Parameter
10-39
10-5* CANopen
10-50
Prozessdaten Konfiguration-Schreiben
10-51
Prozessdaten Konfiguration-Lesen

Par.-Nr.

4.3.11. 10-** CAN/DeviceNet

All
All
All
All

0
0
0
0
2 set-ups
All set-ups
All set-ups
1 set-up
1 set-up
All set-ups
2 set-ups
2 set-ups

0 N/A
[0] Aus
SR
[0] Aus
SR
0 N/A
SR
SR

set-ups
set-ups
set-ups
set-ups

All set-ups
2 set-ups
2 set-ups
All set-ups
2 set-ups
2 set-ups

null
SR
SR
0 N/A
[0] Aus
[0] Aus
N/A
N/A
N/A
N/A

2 set-ups
2 set-ups
2 set-ups
All set-ups
All set-ups
All set-ups

4-Setup (4-Par. Stze)

null
null
SR
0 N/A
0 N/A
0 N/A

Werkseinstellung

nur
FC 302

Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
-

ndern whrend
des Betriebs
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

Uint16
Uint16

Uint8
Uint8
Uint16
Uint8
Uint16
Uint32

Uint16
Uint16
Uint16
Uint16

Uint8
Uint16
Uint16
Uint16
Uint8
Uint8

Uint8
Uint8
Uint8
Uint8
Uint8
Uint8

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

63

64

13-0* SL-Controller
13-00
Smart Logic Controller
13-01
SL-Controller Start
13-02
SL-Controller Stopp
13-03
SL-Parameter Initialisieren
13-1* Vergleicher
13-10
Vergleicher-Operand
13-11
Vergleicher-Funktion
13-12
Vergleicher-Wert
13-2* Timer
13-20
SL-Timer
13-4* Logikregeln
13-40
Logikregel Boolsch 1
13-41
Logikregel Verknpfung 1
13-42
Logikregel Boolsch 2
13-43
Logikregel Verknpfung 2
13-44
Logikregel Boolsch 3
13-5* SL-Programm
13-51
SL-Controller Ereignis
13-52
SL-Controller Aktion

Parameterbeschreibung

2 set-ups
2 set-ups
2 set-ups
1 set-up
2
2
2
2
2
2 set-ups
2 set-ups

null
null
SR
SR
null
null
null
null
null
null
null

set-ups
set-ups
set-ups
set-ups
set-ups

2 set-ups
2 set-ups
2 set-ups
All set-ups

4-Setup (4-Par. Stze)

null
null
null
[0] Kein Reset

Werkseinstellung

nur
FC 302

TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE

TRUE

TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE

ndern whrend
des Betriebs

Par.-Nr.

4.3.12. 13-** Smart Logic

-3

-3

Konvertierungsindex

Uint8
Uint8

Uint8
Uint8
Uint8
Uint8
Uint8

TimD

Uint8
Uint8
Int32

Uint8
Uint8
Uint8
Uint8

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

14-0* IGBT-Ansteuerung
14-00
Schaltmuster
14-01
Taktfrequenz
14-03
bermodulation
14-04
PWM-Jitter
14-1* Netzausfall
14-10
Netzausfall-Funktion
14-11
Netzausfall-Spannung
14-12
Netzphasen-Unsymmetrie
14-2* Reset/Initialisieren
14-20
Quittierfunktion
14-21
Autom. Quittieren Zeit
14-22
Betriebsart
14-23
Typencodeeinstellung
14-25
Drehmom.grenze Verzgerungszeit
14-26
WR-Fehler Abschaltverzgerung
14-28
Produktionseinstellungen
14-29
Servicecode
14-3* Stromgrenze
14-30
Regler P-Verstrkung
14-31
Regler I-Zeit
14-4* Energieoptimierung
14-40
Quadr.Mom. Anpassung
14-41
Minimale AEO-Magnetisierung
14-42
Minimale AEO-Frequenz
14-43
Motor Cos-Phi
14-5* Umgebung
14-50
EMV-Filter
14-52
Lftersteuerung
14-53
Lfterberwachung
14-55
Ausgangsfilter
14-56
Capacitance Output Filter
14-57
Inductance Output Filter
14-7* Compatibility
14-72
VLT Alarm Word
14-73
VLT Warning Word
14-74
VLT Ext. Status Word
14-8* Options
14-80
Option Supplied by External 24VDC

Par.-Nr.

4.3.13. 14-** Sonderfunktionen

All set-ups
All set-ups
All
All
All
All

100 %
0.020 s
66 %
40 %
10 Hz
SR
1 set-up
All set-ups
All set-ups
1 set-up
1 set-up
1 set-up
All set-ups
All set-ups
All set-ups
2 set-ups

[1] Ein
[0] Auto
[1] Warnung
[0] Kein Filter
2.0 uF
7.000 mH
0 N/A
0 N/A
0 N/A
[1] Ja

set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups
All set-ups
2 set-ups
All set-ups
All set-ups
All set-ups
All set-ups

[0] Manual reset


10 s
[0] Normal Betrieb
null
60 s
SR
[0] Normal Betrieb
0 N/A

set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups
All set-ups

All
All
All
All

4-Setup (4-Par. Stze)

[0] Deaktiviert
SR
[0] Alarm

[1] SFAVM
null
[1] Ein
[0] Aus

Werkseinstellung

nur
FC 302

Konvertierungsindex
0
0
0
0
0
0
-3
0
0
0
-2
-7
-6
0
0
0
-

ndern whrend
des Betriebs
TRUE
TRUE
FALSE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
FALSE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

FALSE

Uint8

Uint32
Uint32
Uint32

Uint8
Uint8
Uint8
Uint8
Uint16
Uint16

Uint8
Uint8
Uint8
Uint16

Uint16
Uint16

Uint8
Uint16
Uint8
Uint8
Uint8
Uint8
Uint8
Int32

Uint8
Uint16
Uint8

Uint8
Uint8
Uint8
Uint8

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

65

66

15-0* Betriebsdaten
15-00
Betriebsstunden
15-01
Motorlaufstunden
15-02
Zhler-kWh
15-03
Anzahl Netz-Ein
15-04
Anzahl bertemperaturen
15-05
Anzahl berspannungen
15-06
Reset Zhler-kWh
15-07
Reset Motorlaufstundenzhler
15-1* Echtzeitkanal
15-10
Echtzeitkanal Quelle
15-11
Echtzeitkanal Abtastrate
15-12
Echtzeitkanal Triggerereignis
15-13
Echtzeitkanal Protokollart
15-14
Echtzeitkanal Werte vor Trigger
15-2* Protokollierung
15-20
Protokoll: Ereignis
15-21
Protokoll: Wert
15-22
Protokoll: Zeit
15-3* Fehlerspeicher
15-30
Fehlerspeicher: Fehlercode
15-31
Fehlerspeicher: Wert
15-32
Fehlerspeicher: Zeit
15-4* Typendaten
15-40
FC-Typ
15-41
Leistungsteil
15-42
Nennspannung
15-43
Softwareversion
15-44
Typencode (original)
15-45
Typencode (aktuell)
15-46
Typ Bestellnummer
15-47
Leistungsteil Bestellnummer
15-48
LCP-Version
15-49
Steuerkarte SW-Version
15-50
Leistungsteil SW-Version
15-51
Typ Seriennummer
15-53
Leistungsteil Seriennummer

Parameterbeschreibung

All
All
All
All
All
All
All
All
All
All
All
All
All

0
0
0
0
0
0
0
0
0
0
0
0
0

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All set-ups
All set-ups
All set-ups

0 N/A
0 N/A
0s
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

All set-ups
All set-ups
All set-ups

0 N/A
0 N/A
0 ms

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

2 set-ups
2 set-ups
1 set-up
2 set-ups
2 set-ups

All
All
All
All
All
All
All
All

4-Setup (4-Par. Stze)

0
SR
[0] FALSCH
[0] Kontinuierlich
50 N/A

0h
0h
0 kWh
0 N/A
0 N/A
0 N/A
[0] Kein Reset
[0] Kein Reset

Werkseinstellung

nur
FC 302

FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE

FALSE
FALSE
FALSE

FALSE
FALSE
FALSE

TRUE
TRUE
TRUE
TRUE
TRUE

FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE

ndern whrend
des Betriebs

Par.-Nr.

4.3.14. 15-** Info/Wartung

0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0

0
0
-3

-3
0

74
74
75
0
0
0
-

Konvertierungsindex

VisStr[6]
VisStr[20]
VisStr[20]
VisStr[5]
VisStr[40]
VisStr[40]
VisStr[8]
VisStr[8]
VisStr[20]
VisStr[20]
VisStr[20]
VisStr[10]
VisStr[19]

Uint8
Int16
Uint32

Uint8
Uint32
Uint32

Uint16
TimD
Uint8
Uint8
Uint8

Uint32
Uint32
Uint32
Uint32
Uint16
Uint16
Uint8
Uint8

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

15-6* Install. Optionen


15-60
Option installiert
15-61
SW-Version Option
15-62
Optionsbestellnr.
15-63
Optionsseriennr.
15-70
Option A
15-71
Option A - Softwareversion
15-72
Option B
15-73
Option B - Softwareversion
15-74
Option C0
15-75
Option C0 - Softwareversion
15-76
Option C1
15-77
Option C1 - Softwareversion
15-9* Parameterinfo
15-92
Definierte Parameter
15-93
Genderte Parameter
15-98
Drive Identification
15-99
Parameter-Metadaten

Par.-Nr.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Werkseinstellung

All
All
All
All

All
All
All
All
All
All
All
All
All
All
All
All
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

4-Setup (4-Par. Stze)

nur
FC 302

Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

ndern whrend
des Betriebs
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE

Uint16
Uint16
VisStr[40]
Uint16

VisStr[30]
VisStr[20]
VisStr[8]
VisStr[18]
VisStr[30]
VisStr[20]
VisStr[30]
VisStr[20]
VisStr[30]
VisStr[20]
VisStr[30]
VisStr[20]

Typ

VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

4. Programmieren

67

68

16-0* Anzeigen-Allgemein
16-00
Steuerwort
16-01
Sollwert [Einheit]
16-02
Sollwert %
16-03
Zustandswort
16-05
Hauptistwert [%]
16-09
Benutzerdefinierte Anzeige
16-1* Anzeigen-Motor
16-10
Leistung [kW]
16-11
Leistung [PS]
16-12
Motorspannung
16-13
Frequenz
16-14
Motorstrom
16-15
Frequenz [%]
16-16
Drehmoment [Nm]
16-17
Drehzahl [UPM]
16-18
Therm. Motorschutz
16-19
KTY-Sensortemperatur
16-20
Rotor-Winkel
Drehmoment [%]
16-22
16-3* Anzeigen-FU
16-30
DC-Spannung
16-32
Bremsleistung/s
16-33
Bremsleist/2 min
16-34
Khlkrpertemp.
16-35
FC berlast
16-36
Nenn-WR-Strom
16-37
Max.-WR-Strom
16-38
SL Contr.Zustand
16-39
Steuerkartentemp.
16-40
Echtzeitkanalspeicher voll
16-5* Soll- & Istwerte
16-50
Externer Sollwert
16-51
Puls-Sollwert
16-52
Istwert [Einheit]
16-53
Digitalpoti Sollwert

Parameterbeschreibung
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All

0.00 kW
0.00 hp
0.0 V
0.0 Hz
0.00 A
0.00 %
0.0 Nm
0 RPM
0%
0 C
0 N/A
0%
0V
0.000 kW
0.000 kW
0 C
0%
SR
SR
0 N/A
0 C
[0] Nein
0.0 N/A
0.0 N/A
0.000 ReferenceFeedbackUnit
0.00 N/A

set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

4-Setup (4-Par. Stze)

0 N/A
0.000 ReferenceFeedbackUnit
0.0 %
0 N/A
0.00 %
0.00 CustomReadoutUnit

Werkseinstellung

nur
FC 302

FALSE
FALSE
FALSE
FALSE

FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE

FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
FALSE

FALSE
FALSE
FALSE
FALSE
FALSE
FALSE

ndern whrend
des Betriebs

Par.-Nr.

4.3.15. 16-** Datenanzeigen

-1
-1
-3
-2

0
0
0
100
0
-2
-2
0
100
-

1
-2
-1
-1
-2
-2
-1
67
0
100
0
0

0
-3
-1
0
-2
-2

Konvertierungsindex

Int16
Int16
Int32
Int16

Uint16
Uint32
Uint32
Uint8
Uint8
Uint32
Uint32
Uint8
Uint8
Uint8

Int32
Int32
Uint16
Uint16
Int32
N2
Int16
Int32
Uint8
Int16
Uint16
Int16

V2
Int32
Int16
V2
N2
Int32

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

16-6* Anzeig. Ein-/Ausg.


16-60
Digitaleingnge
16-61
AE 53 Modus
16-62
Analogeingang 53
16-63
AE 54 Modus
16-64
Analogeingang 54
16-65
Analogausgang 42
16-66
Digitalausgnge
16-67
Pulseing. 29 [Hz]
16-68
Pulseing. 33 [Hz]
16-69
Pulsausg. 27 [Hz]
16-70
Pulsausg. 29 [Hz]
16-71
Relaisausgnge
16-72
Zhler A
16-73
Zhler B
16-74
Prziser Stopp-Zhler
16-75
Analogeingang X30/11
16-76
Analogeingang X30/12
16-77
Analogausg. X30/8 [mA]
16-78
Analog Out X45/1 [mA]
16-79
Analog Out X45/3 [mA]
16-8* Anzeig. Schnittst.
16-80
Bus Steuerwort 1
16-82
Bus Sollwert 1
16-84
Feldbus-Komm. Status
16-85
FC Steuerwort 1
16-86
FC Sollwert 1
16-9* Bus Diagnose
16-90
Alarmwort
16-91
Alarmwort 2
16-92
Warnwort
16-93
Warnwort 2
16-94
Erw. Zustandswort

Par.-Nr.

N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

0
0
0
0
0
0
0
0
0
0

0 N/A
[0] Strom
0.000 N/A
[0] Strom
0.000 N/A
0.000 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0.000 N/A
0.000 N/A
0.000 N/A
0.000 N/A
0.000 N/A

Werkseinstellung

All
All
All
All
All

All
All
All
All
All

All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All

set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

4-Setup (4-Par. Stze)

nur
FC 302

Konvertierungsindex
0
-3
-3
-3
0
0
0
0
0
0
0
0
0
-3
-3
-3
-3
-3
0
0
0
0
0
0
0
0
0
0

ndern whrend
des Betriebs
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE

Uint32
Uint32
Uint32
Uint32
Uint32

V2
N2
V2
V2
N2

Uint16
Uint8
Int32
Uint8
Int32
Int16
Int16
Int32
Int32
Int32
Int32
Int16
Int32
Int32
Uint32
Int32
Int32
Int16
Int16
Int16

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

69

70

17-1* Inkrementalgeber
17-10
Signaltyp
17-11
Inkremental Auflsung [Pulse/U]
17-2* Absolutwertgeber
17-20
Protokollauswahl
17-21
Absolut Auflsung [Positionen/U]
17-24
SSI-Datenlnge
17-25
Taktgeschwindigkeit
17-26
SSI-Datentyp
17-34
HIPERFACE-Baudrate
17-5* Resolver
17-50
Resolver Pole
17-51
Resolver Eingangsspannung
17-52
Resolver Eingangsfrequenz
17-53
bersetzungsverhltnis
17-59
Resolver aktivieren
17-6* berw./Anwend.
17-60
Positive Drehgeberrichtung
17-61
Drehgeber berwachung

Parameterbeschreibung

1 set-up
1 set-up
1 set-up
1 set-up
All set-ups
All set-ups
All set-ups

2 N/A
7.0 V
10.0 kHz
0.5 N/A
[0] Deaktiviert
[0] Rechtslauf
[1] Warnung

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All
All
All
All
All
All

All set-ups
All set-ups

4-Setup (4-Par. Stze)

[0] Keine
SR
13 N/A
SR
[0] Gray-Code
[4] 9600

[1] TTL (5V, RS422)


1024 N/A

Werkseinstellung

nur
FC 302

FALSE
TRUE

FALSE
FALSE
FALSE
FALSE
FALSE

FALSE
FALSE
FALSE
FALSE
FALSE
FALSE

FALSE
FALSE

ndern whrend
des Betriebs

Par.-Nr.

4.3.16. 17-** Opt./Drehgeber

0
-1
2
-1
-

0
0
3
-

Konvertierungsindex

Uint8
Uint8

Uint8
Uint8
Uint8
Uint8
Uint8

Uint8
Uint32
Uint8
Uint16
Uint8
Uint8

Uint8
Uint16

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

32-0* Drehgeber 2
32-00
Inkrem. Signaltyp
32-01
Inkrementalauflsung
32-02
Absolutwertprotokoll
32-03
Absolutwertauflsung
32-05
Absolutwertgeber-Datenlnge
32-06
Absolutwertgeber-Taktfrequenz
32-07
Absolutwertgeber Takt
32-08
Absolutwertgeber-Kabellnge
32-09
Drehgeberberwachung
32-10
Drehrichtung
32-11
Nenner Benutzereinheit
32-12
Zhler Benutzereinheit
32-3* Drehgeber 1
32-30
Inkrem. Signaltyp
32-31
Inkrementalauflsung
32-32
Absolutwertprotokoll
32-33
Absolutwertauflsung
32-35
Absolutwertgeber-Datenlnge
32-36
Absolutwertgeber-Taktfrequenz
32-37
Absolutwertgeber Takt
32-38
Absolutwertgeber-Kabellnge
32-39
Drehgeberberwachung
Drehgeberterminierung
32-40
32-5* Feedback Source
32-50
Source Slave

Par.-Nr.

4.3.17. 32-** MCO Grundeinstell.

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

2 set-ups

2
2
2
2
2
2
2
2
2
2

[1] TTL (5V, RS422)


1024 N/A
[0] Keine
8192 N/A
25 N/A
262.000 kHz
[1] Ein
0m
[0] Aus
[1] Ein
[2] Encoder 2

2
2
2
2
2
2
2
2
2
2
2
2

4-Setup (4-Par. Stze)

[1] TTL (5V, RS422)


1024 N/A
[0] Keine
8192 N/A
25 N/A
262.000 kHz
[1] Ein
0m
[0] Aus
[1] Normal Betrieb
1 N/A
1 N/A

Werkseinstellung

nur
FC 302

Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
-

ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

Uint8

Uint8
Uint32
Uint8
Uint32
Uint8
Uint32
Uint8
Uint16
Uint8
Uint8

Uint8
Uint32
Uint8
Uint32
Uint8
Uint32
Uint8
Uint16
Uint8
Uint8
Uint32
Uint32

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

71

72

32-6* PID-Regler
32-60
P-Faktor
32-61
D-Faktor
32-62
I-Faktor
32-63
Grenzwert fr Integralsumme
32-64
PID-Bandbreite
32-65
Vorsteuerung fr Geschwindgkeit
32-66
Vorsteuerung der Beschleunigung
32-67
Max. tolerierter Positionsfehler
32-68
Reversierverhalten fr Slave
32-69
Abtastzeit fr PID-Regler
32-70
Abtastzeit fr Profilgeber
32-71
Gre des Regelfensters (Aktivierung)
32-72
Gre des Regelfensters (Deaktiv.)
32-8* Geschw. u. Beschl.
32-80
Max. Geschw. (Drehgeber)
32-81
Krzeste Rampe
32-82
Rampentyp
32-83
Geschwindigkeitsteiler
32-84
Standardgeschwindigkeit
32-85
Standardbeschleunigung

Parameterbeschreibung
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

1500 RPM
1.000 s
[0] Linear
100 N/A
50 N/A
50 N/A

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

4-Setup (4-Par. Stze)

30 N/A
0 N/A
0 N/A
1000 N/A
1000 N/A
0 N/A
0 N/A
20000 N/A
[0] Reversier. zulssig
1 ms
1 ms
0 N/A
0 N/A

Werkseinstellung

nur
FC 302

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

ndern whrend
des Betriebs

Par.-Nr.

