Automatic burner control unit IFD 244 Technical Information · GB 6.1.1.4 Edition 03.08 • For directly ignited burners of up to 350 kW in continuous operation pursuant to EN 746-2 • Continuous self-testing for faults • Restart following flame failure • Flame control with ionisation sensor • Diverse installation possibilities via holes or snap mechanism for DIN rail • Space-saving installation on site with IFD 244..I with integrated ignition • Display for program status and flame signal intensity www.
Table of contents Automatic burner control unit IFD 244 . . . . . . . . . . . . . . . . . 1 Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Examples of application . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1.1 Atmospheric burners . . . . . . . . . . . . . . . . . . . . . . . .
Table of contents 12 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 12.1 Start-up position/standby . . . . . . . . . . . . . . . . . . . . . . . 31 12.2 Waiting time tW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 12.3 Safety time on start-up tSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 12.4 Ignition time tZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Application Automatic burner control unit IFD 244 ignites and monitors gas burners in continuous operation. As a result of its fully electronic design it reacts quickly to various process requirements and is therefore also suitable for frequent cycling operation. It can be used for directly ignited industrial burners in doubleelectrode operation up to 350 kW. The program status and the level of the flame signal can be read directly from the unit.
Application 5 1.1 Examples of application Intermittent shuttle kiln in the ceramics industry Roller hearth kiln Roller hearth kiln IFD 244 · Edition 03.
Application > Examples of application 6 1.1.1 Atmospheric burners Control: ON/OFF The burner is ignited by the ignition electrode and is monitored by the ionisation electrode. In the event of a flame failure during start-up, an immediate fault lock-out occurs. Following a flame failure during operation, a restart is conducted. L1, N, PE PLC IFD 244..I 6 3 7 8 µC 9 4 ZAI VAS IFD 244 · Edition 03.
Application > Examples of application 7 1.1.2 Forced draught burners Control: ON/OFF Gas valve and air valve are activated simultaneously. In the event of a flame failure during start-up, an immediate fault lock-out occurs. Following a flame failure during operation, a restart is conducted. L1, N, PE PLC 6 IFD 244 3 7 8 µC 9 5 4 TZI/TGI VAS..L VR..R IFD 244 · Edition 03.
Application > Examples of application 8 1.1.3 Two-stage-controlled burner Control: High/Low or High/Low/OFF The burner BIO/BIC starts at low-fire rate. By opening the air valve, the burner is switched to high fire. An external control system, e.g. a PLC, can now pulse the air solenoid valve VR..R in order to control the capacity between high and low fire. In the event of a flame failure during start-up, an immediate fault lock-out occurs.
9 1.1.4 Modulating zone control Control: ON/OFF/continuous The air is set to a constant value for each zone using a manual valve. The burner capacity is controlled by the linear flow control LFC and actuator IC 20. L1, N, PE PLC mA 6 IFD 244..I 3 8 9 µC 9 BVG M IC 20 + LFC 4 VAS AKT BIO/ BIC AKT 6 IFD 244..I 3 8 9 µC 9 AKT 4 VAS BIO/ BIC AKT IFD 244 · Edition 03.
2 Certification The IFD 244 complies with the requirements of the following directives and standards: – Machinery Directive (2006/42/EC) – EN 298 – Low Voltage Directive (2006/95/EC) – Electromagnetic Compatibility Directive (2004/108/EC) Certification pursuant to – Gas Appliances Directive – FM is currently being prepared. IFD 244 · Edition 03.
3 Function IFD 244 3.1 Connection diagrams For the explanation of symbols, see Legend. For cable selection and wiring, see Project planning information. The automatic burner control units IFD 244 are designed for double-electrode operation. Single-electrode operation is not possible. s1 F1 c s2 v1 1 2 3 4 5 6 7 8 9 max. 2 A, 253 V~ Z I * IFD 244 The burner is ignited by an external ignition transformer. L1 (L1) N (L2) PE IFD 244..I The burner is ignited by an integrated ignition unit.
