Honeywell DBC2000E10, DBC2000E20, DBC2000E30 Handbook

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DIGITAL BURNER CONTROLLER

DBC2000 SERIES

1. APPLICATION

The Honeywell DBC2000 is a microprocessor-based

integrated bur ner c ontroller for automatically fired
gas, oil or combination fuel industrial single bur ner
power burner appli c ations. The DBC2000 system
consists of the relay m odule and wir ing subbase.
The DBC2000 Standard Model pr ov ides the
minimum requirements to control an industrial
burner system, such as automatic burner
sequencing, fl am e supervision, system status
indicati on, system or self-diagnostics and
troubleshooting. The DBC2000 Enhanced Model
includes an integrated Valve Proofing System,
whilst the Ultimate model includes bus
communication on top of this.

The DBC2000 is programmed to provide a level of

safety, functi onal c apability and features beyond
the capacity of conventional controls.

2. FEATURES

•

Employs a plug-in mounting method

• Uses a microprocessor to improve performance

• Status and fault indication by indic ator LEDs

• A 4-wire firing rate switching circuit controls an air

damper motor or other auxiliary equi pm ent during
start-up of the bur ner .

• Safe start check before and dur ing pre-purge

• Dual flame amplifier for UV, IR or flam e rod sensor

• Automatic rec ycle once per 24h of uninterrupted

heat demand.

• Frontal jac k plug (Ø 3.5mm) to read the flame

signal with a microampere meter.

• An electrical sub base loc k ( r eset and safety limit

terminals are swapped) to avoid that a Standard
model is used systems wired for an Enhanced or
Ultimate model. The DBC2000 cannot start then.

• Safety shutdown occurs on

- malfuncti on of t he burner controller

- failure to ignite the pilot burner or main burner

- loss of flame duri ng r un peri od

- opening of air flow switch during pr e-pur ge, start-

up, run and post-purge period

- flame signal det ection during standby or pre-

purge period

• Integrated Valv e P r oofing System (Enhanced and

Ultimate models only)

• Remote bus communic ation (Ultimate m odel only)

Contents

1. Application 1

2. Features 1

3. Specifications 2

4. Dimensions 5

5. Installation and wiring 6

6. Operation 12

7. Trouble shooting 14

8. Approval s and Maint enanc e 23
Appendix: VPS calc ulation and diagrams 25

PRODUCT HANDBOOK

Importa nt no t e :

Subject to changes without notice.
Please check our web site

http://hic.emea.honeywell.com

for the most recent version of this document.

All rights reserv ed.

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3. SPECIFICATIONS

Table 1: Model Se le c t io n Guide

Model

Descr ipt io n / A pplicati on Supply voltage

DBC2000E10xx (*) Standard model

115V or 230V

(see detailed specs on page 4)

DBC2000E20xx (*) Enhanced model

DBC2000E30xx (*) Ultimate model (future release)

The Enhanced Model incl udes a Valve Proofing System.

The Ultimate model includes both r emote bus communication and a Valve Proofing System.

(*) xx depends on supply voltage and timings. For exact model num ber, plea se ref er to product selection m atrix ot
technical catalogue on http://products.ecc.emea.honeywell.com/europe.

Table 2: Sequence timing Standard Model

Waiting for

AFS

Waiting for

HF

Pre-

purge

Ignition

Pilot­only

Main

trial

Main

stabilization

Post-

purge

Flame

failure

response

300s (max) 300s (max) 35s1) 3s 5s

3s2) 4s2) 15s3) 1s (max)

1)

Default pre-purge time is 35s. Other timings on request, by OS number selection.

2)

Set to 0s. when DBI function is enabled (terminal 22 jumpered to line voltage).

3)

Set to 0s. when “no post-purge” feature is enabled (terminal 12 jumpered to line voltage).

Sequence at flame failure: immediat e lock out

Table 2a: Sequence timin g Enhanced and Ultimate Models

Waiting for

AFS

Waiting for

HF

Pre-

purge

Ignition

Pilot­only

Main

trial

Main

stabilization

Post-

purge

Flame

failure

response

300s (max) 300s (max) 35s1) 3s 5s

3s2) 4s2) 15s3) 1s (max)

1)

Default pre-purge time is 35s. Other timings on request, by OS number selection.

2)

Set to 0s. when DBI function is enabled using the DIP-switches on the front, at the bottom lef t corner (F ig 4-5).

3)

Set to 0s. when “no post-purge” feature is enabled using the DIP-switches on th e f ront, at the bottom left corner ( Fig 4-5).

Sequence at flame failure: immediate lock out

Table 3: Contact ratings

Terminal

Load Contact rating

3 Blower / Fan 3A @ cosφ=0.6
4 Ignition transformer 3A @ cosφ=0.6
5 Intermittent pilot or main (DBI) valves 3A @ cosφ=0.6
6 Interrupted pilot 3A @ cosφ=0.6
7 Main (PI) valves 3A @ cosφ=0.6

12 Main (PI) valve 2 (ENH/ULT models only) 3A @ cosφ=0.6

8, 9, 10, 11 Control motor 0.5A @ cosφ=0.6

21 Alarm 0.5A @ cosφ=0.6

Total load (based on set): Max 8A (Internal Fuse : 10A)
Total load (based on terminal 4,5,6,7): Max 5A (Internal Fuse : 6.3A)

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Table 4: Flame detection systems

Detector

type

Flame detector model no.