67
-3
0
0
0

0
0
0
0
0
0
0
0
-3
-3
0
0

Konvertierungsindex

Uint32
Uint32
Uint8
Uint32
Uint32
Uint32

Uint32
Uint32
Uint32
Uint16
Uint16
Uint32
Uint32
Uint32
Uint8
Uint16
Uint8
Uint32
Uint32

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

33-0* Ref.punktbeweg.
33-00
Referenzfahrt erzwingen
33-01
Nullpunktversatz von Ref.pkt.
33-02
Rampe fr Referenzfahrt
33-03
Geschw. der Ref.pkt-Bewegung
33-04
Verhalten bei Ref.pkt.-Bewegung
33-1* Synchronisierung
33-10
Synchronisierungsfaktor Master (M: S)
33-11
Synchronisierungsfaktor Slave (M: S)
33-12
Position-Offset fr Synchronisierung
33-13
Gen.fen. fr Pos.syn.
33-14
Relative Slavegeschw.-Grenze
33-15
Markierungszahl fr Master
33-16
Markeranzahl fr Slave
33-17
Mastermarkierungsdistanz
33-18
Slavemarkerdistanz
33-19
Mastermarkertyp
33-20
Slavemarkertyp
33-21
Toleranzfenster Mastermarker
33-22
Toleranzfenster Slavemarker
33-23
Startverh. f. Markersynchronisierung.
33-24
Markeranzahl fr Fehler
33-25
Markeranzahl fr READY
33-26
Geschw.-Filter
33-27
Offset-Filterzeit
33-28
Markerfilterkonfig.
33-29
Filterzeit fr Markerfilter
33-30
Max. Markierungskorrektur
33-31
Synchronisierungstyp
33-4* Grenzwertverarb.
33-40
Verhalten an Endbegren.
33-41
Neg. Software-Endbegren.
33-42
Pos. Software-Endbegren.
33-43
Neg. Software-Endbegren. aktiv
33-44
Pos. Software-Endbegren. aktiv
33-45
Zeit in Zielfenster
33-46
Zielfenster-Grenzwert
33-47
Gre des Zielfensters

Par.-Nr.

4.3.18. 33-** MCO Erw. Einstell.

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

1 N/A
1 N/A
0 N/A
1000 N/A
0%
1 N/A
1 N/A
4096 N/A
4096 N/A
[0] Drehgeber Z positiv
[0] Drehgeber Z positiv
0 N/A
0 N/A
[0] Startfunktion 1
10 N/A
1 N/A
0 us
0 ms
[0] Marker-Filter 1
0 ms
0 N/A
[0] Standard
[0] Fehlerroutine aufr.
-500000 N/A
500000 N/A
[0] Deaktiviert
[0] Deaktiviert
0 ms
1 N/A
0 N/A

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups

4-Setup (4-Par. Stze)

[0] Keine Zwangsrcks.


0 N/A
10 N/A
10 N/A
[0] Rckwrts und Index

Werkseinstellung

nur
FC 302

Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
-6
-3
-3
0
0
0
-3
0
0

ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

Uint8
Int32
Int32
Uint8
Uint8
Uint8
Uint16
Uint16

Int32
Int32
Int32
Int32
Uint8
Uint16
Uint16
Uint32
Uint32
Uint8
Uint8
Uint32
Uint32
Uint16
Uint16
Uint16
Int32
Uint32
Uint8
Int32
Uint32
Uint8

Uint8
Int32
Uint32
Int32
Uint8

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

73

74

33-5* E/A-Konfiguration
33-50
Klemme X57/1 Digitaleingang
33-51
Klemme X57/2 Digitaleingang
33-52
Klemme X57/3 Digitaleingang
33-53
Klemme X57/4 Digitaleingang
33-54
Klemme X57/5 Digitaleingang
33-55
Klemme X57/6 Digitaleingang
33-56
Klemme X57/7 Digitaleingang
33-57
Klemme X57/8 Digitaleingang
33-58
Klemme X57/9 Digitaleingang
33-59
Klemme X57/10 Digitaleingang
33-60
Klemme X59/1 und X59/2 Funktion
33-61
Klemme X59/1 Digitaleingang
33-62
Klemme X59/2 Digitaleingang
33-63
Klemme X59/1 Digitalausgang
33-64
Klemme X59/2 Digitalausgang
33-65
Klemme X59/3 Digitalausgang
33-66
Klemme X59/4 Digitalausgang
33-67
Klemme X59/5 Digitalausgang
33-68
Klemme X59/6 Digitalausgang
33-69
Klemme X59/7 Digitalausgang
33-70
Klemme X59/8 Digitalausgang
33-8* Globale Parameter
33-80
Aktive Programmnummer
33-81
Netz-Ein-Zustand
33-82
Zustandsberw. FC300
33-83
Verhalten nach Fehler
33-84
Verhalten nach Esc.
33-85
Ext. 24 VDC fr MCO

Parameterbeschreibung
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

-1 N/A
[1] Motor ein
[1] Ein
[0] Motorfreilauf
[0] Kontroll. Stopp
[0] Nein

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

4-Setup (4-Par. Stze)

[0] Ohne Funktion


[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[1] Ausgang
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion

Werkseinstellung

nur
FC 302

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

ndern whrend
des Betriebs

Par.-Nr.

0
-

Konvertierungsindex

Int8
Uint8
Uint8
Uint8
Uint8
Uint8

Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8

Typ

4. Programmieren
VLTAutomationDrive FC 300 Produkthandbuch

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

Parameterbeschreibung

34-0* PCD-Par. schreiben


34-01
PCD 1 Schreiben an MCO
34-02
PCD 2 Schreiben an MCO
34-03
PCD 3 Schreiben an MCO
34-04
PCD 4 Schreiben an MCO
34-05
PCD 5 Schreiben an MCO
34-06
PCD 6 Schreiben an MCO
34-07
PCD 7 Schreiben an MCO
34-08
PCD 8 Schreiben an MCO
34-09
PCD 9 Schreiben an MCO
34-10
PCD 10 Schreiben an MCO
34-2* PCD-Par. lesen
34-21
PCD 1 Lesen von MCO
34-22
PCD 2 Lesen von MCO
34-23
PCD 3 Lesen von MCO
34-24
PCD 4 Lesen von MCO
34-25
PCD 5 Lesen von MCO
34-26
PCD 6 Lesen von MCO
34-27
PCD 7 Lesen von MCO
34-28
PCD 8 Lesen von MCO
34-29
PCD 9 Lesen von MCO
34-30
PCD 10 Lesen von MCO
34-4* Anzeig. Ein-/ Ausg.
34-40
Digitaleingnge
34-41
Digitalausgnge
34-5* Prozessdaten
34-50
Istposition
34-51
Sollposition
34-52
Masteristposition
34-53
Slave-Indexposition
34-54
Master-Indexposition
34-55
Kurvenposition
34-56
Schleppabstand
34-57
Synchronisierungsfehler
34-58
Istgeschwindigkeit
34-59
Master-Istgeschwindigkeit
34-60
Synchronisationsstatus
34-61
Achsenstatus
34-62
Programmstatus
34-7* Diagnose-Anzeigen
34-70
MCO Alarmwort 1
34-71
MCO Alarmwort 2

Par.-Nr.

4.3.19. 34-** MCO-Datenanzeigen

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.


0 N/A
0 N/A

N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

All set-ups
All set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

All
All
All
All
All
All
All
All
All
All
All
All
All

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups

0
0
0
0
0
0
0
0
0
0
0
0
0

All
All
All
All
All
All
All
All
All
All

All
All
All
All
All
All
All
All
All
All

All set-ups
All set-ups

N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

4-Setup (4-Par. Stze)

0 N/A
0 N/A

0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0

Werkseinstellung

nur
FC 302

Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE

Uint32
Uint32

Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32

Uint16
Uint16

Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16

Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16

Typ

VLTAutomationDrive FC 300 Produkthandbuch


4. Programmieren

75

5. Allgemeine technische Daten

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5. Allgemeine technische Daten

5. Allgemeine technische Daten

Netzversorgung (L1, L2, L3):


Versorgungsspannung

200-240 V 10 %

Versorgungsspannung

FC 301: 380-480 V / FC 302: 380-500 V 10 %

Versorgungsspannung

FC 302: 525-690 V 10 %

Netzfrequenz

50/60 Hz

Max. Ungleichgewicht zwischen Netzphasen

3,0 % der Versorgungsnennspannung

Wirkleistungsfaktor ()

0,9 bei Nennlast

Verschiebungsleistungsfaktor (cos )

nahe Eins (> 0,98)

Schalten am Netzeingang L1, L2, L3 7,5 kW

max. 2 x/Min.

Schalten am Netzeingang L1, L2, L3 11-75 kW

max. 1 x/Min.

Schalten am Netzeingang L1, L2, L3 90 kW


Umgebung gem EN60664-1

max. 1 x/2 min.


berspannungskategorie III/Verschmutzungsgrad 2

Das Gert ist fr Netzversorgungen geeignet, die maximal 100,000 ARMS (symmetrisch) bei maximal je 240/500/600/690 V liefern knnen.
Motorausgang (U, V, W):
Ausgangsspannung

0 - 100 % der Versorgungsspannung

Ausgangsfrequenz (0,25-75 kW)

FC 301: 0,2 Hz - 1000 Hz / FC 302: 0 - 1000 Hz

Ausgangsfrequenz (90-560 kW)

0 - 800* Hz

Ausgangsfrequenz bei Fluxvektorbetrieb (nur FC 302)


Schalten am Ausgang

0 - 300 Hz
Unbegrenzt

Rampenzeiten

0,01 - 3600 s

Spannungs- und leistungsabhngig


Drehmomentkennlinie:
Anlaufmoment (konstantes Drehmoment)

maximal 160 % fr 60 s*

Anlaufmoment

maximal 180 % bis 0,5 s*

berlastmoment (konstantes Drehmoment)

maximal 160 % fr 60 s*

Anlaufmoment (variables Drehmoment)

maximal 110 % fr 60 s*

berlastungsstrom (variables Drehmoment)

maximal 110 % fr 60 s

*Prozentwert auf Nenndrehmoment bezogen.


Digitaleingnge:
Programmierbare Digitaleingnge

FC 301: 4 (5) / FC 302: 4 (6)


18, 19, 271), 294), 32, 33,

Klemmennummer
Logik

PNP oder NPN

Spannungsbereich

0 - 24 V DC

Spannungsniveau, logisch '0' PNP

< 5 V DC

Spannungsniveau, logisch '1' PNP

> 10 V DC

Spannungsniveau, logisch '0' NPN2)

> 19 V DC

Spannungslevel, logisch '1' NPN2)

< 14 V DC

Max. Spannung am Eingang

28 V DC

Pulsfrequenzbereich

0 - 110 kHz

(Arbeitszyklus) Min. Pulsbreite

4,5 ms

Eingangswiderstand, Ri

ca. 4 k

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5. Allgemeine technische Daten


Sicherer Stopp, Klemme 373) (Klemme 37 ist feste PNP-Logik):
Spannungsbereich

0 - 24 V DC

Spannungsniveau, logisch '0' PNP

< 4 V DC

Spannungsniveau, logisch '1' PNP

>20 V DC

Eingangsnennstrom bei 24 V

50 mA rms

Eingangsnennstrom bei 20 V

60 mA rms

Eingangskapazitt

400 nF

Alle Digitaleingnge sind galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.
1) Klemmen 27 und 29 knnen auch als Ausgang programmiert werden.
Auer Eingang fr Sicheren Stopp, Klemme 37.
3) Klemme 37 ist nur beim FC 302 und beim FC 301 A1 mit Sicherem Stopp verfgbar. Sie kann nur als Eingang fr die Funktion Sicherer Stopp
verwendet werden. Klemme 37 ist geeignet fr Installationen bis Sicherheitskategorie 3 nach EN 954-1 (Stoppkategorie 0 EN 60204-1) gem EU-

Maschinenrichtlinie 98/37/EG. Klemme 37 und die Funktion Sicherer Stopp sind entsprechend EN 60204-1, EN 50178, EN 61800-2, EN 61800-3 und
EN 954-1 ausgelegt. Fr korrekten und sicheren Gebrauch der Funktion Sicherer Stopp folgen Sie den entsprechenden Informationen und Anweisungen
im Projektierungshandbuch.
4) nur FC 302
Analogeingnge:
Anzahl Analogeingnge

Klemmennummer

53, 54

Betriebsart

Spannung oder Strom

Betriebsartumschaltung
Einstellung fr Spannung
Spannungsbereich

Schalter S201 und Schalter S202


Schalter S201/Schalter S202 = AUS (U)
FC 301: 0 bis + 10 V DC/FC 302: -10 bis +10 V DC (skalierbar)

Eingangswiderstand, Ri

ca. 10 k

Max. Spannung

20 V

Einstellung fr Strom

Schalter S201/Schalter S202 = EIN (I)

Strombereich

0/4 bis 20 mA (skalierbar)

Eingangswiderstand, Ri

ca. 200

Max. Strom

30 mA

Auflsung der Analogeingnge

10 Bit (+ Vorzeichen)

Genauigkeit der Analogeingnge

Max. Fehler 0,5 % der Gesamtskala

Bandbreite

FC 301: 20 Hz/FC 302: 100 Hz

Die Analogeingnge sind galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.

78

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5. Allgemeine technische Daten

Puls-/Drehgebereingnge:
Programmierbare Puls-/Drehgebereingnge

2/1
291), 332) / 323), 333)

Klemmennummer Puls/Drehgeber
Max. Frequenz bei Klemme 29, 32, 33

110 kHz (Gegentakt)

Max. Frequenz bei Klemme 29, 32, 33

5 kHz (offener Kollektor)

Min. Frequenz bei Klemme 29, 32, 33

4 Hz

Spannungsbereich

siehe Digitaleingnge

Max. Spannung am Eingang

28 V DC

Eingangswiderstand, Ri

ca. 4 k

Pulseingangsgenauigkeit (0,1-1 kHz)

Max. Fehler: 0,1 % der Gesamtskala

Drehgebereingangsgenauigkeit (1-110 kHz)

Max. Fehler: 0,05 % der Gesamtskala

Die Puls- und Drehgebereingnge (Klemmen 29, 32, 33) sind galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen
isoliert.

1) Nur FC 302
2) Pulseingnge sind 29 und 33
3) Drehgebereingnge: 32 = A und 33 = B
Digitalausgang:
Programmierbare Digital-/Pulsausgnge

Klemmennummer

27, 29

1)

Spannungsbereich am Digital-/Frequenzausgang

0 - 24 V

Max. Ausgangsstrom (Krper oder Quelle)

40 mA

Max. Last am Pulsausgang

1 k

Max. kapazitive Last am Frequenzausgang

10 nF

Min. Ausgangsfrequenz am Pulsausgang

0 Hz

Max. Ausgangsfrequenz am Pulsausgang

32 kHz

Genauigkeit am Pulsausgang

Max. Fehler: 0,1 % der Gesamtskala

Auflsung an Pulsausgngen

12 Bit

1) Klemmen 27 und 29 knnen auch als Digitaleingang programmiert werden.


Die Digitalausgnge sind galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.

Analogausgnge:
Anzahl programmierbarer Analogausgnge

Klemmennummer

42

Strombereich am Analogausgang

0/4 - 20 mA

Max. Last gegen Masse am Analogausgang


Genauigkeit am Analogausgang

500
Max. Fehler: 0,5 % der Gesamtskala

Auflsung am Analogausgang

12 Bit

Der Analogausgang ist galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.

Steuerkarte, 24 V DC-Ausgang:
Klemmennummer

12, 13

Ausgangsspannung

24 V +1, -3 V

Max. Last

FC 301: 130 mA/FC 302: 200 mA

Die 24 V DC-Versorgung ist von der Versorgungsspannung (PELV) getrennt, hat aber das gleiche Potenzial wie die analogen und digitalen Ein- und
Ausgnge.
Steuerkarte, 10 V DC-Ausgang:
Klemmennummer

50

Ausgangsspannung

10,5 V 0,5 V

Max. Last

15 mA

Die 10 V DC-Versorgung ist galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.

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5. Allgemeine technische Daten


Steuerkarte, RS 485 serielle Schnittstelle:
Klemmennummer

68 (P,TX+, RX+), 69 (N,TX-, RX-)

Klemmennummer 61

Masse fr Klemmen 68 und 69

Die serielle RS 485-Schnittstelle ist von anderen zentralen Stromkreisen funktional und von der Versorgungsspannung (PELV) galvanisch getrennt.

Steuerkarte, USB (serielle Schnittstelle):


USB-Standard

1.1 (Full Speed)

USB-Stecker

USB-Stecker Typ B

Der Anschluss an einen PC erfolgt ber ein USB-Standardkabel.


Die USB-Verbindung ist galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.
Die USB-Verbindung ist nicht galvanisch von Schutzerde (PE) getrennt. Benutzen Sie nur einen isolierten Laptop als PC-Verbindung zum USB-Anschluss
am Frequenzumrichter.

Relaisausgnge:
Programmierbare Relaisausgnge

FC 301 7,5 kW: 1/FC 302 alle kW: 2

Klemmennummer Relais 01

1-3 (ffnen), 1-2 (schlieen)

Max. Klemmenleistung (AC-1)1) an 1-3 (ffnen), 1-2 (schlieen) (ohmsche Last)

240 V AC, 2 A

Max. Klemmenleistung (AC-15)1) (induktive Last @ cos 0,4)

240 V AC, 0,2 A

Max. Klemmenleistung (DC-1)1) an 1-2 (schlieen), 1-3 (ffnen) (ohmsche Last)

60 V DC, 1 A

Max. Klemmenleistung (DC-13)1) (induktive Last)

24 V DC, 0,1A

Klemmennummer Relais 02 (nur FC 302)


Max. Klemmenleistung

(AC-1)1)

4-6 (ffnen), 4-5 (schlieen)

an 4-5 (schlieen) (ohmsche

Last)2)3)

400 V AC, 2 A

Max. Klemmenleistung (AC-15)1) an 4-5 (schlieen) (induktive Last @ cos 0,4)

240 V AC, 0,2 A

Max. Klemmenleistung (DC-1)1) an 4-5 (schlieen) (ohmsche Last)

80 V DC, 2 A

Max. Klemmenleistung (DC-13)1) an 4-5 (schlieen) (induktive Last)

24 V DC, 0,1A

Max. Klemmenleistung (AC-1)1) an 4-6 (ffnen) (ohmsche Last)

240 V AC, 2 A

Max. Klemmenleistung (AC-15)1) an 4-6 (ffnen) (induktive Last @ cos 0,4)

240 V AC, 0,2 A

Max. Klemmenleistung (DC-1)1) an 4-6 ffnen) (ohmsche Last)


Max. Klemmenleistung

(DC-13)1)

50 V DC, 2 A

an 4-6 (ffnen) (induktive Last)

24 V DC, 0,1 A

Min. Klemmenleistung an 1-3 (ffnen), 1-2 (schlieen), 4-6 (ffnen) 4-5 (schlieen)
Umgebung nach EN 60664-1

24 V DC 10 mA, 24 V AC 20 mA
berspannungskategorie III/Verschmutzungsgrad 2

1) IEC 60947 Teil 4 und 5


Die Relaiskontakte sind galvanisch durch verstrkte Isolierung (PELV) vom Rest der Stromkreise getrennt.
2) berspannungskategorie II
3) UL-Anwendungen 300 V AC, 2 A
Kabellngen und -querschnitte fr Steuerkabel:
Max. Motorkabellnge, abgeschirmtes Kabel

FC 301: 50 m/FC 301 (A1-Gehuse): 25 m/FC 302: 150 m

Max. Motorkabellnge, nicht abgeschirmtes Kabel

FC 301: 75 m/FC 301 (A1-Gehuse): 50 m/FC 302: 300 m

Maximaler Querschnitt fr Steuerkabel, flexibler/starrer Draht ohne Aderendhlsen.


Maximaler Querschnitt fr Steuerkabel, flexibler Draht ohne Aderendhlsen.
Maximaler Querschnitt fr Steuerkabel, flexibler Draht mit Aderendhlsen und mit Bund.

