Automatic burner control unit IFD 258 Technical Information · GB 6.1.1.5 Edition 03.08 • For directly ignited burners of unlimited capacity in continuous operation pursuant to EN 746-2 • Continuous self-testing for faults • Immediate fault lock-out or restart following flame failure available as a switchable function • Flame control with UV sensor or ionisation sensor • Diverse installation possibilities via holes or snap mechanism for DIN rail • Space-saving installation on site with IFD 258..
Contents Automatic burner control unit IFD 258 . . . . . . . . . . . . . . . . . 1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Examples of application . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1.1 Forced draught burners . . . . . . . . . . . . . . . . . . . . . .
Contents 12 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 12.1 Waiting time tW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 12.2 Safety time on start-up tSA . . . . . . . . . . . . . . . . . . . . . 34 12.3 Ignition time tZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 12.4 Flame simulation/Flame simulation delay time tLV . 34 12.5 Safety time during operation tSB . . . . . . . . . . . . . .
1 Application IFD 258 IFD 258 · Edition 03.08 Automatic burner control unit IFD 258 ignites and monitors gas burners. 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 of unlimited capacity. The burners may be modulating or stagecontrolled. 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 Bogie hearth furnace IFD 258 · Edition 03.
Application > Examples of application 6 1.1.1 Forced draught burners Control: ON/OFF Gas valve and air valve are activated simultaneously. The burner is ignited and monitored by a single electrode. In the event of a flame failure, an immediate fault lock-out occurs. L1, N, PE PLC 4 3 IFD 258 µC 8 9 13 14 11 VAS..L VR..R IFD 258 · Edition 03.
Application > Examples of application 7 1.1.2 Two-stage-controlled burner Control: ON/OFF or ON/HIGH/LOW/OFF The burner BIO/BIC starts at low-fire rate. Once the normal operating state is reached, the automatic burner control unit for continuous operation IFD 258 will release control. The PLC can now pulse the air solenoid valve VR..R in order to control the capacity between high and low fire. L1, N, PE PLC 4 3 IFD 258 µC 8 9 13 14 10 11 5 GIK..B VAS VR..R IFD 258 · Edition 03.
Application > Examples of application 8 1.1.3 Modulating-controlled burner Control: ON/OFF/continuous The PLC uses the actuator IC 20 to move the air butterfly valve BVA to ignition position. The burner BIO/BIC starts at low-fire rate. Once the normal operating state is reached, the PLC uses the actuator IC 20 and the air butterfly valve BVA to control the burner capacity. . L1, N, PE mA 4 PLC 3 IFD 258 µC 8 9 13 14 11 10 5 VAS GIK IC 20 M BVA IFD 258 · Edition 03.
2 Certification The IFD 258 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 258 · Edition 03.
3 Function IFD 258 3.1 Connection diagrams s1 For the explanation of symbols, see Legend. For cable selection and wiring, see Project planning information. 230V F1 s2 v1 c v2 3.1.1 IFD 258 Ionisation control in double-electrode operation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 max. 2 A, 253 V~ max. 2 A, 253 V~ Z * I L1 (L1) N (L2) PE Ionisation control in single-electrode operation IFD 258 t s1 230V F1 s2 c v1 v2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 max. 2 A, 253 V~ max.
Function > Connection diagrams > IFD 258 11 UV control In the case of UV control, only intermittent operation is possible. IFD 258 s1 230V F1 s2 c v1 v2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 UVS 2 3 max. 2 A, 253 V~ max. 2 A, 253 V~ * L1 (L1) N (L2) PE IFD 258 · Edition 03.
Function > Connection diagrams 12 3.1.2 IFD 258..I The IFD 258..I is suitable for double-electrode operation and for UV control. Single-electrode operation is not possible. IFD 258..I s1 c Ionisation control in double-electrode operation 230V F1 s2 v1 v2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 max. 2 A, 253 V~ Z max. 2 A, 253 V~ * I L1 (L1) N (L2) PE UV control In the case of UV control, only intermittent operation is possible. IFD 258..
Function 13 Connect voltage In the event of fault signal: reset 00 Safety interlocks (Li) 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 signalling contact closes Flame fails: Safety time during operation tSB starts to elapse, restart or fault lock-out 04 Normal shut-down via * signal 00 Operation signal
Function 3.3 Animation The interactive animation shows the function of the automatic burner control unit IFD. 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 258 · Edition 03.08 14 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 15 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 (> 2 seconds) the Reset/Information button. 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 258 · Edition 03.