Function 12 Connect voltage In the event of fault signal: reset 00 Safety interlocks (Limits) Start-up position/standby 01 Waiting time tW running, start-up with * signal Flame simulation check 02 Safety time on start-up tSA running, gas valve opens, ignition in process No flame detected: fault lock-out 04 Flame detected: operation Flame fails: safety time during operation tSB starts to elapse, restart or fault lock-out 04 Normal shut-down via * signal 00 Gas valve closes IFD 244 · Edition 03
Function 3.3 Animation The interactive animation shows the function of the automatic burner control unit IFD 244. Click on the picture. The animation can be controlled using the control bar at the bottom of the window (as on a DVD player). IFD 244 · Edition 03.08 13 To play the animation, you will need Adobe Reader 6 or a newer version. If you do not have Adobe Reader on your system, you can download it from the Internet. Go to www.adobe.com, click on “Get Adobe Reader” and follow the instructions.
Function 14 3.4 Program status and fault messages Operating controls A: 2-digit 7-segment display for indicating program status and flame signal. B: Reset/Information button to reset the system after a fault or to call up the flame signal on the display. C: Mains On/Off button. A C B The 7-segment display (A) shows the program status. In the event of a fault, the IFD halts the program run and the display starts to blink. The program status and cause of the fault are displayed in coded form.
Function > Program status and fault messages 3.4.1 Reading off the flame signal Internally: The flame signal can be called up on the display by pressing the Reset/Information button (for 2 seconds). The flame signal of the burner is indicated in µA. A value between 0 and 25 µA is displayed. Important! When using an external μ-ammeter, you must make sure that this μ-ammeter cannot trigger an incorrect flame signal. IFD 244 · Edition 03.
4 Parameters Description Burner flame signal Burner switch-off threshold Burner restart Safety time during operation for V1 tSB Safety time on start-up tSA Last fault Second to last occurring fault Third to last occurring fault Tenth to last occurring fault 1) Quote in your order. On parameterisation, ensure that the program sequence matches the application. Select the parameters so that the burner can be operated as intended in all operating phases. 4.
Parameters 4.2 Flame control 4.2.1 Burner flame signal Parameter 01 Flame signal of the burner, display in μA, measuring range: 0 – 25 µA. 4.2.2 Switch-off threshold of the flame amplifier Parameter 04 The sensitivity at which the burner control unit still detects a flame is set at the factory to 2 µA. The measured flame signal of the monitored burner should be at least 3 µA (empirical value) higher than the pre-set switchoff threshold. IFD 244 · Edition 03.
Parameters 18 4.3 Behaviour during start-up 4.3.2 Start-up without flame signal 4.3.1 Normal start-up Parameter 22 The safety time tSA can be displayed or read on the type label. 01 02 tW tZ 04 1 3 5 9 4 7-8 tW 88 L1 * tZ 02 1 3 5 9 4 7–8 88 L1 ϑ t tSA t tSA Once the start-up signal (J) has been applied, the automatic burner control unit checks the burner for flame simulation during the waiting time tW.
Parameters > Behaviour during start-up 19 4.3.3 Flame simulation 00 01 02 . . . 88 V1 t tW The flame simulation check is conducted after applying the start-up signal (ϑ) during the waiting time tW. 00 02 . . . 01 tW 01 tLV 1 3 5 9 4 7–8 88 L1 ϑ V1 t t If flame simulation is signalled during start-up, the flame simulation delay time tLV starts to elapse. If the flame simulation is discontinued during the flame simulation delay time tLV (max. 25 s), the burner will start up.
Parameters 20 4.4 Behaviour during operation 4.4.1 Safety time during operation tSB for V1 and V2 Parameter 14 This indicates the safety time during operation tSB for valve V1. Standard: 1 s. The IFD is also available with a safety time during operation tSB of 2 s. Prolonging the time increases the installation availability in the case of brief-duration signal fades (e.g. fades of the flame signal).
5 Replacement possibilities The automatic burner control unit IFD 244 is interchangeable with the IFS 244 and provides almost all of the previous functions of the IFS 244. The housing dimensions and hole pattern are unchanged. The new upper section of the housing will fit on the existing lower section (for further information see operating instructions “Automatic burner control unit for continuous operation IFD 244”).
6 Selection 6.1 Determining the safety time tSA The safety time on start-up tSA = 3 s, 5 s or 10 s should be indicated when ordering. The details are based on the 1997 edition of EN 746-2.