1 mm2/18 AWG
0,5 mm2/20 AWG
0,25 mm2/ 24 AWG

Minimaler Querschnitt fr Steuerklemmen

* Weitere Informationen zu Stromkabeln finden Sie im Abschnitt Elektrische Daten des Projektierungshandbuchs.
Nhere Informationen siehe Abschnitt Elektrische Daten im FC 300-Projektierungshandbuch MG.33.BX.YY.

80

1,5 mm2/16 AWG

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5. Allgemeine technische Daten

Steuerkartenleistung:
Abfragezeit

FC 301: 5 ms/FC 302: 1 ms

Steuerungseigenschaften:
Auflsung von Ausgangsfrequenz bei 0-1000 Hz

+/- 0,003 Hz

Wiederholgenauigkeit fr Prziser Start/Stopp (Klemmen 18, 19)

0,1 ms

System-Reaktionszeit (Klemmen 18, 19, 27, 29, 32, 33)

2 ms

Drehzahlregelbereich (ohne Rckfhrung)

1:100 der Synchrondrehzahl

Drehzahlsteuerbereich (mit Rckfhrung)

1:1000 der Synchrondrehzahl

Drehzahlgenauigkeit (ohne Rckfhrung)

30-4000 UPM, Fehler: 8 UPM

Drehzahlgenauigkeit (mit Rckfhrung), je nach Auflsung

0-6000 UPM, Fehler: 0,15 UPM

Alle Angaben basieren auf einem vierpoligen Asynchronmotor.

Umgebung:
IP 201)/Typ 1, IP 212)/Typ 1, IP 55/Typ 12, IP 66

Gehuse
Vibrationstest

1,0 g

Max. relative Luftfeuchtigkeit

5 % - 95 % (IEC 721-3-3; Klasse 3K3 (nicht kondensierend) bei Betrieb


Klasse H25

Aggressive Umgebung (IEC 60068-2-43


Umgebungstemperatur3)

Max. 50 C (24-Std.-Durchschnitt max. 45 C)

1) Nur fr 3,7 kW (200-240 V), 7,5 kW (400-480/500 V)


2) Als Gehuse-Kit fr 3,7 kW (200-240 V), 7,5 kW (400-480/500 V)
3) Angaben zur Leistungsreduzierung wegen hoher Umgebungstemperatur finden Sie unter Besondere Bedingungen im Projektierungshandbuch
Minimale Umgebungstemperatur bei Volllast

0 C

Minimale Umgebungstemperatur bei reduzierter Leistung

- 10 C

Temperatur bei Lagerung/Transport

-25 - +65/70 C

Maximale Hhe ber Meeresspiegel ohne Leistungsreduzierung

1000 m

Leistungsreduzierung bei niedrigem Luftdruck/groer Hhe; siehe Besondere Bedingungen im Projektierungshandbuch.


EMV-Normen, Straussendung

EN 61800-3, EN 61000-6-3/4, EN 55011


EN 61800-3, EN 61000-6-1/2,
EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6

EMV-Normen, Strfestigkeit

Siehe Abschnitt zu besonderen Bedingungen im Projektierungshandbuch


Schutz und Merkmale:

Elektronisch thermischer Motor-berlastschutz.


Temperaturberwachung des Khlkrpers stellt sicher, dass der Frequenzumrichter abgeschaltet wird, wenn die Temperatur einen festgelegten
Wert erreicht. Eine berlasttemperatur kann erst zurckgesetzt werden, nachdem die Khlkrpertemperatur wieder unter die in den folgenden
Tabellen festgelegten Werte gesunken ist (dies ist nur eine Richtlinie: Temperaturen knnen je nach Leistungsgre, Gehuse usw. verschieden
sein).

Der Frequenzumrichter ist gegen Kurzschlsse an den Motorklemmen U, V, W geschtzt.

Bei fehlender Netzphase schaltet der Frequenzumrichter ab oder gibt eine Warnung aus (je nach Last).

Die berwachung der Zwischenkreisspannung gewhrleistet, dass der Frequenzumrichter abschaltet, wenn die Zwischenkreisspannung zu niedrig bzw. zu hoch ist.

Es erfolgt eine permanente berwachung hinsichtlich kritischer Werte bei interner Temperatur, Laststrom, Spannung im Zwischenkreis und
Motordrehzahl. Wenn ein kritisches Niveau erreicht wird, kann die Taktfrequenz angepasst und/oder der Schaltmodus gendert werden, damit
der Frequenzumrichter weiter betrieben werden kann.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

81

6. Fehlersuche und -behebung

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6. Fehlersuche und -behebung

6. Fehlersuche und -behebung


6.1.1. Warnungen/Alarmmeldungen
Eine Warnung oder ein Alarm wird durch die entsprechende LED auf der Frontseite des Frequenzumrichters signalisiert und mit einem Code im Display
angezeigt.

Eine Warnung bleibt so lange bestehen, bis die Ursache nicht mehr zutrifft. Der Motor kann dabei eventuell weiter betrieben werden. Warnmeldungen
knnen, mssen aber nicht unbedingt kritisch sein.

Bei einem Alarm hat der Frequenzumrichter abgeschaltet. Alarme mssen zur Wiederaufnahme des Betriebs durch Beseitigung der Ursache quittiert
werden.
Dies kann auf drei Arten geschehen:
1.

Mit der Bedientaste [RESET] an der LCP-Bedieneinheit.

2.

ber einen Digitaleingang mit der Funktion Reset.

3.

ber serielle Kommunikation/optionalen Feldbus.

ACHTUNG!
Nach manuellem Quittieren ber die [RESET]-Taste am LCP muss die Taste [AUTO ON] gedrckt werden, um den Motor neu zu starten!

Wenn sich ein Alarm nicht quittieren lsst, kann dies daran liegen, dass die Ursache noch nicht beseitigt ist oder der Alarm mit einer Abschaltblockierung
versehen ist (siehe auch Tabelle auf der nchsten Seite).

Alarme mit Abschaltblockierung bieten einen zustzlichen Schutz, d. h., es muss vor der Quittierung die Netzversorgung abgeschaltet werden. Nach dem
Wiederzuschalten ist der Frequenzumrichter nicht mehr blockiert und kann nach Beseitigung der Ursache wie oben beschrieben quittiert werden.

Alarme ohne Abschaltblockierung knnen auch mittels der automatischen Quittierfunktion in Parameter 14-20 zurckgesetzt werden (Achtung: automatischer Wiederanlauf ist mglich!).

Ist in der Tabelle auf der folgenden Seite fr einen Code Warnung und Alarm markiert, bedeutet dies, dass entweder vor einem Alarm eine Warnung
erfolgt oder dass Sie festlegen knnen, ob fr einen bestimmten Fehler eine Warnung oder ein Alarm ausgegeben wird.
Dies ist beispielsweise in Parameter 1-90 Thermischer Motorschutz mglich. Nach einem Alarm/einer Abschaltung bleibt der Motor im Freilauf, und Alarm
und Warnung blinken. Nachdem das Problem behoben wurde, blinkt nur noch der Alarm.

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6. Fehlersuche und -behebung

No. Beschreibung

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
23
24
25
26
27
28
29
30
31
32
33
34
36
38
40
41
42
42
47
48
49
50
51
52
53
54
55
56
57
58
59

10 Volt niedrig
Signalfehler
Kein Motor
Netzunsymmetrie
DC-Spannung hoch
DC-Spannung niedrig
DC-berspannung
DC-Unterspannung
WR-berlast
Motortemperatur ETR
Motor Thermistor
Drehmomentgrenze
berstrom
Erdschluss
Inkompatible Hardware
Kurzschluss
Steuerwort-Timeout
Interne Lfter
Externe Lfter
Bremswiderstand Kurzschluss
Bremswiderstand Leistungsgrenze
Bremse IGBT-Fehler
Bremstest
Umrichter bertemperatur
Motorphase U fehlt
Motorphase V fehlt
Motorphase W fehlt
Inrush Fehler
Feldbus-Fehler
Netzausfall
Interner Fehler
Digitalausgang 27 ist berlastet
Digitalausgang 29 ist berlastet
Digitalausgang X30/6 ist berlastet
Digitalausgang X30/7 ist berlastet
24-V-Versorgung - Fehler
1,8-V-Versorgung - Fehler
Drehzahlgrenze
AMA-Kalibrierungsfehler
AMA-Motordaten Unom und Inom berprfen
AMA-Strom Inom
AMA-Motor zu gro
AMA-Motor zu klein
AMA-Daten auerhalb des Bereichs
AMA-Abbruch
AMA-Timeout
AMA - Interner Fehler
Stromgrenze

Warnung
X
(X)
(X)
(X)
X
X
X
X
X
(X)
(X)
X
X
X
(X)
X
X
X
(X)
X
(X)
X
(X)
(X)
(X)
X
X
(X)
(X)
(X)
(X)
X
X

X
X

Alarm/Abschaltung

Alarm/Abschaltblockierung

Parameter
Sollwert

(X)

6-01
1-80
14-12

(X)
(X)
X
X
X
(X)
(X)
X
X
X
X
X
(X)

1-90
1-90
X
X
X
X
8-04
14-53

(X)
X
(X)
X
(X)
(X)
(X)
X
X
X
X

X
X

2-13
X
(X)
(X)
(X)
X

4-58
4-58
4-58

X
X

X
X
X
X
X
X
X
X
X

Tabelle 6.1: Alarm-/Warncodeliste

84

2-15

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5-00, 5-01
5-00, 5-02
5-32
5-33

VLTAutomationDrive FC 300 Produkthandbuch

No.

Beschreibung

61
62

Drehgeber-Fehler
Ausgangsfrequenz-Grenze

63
64

Mechanische Bremse - Fehler


Motorspannung

65
66
67
68
70
71
72
80
90
91
100199
250
251

Steuerkarte bertemperatur
Temperatur zu niedrig
Optionen neu
Sich. Stopp
Ungltige FC-Konfiguration
PTC 1 Sicherer Stopp
Gefhrlicher Fehler
Initialisiert
Drehgeberberwachung
Falsche Einstellungen fr Analogeingang 54

6. Fehlersuche und -behebung

Warnung
(X)
X

Alarm/Abschaltung Alarm/Abschaltblockierung
(X)
(X)

Parameter
Sollwert
4-30
2-20

X
X
X
(X)

X
(X)1)

5-19
X

(X)

X1)

5-19
5-19

17-61
S202

X1)
X
(X)

Siehe Produkthandbuch zur MCO 305


Neues Ersatzteil
Neuer Typencode

X
X

14-23

Tabelle 6.2: Alarm-/Warncodeliste


(X) Parameterabhngig
1) Kann nicht automatisch ber Par. 14-20 quittiert werden
Bei einem Alarm folgt eine Abschaltung. Die Abschaltung fhrt zum Motorfreilauf und kann durch Drcken der Reset-Taste oder durch einen
Reset ber Digitaleingang (Par. 5-1* [1]) quittiert werden. Das ursprngliche Ereignis, das den Alarm hervorgerufen hat, kann den Frequenzumrichter nicht beschdigen oder gefhrliche Bedingungen schaffen. Bei
einem Alarm tritt die Abschaltblockierung in Kraft, die ggf. den Frequenzumrichter oder angeschlossene Teile beschdigen kann. Eine Abschaltblockierung kann nur durch Aus- und Einschalten des Frequenzumrichters
quittiert werden.

LED-Anzeige
Warnung
Alarm
Abschaltung blockiert

gelb
Blinkt ROT
gelb und rot

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6. Fehlersuche und -behebung

Alarmwort, erweitertes Zustandswort


Bit
Hex
Dez
Alarmwort

00000001

Bremstest

00000002

Umr. bertemp.

00000004

Erdschluss

00000008

Steuer.Temp.

00000010

16

STW- Timeout

5
6
7
8

00000020
00000040
00000080
00000100

32
64
128
256

berstrom
Moment.grenze
Motor Therm.
Motortemp.ETR

9
10
11
12
13
14

00000200
00000400
00000800
00001000
00002000
00004000

512
1024
2048
4096
8192
16384

15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

00008000
00010000
00020000
00040000
00080000
00100000
00200000
00400000
00800000
01000000
02000000
04000000
08000000
10000000
20000000
40000000

32768
65536
131072
262144
524288
1048576
2097152
4194304
8388608
16777216
33554432
67108864
134217728
268435456
536870912
1073741824

31

80000000

2147483648

WR-berlast
DC-Untersp.
DC-bersp.
Kurzschluss
Inrush Fehler
Netzunsymm. Verlust
AMA nicht OK
Signalfehler
Interner Fehler
Bremswid.kW
Mot.Phase U
Mot.Phase V
Mot.Phase W
Feldbus-Fehl.
24 V Fehler
Netzausfall
1,8 V Fehler
Bremswiderst.
Bremse IGBT
Optionen neu
Initialisiert
Sicherer
Stopp
(A68)
Mech. Bremse

Alarmwort 2

Warnwort

Serviceabschaltung,
Lesen/
Schreiben
Serviceabschaltung, (reserviert)
Serviceabschaltung, Typencode/
Ersatzteil
Serviceabschaltung, (reserviert)
Serviceabschaltung, (reserviert)

Bremstest

Warnwort Erweitertes Men


2
Zustandswort
Rampe

Umr. bertemp.

AMA luft

Erdschluss

Start
lauf

Steuer.Temp.

Freq.korr. Ab

STW- Timeout

Freq.korr. Auf

berstrom
Moment.grenze
Motor Therm.
Motortemp.ETR

Istwert hoch
Istwert niedr.
Ausgangsstrom hoch
Ausgangsstrom niedrig
Ausgangsfreq. hoch
Ausgangsfreq. niedr.
Bremstest i.O.
Max. Bremsung
Bremsung
Auerh.Frequenzber.

WR-berlast
DC-Untersp.
DC-bersp.
DC-niedrig
DC-hoch
Netzunsymm. Verlust
Kein Motor
Signalfehler
KTY-Fehler
10 V niedrig
Lfterfehler
Bremswid.kW
ECB-Fehler
Bremswiderst.
Bremse IGBT
Drehz.grenze
Feldbus-Fehl.
24 V Fehler
Netzausfall
Stromgrenze
Temp. niedrig
Motorspannung
Drehgeber-Fehler
Ausg.Frequenz
PTC 1 Sicherer Sicherer Stopp (W68)
Stopp (A71)

Rechts-/Links-

bersp.-Steu.
AC Bremse
KTY-Warn. Passwort-Zeitblockier.
Lfterwarn. Passwort-Schutz
ECB-Warn.

Reserviert
Reserviert
Reserviert
Reserviert
Reserviert
Reserviert
Reserviert
Reserviert
PTC 1 Siche- Reserviert
rer
Stopp
(W71)
Gefhrlicher Fehler Erweitertes Zustandswort
Reserviert
(A72)

Tabelle 6.3: Beschreibung des Alarmworts, Warnworts und erweiterten Zustandsworts


Die Alarmworte, Warnworte und erweiterten Zustandsworte knnen ber den seriellen Bus oder optional ber den Feldbus zur Diagnose ausgelesen
werden. Sie auch Par. 16-90 - 16-94.

WARNUNG 1, 10 Volt niedrig:

oder ein Defekt im Gleichrichter.

Die 10-Volt-Spannung von Klemme 50 an der Steuerkarte ist unter 10

Siehe auch Par.14-12 Rcksetzen des Alarms nur nach Netz-AUS.

Volt.

WARNUNG 5, DC-Spannung hoch:

Die 10-Volt-Versorgung ist berlastet. Verringern Sie die Last an Klemme

Die Zwischenkreisspannung (VDC) liegt oberhalb der berspannungs-

50. Max. 15 mA bzw. minimal 590 Last.

grenze des Steuersystems. Eventuell wird die Steuerung ber externe 24

WARNUNG/ALARM 2, Sollwertfehler:

V versorgt. berprfen Sie die Netzspannung.

Das Analogsignal an Klemme 53/54 ist kleiner als 50 % der zugehrigen


Skalier.Min (Par.6-1*/6-2*), und eine Signalausfall-Funktion wurde in
Par. 6-01 aktiviert. berprfen Sie die Analogsignale an Klemme 53/54.
berprfen Sie die Einstellung in Par. 6-01.

spannungsgrenze erreicht. Eventuell wird die Steuerung ber externe 24

WARNUNG/ALARM 7, DC-berspannung:

In Par. 1-80 wurde als Stoppfunktion Motortest gewhlt, und es kann


am Umrichterausgang kein Motor gemessen werden. berprfen Sie die
Motorklemmen und die Einstellung in Par. 1-80.

Der Umrichter hat aufgrund einer berspannung im Zwischenkreis abgeschaltet.


berprfen Sie Netzspannung,

WARNUNG/ALARM 4, Netzunsymmetrie:

evtl. den Bremswiderstand (Option),

Es wurde zu hohes Ungleichgewicht in der Netzversorgung erkannt. Mgliche Ursachen: Eine fehlende Netzphase, zu hohe Unsymmetrie in der

86

Die Spannung (DC) im Umrichter-Zwischenkreis hat die interne UnterV versorgt. berprfen Sie die Netzspannung.

WARNUNG/ ALARM 3, Kein Motor:

Netzspannung

WARNUNG 6, DC-Spannung niedrig

Rampenzeiten (Par. 3-**),


Bremsfunktionen (Par. 2-10)

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6. Fehlersuche und -behebung


ALARM 15, Inkompatible Hardware:

und Motor/Last.

Eine installierte Option wird von der Steuerkartenfirmware nicht unterAlarm-/Warngrenzen:


3 x 200 - 240 3 x 380 - 500 3 x 525 - 600 V
V
V
[VDC]
[VDC]
[VDC]
Unterspannung
185
373
532
Unterer Spannungs205
410
585
grenzwert
Oberer Spannungs390/405
810/840
943/965
grenzwert (ohne/
mit Bremse)
berspannung
410
855
975

sttzt. Bitte wenden Sie sich an den Danfoss-Service.

Die angegebenen Spannungen sind die Zwischenkreisspannung des


Frequenzumrichters mit einer Toleranz von 5 %. Die entsprechende Netzspannung ist die Zwischenkreisspannung (Gleichstrom)
geteilt durch 1,35.

ist.

WARNUNG/ALARM 8, DC-Unterspannung:
Wenn die Zwischenkreisspannung (VDC) unter den unteren Spannungs-

ALARM 16, Kurzschluss:


Es wurde ein Kurzschluss an den Ausgangsphasen festgestellt.
berprfen Sie die Isolation des Motors und des Motorkabels. berprfen
Sie die Lastverhltnisse. Rcksetzen des Alarms nur nach Netz-Aus.
WARNUNG/ALARM 17, Steuerwort-Timeout:
In Par. 8-04 wurde eine Timeout-Funktion aktiviert, und die in Par. 8-03
eingestellte Zeit wurde berschritten (Kommunikationsfehler).
Die Warnung wird nur angezeigt, wenn Par. 8-04 NICHT auf AUS gesetzt
Wenn Par. 8-04 auf Stopp und Alarm eingestellt ist, erscheint eine Warnung, und der Frequenzumrichter fhrt herunter, bis er mit einem Alarm
abschaltet.
Erhhen Sie gegebenenfalls den Wert in Par. 8-03 Steuerwort Timeout-

Zeit.

grenzwert (siehe Tabelle) sinkt, prft der Frequenzumrichter, ob eine

WARNUNG 23, Interne Lfter:

externe 24 V-Versorgung angeschlossen ist.

Die Funktion ist ein zustzlicher Schutz, mit der geprft wird, ob Lfter

Wenn keine externe 24 V-Versorgung angeschlossen ist, schaltet der

vorhanden sind und laufen. Die Warnung kann in Par. 14-53 Lfterber-

Frequenzumrichter nach einer festgelegten Zeit (gerteabhngig) ab.

wachung deaktiviert [0] werden.

berprfen Sie die Netzspannung und die Einstellungen in Par. 14-1*.