4 Parameters Description Burner flame signal Burner switch-off threshold Burner restart Safety time during operation for V1 and V2 tSB Burner safety time on start-up tSA Last fault Second to last occurring fault Third to last occurring fault Tenth to last occurring fault Parameter 01 04 12 14 22 81 82 83 … 90 1) Via potentiometer in lower section of housing. 2) Via switch in lower section of housing. 3) Quote in your order.
Parameters 4.2 Flame control 4.2.1 Burner flame signal Parameter 01 Flame signal of the burner, display in µA, measuring range: 0 – 30 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 can be set between 2 and 20 µA. Example: In the case of UV control with the UV sensor UVS, the signal of the burner to be monitored is influenced by other burners.
Parameters 19 4.3 Behaviour during start-up 4.3.2 Start-up without flame signal 4.3.1 Normal start-up The safety time tSA can be read on the type label (parameter 22). 01 02 tW tZ 04 1 3 10 11 5 13-14 8-9 88 L1 * tW tZ 02 1 3 10 11 5 13–14 8–9 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 20 4.3.3 Flame simulation 00 01 02 . . . 88 V1 t tW The flame simulation check is conducted after applying the start-up signal 00 (J) during the waiting time 02 . . . tW.88 01 tW 01 tLV V1 1 3 10 11 5 13–14 8–9 L1 ϑ 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. 15 s), the burner will start up.
Parameters 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 valves V1 and V2. The default in accordance with EN 298 is 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).
Parameters > Behaviour during operation 22 Restart following flame failure Parameter 12 = 1, Switch in restart position : 1x 04 01 02 >2 s tSB tW tZ tSA 04 1 3 10 11 5 13–14 8–9 88 L1 ϑ t If the IFD detects a flame failure after a minimum operating time of 2 s, the valves are closed and the operation signalling contact (terminals 13 and 14) is opened within time tSB. The automatic burner control unit now attempts to restart the burner once.
5 Replacement possibilities The new automatic burner control unit IFD 258 is interchangeable with the IFS 258 and provides almost all of the previous functions of the IFS 258. 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 258”).
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 25 6.2 Selection table IFD 2 ● 5 ● 8 ● -3 -5 -10 /1 ● ● ● ● * Only available for IFD 258..Q and IFD 258..W. = standard, = available Order example IFD 258-5/1W 6.2.
7 Project planning information 7.1 Cable selection 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. Ionisation cable and ignition cable Use unscreened high-voltage cable for both lines (see “Accessories”). Recommended cable length: Ionisation cable – max.
Project planning information 27 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 28 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).
Project planning information 29 safety time tSA has elapsed, the operation signalling contact closes and valve V2 is opened. The IFD is equipped with two signallings1contacts for operating and fault signals. For controlling two-stage burners, a bridge F1 in the lower section of the housing between must be installed terminals 12 and 13. Valve V2 is connected to terminal 14. Example of application Control: ON/OFF or ON/HIGH/LOW/OFF The burner BIO/BIC starts at low-fire rate.
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 258 · Edition 03.
9 Technical data Mains voltage for grounded and ungrounded mains: 200 V AC, -15/+10%, 50/60 Hz, 120 V AC, -15/+10%, 50/60 Hz, 100 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 258: approx. 9 VA, IFD 258..I: approx. 9 VA + 25 VA during ignition. Output voltage for valves and ignition transformer = mains voltage.
Technical data 32 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 258 · 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 258 requires little servicing. 11 Legend Symbol Description 88 Affichage 88 Affichage clignotant Chaîne de sécurité Signal de démarrage Transformateur d’allumage Vanne gaz Signal de flamme Indication de service / RUN Indication de défaut Réarmement / info Signal d’entrée Signal de sortie Z I Allumage / haute tension Ionisation Entrée / sortie circuit de sécurité IFD 258 · Edition 03.
12 Glossary 12.3 Ignition time tZ 12.1 Waiting time tW If no malfunction is detected during the waiting time tW, the ignition time tZ then starts to elapse. Voltage is supplied to the gas valve V1 and the ignition transformer and the burner is ignited. The duration of the ignition time is either 2, 3 or 6 seconds (see Technical data).
Glossary 35 12.5 Safety time during operation tSB 04 04 tSB 1 3 10 11 5 13–14 8–9 12.9 Safety interlocks (Limits) The limiters in the safety interlock (linking of all the relevant safety control and switching equipment for the use of the application, for example STB (safety temperature limiter), Gasmin, Gasmax ...) must isolate input 3 from the voltage supply. 88 L1 ϑ 12.10 Gas valve V1 t If the flame fails during operation, the valves are closed within the safety time tSB.
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