Selection 23 6.2 Selection table IFD 2 4 4 -3 -5 -10 /1 /2 Q W I = standard, = available Order example IFD 244-5/1W 6.2.1 Type code Code IFD 2 4 4 -3 -5 -10 /1 /2 Q W I IFD 244 · Edition 03.
7 Project planning information 7.2 Star electrodes 7.1 Cable selection We recommend using 7.5 kV ignition transformers on burners with star electrodes. Use mains cable suitable for the type of operation and complying with local regulations. Signal and control line: max. 2.5 mm². Cable for burner earth/PE wire: 4 mm². Do not route IFD cables in the same cable duct as frequency converter cables or other cables emitting strong fields. 7.1.
Project planning information 25 7.4 Emergency stop in the event of fire or electric shock If there is a risk of fire, electric shock or similar, inputs L1, N and 3 (start-up/safety interlock signal) of the IFD should be disconnected from the electrical power supply. Important! This should be reflected in the wiring on site! 7.
Project planning information 26 7.10 Wiring 7.13 Flame control The IFD is suitable for hard wiring only. Do not reverse phase and neutral conductor. Different phases of a three-phase current system must not be installed at the IFD. No voltage may be connected to the valve and ignition outputs. Do not use unused terminals as support terminals. The signalling contacts for operating and fault signals do not meet the requirements for safety extra low voltage (SELV/ PELV).
8 Accessories 8.1 High-voltage cable FZLSi 1/7 -50°C (-58°F) to 180°C (356°F), Order No.: 04250410. FZLK 1/7 -5°C (23°F) to 80°C (176°F), Order No.: 04250409. 8.2 Radio interference suppressed electrode adapters Plug cap, 4 mm (0.16 inch), interference-suppressed, Order No. 04115308. Straight adapter, 4 mm (0.16 inch), interference-suppressed, Order No. 04115307. Straight adapter, 6 mm (0.2 inch), interference-suppressed, Order No. 04115306. IFD 244 · Edition 03.
9 Technical data Mains voltage for grounded and ungrounded mains: 120 V AC, -15/+10%, 50/60 Hz, 230 V AC, -15/+10%, 50/60 Hz. Safety time on start-up tSA: 3, 5 or 10 s. Safety time during operation tSB: < 1 s, < 2 s. Ignition time tZ: approx. 2, 3 or 6 s. Power consumption: IFD 244: approx. 9 VA, IFD 244..I: approx. 9 VA + 25 VA during ignition. Valve connections: 1. Output voltage for valves and ignition transformer = mains voltage. Contact rating: Ignition output: max. 2 A, cos ϕ = 0.
Technical data 29 9.1 Operating controls 112,8 ) (4.44" 75,5 (2.97") A C B 35 (1.3 8" ) 85, (3.3 5 6") 70 ") (2 .75 9.2 Installation M5 M5 35 IFD 244 · Edition 03.08 (1.38") M16 A: 2-digit 7-segment display to display program status and flame signal. B: Reset/Information button to reset the system after a fault or to call up the flame signal on the display. C: Mains On/Off button The unit can be installed in any position.
10 Maintenance cycles The automatic burner control unit IFD 244 requires little servicing. 11 Legende 88 Display 88 Blinking display Safety interlocks (Limits) Start-up signal Ignition transformer Gas valve Flame signal Fault signal Reset/Information Input signal Output signal Z I Ignition/High voltage Ionisation Input/Output safety circuit IFD 244 · Edition 03.
12 Glossary 12.3 Safety time on start-up tSA 12.1 Start-up position/standby 01 02 04 After switching on, the unit switches to the start-up position/ standby. There is no fault lock-out. The unit is ready for startup. The display indicates 00 . 12.2 Waiting time tW 01 02 tW tZ tW 02 1 3 5 9 4 7–8 88 L1 * tZ t tSA 88 L1 ϑ t tSA Once the start-up signal ϑ has been applied, the waiting time tW starts to elapse.
Glossary 32 12.5 Flame simulation/Flame simulation delay time tLV 01 tW 01 1 3 5 9 4 7–8 L1 ϑ t tLV 12.6 Safety time during operation tSB 04 tSB 1 3 5 9 4 7–8 In the event of a fault lock-out, all valves are closed and a fault signalled. Resetting must take place manually following a fault lock-out. 12.
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