WARNUNG 24, Externe Lfter:

WARNUNG/ALARM 9, Wechselrichterberlast:

Die Funktion ist ein zustzlicher Schutz, mit der geprft wird, ob Lfter

Der Frequenzumrichter schaltet aufgrund von berlastung (zu hoher

vorhanden sind und laufen. Die Warnung kann in Par. 14-53 Lfterber-

Strom ber zu lange Zeit, vgl. Typenschild/Motorstrom) gleich ab. War-

wachung deaktiviert [0] werden.

nung bei 98 %, Abschaltung bei 100 %. Alarm kann erst quittiert werden,

WARNUNG 25, Bremswiderstand Kurzschluss:

wenn der Wert unter 90 % gefallen ist.

WARNUNG: Bei einem Kurzschluss im Bremskreis wird die Bremselektro-

(Aktuelle berlastung kann in Par. 16-35 berprft werden.)

nik nicht mehr angesteuert, wodurch generatorisches Bremsen nicht

WARNUNG/ALARM 10, Motortemperatur ETR:

mehr mglich ist! Schalten Sie den Frequenzumrichter aus, und berpr-

Die ETR-Funktion hat eine thermische berlastung des Motors errechnet.

fen Sie den Bremswiderstand (siehe Par. 2-15 Bremswiderstand Test).

In Par. 1-90 kann das thermische berlast-Relais (ETR) aktiviert werden.

ALARM/WARNUNG 26, Bremswiderstand Leistungsgrenze:

Der Motor ist zu lange Zeit mit mehr als 100 % belastet worden. ber-

Die zum Bremswiderstand whrend der letzten 120 s bertragene Leis-

prfen Sie die Motortemperatur und die Parameter 1-24 und 1-90.

tung bersteigt dessen Grenzwert (bertragene Bremsleistung ist hher

WARNUNG/ ALARM 11, Motor Thermistor:

als 90 %). berprfen Sie Motor/Last, die Rampen in Par. 3-** und die

Der Thermistor hat ausgelst bzw. die Verbindung zum Thermistor ist

Leistungsdaten des Widerstands in Par. 2-11, 2-12, 2-13.

unterbrochen. In Par. 1-90 kann das thermische berlast-Relais (ETR)

ALARM/WARNUNG 27, Bremse IGBT-Fehler:

aktiviert werden. berprfen Sie die Verbindung zwischen Klemme 53/54

Whrend des Betriebs wird der Bremstransistor berwacht. Bei einem

(analoger Spannungseingang) und Klemme 50 (10-V-Eingang) bzw. zwi-

Kurzschluss wird die Bremsfunktion abgebrochen und die Warnung aus-

schen Klemme 18/19 (digitaler Eingang, nur PNP) und Klemme 50. Wenn

gegeben. Der Frequenzumrichter kann weiterhin betrieben werden, auf-

ein KTY-Sensor benutzt wird, prfen Sie, ob der Anschluss zwischen

grund des Kurzschlusses wird jedoch eine hohe Leistung an den

Klemme 54 und 55 korrekt ist.

Bremswiderstand abgegeben, auch wenn dieser nicht gebremst wird.

WARNUNG/ ALARM 12, Drehmomentgrenze:

Schalten Sie den Frequenzumrichter ab, und bauen Sie den Bremswider-

Das Drehmoment ist hher als der Wert in Parameter 4-16 (bei motor-

stand aus.

ischem Betrieb) bzw. in Parameter 4-17 (bei generatorischem Betrieb).

Dieser Alarm bzw. diese Warnung kann ebenfalls auftreten, wenn der

berprfen Sie Motor/Last und Par. 4-16, 4-17 und 4-25.

Bremswiderstand berhitzt. Klemme 104 bis 106 sind als Bremswider-

stand verfgbar. Zu Klixon-Eingngen siehe Abschnitt Temperaturschal-

WARNUNG/ALARM 13, berstrom:


Die Spitzenstromgrenze des Wechselrichters (ca. 200 % des Nennstroms)
wurde berschritten. Die Warnung wird ca. 8 bis 12 Sekunden lang angezeigt. Danach schaltet der Umrichter ab und gibt einen Alarm aus.
berprfen Sie Motor/Last und die Motordaten in Par. 1-**.
Bei Auswahl der erweiterten mechanischen Bremssteuerung kann die Ab-

ter Bremswiderstand.
Warnung: Bei einem Kurzschluss des Bremstransistors
besteht das Risiko einer erheblichen Leistungsbertragung zum Bremswiderstand (Brandgefahr!).

schaltung extern zurckgesetzt werden.


ALARM 14, Erdschluss:

ALARM/WARNUNG 28, Bremstest Fehler:

Es wurde ein Erdschluss zwischen einer Ausgangsphase und Erde fest-

Es wurde ein Fehler am Bremskreis festgestellt. berprfen Sie Brems-

gestellt. berprfen Sie die Isolation des Motors und des Motorkabels.

widerstand und Verdrahtung. Siehe auch Par. 2-15.

Der Alarm kann nur nach Netz-Aus quittiert werden.

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6. Fehlersuche und -behebung


ALARM 29, Umrichter bertemperatur:

519 Fehlende oder ungltige BarCode-Daten in EEPROM

Bei Schutzart IP20 oder IP21/NEMA 1 liegt die Abschaltgrenze fr die

1024 1279 CAN-Telegramm kann nicht gesendet wer-

Khlkrpertemperatur bei 95 C 5 C. Der Temperaturfehler kann erst

den. (1027 deutet auf mglichen Hardwarefehler hin)

dann quittiert werden, wenn die Khlkrpertemperatur 70 C +5 oC wie-

1281 Timeout beim digitalen Signalprozessor

der unterschritten hat.

1282 Die Versionen der Power Micro-Software stimmen nicht

Mgliche Ursachen:
-

Umgebungstemperatur zu hoch

Motorkabel zu lang

berein
1283 Die Versionen der EEPROM-Leistungsdaten stimmen
nicht berein
1284 Softwareversion des digitalen Signalprozessors kann

ALARM 30, Motorphase U fehlt:

nicht gelesen werden

Es wurde festgestellt, dass die Motorphase U am Umrichterausgang fehlt.

1299 Options-Software in Steckplatz A ist zu alt

berprfen Sie die Umrichter-Ausgangsklemmen, das Motorkabel und

1300 Options-Software in Steckplatz B ist zu alt

den Motor. Rcksetzen des Alarms nur nach Netz-Aus.

1311 Options-Software in Steckplatz C0 ist zu alt

ALARM 31, Motorphase V fehlt:

1312 Options-Software in Steckplatz C1 ist zu alt

Es wurde festgestellt, dass die Motorphase V am Umrichterausgang fehlt.

1315 Options-Software in Steckplatz A nicht untersttzt (nicht

berprfen Sie die Umrichter-Ausgangsklemmen, das Motorkabel und

zulssig)

den Motor. Rcksetzen des Alarms nur nach Netz-Aus.

1316 Options-Software in Steckplatz B nicht untersttzt (nicht

ALARM 32, Motorphase W fehlt:

zulssig)

Motorphase W zwischen Frequenzumrichter und Motor fehlt.

1317 Options-Software in Steckplatz C0 nicht untersttzt

berprfen Sie die Umrichter-Ausgangsklemmen, das Motorkabel und

(nicht zulssig)

den Motor. Rcksetzen des Alarms nur nach Netz-Aus.

1318 Options-Software in Steckplatz C1 nicht untersttzt


(nicht zulssig)

ALARM 33, Inrush Fehler:

1536 Es wurde eine AOC-Ausnahme festgestellt. Fehlerbehe-

Der Frequenzumrichter ist in kurzer Zeit zu oft eingeschaltet worden.

bungsinformationen auf LCP-Konsole

berprfen Sie eine eventuell vorhandene externe 24-V-Versorgung und

1792 DSP Watchdog ist aktiv. Behebung von Fehlern bei der

den Bremswiderstand. Wie viele Einschaltzyklen pro Minute zulssig sind,

bertragung von MOC-Leistungsdaten

ist den Allgemeinen technischen Daten zu entnehmen.

2049 Leistungsdaten neu gestartet

WARNUNG/ALARM 34, Feldbus-Fehler:

2315 Fehlende Software-Version von Antrieb

Der Feldbus auf der Optionskarte funktioniert nicht. Siehe Beschreibung

2816 Stapelberlauf an Steuerkartenmodul

im Handbuch zur Feldbus-Option.

2817 Planung langsame Aufgaben

WARNUNG/ALARM 36, Netzausfall:

2818 Schnelle Aufgaben

In Par. 14-10 wurde eine Netzausfall-Funktion eingestellt, und es wurde

2819 Parameter-Thread

ein Netzfehler festgestellt. berprfen Sie die Netzversorgung und Par.

2820 LCP-Stapelberlauf

14-10.

2821 berlauf an der seriellen Schnittstelle

Alarm 38, interner Fehler:

2822 berlauf an der USB-Schnittstelle

Es ist ein interner Fehler aufgetreten. Wenden Sie sich an den Danfoss-

3072-512 Parameterwert liegt nicht im zulssigen Grenzwertbe-

Service. Einige typische Alarmmeldungen:

reich. Fhren Sie eine Initialisierung durch. Parameternummer, die den Alarm ausgelst hat: Ziehen Sie vom
Code den Wert 3072 ab. Beispiel: Fehlercode 3238:

0 Die serielle Kommunikationsschnittstelle kann nicht ini-

3238-3072 = 166 (auerhalb des Grenzwertbereichs)

tialisiert werden. Schwerer Hardwarefehler

5123 Option in Steckplatz A: Hardware mit Steuerkartenhard-

256 Die EEPROM-Leistungsdaten sind beschdigt oder ver-

ware nicht kompatibel

altet

5124 Option in Steckplatz B: Hardware mit Steuerkartenhard-

512 Die EEPROM-Daten der Steuerkarte sind beschdigt

ware nicht kompatibel

oder veraltet

5125 Option in Steckplatz C0: Hardware mit Steuerkarten-

513 Timeout beim Lesen von EEPROM-Daten

hardware nicht kompatibel

514 Timeout beim Lesen von EEPROM-Daten

5126 Option in Steckplatz C1: Hardware mit Steuerkarten-

515 AOC erkennt EEPROM-Daten nicht

hardware nicht kompatibel

516 Schreiben in EEPROM nicht mglich, da ein Schreibvorgang durchgefhrt wird


517 Timeout fr den Schreibvorgang

5376-623 Unzureichender Speicher


1

518 Fehler im EEPROM


WARNUNG 40, Digitalausgang 27 ist berlastet
berprfen Sie die Last an Klemme 27, oder beseitigen Sie den Kurzschluss. Prfen Sie die Parameter 5-00 und 5-01.
WARNUNG 41, Digitalausgang 29 ist berlastet:
berprfen Sie die Last an Klemme 29, oder beseitigen Sie den Kurzschluss. Prfen Sie die Parameter 5-00 und 5-02.

88

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6. Fehlersuche und -behebung

WARNUNG 42, Digitalausgang X30/6 ist berlastet:

WARNUNG 62, Ausgangsfrequenz Grenze:

berprfen Sie die Last an Klemme X30/6, oder beseitigen Sie den Kurz-

Die in Par. 4-19 eingestellte Frequenzgrenze wurde berschritten. ber-

schluss. Prfen Sie Parameter 5-32.

prfen Sie Motor/Last, die Motordaten in Par. 1-** und ggfs. bei einer

WARNUNG 42, Digitalausgang X30/7 ist berlastet:

PID-Regelung das Istwertsignal und die Regelparameter in Par. 7-**.

berprfen Sie die Last an Klemme X30/7, oder beseitigen Sie den Kurz-

ALARM 63, Mechanische Bremse Fehler:

schluss. Prfen Sie Parameter 5-33.

Der Motorstrom hat whrend der eingestellten Startverzgerung (Par.

WARNUNG 47, 24-V-Versorgung - Fehler:

1-71) nicht den Wert zum Lften der mechanischen Bremse (Par. 2-20)

Die externe 24-V-DC-Backup-Stromversorgung ist mglicherweise ber-

berschritten. ACHTUNG: Falsche Einstellungen knnen zum ffnen der

lastet. Andernfalls wenden Sie sich an Ihre Danfoss-Vertretung.

Bremse oder Absturz der Last fhren!

WARNUNG 48, 1,8-V-Versorgung - Fehler:

WARNUNG 64, Motorspannung Grenze:

Bitte wenden Sie sich an den Danfoss-Service.

Die Belastung des Motors bei dieser Drehzahl wrde eine noch hhere
Motorspannung erfordern, die vom Umrichter nicht zur Verfgung gestellt

WARNUNG 49, Drehzahlgrenze:


Die aktuelle Motordrehzahl unter- oder berschreitet die Einstellungen in

werden kann.

Par.4-11 und 4-13. berprfen Sie Motor/Last und die Einstellungen in

WARNUNG/ALARM/ABSCHALTUNG 65, Steuerkarte bertem-

den Parametern.

peratur:
Es wurde eine bertemperatur an der Steuerkarte festgestellt. berpr-

ALARM 50, AMA-Kalibrierungsfehler:


Bitte wenden Sie sich an den Danfoss-Service.
ALARM 51, AMA-Motordaten berprfen:
Bitte berprfen Sie die Verschaltung am Motorklemmbrett und die Einstellung der Motordaten in Par. 1-20 bis 1-24.
ALARM 52, AMA Motornennstrom berprfen:
Bitte berprfen Sie die Verschaltung am Motorklemmbrett und die Einstellung der Motordaten in Par. 1-20 bis 1-24.
ALARM 53, AMA-Motor zu gro:

fen Sie die Umgebungsbedingungen und die eingebauten Khllfter.

WARNUNG 66, Temperatur zu niedrig:


Die Temperatur im Frequenzumrichter ist kleiner als 0 C. berprfen Sie
die Umgebungsbedingungen. Da auch ein Ausfall der Temperaturfhler
nicht ausgeschlossen werden kann, laufen die eingebauten Lfter auf
max. Drehzahl.
ALARM 67, Optionen neu:
Eine oder mehrere Optionen sind seit dem letzten Netz-Ein hinzugefgt
oder entfernt worden. Siehe auch Par. 15-6*.

Bitte berprfen Sie die Leistung des Motors am Typenschild und die
Einstellungen in Par. 1-20. Wenn der Motor mehrere Gren kleiner als
der Umrichter ist, kann keine AMA durchgefhrt werden.

ALARM 68, Sicherer Stopp:


Die Funktion Sicherer Stopp wurde durch die Steuerklemme 37 aktiviert
(Signal 0 V). Um den Betrieb wieder aufzunehmen, legen Sie 24 VDC an

ALARM 54, AMA-Motor zu klein:

Kl. 37, und setzen Sie den Alarm zurck (ber Bus, Digitaleingang oder

Bitte berprfen Sie die Leistung des Motors am Typenschild und die

durch Drcken von [RESET]).

Einstellungen in Par. 1-20. Wenn der Motor mehrere Gren kleiner als
der Umrichter ist, kann keine AMA durchgefhrt werden.

WARNUNG 68, Sicherer Stopp:


Die Funktion Sicherer Stopp wurde durch die Steuerklemme 37 aktiviert

ALARM 55, AMA-Daten auerhalb des Bereichs:

(Signal 0 V). Nach Deaktivieren des sicheren Stopps wird der Normalbe-

Die gefundenen Parameterwerte vom Motor liegen auerhalb des zuls-

trieb wieder aufgenommen. Warnung: Automatischer Wiederanlauf er-

sigen Bereichs. berprfen Sie die Motordaten in Par. 1-20 bis 1-25.

folgt!

ALARM 56, AMA Abbruch:

ALARM 70, Ungltige FC-Konfiguration:

Die AMA wurde durch den Benutzer abgebrochen.

Die aktuelle Kombination aus Steuerkarte und Leistungskarte ist ungltig.

ALARM 57, AMA-Timeout:

ALARM 71, PTC 1 Sicherer Stopp:

Die AMA-Funktion wurde in Par. 1-29 aktiviert, jedoch wurde kein Start-

Sicherer Stopp wurde von der MCB 112 PTC-Thermistorkarte aktiviert

signal (z. B. [Hand-on]-Taste) gegeben. Im Regelfall ist dies jedoch nicht

(Motor zu warm). Normaler Betrieb kann wieder aufgenommen werden,

kritisch.

wenn die MCB 112 wieder 24 V DC an Kl. 37 anlegt (wenn die Motor-

ALARM 58, AMA - Interner Fehler:

temperatur einen akzeptablen Wert erreicht) und wenn der Digitalein-

Bitte wenden Sie sich an den Danfoss-Service.

gang von der MCB 112 deaktiviert wird. Wenn dies geschieht, muss ein
Reset-Signal (ber Bus, Digitalein-/-ausgang oder durch Drcken von

WARNUNG 59, Stromgrenze:


Der Ausgangsstrom hat den Grenzwert in Par. 4-18 berschritten und der
Strom wird begrenzt. Bitte wenden Sie sich an den Danfoss-Service.

[Reset]) gesendet werden.


WARNUNG 71, PTC 1 Sicherer Stopp:
Sicherer Stopp wurde von der MCB 112 PTC-Thermistorkarte aktiviert

WARNUNG 61, Drehgeber-Fehler:


Eine Abweichung zwischen der berechneten Drehzahl und der Drehzahlmessung vom Istwertgeber. Die Einstellung Warnung/Alarm/Deaktivierung fr diese Funktion erfolgt in Par. 4-30. In Par. 4-31 wird die
akzeptierte Abweichung eingestellt und die Zeit, wie lange der Drehzahlfehler berschritten sein muss, in Par. 4-32. Whrend eines Inbetriebnahmevorgangs kann die Funktion wirksam sein.

(Motor zu warm). Normaler Betrieb kann wieder aufgenommen werden,


wenn die MCB 112 wieder 24 V DC an Kl. 37 anlegt (wenn die Motortemperatur einen akzeptablen Wert erreicht) und wenn der Digitaleingang von der MCB 112 deaktiviert wird. Warnung: Automatischer
Wiederanlauf erfolgt.
ALARM 72, Gefhrlicher Fehler:
Sicherer Stopp mit Abschaltblockierung. Unerwartete Signalpegel bei sicherem Stopp und Digitaleingang von der MCB 112 PTC-Thermistorkarte.

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

89

VLTAutomationDrive FC 300 Produkthandbuch

6. Fehlersuche und -behebung


ALARM 80, Initialisiert:
Der Frequenzumrichter wurde manuell (3-Finger-Methode) oder ber
Par. 14-22 initialisiert (Werkseinstellung der Parameter laden).
ALARM 90, Drehgeber Fehler:
berprfen Sie die Verbindung zur Drehgeberoption, und ersetzen Sie die
MCB 102 oder MCB 103, falls erforderlich.
ALARM 91, Falsche Einstellungen fr Analogeingang 54:
Schalter S202 muss auf U (Spannungseingang) eingestellt sein, wenn
ein KTY-Thermistor angeschlossen ist.
ALARM 250, Neues Ersatzteil:
Die Leistungs-/SMPS-Karte wurde ausgetauscht. Der Typencode des Frequenzumrichters muss im EEPROM wiederhergestellt werden. Whlen Sie
den richtigen Typencode in Par. 14-23 vom Typenschild des Gerts. Whlen Sie abschlieend unbedingt In EEPROM speichern.
ALARM 251, Typencode neu:
Der Frequenzumrichter hat einen neuen Typencode.

90

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

Index

Index
2
24 V Dc Backup

A
Abgeschirmt

36

Abkrzungen

Ableitstrom

Abmessungen

17

Abschirmblech

25

Alarmmeldungen

83

Allgemeine Warnung

Ama

38

Analogausgang

79

Analogeingnge

78

Ausbrechen Von Zustzlichen ffnungen Fr Kabeldurchfhrungen

22

Ausgangsleistung (u, V, W)

77

Autom. Motoranpassung

46

Automatische Motoranpassung (ama)

38

B
Bremssteuerung

87

D
Dc-spannung

86

Devicenet

Digitalausgang

79

Digitaleingnge:

77

Drehmomentkennlinie

77

Drehzahl Auf/ab

34

E
Elektrische Installation

32, 35

Entsorgungshinweise

Etr

87

F
Fehlerstrom-schutzeinrichtungen

G
Grafikdisplay

41

H
Hauptreaktanz

46

I
Installation Nebeneinander

16

Ip21 / Typ 1

K
Kabellngen Und -querschnitte

80

Keine Ul-konformitt

28

Klemmen

35

Kty-sensor

87

Khlbedingungen

16

L
Lc-filter

27

Lcp 101

42

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

91

Index

VLTAutomationDrive FC 300 Produkthandbuch

Lcp 102

41

Lcp-bedieneinheit

41

Leds

41, 42

M
Max. Sollwert

47

Mct 10

Mechanische Bremssteuerung

40

Mechanische Installation

16

Minimaler Sollwert

47

Motoranschluss

25

Motorausgang

77

Motornenndrehzahl, 1-25

45

Motornennfrequenz

45

Motornennleistung

44

Motornennspannung

45

Motornennspannung, 1-22

44

Motornennstrom

45

Motor-typenschild

38

Motor-berlastschutz

81

N
Netzanschluss

22

Netzversorgung (l1, L2, L3)

77

Numerischen Lcp-bedieneinheit

42

Numerisches Display

42

P
Parallelschaltung Von Motoren

40

Potentiometer-sollwert

34

Profibus

Puls Start/stopp

33

Puls-/drehgebereingnge

79

R
Rampenzeit Ab 1

47

Rampenzeit Auf 1

47

Relaisausgnge

80

Reparaturarbeiten

S
Schalter S201, S202 Und S801

36

Schutz

28

Schutz Und Funktionen

81

Serielle Schnittstelle

80

Sicherer Stopp

Sicherheitshinweise

Sicherungen

28

Spannungsbereich

77

Spannungssollwert ber Potentiometer

34

Sprache

44

Sprachpaket 2

44

Sprachpakets 1

44

Sprachpakets 3

44

Sprachpakets 4

44

Standardeinstellungen

48

Start/stopp

33

Statorstreureaktanz

46

Steueranschlsse

32

Steuerkabel

35, 36

Steuerkarte, +10 V Dc-ausgang

79

Steuerkarte, 24 V- Dc-ausgang

79

Steuerkarte, Rs 485 Serielle Schnittstelle

79

Steuerkarte, Usb (serielle Schnittstelle)

80

92

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

VLTAutomationDrive FC 300 Produkthandbuch

Index

Steuerkartenleistung

81

Steuerungseigenschaften

81

Symbole

T
Thermischer Motorschutz

40

Typenschild

38

Typenschilddaten

38

U
Umgebung

81

Unerwarteten Anlaufs

W
Warnungen

83

Wellenleistungsniveau

Z
Zugang Zu Den Steuerklemmen

31

Zulassungen

Zustandsmeldungen

41

Zwischenkreis

86

MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.

93

Equipment for water


and steam supply

Operating Instructions

Return flow temperature safeguard


for shell hot water generators

E016
Version 2 (07/09)

Contents
1

Scope of the Operating Instructions ........................................................................................................................ 1

Use in Accordance with Regulations ....................................................................................................................... 1

Safety .......................................................................................................................................................................... 2

Operating and Maintenance Staff ............................................................................................................................. 2

General Risks and Accident Prevention .................................................................................................................. 2

Description of Structure and Function / Description of Process ........................................................................... 2

Technical Data (Dimensions, Weight, Operating Conditions)................................................................................ 2

Assembly .................................................................................................................................................................... 3

8.1

Three-way regulator valve assembly (in case of return flow temperature maintenance).............................................. 3

8.2

Assembly instructions for return flow temperature boosting ......................................................................................... 4

8.2.1

Orifice........................................................................................................................................................................... 4

8.2.2

Flow monitor and temperature limiter ........................................................................................................................... 5

Electrical Installation ................................................................................................................................................. 5

10

Controls ...................................................................................................................................................................... 5

11

Start-up ....................................................................................................................................................................... 5

12

Measures in the event of unusual observations and operating faults .................................................................. 5

13

Care and Maintenance ............................................................................................................................................... 6

14

Replacement Parts ..................................................................................................................................................... 6

Scope of the Operating Instructions

These Operating Instructions contain basic information. They apply in combination with the following operating instructions:

A002 Basic Safety Instructions

C014 Shell boilers for the generation of hot water

Pump operating instructions

Operating instructions for the motor-driven three-way control valve (in the event of return flow temperature
maintenance)

Operating Instructions on the motorized shut-off valve (in case of return flow temperature boosting)

For the operation of the system as a whole, the operating instructions for the individual components are binding along with
the relevant statutory provisions and official requirements.

Use in Accordance with Regulations

The return flow temperature safeguard on a hot water generator is used to prevent excessive temperature differences
between the boiler forward and return flows and boiler return flow temperatures that are too low, in order to avoid the

Page 1 of 6

Operating Instructions

Return flow temperature safeguard


for shell hot water generators

E016
Version 2 (07/09)

temperature falling below the dew point and the resultant corrosion in the boiler. The temperatures may not fall below the
values for boiler forward and return flow temperatures laid down in the order confirmation (except for start-up operation).

Safety

Please read the Operating Instructions:

A002 Basic Safety Instructions

Operating and Maintenance Staff

Please read the Operating Instructions:

A002 Basic Safety Instructions

General Risks and Accident Prevention

Please read the Operating Instructions:

A002 Basic Safety Instructions

Description of Structure and Function / Description of Process

The return flow temperature safeguard on a hot water generator can be realised by maintaining or raising the return flow
temperature.

Maintaining the return flow temperature:


The system for maintaining the return flow temperature consists of the main components boiler circulating pump, motordriven three-way regulating valve and return flow temperature regulator (see Data Sheet DA114). This type of system
can only be used if a hydraulic diplexer or a differential pressure-free distributor (supply flow distributor and return flow
collector with hydraulic balancer) are provided on the network side. The boiler circulating pump is responsible for
pumping round the water in the boiler circle (boiler diplexer boiler, or boilers supply flow distributor return flow
collector boiler). The heat produced in the boiler is made available to the diplexer or the supply flow distributor. It is
crucially important for the working life of the boiler that, during operation of the firing, the boiler circulating pump is
running. If there is a fault in the boiler circulating pump, the burner must be switched off. If this is not done, the heat
produced in the boiler will not be taken away, resulting in local overheating, which can quickly cause boiler damage.
The motor-driven three-way regulating valve is controlled by the return flow temperature regulator. If the network return
flow temperature falls, a part-flow from the supply flow of the boiler is mixed with the return flow to the boiler in order to
reach the set boiler return flow temperature. In extreme cases and if the boiler is started up from cold, the motor-driven
three-way regulating valve can be opened completely in the direction of the boiler circuit.

Raising the return flow temperature.


The system for raising the return flow temperature consists of the main components of a booster pump and return flow
temperature regulator (see Data Sheet DA115). this type of system is logical if only a supply flow distributor and a return
flow collector are used on the network side. Network pumps are responsible for removing the heat from the boiler.
the booster pump is controlled by the return flow temperature regulator. In the simplest cases, the booster pump is
switched parallel to the burner. This means that the booster pump always runs when the firing is also in operation.

Technical Data (Dimensions, Weight, Operating Conditions)

The technical data are fixed in the order confirmation. A copy of the technical data forms part of the delivery documentation
and is generally found in Register M. For further information, please consult the enclosed data sheets.

Page 2 of 6

Operating Instructions

Return flow temperature safeguard


for shell hot water generators

E016
Version 2 (07/09)

Assembly

Please read the Operating Instructions:

C014 Shell boilers for the generation of hot water

If the return flow temperature safeguard is not supplied as a completely assembled module, the pipeline diagrams for
maintaining the return flow temperature DA114 or for raising the return flow temperature DA115 must be followed during
installation. When installing all valves, pay attention to the direction of flow.

8.1

Three-way regulator valve assembly (in case of return flow temperature maintenance)

The position of the connections on the water side should particularly be observed during assembly and electrical connection
of the motorized three-way regulator valve with return flow temperature maintenance:
A

network return flow

admixing line

AB

boiler return flow

If the piping parts are not delivered by Loos International it must be observed that the distance between the admixing line
orifice and the boiler inlet is dimensioned sufficiently to ensure complete water mixing upstream of the boiler inlet and the
formation of streaks is avoided.

Page 3 of 6

Operating Instructions

Return flow temperature safeguard


for shell hot water generators

E016
Version 2 (07/09)

8.2

Assembly instructions for return flow temperature boosting

D13.020
D13.004
D13.020

D13.008

A
D13.003
D13.004

D13.006

B
D13.005
D13.020

D13.004

D13.020

D13.008

D10.004
D10.013

D10.004

Temperature limiter

D13.005

Shut-off valve

D10.013

Flow monitor

D13.006

Lifting pump

D13.003

Shut-off valve

D13.008

Orifice (if available)

D13.004

Non-return valve

D13.020

Seal

Case A

Nominal diameters of lifting pump and


admixing line are equal

Fall B

Nominal diameters of lifting pump and


admixing line are different

Figure 1: schematic diagram of return flow temperature boosting

8.2.1

Orifice

In some cases the return flow temperature boosting equipment contains an orifice (D13.008), see Figure 1. This orifice
should be installed directly downstream of the pump (in flow direction) between two seals. In case A (equal nominal width of
lifting pump and admixing line) it is installed between the flange of the admixing pump and the non-return valve. In case B
(different nominal width of lifting pump and admixing line) the orifice is installed between flange and admixing pump and the
flange adapter.

Page 4 of 6

Operating Instructions

Return flow temperature safeguard


for shell hot water generators

E016
Version 2 (07/09)

Important! Ensure that the orifice is installed centrally between the two flanges.

8.2.2

Flow monitor and temperature limiter

The flow monitor (D10.013) and the temperate limiter (D10.004) must be installed upstream of the admixing line branching
point (see Figure 1). Installation of these safety devices upstream of the point where the admixing line branches off from the
supply flow line is the only way to ensure monitoring of the necessary minimum flow and the maximum admissible
temperature even with exclusive flow in the boiler circuit when the motorized shut-off valve is closed during return flow.
Warning! Faulty installation of the flow monitor or temperature limiter can cause severe damage to the boiler.
The consequence can be total loss of the boiler. In extreme cases, severe damage to the system may result and
people could suffer fatal injuries.

Electrical Installation

Please read the Operating Instructions:

C014 Shell boilers for the generation of hot water

10 Controls
Note: If the system's controls are not supplied by Loos International, the system must be operated according to
the operating instructions for the controls that are actually used.
Notes on the controls are given in the circuit diagram and the operating instructions for the controls and process technology
in Registers G and/or H.

11 Start-up
Please read the Operating Instructions:

C014 Shell boilers for the generation of hot water


Important! If the return flow temperature safeguard works by raising the return flow temperature, take care
during initial commissioning that the boiler is powered up at the beginning in its own boiler circulation at burner
low load and that the shut-off valves to the network are only opened slowly afterwards, so that only as much cold
network water flows into the boiler to prevent the temperature falling below the minimum boiler intake
temperature.

12 Measures in the event of unusual observations and operating faults


If anything unusual is observed and/or operating faults are displayed, the following table provides initial information on
repair:

Observation/fault:

Mean boiler return flow temperature is not reached

Cause

Repair

Performance regulation on released for low load

Release performance regulation in the regulation


menu

By whom?

Page 5 of 6

Operating Instructions

Return flow temperature safeguard


for shell hot water generators

E016
Version 2 (07/09)

Cause

Repair

Too much heat being removed from boiler

Throttle return flow water volume

Observation/fault:

By whom?

Return flow temperature too low, or return flow temperature monitoring triggered

Cause

Repair

Return flow temperature too low

Check mixer pump or boiler circulating pump.

By whom?

If using return flow temperature maintenance, check


the motor-driven three-way regulating valve.

13 Care and Maintenance


For general maintenance instructions, please read the Operating Instructions:
Please read the Operating Instructions:

C014 Shell boilers for the generation of hot water

the relevant operating instructions of the manufacturer of the valves and pumps installed in the return flow temperature
safeguard system, listed in Register K

14 Replacement Parts
For spare parts orders or spare parts inquiries, please use the special ordering and inquiries form L006 After Sales Services
in Register L (Forms).
Alternatively, you can place your spare parts order or your spare parts offer online at www.loos.de / Kundendienst /
Ersatzteilversorgung (customer service / spare parts supply).

Page 6 of 6

Operating Instructions
1146.81/8-10

Etaline
In-line Pumps

Order No.:
Type Series:

Etaline

Operating Instructions
These
operating
instructions
contain
fundamental information and precautionary
notes. Please read the manual thoroughly prior
to installation of unit, electrical connection and
commissioning. It is imperative to comply with all
other operating instructions referring to
components of individual units.
This manual shall always be kept close to the
units location of operation or directly on the
pump set.

Etaline
D
GB
F
E
P
I
CZ
DK
EST
H
LT
LV
N
NL
PL
S
FIN
SK
SLO
GR

Erklrung des Herstellers im Sinne der EU-Maschinenrichtlinie 98/37/EG


Declaration by the manufacturer as defined by machinery directive 98/37/EC
Dclaration du fabricant conformment la directive CE relative aux machines 98/37/CE
Declaracin del fabricante conforme con la Directiva UE sobre mquinas 98/37/UE
Declarao do Fabricante segundo a directiva CE 98/37/CE
Dichiarazione del costruttore ai sensi della direttiva CE 98/37/CE relativa a macchinari
Prohlen vrobce ve smyslu smrnice EU pro stroje 98/37/EU
Fabrikantens erklring i henhold til EU--lovgivning om maskiner 98/37/EU,
Tootja deklaratsioon EU-seadmete direktiivi 98/37/EC jrgi
Gyrti nyilatkozat 98/37 EU-irnyelv rtelmben
Gamintojo pareikimas pagal ES 98/37/EG Main direktyvos II B priedo nuostatas
Raotaja deklarcija saska ar manbves direktvu 98/37/ES
Erklring fra produsent iflge EUs--maskindirektiv 98/37/EC
Verklaring van de fabrikant inzake richtlijn 98/37/EG, voor machines
Deklaracja producenta zgodnie z dyrektywa UE dotyczaca urzadzen nr 98/37/UE
Tillverkardeklaration enligt EU:s Maskindirektiv 98/37/EC
Valmistajanvakuutus EU-konedirektiivin 98/37/ETY mukaan
Prehlsenie vrobcu v zmysle Smernice E 98/37/EG pre stroje
Izjava proizvajalca kot definira ES direktiva 98/37/ES

D
GB
F
E
P
I
CZ
DK
EST
H

Hiermit erklren wir, dass die Pumpe


Herewith we declare that the pump
Par la prsente, nous dclarons que la pompe
Por la presente declaramos que la bomba
Com a presente, declaramos que a bomba
Si dichiara che la pompa
Tmto prohlaujeme, e erpadlo
Hermed erklres, at pumpetype
Kinnitame, et pump
Igazol juk, hogy a szivatty

LT
LV
N
NL
PL
S
FIN
SK
SLO
GR

iuo ratu mes pareikiame, kad siurblys


Ar o deklarjm, ka sknis
Herved erklrer vi at pumpen
Hiermee verklaren wij, dat de pomp
Niniejszym deklarujemy, e pompa
Hrmed frskrar vi att pumpen
Vakuutamme, ett pumppu
Tmto prehlasujeme, e erpadlo
Izjavljamo, da je rpalka
m

Etaline
D

zum Einbau in eine Maschine 1) / Zusammenbau mit anderen Maschinen zu einer Maschine 1) bestimmt ist. Ihre
Inbetriebnahme ist solange untersagt, bis festgestellt wurde, da die Maschine, in die diese Pumpe eingebaut werden
soll, bzw. mit der diese Pumpe zusammengebaut werden soll, den Bestimmungen der EU--Richtlinie in der jeweils
gltigen Fassung entspricht.

GB

is intended to be incorporated into machinery 1) or assembled with other machinery to constitute machinery 1) covered
by this directive and must not be put into service until the machinery into which it is be incorporated or with which it is
to be assembled has been declared in conformity with the provisions of the directive in its current version.

est destine tre incorpore dans une machine 1) / tre assemble avec dautres machines afin de constituer une
machine 1) et que sa mise en service est interdite avant que la machine dans laquelle elle sera incorpore / avec laquelle
elle sera assemble nait t dclare conforme aux dispositions de la directive, dans la version respective en vigueur.

Etaline
E

est destinada a ser incorporada en una mquina 1) /a ser ensamblada con otras mquinas para conformar una
mquina 1) y que su puesta en servicio est prohibida antes de que la mquina en la que vaya a ser incorporada o con la
que vaya a ser ensamblada haya sido declarada conforme con las disposiciones de la Directiva en su redaccin vigente.

se destina a ser instalada numa mquina 1) / ser montada com outras mquinas de modo a formar uma mquina 1)
coberta por esta directiva e que proibida a sua colocao em servio da mesma antes de a mquina em que essa
bomba vier a ser incorporada/montada ser declarada em conformidade com o disposto na directiva CE na sua verso
corrente.

destinata al montaggio in una macchina 1) / allassemblaggio con altre macchine a formare un macchinario 1) e che
la sua messa in marcia vietata fin quando non sar stata accertata la conformit del macchinario, nel quale questa
pompa viene montata o col quale detta pompa deve venir assiemata, alle disposizioni delle direttiva CE nella versione
vigente.

CZ

je ureno pro mont do stroje 1) / pro mont s jinm strojem pro kompletaci stroje 1). Jeho uveden do provozu je
zakzno do t doby, dokud nebude zjiteno, e stroj, ve kterm m bt erpadlo zamontovno, pop. kter m bt s
tmto erpadlem smontovn, odpovd ustanovenm smrnice EU v prv platnm znn.

DK

er bestemt til indbygning i en maskine 1) / samling med andre maskiner med henblik p at udgre en maskine 1) og at
igangstningen forbydes indtil det er konstateret, at maskinen, som vor pumpe skal monteres i, svarer til
EU--bestemmelserne af EU--lovgivningen til en hver tid gyldig udgave.

EST

on meldud paigaldamiseks seadmele 1) / komplekteerimiseks muude seadmetega heks seadmeks 1). Pumba
kasutuselevtt on keelatud kuni on selgunud, et seade kuhu pump paigaldatakse vi kuhu pump hendatakse , vastab
EU jusolevatele normidele

egy gpbe trtn beptsre 1) / egy msik gppel trtn sszeptsre 1) alkalmas. zembehelyezse mindaddig
tiltott, mg megllaptsra nem kerl, hogy a gp, ahova a szivatty kerl, illetve amivel a szivatty sszeptsre ker,
l a kvetkez rendelkezseknek a mindenkor rvnyes vltozat szerint megfelel

LT

numatytas taisyti mainoje 1) / sumontuoti kartu su kitomis mainomis sukuriant vien main 1). Atiduoti naudoti
neleidiama tol, kol nebus nustatyta, kad maina, kuri turi bti taisytas is siurblys arba su kuria is siurblys bus kartu
montuojamas, atitinka ES direktyvos galiojanios redakcijos nuostatas.

LV

Paredzta iebvanai iekrta 1) vai savienoanai ar citu iekrtu lai izveidotu agregtu 1) un to nedrkst nodot
ekspluatacij ldz iebvtas vai pievienotas iekrtas deklaranas brdim saska ar spk esom direktvm

er bestemt for montering i en maskin 1) / for sammenbygning med andre maskiner til en maskin 1). Igangkjring skal ikke
skje, fr det er klargjort at maskinen som pumpen skal monteres i, h.h.v. som pumpen skal bygges sammen med oppfyller
kravene i EUs retningslinjer i den til enhver tid gjeldende utgave.

NL

ertoe bestemd is, ingebouwd te worden in een machine 1) / samengebouwd wordt met andere machines tot n machine
1) en dat het in gebruik stellen verboden is, voordat vastgesteld is, dat de machine, waarin deze pomp wordt ingebouwd,
in overeenstemming met de bepalingen van de richtlijn is.

PL

jest przewidziana do zabudowy w urzdzeniu 1) / do wsplnej zabudowy z innym urzdzeniem jako cao 1).
Uruchomienie nie jest moliwe do czasu, kiedy nie zostanie stwierdzone, e urzdzenie, w ktrym ma zosta
zabudowana pompa, wzgldnie w przypadku wsplnej zabudowy pompy z tym urzdzeniem, odpowiada przepisom
wytycznych UE w wersji obowiazujcej w danej chwili

r avsedd fr inbyggnad i en maskin 1) / montering med annan maskin fr att utgra en maskin 1). Idrifttagning fr inte
ske frrn klarstllts att maskinen, i vilken pumpen skall inbyggas respektive med vilken denna pump skall
sammanbyggas, r tillverkad i verensstmmelse med EU:s ifrgavarande gllande riktlinjer.

FIN

on tarkoitettu asennettavaksi koneeseen 1) / koottavaksi muiden koneiden kanssa yhdeksi koneeksi 1). Pumpun
kyttnotto on kielletty siihen saakka, kunnes on todettu, ett kone, johon tm pumppu on tarkoitus asentaa tai johon
pumppu on tarkoitus yhdist, vastaa EU-direktiivi kulloinkin voimassa olevassa muodossa.

SK

Zabudovanie do stroja 1) / zmontovanie s inmi strojmi do jednho stroja 1) je uren. Uvedenie do prevdzky je mon
a po zisten, e mechanizmy, ktor maj by do erpadla zabudovan, prp. S erpadlom zmontovan, zodpovedaj
platnmu obsahu smernice E.

SLO

namenjena za vgradnjo v stroje 1) ali zdruitev z ostalimi stroji v enoten stroj 1). Njena uporaba je prepovedana, dokler
ni potrjeno, da stroj, v katerega naj bi bila rpalka vgrajena oz. naj bi bil z njo skupaj zdruen, ustreza doloilom direktiv
ES v njeni trenutno veljavni obliki.

GR

Etaline

Angewendete harmonisierte Normen, insbesondere


Applied harmonized standards, in particular
Normes harmonises utilises, notamment
Normas concordantes aplicadas; en especial
Normas harmonizadas utilizadas, em particula
Norme armonizzate applicate, in particolare
Pouit harmonizovan normy, zejmna
De harmoniserde standarder, der er blevet anvendt,
er i srdeleshed
EST Kohaldatud rahvusvahelised tehnilised normid, eriti
H
Alkalmazott harmonizlt szabvnyok, klnsen
D
GB
F
E
P
I
CZ
DK

Taikyti suderintieji standartai, ir ypa:


Pielietoti saskaotie standarti, piemram
Anvendte harmoniserte normer, spesielt
Gebruikte geharmoniseerde normen, in het bijzonder:
Normy zharmonizowane, a zwaszcza
Tillmpade harmoniserade standarder, speciellt
Sovelletut, harmonisoidut normit, erityisesti
Pouit harmonizovan normy, najm
Veljavnim usklajenim standardom, e posebej
j m
j,

LT
LV
N
NL
PL
S
FIN
SK
SLO
GR

EN 809, EN ISO 12100--1, EN ISO 12100--2


EN 1050

01.07.2005

KSB Aktiengesellschaft
Leiter Produktentwicklung /
Head of Product Development / Responsable Dveloppement Produits
Pumpen fr Industrietechnik /
Pumps for Industrial Applications / Pompes pour lIndustrie
KSB Aktiengesellschaft, Johann-Klein-Str. 9, D-67225 Frankenthal

1)

D
GB
F
E
P
I
CZ
DK
EST
H

Nichtzutreffendes streichen.
Delete if not applicable.
Rayer la mention inutile.
Tchese lo que no se aplica.
Ricar o que no for aplicvel.
Cancellare ci che non interessa.
Nehodc se krtnte.
Det ikke passende streges.
Mittevajalik tmmata maha.
A nem megfelelt thzni.

LT
LV
N
NL
PL
S
FIN
SK
SLO
GR

Ubraukti netinkam variant.


nevajadzgo izslgt.
Stryk det som ikke passer.
Doorhalen, wat niet van toepassing is.
Niepotrzebne skreli.
Det icke tillmpliga verstrykes.
Tarpeeton yliviivataan.
Nehodiace sa vymaza.
Prertajte, kar ne ustreza.

Etaline

Contents
Page
Declaration of Conformity

General

2
2.1
2.2
2.3
2.4
2.5
2.6

6
6
6
6
6
6

2.8

Safety
Marking of Instructions in the Manual
Personnel Qualification and Training
Non-compliance with Safety Instructions
Safety Awareness
Safety Instructions for the Operator / User
Safety Instructions for Maintenance, Inspection
and Installation Work
Unauthorised Modification and Manufacture of
Spare Parts
Unauthorised Modes of Operation

3
3.1
3.2

Transport and Interim Storage


Transport
Interim Storage / Preservation

7
7
7

4
4.1
4.2
4.3
4.4
4.5

Description of the Product and Accessories


Technical Specification
Designation
Design Details
Accessories
Noise Characteristics

7
7
7
8
8
8

5
5.1
5.2
5.3
5.4
5.5
5.5.1
5.5.2
5.5.3

Installation at Site
Safety Regulations
Checks to Be Carried out Prior to Installation
Installing the Unit
Connecting the Piping
Connection to Power Supply
Connecting the Motor
Setting the Time Relay
Checking the Direction of Rotation

8
8
8
8
8
8
9
9
9

2.7

7
7
7

Page
6
6.1
6.1.1
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.3
6.3.1
6.3.2
6.4

Commissioning, Start-up / Shutdown


Commissioning
Priming and Venting the Pump
Operating Limits
Temperature of Medium Handled
Switching Frequency
Minimum Flow
Density of the Medium Handled
Tightening Torques
Shutdown / Storage / Preservation
Storage of New Pumps
Measures to Be Taken for Prolonged Shutdown
Returning to Service after Storage

9
9
9
9
9
10
10
10
10
10
10
10
10

7
7.1
7.2
7.2.1
7.2.2
7.2.2.1
7.2.2.2
7.2.2.3

Maintenance / Repair
General Instructions
Maintenance / Inspection
Supervision of Operation
Lubrication and Lubricant Change
Lubrication
Grease Quality / Grease Change
Deep-groove Ball Bearings / Lubricant Quantity
-- for KSB IEC motor
Drainage / Disposal
Dismantling
Fundamental Instructions and Recommendations
Preparations for Dismantling
Pump
Mechanical Seal
Reassembly
Pump
Mechanical Seal
Motor for Etaline GN, MN
Spare Parts Stock
Interchangeability of Etaline and Etabloc
Components and Interchangeability of
Components among Each Other
Ordering Spare Parts
Recommended Spare Parts Stock for 2 Years
Continuous Operation in Accordance with
VDMA 24 296

10
10
10
10
11
11
11

Trouble-shooting

15

9
9.1
9.2
9.3

Relevant Documentation
Typical Installation Positions
Exploded Views / Lists of Components
Sectional Drawing

16
16
18
20

7.3
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.5
7.5.1
7.5.2
7.5.3
7.6
7.6.1
7.6.2
7.6.3

11
11
11
11
11
11
12
12
12
12
12
13
13
14
14

Etaline
1

General

Caution
This KSB pump has been developed in accordance with
state-of-the-art technology; it is manufactured with utmost care
and subject to continuous quality control.
These operating instructions are intended to facilitate
familiarisation with the pump and its designated use.
The manual contains important information for reliable, proper
and efficient operation. Compliance with the operating
instructions is of vital importance to ensure reliability and a long
service life of the pump and to avoid any risks.
These operating instructions do not take into account local
regulations; the operator must ensure that such regulations are
strictly observed by all, including the personnel called in for
installation.
This pump / unit must not be operated beyond the limit values
specified in the technical documentation for the medium
handled, capacity, speed, density, pressure, temperature and
motor rating. Make sure that operation is in accordance with the
instructions laid down in this manual or in the contract
documentation.
The name plate indicates the type series / size, main operating
data and order / ident. No.; please quote this information in all
queries, repeat orders and particularly when ordering spare
parts.
If you need any additional information or instructions exceeding
the scope of this manual or in case of damage please contact
KSBs nearest customer service centre.

Safety

These operating instructions contain fundamental information


which must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read
and understood both by the installing personnel and the
responsible trained personnel / operators prior to installation
and commissioning, and it must always be kept close to the
location of operation of the machine / unit for easy access.
Not only must the general safety instructions laid down in this
chapter on Safety be complied with, but also the safety
instructions outlined under specific headings.

2.1

Marking of Instructions in the Manual

The safety instructions contained in this manual whose


non-observance might cause hazards to persons are specially
marked with the symbol

general hazard sign to ISO 7000 -- 0434.


The electrical danger warning sign is

safety sign in accordance with IEC 417 -- 5036.

The word
Caution
is used to introduce safety instructions whose non-observance
may lead to damage to the machine and its functions.
Instructions attached directly to the machine, e.g.
-- arrow indicating the direction of rotation
-- markings for fluid connections
must always be complied with and be kept in perfectly legible
condition at all times.

2.2

Personnel Qualification and Training

2.3

Non-compliance with Safety Instructions

2.4

Safety Awareness

2.5

Safety Instructions for the Operator / User

All personnel involved in the operation, maintenance,


inspection and installation of the machine must be fully qualified
to carry out the work involved.
Personnel responsibilities, competence and supervision must
be clearly defined by the operator. If the personnel in question
is not already in possession of the requisite know-how,
appropriate training and instruction must be provided. If
required, the operator may commission the manufacturer /
supplier to take care of such training. In addition, the operator
is responsible for ensuring that the contents of the operating
instructions are fully understood by the responsible personnel.

Non-compliance with safety instructions can jeopardise the


safety of personnel, the environment and the machine itself.
Non-compliance with these safety instructions will also lead to
forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
-- failure of important machine / unit functions
-- failure of prescribed maintenance and servicing practices
-- hazard to persons by electrical, mechanical, thermal and
chemical effects
-- hazard to the environment due to leakage of hazardous
substances.

It is imperative to comply with the safety instructions contained


in this manual, the relevant national health and safety
regulations and the operators own internal work, operation and
safety regulations.

-- Any hot or cold components that could pose a hazard must


be equipped with a guard by the operator.
-- Guards which are fitted to prevent accidental contact with
moving parts (e.g. motor fan hood) must not be removed
whilst the machine is operating.
-- Leakages (e.g. at the shaft seal) of hazardous media
handled (e.g. explosive, toxic, hot) must be contained so as
to avoid any danger to persons and the environment.
Pertinent legal provisions must be adhered to.
-- Electrical hazards must be eliminated. (In this respect refer
to the relevant safety regulations applicable to different
countries and/or the local energy supply companies.)

Etaline
2.6

Safety Instructions for Maintenance,


Inspection and Installation Work

The operator is responsible for ensuring that all maintenance,


inspection and installation work be performed by authorised,
qualified specialist personnel who are thoroughly familiar with
the manual.
The pump must have cooled down to ambient temperature,
pump pressure must have been released and the pump must
have been drained.
Work on the machine must be carried out only during standstill.
The shutdown procedure described in the manual for taking the
machine out of service must be adhered to without fail (see
chapter 6).
Pumps or pump units handling media injurious to health must
be decontaminated.
Immediately following completion of the work, all
safety-relevant and protective devices must be re-installed
and/or re-activated.
Please observe all instructions set out in chapter 6.1
Commissioning before returning the machine to service.

2.7

When transporting the pump without motor the shaft 210 must
be fixed.
1. Remove screws on cover plates 68-3, press cover plates
slightly together and remove from the drive lantern 341.
2. Slide lockwasher 931 into the shaft keyway and secure by
using hexagon head bolts 901.1.

Unauthorised Modification and


Manufacture of Spare Parts

Modifications or alterations of the machine are only permitted


after consultation with the manufacturer. Original spare parts
and accessories authorised by the manufacturer ensure safety.
The use of other parts can invalidate any liability of the
manufacturer for consequential damage.

2.8

Unauthorised Modes of Operation

3
3.1

Transport and Interim Storage


Transport

The warranty relating to the operating reliability and safety of


the pump / unit supplied is only valid if the machine is used in
accordance with its designated use as described in chapter 4.
The limits stated in the data sheet must not be exceeded under
any circumstances.

Transport of the unit requires proper preparation and handling.


Always make sure that the pump or the unit remains in
horizontal position during transport and cannot slip out of the
transport suspension arrangement. Do not use lifting sling on
the free shaft end of pump or motor eyebolt.
If the pump / unit slips out of the suspension arrangement, it may cause personal injury and damage to
property.

Fig. 2

3.2

Transport of the pump

Interim storage (indoors) / Preservation

When the unit is temporarily put into storage, only the wetted
low alloy components (e.g. grey cast iron JL10401), nodular
cast iron JS 10252), etc.) must be preserved. Commercially
available preservatives can be used for this purpose. Please
observe
the
manufacturers
instructions
for
application/removal.
The unit / pump should be stored in a dry room where the
atmospheric humidity is as constant as possible.
If stored outdoors, the unit and crates must be covered by
waterproof material to avoid any contact with humidity.
Caution
Protect all stored goods against humidity, dirt, vermin and
unauthorised access! All openings of the assembled unit
components are closed and must only be opened when
required during installation.
All blank parts and surfaces of the pump are oiled or greased
(silicone-free oil and grease) to protect them against corrosion.

4
4.1

Description of the Product and Accessories


Technical Specification

4.2

Designation

Single-stage, non-self-priming in-line pump for handling liquids


not chemically or mechanically aggressive to the pump
materials.
The pump designation is stated on the name plate.
Example:
Etaline G N 65 - 160 / 40 2
Type series
Casing material, for ex. JL 1040 1)
S = casing of JS 1025 2)
M = impeller of tin bronze
Stub shaft variant with
standardised motor
Pump unit size
Nom. dia. of suction/discharge nozzle
Approx. impeller diameter
Motor rating: kW x 10 (example 4.0 kW)
No. of motor poles
1)

Fig. 1

Transport of the pump unit

2)

to EN 1561 = GJL-250
to EN 1563 = GJL-400-18-LT

Etaline
4.3

Design Details

Pump
Etaline GN, MN: Single-stage, close-coupled, in-line pump,
with standardised motor to DIN 42 677. The pump shaft is
rigidly connected to the motor shaft.
Shaft seal
Uncooled mechanical seal to EN 12 756 with replaceable shaft
sleeve.

4.4

Accessories

4.5

Noise Characteristics

Pump foot for vertical installation of the motor.


Y-pipes for duplex pumps (DN 40 to DN 100).
Switchgear for single and duplex pumps.

Rated p
power
i
input
PN
(kW)

1)

Sound pressure level LpA (dB) 1)


Pump with motor
1450 1/min
2900 1/min

0.25

53

--

0.37

54

--

0.55

55

--

0.75

56

66

1.1

57

66

1.5

58

67

2.2

59

67

3.0

60

68

4.0

61

68

5.5

62

70

7.5

64

71

11.0

65

73

15.0

67

74

18.5

68

75

22.0

69

76

30.0

70

77

37.0

71

78

45.0

73

78

55.0

74

--

Measured at a distance of 1 m from the pump outline (ISO 3744)

The above noise characteristics refer to non-cavitating pump


operation in the Qopt range.

5
5.1

Installation at Site
Safety Regulations

When mounting the pump on a foot, make sure that the


foundation or bracket has sufficient strength (min. class X0 to
DIN 1045 for concrete foundations).

5.3

Installing the Pump Unit

Etaline pumps may be flanged directly into the piping


irrespective of the installation position.
Caution
For safety reasons the arrangement of motor below is
however not permitted.
Make sure that the condensation water holes in the motor are
properly positioned (see page 14). The screwed plug needs to
be changed depending on the installation position.
Motors from size 180 on pump units with horizontal motor axis
need to be supported without transmitting any stresses or
strains.
On duplex pumps, direction of flow from top to bottom is not
permitted, since the Y-pipes changeover flap does not close
completely in certain modes of operation, and the other pump
would then be subjected to reverse flow.
When changing over from one pump to the other, this
arrangement might result in damage.

5.4

Connecting the Piping

Caution
Never use the pump itself as an anchorage point for the piping.
The pump must not be subjected to any pipeline
forces and moments (for example by torsion,
thermal expansion).
The pipelines should be anchored in close proximity to the
pump and should be connected without transmitting any
stresses or strains.
With short pipelines, the nominal diameters should be at
least equal to the nominal diameters of the pump nozzles.
For long pipelines, the most economical nominal diameter
has to be determined from case to case.
Adapters to larger diameters should have a diffuser angle
of approx. 8 in order to avoid any increase in pressure
losses.
It is recommended to install check and shut-off elements
in the system, depending on the type of plant and pump.
Thermal expansions of the pipelines must be compensated by
appropriate measures so as not to impose any extra loads on the
pump exceeding the permissible pipeline forces and moments.
An excessive, impermissible increase in the
pipeline forces may cause leaks on the pump
where the medium handled can escape into the
atmosphere. Danger of life when toxic or hot media
are handled.

Electrical equipment operated in hazardous


locations must comply with the explosion
protection regulations. This is indicated on the
motor rating plate.
If the equipment is installed in hazardous locations, the
applicable local explosion protection regulations and the
regulations of the test certificate supplied with the
equipment and issued by the responsible approval
authorities must be observed and complied with. The test
certificate must be kept close to the location of operation
for easy access (e.g. foremans office).

Before commissioning new installations thoroughly clean, flush


and blow through all vessels, pipelines and connections.

5.2

Connection to the power supply must be effected in


accordance with the technical regulations of the
responsible local energy supply company.
We strongly recommend to use a motor protection switch
or to connect the motors PTC resistors to a trip device.

Checks to Be Carried out Prior to


Installation

All structural work required must have been prepared in


accordance with the dimensions stated in the dimension
table / installation plan.
8

5.5

Connection to Power Supply

Connection to the power supply must be effected


by a trained electrician only.
The applicable VDE regulations 0100 and, for
explosion-proof units, 0165 must be complied
with.

Check available mains voltage against the data on the motor


rating plate and select appropriate start-up method.

Etaline
5.5.1

Motor Connection

Connect the motor in accordance with the circuit diagram in the


terminal box or as illustrated in Fig. 3 or Fig. 4.
Delta starting (low voltage)
for example for motor winding: 220--240 V / 380--420 V / Y

Fig. 3

Connection diagram for three-phase motors,


delta starting

Star starting (high voltage)


for example for motor winding: 380--420 V / 660--725 V / Y

6.1.1

Priming and Venting the Pump

Before start-up, the pump and suction line must be vented and
primed with the liquid to be pumped.
The shut-off valves in the suction and discharge lines must be
fully open before venting and starting up the pump.
Depending on the system pressure and
temperature of the medium handled hot liquid or
steam may escape or spurt out under high
pressure when opening the vent plug.
Risk of burns!
Protect the electrical components against
escaping liquid.
Caution
Dry running will result in increased wear and must be
avoided!
After having started up the pump, adjust the duty point using the
discharge-side shut-off valve.
Caution

Fig. 4

5.5.2

Connection diagram for three-phase motors,


star starting

Setting the Time Relay

Make sure that in the case of three-phase motors with star-delta


starting method switching over from star to delta will be effected
at very short intervals. Prolonged switch-over intervals will
result in pump damage.
Time relay setting for star-delta starting: <3 seconds.
Explosion-proof motors must always be connected via a motor
protection switch or, if they are fitted with PTC resistors
(thermistors), via a trip device.

Once the operating temperature has been reached and/or in


the event of leakage at the joint between discharge cover 163
and volute casing 102, switch off the unit and re-tighten the
hexagon nuts 920.1 or 920.2 (see 6.2.5).
Depending on the pumps or the systems
operating mode the pump may run very hot.
Do not touch the pump, risk of burns!
When switching off the pump, make sure that the unit runs
smoothly down to a standstill.
In the event of frost during prolonged shutdowns, the pump
must be drained or otherwise protected against freezing.

6.2
6.2.1

Operating Limits
Temperature of the Medium Handled

Caution
Do not operate the pump at temperatures exceeding those
specified on the data sheet or the name plate.

5.5.3

Checking the Direction of Rotation

The motors direction of rotation must correspond to the


direction indicated by the arrow on the pumps volute casing
(clockwise seen from the motor end). This can be verified by
switching the pump on and then off again immediately.
If the unit runs in the wrong direction of rotation, interchange two
of the three phases L1, L2 or L3 of the power supply cable of
the motor terminal box.

6
6.1

Commissioning, Start-up / Shutdown


Commissioning

Caution
Before starting up the pump make sure that
-- the lockwashers 931 have been withdrawn from the shaft
keyway and fastened using hexagon head bolts 901.1 (see
Fig. 6);
-- the pump unit has been properly connected to the electric
power supply and is equipped with all protection devices;
-- the pump has been primed with the liquid to be pumped;
-- the direction of rotation has been checked;
-- all auxiliary connections have been properly connected.

6.2.2

Switching Frequency

6.2.3

Minimum Flow

6.2.4

Density of the Medium Handled

To prevent high temperature increases in the motor and


excessive loads on the pump, motor, seal elements and
bearings, the switching frequency should not exceed 15
start-ups per hour.

If the type of plant permits operation of the pump against a


closed discharge-side shut-off valve, the following minimum
flow rates are required during this time at the temperatures
stated:
t --30 to +70 C 15 % of Qopt
t >70 to + 140 C 25 % of Qopt.

The power input of the pump will increase in proportion to the


density of the medium handled. To avoid overloading of the
motor and pump, the density of the medium must comply with
the data specified on the purchase order.

Etaline
6.2.5

Tightening Torques
Version with clamped
discharge cover

2. The pump is dismantled and stored


Before putting the pump into storage carry out all checks
specified in 7.1. Then apply appropriate preservatives:
-- Spray-coat the inside wall of the pump casing, and in
particular the impeller clearance areas, with a
preservative. Spray the preservative through the suction
and discharge nozzles. It is advisable to close the nozzles
(for ex. with plastic caps or similar).

6.4

Returning to Service after Storage

Before returning the pump to service carry out all checks and
maintenance work specified in sections 7.1 and 7.2.
In addition, the instructions laid down in the sections
on Commissioning (6.1) and Operating Limits (6.2)
must be observed.
Fig. 5

Bolt/nut tightening points on the pump unit

Item

Thread size
mm

920.1
920
1
920 2
920.2
920.3

M 10

40

M 12

55

M 12 x 1,5

25

M 24 x 1,5

85

M 30 x 1,5

140

920.5

Tightening torque
MA Nm

901.1

M6

920.4

M8

15

M 10

30

M 12

45

M 16

80

M6

10

M8

25

M 10

40

914.1

6.3

Storage of New Pumps

-- New pumps are supplied by our factory duly prepared for


storage.
Maximum protection for up to 12 months, if the pump is
properly stored indoors.
-- Store the pump in a dry location.

6.3.2

Measures to Be Taken for Prolonged


Shutdown

1. The pump remains installed; operation check run


In order to make sure that the pump is always ready for instant start-up and to prevent the formation of deposits within
the pump and the pump intake area, start up the pump set
regularly once a month or once every 3 months for a short
time (approx. 5 minutes) during prolonged shutdown
periods. Prior to an operation check run ensure that there is
sufficient liquid available for operating the pump.
10

7
7.1

Maintenance / Repair
General Instructions

The operator is responsible for ensuring that all maintenance,


inspection and installation work is carried out by authorised,
duly qualified staff who are thoroughly familiar with these
operating instructions.
A regular maintenance schedule will help avoid expensive
repairs and contribute to trouble-free, reliable operation of
the pump with a minimum of maintenance expenditure and
work.
Work on the unit must only be carried out with the
electrical connections disconnected. Make sure
that the pump set cannot be switched on
accidentally (danger of life!).
Pumps handling liquids posing health hazards
must be decontaminated. When draining the
medium see to it that there is no risk to persons or
the environment. All relevant laws must be
adhered to.

Shutdown / Storage / Preservation

Each KSB pump leaves the factory carefully assembled. If


commissioning is to take place some time after delivery, we
recommend that the following measures be taken for pump
storage.

6.3.1

Upon completion of the work, all safety-related and


protective equipment must be properly refitted and/or
re-activated before starting the pump set.

7.2
7.2.1

Maintenance / Inspection
Supervision of Operation

Caution
The pump should run quietly and free from vibrations at all
times.
The pump must never be allowed to run dry.
The room temperature must never rise above 40 C.
The bearing temperature may exceed room temperature by up
to 50 C but must never rise above 90 C.
Do not run the pump against a closed shut-off valve
for prolonged periods of time so as to avoid heating up
of the medium pumped.
For required minimum flows please refer to section 6.2.3.
During pump operation the shut-off valve in the suction line must not be closed.
The mechanical seal leaks only slightly or invisibly (vapour)
during operation. It is maintenance-free.

Etaline
Any stand-by pumps installed should be switched on and then
immediately off again once a week to keep them operational.
Attention should be paid to the correct functioning of the auxiliary connections.

7.2.2 Lubrication and Lubricant Change


7.2.2.1 Lubrication

The rolling element bearings of the KSB IEC motor are


grease-lubricated. The lubricant change intervals as well as the
required quantity and quality are specified below.

7.2.2.2 Grease Quality / Grease Change

The bearings are packed with high-quality lithium-soap grease.


Under normal conditions grease-lubricated rolling element
bearings will run for 25,000 operating hours or for 2 years.
Under unfavourable operating conditions, e.g. high room
temperature, high atmospheric humidity, dust-laden air,
aggressive industrial atmosphere etc., the bearings should be
checked earlier and cleaned and re-lubricated, if required.
Use a lithium-soap grease, free of resin and acid, not liable to
crumble and with good rust-preventive characteristics. The
grease should have a penetration number between 2 and 3,
corresponding to a worked penetration between 220 and
295 mm/10. Its drop point must not be below 175 C. The
bearing cavities must only be half-filled with grease.
If required, the bearings may be lubricated with greases of other
soap bases. Since greases of differing soap bases must not be
mixed, the bearings must be thoroughly cleaned beforehand.
The re-lubrication intervals required must then be adjusted to
the greases used.
Caution
Please observe the local laws applicable to the disposal of such
substances!

7.2.2.3 Deep-groove Ball Bearings / Lubricant


Quantity
-- for KSB IEC motor
Deep-groove ball bearings to DIN 625
Code
Grease g
6004 C3
2
6205 C3
3
6206 C3
4
6208 C3
6
6209 C3
7
6210 C3
7
6212 C3
7
6213 C3
11

7.3

Drainage/Disposal
If the pump was used for handling liquids posing
health hazards, see to it that there is no risk to persons
or the environment when draining the medium. All
relevant laws must be heeded. If required, wear
safety clothing and a protective mask.

The flushing liquid used and any liquid residues in the pump
must be properly collected and disposed of without posing any
risk to persons or the environment.

7.4

Dismantling
Before dismantling, secure the unit so as to make
sure it cannot be switched on accidentally.

The shut-off valves in the inlet/suction and discharge lines must


be closed.
The pump must have cooled down to ambient temperature, it
must have been drained and its pressure must be released.

7.4.1

Fundamental Instructions and


Recommendations

Repair and maintenance work to the pump must only be carried


out by specially trained personnel, using original spare parts
(see 2.7).
Observe the safety regulations laid down in section 7.1.
Any work on the motor shall be governed by the
specifications and regulations of the respective motor
supplier.
Dismantling and reassembly must always be carried out in
the sequence shown in the relevant exploded views on
pages 18 and 19.
In case of damage please contact our nearest customer service
centre.
For customer service centres please refer to the attached list
of addresses.

7.4.2

Preparations for Dismantling

7.4.3

Pump

1
2
2.1
2.2

Interrupt power supply.


Dismantling the complete unit:
Disconnect the motor.
Disconnect the discharge and suction nozzle from the
piping.
2.3 Depending on the pump/motor size, unscrew the bolts
that fix the support foot to the foundation.
2.4 Remove the complete unit from the piping.
3
The pump casing remains in the piping during dismantling.
3.1 Disconnect the motor.
3.2 Unscrew hex. nuts 920.1 and 920.2.
3.3 Withdraw the complete rotating assembly with the motor
from the pump casing.
4
Pump remains in the piping, motor is removed
4.1 Disconnect the motor.
4.2 Remove screws on cover plates 68-3, press cover plates
slightly together and remove from the drive lantern 341.
4.3 Undo hex. nuts 920.4.
4.4 Undo socket head cap screws 914.1.
4.5 Undo hex. head bolts 901.1.
4.6 Insert both lockwashers 931 into the keyway in shaft 210.
4.7 Tighten hex. head bolts 901.1.
4.8 Remove the motor.
After a prolonged period of operation the individual components may be hard to pull off the shaft. If this is the case, use
a brand name penetrating agent and/or -- if possible -- an appropriate pull-off device.
Under no circumstances use force.

Dismantle the pump in the sequence shown in the exploded


views on pages 18 and 19.

11

Etaline
7.4.4

Mechanical Seal

7.5
7.5.1

Reassembly
Pump

In order to replace the mechanical seal the pump must be


dismantled.
After removing the impeller 230 pull the mechanical seal 433 off
the shaft by hand.
Prior to reassembly, clean the shaft sleeve 523 and touch up
score marks or scratches, if any, with a polishing cloth. If the
score marks are still visible, fit a new shaft sleeve. Clean the
seat ring location.

The pump should be reassembled in accordance with the rules


of sound engineering practice.
The locating surfaces of the individual components should be
coated with graphite or similar before reassembly. The same
applies to screwed connections.
O-rings should be should be examined for signs of damage and
replaced by new ones, if necessary.
Gaskets should always be replaced by new ones. Make sure
that new gaskets have the same thickness as the old ones.
Gaskets of asbestos-free materials or graphite must always be
fitted without using lubricants.
Avoid the use of mounting aids as far as possible. Should a
mounting aid be required after all, use a commercially available
contact adhesive (e.g. Pattex) or sealing agent (HYLOMAR or
Epple 33). The adhesive should only be applied at selected
points and in thin layers. Do not use cyanoacrylate
adhesives (quick-setting adhesives).
If the seal area between the impeller neck and the casing wear
ring is worn, the casing wear rings 502.1 and 502.2 (if fitted)
must be replaced by new ones.
Clearances:
Etaline GN, MN:
New 0.3 mm in diameter
Max. permissible enlargement to 0.9 mm in diameter
Reassembly is effected in reverse order to dismantling. Make
sure to assemble the components in their correct sequence.

7.5.2

7.5.3

Motor for Etaline GN, MN

The motor is reassembled in reverse order to dismantling.


Prior to commissioning make sure that the lockwashers 931 are
withdrawn from the shaft keyway and fixed with hex. head bolts
901.1.

Fig. 6

Lockwasher

Part No.
210
515
901.1
914.1
931

Part designation
Shaft
Taper lock ring
Hexagon head bolt
Socket head cap screw
Lockwasher

Caution
When mounting the shaft 210 onto the motor shaft butt the
motor shafts keyway and the slot of shaft 210 must be arranged
in line with each other and opposite the slot of taper lock ring
515.

Section A -- A

Mechanical Seal

Reassembly is effected in reverse order to dismantling.


The following rules must be observed when mounting the
mechanical seal:
Extreme care and cleanliness.
Prior to reassembly, clean the shaft sleeve 523 and touch up
grooves or scratches, if any, with a polishing cloth. If the score
marks are still visible, fit a new shaft sleeve.
The protecting wrapping of the contact faces should only be
removed immediately before assembly takes place.
Take care not to damage the seal faces and O-rings.
When mounting the seal, the shaft sleeve 523 may be
wetted with water to reduce the friction forces.
Caution
Epoxy rubber elastomers must never come into contact
with oil or grease. Water should be used as a lubricant
during fitting.

12

901.1

Fig. 7

Shaft assembly

Etaline
7.6
7.6.1

Spare Parts Stock


Interchangeability of Etaline and Etabloc Components and Interchangeability of Components
among Each Other

502.2

Shaft sleeve

Casing wear ring,


suction side
Casing wear ring,
discharge side
502.1

Mechanical seal
433

32-160.1/...

32-200/... 25

12

32-200.1/...

40-160/... 25

32-160/...

40-250/... 25

32-250/...

50-160/... 25

40-160/...

50-250/... 25

40-250/...

65-160/... 25

50-160/...

65-250/... 25

16

50-250/...

80-160/... 25

11

65-160/...

80-210/... 25

16

65-200/...

Motor
71

80

90

100/
112

132

160

180

200

225

523

102

32-160/... 25

Etaline 1)

163

Shaft unit

210

Part No.

Impeller

Shaft (with taper lock ring)

230

Discharge cover

Volute casing

Part designation

250

Etabloc

80-250/... 35

65-250/...

100-125/... 25

10

65-125/...

100-160/... 25

65-160/...

100-170/... 25

80-160/...

100-200/... 35

80-200/...

100-250/... 35

10

80-250/...

125-160/... 35

11

100-160/...

125-200/... 35

12

17

100-200/...

125-250/... 35

10

100-250/...

150-200/... 35

10

125-200/...

150-250/... 35

10

11

125-250/...

200-250/... 35

13

10

11

12

150-250/...

200-315/... 55

14

13

14

15

150-315/...

Motor Power rating

1
1

Same number means same component

Components differ

When other frequencies or power reserves are required for this pump/motor combination, consult KSB.

This pump/motor combination is not possible


Components are interchangeable with Etabloc

1)

The pump components of Etaline single pump units and twin pump
units are identical, except for the volute casing.

71

.../024, .../034

80

.../054, .../074, .../072, .../112

90

.../114, .../154, .../152, .../222

100

.../224, .../304, .../302

112

.../404, .../402

132

.../554, .../754, .../552, .../752

160

.../1104, .../1504, .../1102, .../1502, .../1852

180

.../1854, .../2204, .../2202

200

.../3004, .../3002, .../3702

225

.../3704, .../4504, .../4502

250

.../5504
13

Etaline
7.6.2

Ordering Spare Parts

When ordering spare parts please always quote the following


data stated on the name plate, for example:
Name plate specimen
KSB Aktiengesellschaft
D-67227 Frankenthal

Type series and size

ETALINE-GN 65-160/752.2

Design and Ident No..

GN 6

Order No.

0005130825

48 859 104
003000 01
m3/h

Capacity and head

Q 13,5 -- 90,0

Speed and serial No.

n = 2900 1/min

H 33 -- 20 m
Jahr 2006

The following data are required as well:


part designation, part number, quantity of spare parts, address
and mode of dispatch (freight, mail, express freight, airfreight).

7.6.3
Part No.

Recommended Spare Parts Stock for 2 Years Continuous Operation in Accordance with VDMA 24 296
Part designation

Number of pumps (including stand-by pumps)


2

6 and 7

8 and 9

10 and more

Quantity of spare parts


210

Shaft complete, consisting of


Shaft 210
Disc 550 1)
Socket head cap screw 914.1
Hexagon nut 920.5
Safety device 930
Key 940
Taper lock ring 515

30 %

230

Impeller (including casing wear ring 502.2) 2)

30 %

400.1

Gasket

12

150 %

433

Mechanical seal, complete

90 %

502.1

Casing wear ring

50 %

523

Shaft sleeve (incl. gasket 400.2)

50 %

1)
2)

14

Only for Etaline with shaft unit 25


Not for Etaline 40-125/..., 50-125/..., 65-125/...

Etaline

Excessive rise of temperature inside the pump

Vibrations during pump operation

Excessive leakage at the shaft seal

Leakage at the pump

Motor protection switch/thermistor trip device trips the unit


Increase in bearing temperature

Trouble-shooting

Drive is overloaded

Pump delivers insufficient flow rate

Cause

Remedy 1)

Pump delivers against an excessively high discharge


pressure.

Re-adjust duty point.

Excessively high back pressure.

Check plant for impurities.

D D Pump or piping are not completely vented or primed.

Vent and/or prime.

Supply line or impeller clogged.

Remove deposits in the pump and/or piping.

Formation of air pockets in the piping.

Alter piping layout.


Fit a vent valve.

D D Suction head is too high/NPSH available (positive suction


head) is too low.

Reverse rotation.

Interchange two of the phases of the power supply cable.

Worn internal parts.

Replace worn components by new ones.

Pump back pressure is lower than specified in the purchase order.

Adjust duty point accurately.

Density or viscosity of the fluid pumped is higher than


stated in the purchase order.

2)

D
D
D D
D

Defective seal element.

Fit new seal between volute casing and discharge cover.

Worn shaft seal.

Fit new shaft seal.

Score marks or roughness on shaft sleeve.

Fit new shaft sleeve.


Fit new shaft seal.

Vibrations during pump operation.

Improve suction conditions.


Increase the pressure at the pump suction nozzle.

D D

Pump is warped.

Check pipeline connections and secure fixing of pump; if


required, reduce the distances between the pipe clamps.
Fix the pipelines using anti-vibration material.

Increased axial thrust. 2)

Clean balancing holes in the impeller. Fit new wear rings.

Insufficient or excessive quantity of lubricant or unsuitable lubricant.

Top up, reduce or change lubricant.

Motor is running on two phases only.

Replace the defective fuse.


Check the electric cable connections.
Check the motor winding

Rotor is out of balance.

Clean the impeller.


Re-balance the impeller.

Defective bearings.

Fit new bearings.

D
D

D
D

D D

D D Insufficient rate of flow.


D
D D

Increase system pressure.


Check/alter liquid level.
Fully open shut-off valve in the suction head line.
Change suction head line, if the friction losses in the suction head line are too high.

Increase the minimum rate of flow.

Incorrect adjustment of motor protection switch.

Check setting.
Fit new motor protection switch.

Transport safety device has not been removed from the


shaft groove.

Remove.

1)

The pump pressure must be released before attempting to remedy


faults on parts which are subjected to pressure.
2) Please contact KSB.

15

Etaline
9
9.1

Relevant Documentation
Typical Installation Positions

5B

Fig. 8

Horizontal installation, direction of flow from bottom


to top

Fig. 9

Horizontal installation, direction of flow from top to


bottom. The pump casing must be turned by 180,
so that the condensation water holes point downwards and the terminal box remains in its position on
top.

Fig. 10

Vertical installation
If the pump set is installed vertically, the pump must
be vented through vent valve B5 (special design) so
as to avoid dry running of the mechanical seal.

Fig. 11

Horizontal installation (for ex. under the ceiling)

Duplex pumps must not be arranged in flow direction from top to bottom, since under certain operating conditions the changeover flap will not shut off
completely, which might produce reverse flow in the
second pump. In this case, changeover from the first
to the second pump might cause damage.

16

Etaline

To be
supported

Blind flange (accessory)

The motors of Etaline units with motors from size 180


and horizontal axis must be supported without transmitting any stresses or strains.
To this end, use the foot fixing holes on the motor housing.

Etaline fixed without feet

Etaline pump sizes


32-160/... to 100-160/...
fixed with three feet

Etaline pump sizes


100-170/...to 200-315/...
fixed with a pump foot
made of EN-GJL

If flexible pipe unions (expansion joints) are used or if the pump


set is installed with a pump foot, Etaline pumps must be fixed.
Appropriate fixing elements are available as pump accessories.
When dismantling the motor the volute casing may remain in
the piping.

17

Etaline
9.2

Exploded View and List of Components

Etaline GN
Variant with bolted-on discharge cover
Etaline GN
32-200/...
40-250/...
50-250/...
65-250/...
80-210/...
80-250/...

Etaline GN
100-250/...
125-250/...
150-250/...
200-250/...
( )

Not available as individual spare part

Part No.
102
163
182
210
230
341
400.1/.2
433
502.1/.2
515
523
550.1/.2
68-3
741
801
18

Part designation
Volute casing
Discharge cover
Foot
Shaft
Impeller
Drive lantern
Gasket
Mechanical seal
Casing wear ring
Taper lock ring
Shaft sleeve
Disc 1)
Cover plate
Vent valve
Flanged motor

[ ]

Supplied in packaging units only

Part No.
901.1
902.1-.4
903
914.1
920.2-.5
930
931
940

Part designation
Hexagon head bolt
Stud
Screwed plug
Socket head cap screw
Hexagon nut
Safety device
Lockwasher
Key

Auxiliary connections:
1 M.1/.2
Pressure gauge
5B
Vent, mechanical seal chamber
6 B.1/.3
Pumped medium drain
6 D.1
Priming with pumped medium and venting
1)

Only for Etaline with shaft unit 25

Etaline
Etaline GN
Variant with clamped discharge cover
Etaline GN
32-160/...
40-160/...
50-160/...
65-160/...
80-160/...
100-125/...
100-160/...

Etaline GN
100-170/...
100-200/...
125-160/...
125-200/...
150-200/...
200-315/...
( )

Not available as individual spare part

Part No.
102
163
182
210
230
341
400.1/.2
433
502.1/.2
515
523
550.1
68-3
741
801

Part designation
Volute casing
Discharge cover
Foot
Shaft
Impeller
Drive lantern
Gasket
Mechanical seal
Casing wear ring
Taper lock ring
Shaft sleeve
Disc 1)
Cover plate
Vent valve
Flanged motor

[ ]

Supplied in packaging units only

Part No.
901.1
902.2/.4
903
914.1
920.1/.3-.5
930
931
940

Part designation
Hexagon head bolt
Stud
Screwed plug
Socket head cap screw
Hexagon nut
Safety device
Lockwasher
Key

Auxiliary connections:
1 M.1/.2
Pressure gauge
5B
Vent, mechanical seal chamber
6 B.1/.3
Pumped medium drain
6 D.1
Priming with pumped medium and venting
1)

Only for Etaline with shaft unit 25

19

Etaline
Sectional Drawing

Etaline GN with
bolted-on
discharge cover
32-200/...
40-250/...
50-250/...
65-250/...
80-210/...
80-250/...
100-250/...
125-250/...
150-250/...
200-250/...

Etaline GN with
clamped
discharge cover
32-160/...
40-160/...
50-160/...
65-160/...
80-160/...
100-125/...
100-160/...
100-170/...
100-200/...
125-160/...
125-200/...
150-200/...
200-315/...
( )

Not available as individual spare part

[ ]

Supplied in packaging units only

1146.81/8-10 / 1.6.2007

Fixing impeller on shaft unit 35

Subject to technical modifications without prior notice.

01 044 056

9.3

Quick Start--Up Guide


4070.801--11

PumpDrive
Self-- Cooled,
Motor-- Independent
Frequency Converter

Mounting options:
Motor mounting (MM)
Wall mounting (WM)
Control cabinet mounting (CM)

Quick Start--Up Guide

PumpDrive
1 About this Guide
For detailed descriptions and instructions on how to properly use, maintain and
troubleshoot the pump, please refer to the operating manual of the
PumpDrive.
This guide
D is part of the PumpDrive
D helps you quickly put the PumpDrive into operation
D contains descriptions of the following subjects:
-- Location
-- Connecting cable
-- Installation
-- Start--up
-- Configuring the parameters
Warning labels and symbols
Symbol

Meaning
Safety warning sign
" Follow the instructions that appear next to the safety
warning sign to avoid injury or material damage.
Information, note

"

Instruction

Result

Risk of injury or material damage if unsafe work is done

CAUTION

" Observe the safety instructions (see operating instructions with the
number 4070.81, chapter 2, chapter 6.4.1).
" Keep the operating instructions constantly available at the location
of use.

PumpDrive
2 Location
The following requirements must be met:
D It must be well ventilated
D No exposure to direct sunlight or weather influences
D When installed outside it must protected against condensed water and sunlight
D Temperature range for pump operation: 0--40 C
D two separate copper rails must be provided to earth the pump (mains connection
rail and control connection rail)

3 Connecting cable
The following requirements must be met:
3.1 Power cable
D unshielded (shielding is optional)
D a motor circuit breaker that is capable of handling 1.4 x the nominal current
D maximum cable cross section, see Table1, on page 7
3.2 Control cable
D Shielded cable for the control cables, a minimum cross section of 0.5 mm2
D shielded cable for LON and Profibus
D between the control and power cables minimum clearance 0.3 m
3.3 Connecting cable between the PumpDrive and motor (with stray
capacitance Cs < 5 nF)
D to 7.5 kW class B, maximum cable length 5 m
D over 7.5 kW class A1, maximum cable length 50 m
D shielded

PumpDrive
4 Mounting the PumpDrive
Risk of injury or material damage if installed improperly

CAUTION

" Observe the safety instructions (see the operating manual,


chapter 2).
" To avoid starting the pump accidentally: Switch off the power and
lock to prevent power being reapplied.

In the installation option MM, the PumpDrive is already mounted on a standard


motor.
" For the installation options WM and CM: Mount the PumpDrive to the wall, to a rack
or into a control cabinet according to the enclosed installation instructions.

PumpDrive
5 Installation
Improper installation can cause material damage!

CAUTION

" Ensure that the power feed, motor connection wiring and control
wiring are all powered off and are protected from being powered up
again.
" Never remove the plastic housing from the metallic heat sink.
" Remove covers only as described in the guide.
" Make sure that earthing is provided meeting local and national
regulations.

5.1 Connection of motor and power wiring

Fig.1) Removing the V--shaped cover


" Unscrew the three cross head screws (1) on the V--shaped cover (1) for the mains
and motor connection and then remove the cover (see Fig.1).
" Connect the power or motor cable to the terminals in the connection compartment
on the PumpDrive (see Fig.2andFig.3). Use suitable cable connections (see
table 1, page 7).

Fig.2) Connection compartment for the power and motor cables


5

PumpDrive

1 terminal for the power connection 3 terminal for the motor connection
2 analogue input 2
4 terminal for control connection
Fig.3) Power and motor connections in the connection compartment of the PumpDrive

PumpDrive
Risk of injury or material damage if improperly earthed

CAUTION

" Do not connect the shielding of the connection cable to the earthing
rail in the control cabinet or to the control earthing rail.
" Provide the shielding of the connection cable in a single piece and
earth it on both ends.
" Connect the shielding of the control cables to the signal earth.

Size
PumpDrive

Power
[kW]

Cable glands for


Mains
supply
cable

Sensorcable

Motor
cable

PTC
therm
istor

Input
p
current1)
[A]

.. 000K55 ..

0,55

1,9

.. 000K75 ..

0,75

2,6

.. 001K10 ..

1,1

.. 001K50 ..

1,5

.. 002K20 ..

2,2

6,3

.. 003K00 ..

8,5

.. 004K00 ..

10,5

.. 005K50 ..

5,5

.. 007K50 ..

7,5

.. 011K00 ..

11

.. 015K00 ..

15

.. 018K50 ..

18,5

.. 022K00 ..

22

.. 030K00 ..

30

.. 037K00 ..

37

.. 045K00 ..

45

M25

M25

M16

M16

M25

M25

M16

M16

3,7
5

13,7

Max.
Cable
cross
section
[mm2]

25
2,5

2,5

17,3
26,5
M32

M16

M32

M16

32,6
41

10

47,3
68,3
M40

M16

M40

M16

84

35

97,7

1) Observe the notes on using line chokes (see the operating manual, section Accessories and options under
Line chokes!

Table1) Cable connections for power and motor connections

PumpDrive
5.2 Connecting the control wiring
" Unscrew the three cross head screws (1) on the L--shaped cover (2) for the
control cables and then remove the cover (see Fig.4).

Fig.4) Removing the L--shaped cover


Material damage due to improper removal of the
control unit
CAUTION

" When removing the control unit: Use a flat screwdriver at the top end
as a lever.

" Unscrew the cross head screws (1) on the control unit and then remove the
control unit (see Fig.5).

Fig.5) Removing the L--shaped cover


The terminal strips P4 and P7 are located under the control unit (see Fig.6).

PumpDrive

Fig.6) Position of the terminal strips P4 and P7 (1)

PumpDrive
6 Start--up
" Depending on the version and operating mode, choose a chapter from the table.
Operating mode

Version
without control unit

with control unit

Internal setpoint specification

Section 6.1, page 10

Section 6.3, page 11

External setpoint specification

Section 6.1, page 10

Section 6.4, page 11

Internal setpoint specification

Section 6.2, page 10

Section 6.5, page 12

External setpoint specification

Section 6.2, page 10

Section 6.6, page 13

Actuated operation:

Regulated operation:

6.1 Without control unit -- actuator operation -- setpoint specification


internal/external
With the assistance of the PumpDrive PC software, PumpDrive can also be
configured without a control unit, as follows:
-- via the serial interface with a special connecting cable
(mini USB--RS232), connect a PC/Notebook
-- configure as with the control unit (see section 6.4, page 11)
" If the setpoint signal is only between 0 and 10 V: connect the setpoint signal to
terminal P7, analogue input 1
" Check the direction of rotation (see section 6.8, page 14).
6.2 Without control unit -- regulated operation -- setpoint specification
internal/external
With the assistance of the PumpDrive PC software, PumpDrive can also be
configured without a control unit, as follows:
-- via the serial interface with a special connecting cable
(mini USB--RS232), connect a PC/Notebook
-- configure as with the control unit (see section 6.6, page 13)
" If the setpoint signal is only between 0 and 10 V: connect the setpoint signal to
terminal P7, analogue input 1
" For an actual signal between 4 and 20 mA: connect the actual signal to
terminal P7, analogue input 2.
" Check the direction of rotation (see section 6.8, page 14).
10

PumpDrive
6.3 With control unit -- actuator operation -- setpoint specification internal
" Configure the source for the setpoint on the control unit:
-- Select parameter 3--5--4--1 and set menu point 4.
-- Select parameter 3--5--2--1 and set value between the lower and the upper
setpoint limits.
" Check the direction of rotation (see section 6.8, page 14).
" If the lower and upper setpoints differ from the factory set 0 % and 100 %: Set
lower and upper setpoints:
-- Select parameter 3--5--1--2 and set the value.
-- Select parameter 3--5--1--3 and set the value.
" Select parameter 3--5--1--4 and set to AUTO.
6.4 With control unit -- actuator operation -- setpoint specification external
" If the setpoint signal is only between 0 and 10 V: connect the setpoint signal to
terminal P7, analogue input 1
" If the setpoint signal does not lie between 0 and 10 V, or if more than one setpoint
should be used, see section Configure source for setpoint signal.
" Check the direction of rotation (see section 6.8, page 14).
Set source for setpoint signal
A maximum of 3 sources can be set for setpoints
" Set sources for setpoints (see Table2 and section 6.9).
" If setpoint signal is not between 0 and 10 V:
-- Configure source for setpoint (see operating instructions, section 8.3, table 22).
-- If analogue input 1 is set as the source for setpoint: Configure analogue input 1
(see operating instructions, section 8.2, table 18).
-- If analogue input 2 is set as the source for setpoint: Configure analogue input 2
(see operating instructions, section 8.3, table 26).

11

PumpDrive
Parameter

Description

Setting options

3--5--4--1

Source for setpoint signal 1

1, 2, 3, 4, 5, 6

3--5--4--2

Source for setpoint signal 2

1, 2, 3, 4, 5, 6

3--5--4--3

Source for setpoint signal 3

1, 2, 3, 4, 5, 6

1 -- No source
2 -- Analogue input 1
3 -- Analogue input 2

4 -- Configurable setpoint
5 -- Fieldbus setpoint
6 -- RS232 -- setpoint

Table2) Source for setpoint


6.5 With control unit -- regulated operation -- setpoint specification internal
" Configure the source for the setpoint on the control unit:
-- Select parameter 3--5--4--1 (see section 6.9).
-- Set parameter to 4.
-- Select parameter 3--5--2--1 and set value between the lower and the upper
setpoint limits.
" For an actual signal between 4 and 20 mA: connect the actual signal to
terminal P7, analogue input 2.
" If the actual signal does not lie between 4 and 20 mA: see section Configure
source for actual signal.
" Check the direction of rotation (see section 6.8).
Set source for actual signal
The actual signal can be read in from 7 different sources.
" Set sources for actual signals (see Table3 and section 6.9).
" If the actual signal does not lie between 4 and 20 mA: Configure source for actual
value (see operating instructions, section 8.3, table 26).
Parameter

Description

Setting options

3--9--2--1

Source for actual signal 1

1, 2, 3, 4, 5, 6

1
2
3
4

-----

Analogue input 1
Analogue input 2
DIFF (AI1, AI2)
MIN (AI1, AI2)

Table3) Sources for actual


12

5 -- MAX (AI1, AI2)


6 -- AVE (AI1, AI2)
7 -- Rem actual

PumpDrive
6.6 With control unit -- regulated operation -- setpoint specification external
" If the setpoint signal is only between 0 and 10 V: connect the setpoint signal to
terminal P7, analogue input 1
" If the setpoint signal does not lie between 0 and 10 V, or if more than one setpoint
should be used, see section Configure source for setpoint signal.
" For an actual signal between 4 and 20 mA: connect the actual signal to
terminal P7, analogue input 2.
" If the actual signal does not lie between 4 and 20 mA: see section Configure
source for actual signal.
" Check the direction of rotation (see section 6.8).
Set source for setpoint signal
A maximum of 3 sources can be set for setpoints.
" Set sources for setpoints (see Table4 and section 6.9).
" If setpoint signal is not between 0 and 10 V:
-- Configure source for setpoint (see operating instructions, section 8.3, table 22).
-- If analogue input 1 is set as the source for setpoint: Configure analogue input 1
(see operating instructions, section 8.2, table 18).
-- If analogue input 2 is set as the source for setpoint: Configure analogue input 2
(see operating instructions, section 8.3, table 26).
Parameter

Description

Setting options

3--5--4--1

Source for setpoint signal


1

1, 2, 3, 4, 5, 6

3--5--4--2

Source for setpoint signal


2

1, 2, 3, 4, 5, 6

3--5--4--3

Source for setpoint signal


3

1, 2, 3, 4, 5, 6

1 -- No source
2 -- Analogue input 1
3 -- Analogue input 2

4 -- Internal setpoint
5 -- Fieldbus setpoint
6 -- RS232 -- setpoint

Table4) Source for setpoint

13

PumpDrive
Set source for actual signal
The actual signal can be read in from 7 different sources.
" Set source for actual signal (see Table5 and section 6.9).
" If the actual signal does not lie between 4 and 20 mA: Configure source for actual
value (see operating instructions, section 8.3, table 26).
Parameter

Description

Setting options

3--9--2--1

Source for actual signal 1

1, 2, 3, 4, 5, 6

1
2
3
4

-----

Analogue input 1
Analogue input 2
DIFF (AI1, AI2)
MIN (AI1, AI2)

5 -- MAX (AI1, AI2)


6 -- AVE (AI1, AI2)
7 -- Rem actual

Table5) Sources for actual


6.7 Configuring motor data
" Call up the following parameters and set suitable values for the motor:
Parameter

Description

Setting options

3--3--2--1

Nominal power

0.55..110 [kW]

3--3--2--2

Nominal voltage

342..528 [V]

3--3--2--3

Nominal frequency

45..65 [Hz]

3--3--2--4

Nominal current

0.1..999 [A]

3--3--2--5

Nominal motor speed

300..3600 [rpm]

3--3--2--6

Nominal phase shift

Table6) Configuring motor data


6.8 Checking the direction of rotation
" If control unit available: Press the <Man> button on the control unit.
The drive will then be operated at a speed below the minimum limit value of the
motor frequency.
" If no control unit available: Connect 24 V to digital input 1.
" If direction of rotation incorrect: Swap two motor phases.

14

PumpDrive
6.9 Configuring the parameters

Fig.7) Front panel of control unit

Fig.8) Parameter 3--2--1--3 (example)

" Select the related four--digit parameter value from the table and enter it as follows
via the control unit (see Fig.7 and Fig.8):
-- Enter the first digit with the four yellow buttons on the control unit. The four
buttons represent the digits 1 to 4.
-- For all other digits press the <Up/Down> buttons on the control unit until the digit
of the parameter appears in the left top corner and then confirm by pressing
<OK>.

15

We reserve the right to make technical changes.


14.02.2006
4070.801--11

KSB Aktiengesellschaft
67225 Frankenthal Johann-Klein-Str. 9 67227 Frankenthal
(Germany)
Tel. +49 (0)6233 86-0 Fax +49 6233 86-3401 www.ksb.de

PumpDrive
13.3

Connection examples

13.3.1

Open-loop control mode

Fig. 39: Connection example for open-loop control mode


121

description

parameter setting and


adjustment for all pumps

Multitec 2-pol
2900 1/min

Rated power
Rated voltage
Rated frequency
Rated current
Rated speed
Rated cosphi

Resetting to factory settings

information resp. changing motor frequency <> 50 Hz


max. motor frequency
3-11-4-1
Max Out Freq

on demand:
3-1-5-5
Back Fac Settgs

motor identification plate

preset: 50 Hz

factory-made preset

84% = 42Hz
800 1/min

84% = 42Hz
800 1/min

Etanorm RSY 6-pol


960 1/min

56% = 28Hz
800 1/min

56% = 28Hz
800 1/min

Etaline SY 4-pol
1450 1/min

Presetting of frequency controller in case of


motor mounted frequency controller
"motor mounted" version not possible for Etaline SY, Etablock SY

56% = 28Hz
800 1/min

56% = 28Hz
800 1/min

Etanorm SYA 4-pol


1450 1/min

customer level
0000
change of language
english
change of KSB password
operating values in the main 1: power [kW]
menue
2: motor current [A]
3: operating hours counter [h]
4: energy meter [kWh]
manual operation
[Man] Key
locked
off
[Off] Key
locked
function
[Func] Key
Trip Reset
32% = 16Hz
Frequence lo
Min. frequence, refered to
900 1/min
3-11-4-1 Max Out Freq
if motor frequency (3-3-2-3) e.g. 60Hz, all percentage values for 3-6-1-2 must be adjusted refered to 3-11-4-1
Stop & Trip
Life Zero Fnc
sensor monitoring wire
break
set point signal
AI 1 Setting
current
adjusting range 4-20mA =
32% = 16Hz
AnIn1 Lo
Fmin to Fmax
900 1/min

Login
Language
Customer Passwd
User config

Saving of parameter settings:


Turning on and off frequency controller

Check:
3-3-2-1
3-3-2-2
3-3-2-3
3-3-2-4
3-3-2-5
3-3-2-6

3-8-2-1
3-8-2-7

attention:
3-8-1-2

3-1-4-1
3-1-4-2
3-1-4-3
3-6-1-2

3-1-6-1
3-1-1-1
3-1-6-4
3-1-3-1

adjust:
parameter

PumpDrive parameter settings company LOOS

35% = 17,5Hz
500 1/min

35% = 17,5Hz
500 1/min

56% =28Hz 84% = 42Hz


800 1/min
800 1/min

56% =28Hz 84% = 42Hz


800 1/min
800 1/min

Etaline GN 4-pol HPK-L 4-pol HPK-L 6-pol


1450 1/min
1450 1/min 960 1/min

Equipment for fuel supply


and heat recovery

VENTA Luft- u. Wrmetechnik GmbH


Postfach 40 01 89, D-74510 Schwbisch Hall
Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24

VENTA

Operating Instructions
High performance fans
For product line
Radial fans,
Axial fans

MHI, NHI, SgHI, HI, SI, UV, RFPK


A, AL

VENTA Luft- u. Wrmetechnik GmbH


Postfach 40 01 89, D-74510 Schwbisch Hall
Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24

VENTA

Table of Contents
1.

Order data ......................................................................................................... 3


1.1. Performance data ....................................................................................... 3
1.2. Motor data................................................................................................... 3

2.

Introduction ...................................................................................................... 3

3.

Safety ................................................................................................................ 3
3.1. Symbols ...................................................................................................... 3
3.2. General occupational safety references ..................................................... 3
3.3. Special occupational safety references ...................................................... 4
3.4. Warranty ..................................................................................................... 4

4.

Design and operation ...................................................................................... 5

5.

Transportation, delivery and storage ............................................................. 5


5.1. Transportation............................................................................................. 5
5.2. Delivery ....................................................................................................... 6
5.3. Storage .................................