Max. lead wire

lengths

Standard stable flame

current on jack plug

UV detector C7027A, C7035A, C7044A < 100m 4µA (min)

14µA (max)

Flame rod Flame rod or rectifyi ng optical sensors,

C7012A,G (UV) or IRD1020.1 (IR)

< 15m 14µA (min)*

4µA (max)*

* When using a flame rod, the current on the flame jack plug is inverted. S ee also Fig 4-2.

Flame detector l eads are colour coded. The blue lead wire must be connected to the F terminal (T23) and the

white lead wire to the G terminal (T24). The UV sensing tube is polari ty sensit ive. Reversing the lead wires
even momentaril y will destr oy the UV sensing tube.

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Mains input: Supply voltage

220 to 240Vac -15% +10% 50/60Hz or
110 to 120Vac -15% +10% 50/60Hz

Allowable ambien t Temperature & Humidity

-10 °C; +60°C
90% RH max. at 40°C (non-condensing)

Classificatio n to EN298 ( Chapter 4)
F/B/L/L/X/N

Where:

F = Fan assisted
B = Interrupted and Intermittent pilot capable

L (1

st

) = non-volatile lockout after flame loss

L (2

nd

) = non-volatile lockout after flame loss final stage
X = Fixed timings per model number
N = Intermittent operation (non-self-check)

Approvals

CE certification to EN298:2003 (gas, UV & flame rod)
CE certification to EN230:2005 (oil, UV only)
EN746-2 compliant
AGA certified
GOST-R listed

Power consumption

9VA

Protection class

IP40

Mounting

Plug-in mounting method using sub-base

Dimensions

103mm x 103mm x 124mm (W x D x H) incl. sub base

Status in dic a t or LEDs

- Standby

- Purge

- Ignition

- Pilot

- Main

- Modulate

- Flame On

- Alarm
The LEDs will shortl y blink as soon as power is appli ed to t he

DBC2000 and then as soon as there is a heat demand,
indicate the bur ner sequence.

The LEDs are also used to indicate faults. For example, if a
loss of flame signal oc c ur s during RUN, the LEDs for Alarm,
Flame and Main will blink the fault code.

Jack plug

The flame signal can be measured using the jack plug (Ø

3.5mm) on the front, using a microampere meter. The
measuring device m ust be c apable of reading microamperes
between 2 and 15~20 µA.

CAUTION

Although the v oltage on t he jac k pl ug is of low
voltage, it is not consi der ed to be safe when touching
the wires connected to t he jac k plug, in case of a
malfuncti on of t he devi c e. Therefor e av oid touching
the lead wires to avoid an electrical shock.

Reset switch

When the DBC2000 is in Lockout condition* press
the internal or remote reset button one time to reset
the DBC2000 and stop the alarm. The reset button
must be held for a minimum of 3 seconds.
If the heat demand is still present, the DBC2000 will
perform the start sequence normally when the fault
condition has been resolved. Otherwise the lockout
will repeat.
If during the lock out condition the DBC2000 is de­energized and power is reapplied afterwards, the
DBC2000 will rem ain in loc k out ( non-volatile lock
out).
A remote reset push button switc h c an be c onnec ted
between termi nals 15 and 19 (Standard Model) or
between termi nals 15 and 18 (Enhanc ed and
Ultimate Model s). The f unctionality of the remote
reset is the same as the red push butt on on the f r ont
of the device, with one exc eption; the remote reset
may occur only 5 times during 15 mi nutes of
operation, whilst the internal reset button is
unlimited.

* Remark:
Lockout condition refers to the state the DBC2000 is
in after a safety shut-down occurs and the lockout
timing (20 Seconds), plus the post purge timing (15
Seconds - if enabled) have been completed. For
safety reasons the reset button is disabled
immediately aft er a safety shut-down until both of
these above timings are completed.
The lockout timi ng is fixed at 20 seconds for all
models, to allow tim e for the air dampers to return to
the start position, and to allow a safety time between
ignition att em pts, for applications without pre- and
post-purge.

Note: The Alarm and LED’s will indicate the fault
immediately, but c annot be reset until the unit has
progressed to the Lockout Condition.

Remote communication

- Under construction

.

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4. DIMENSIONS

Fig. 1: External Dimensions (in mm)

Fig. 2: Mounting dimensions of sub-base and terminal layout

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5. INSTALLATION AND WIRING

CAUTION

INSTALLATION

When Installing this Product…

1. Read these instructions carefully. Failure to follow
them could damage the produc t or cause a
hazardous condition.

2. Check the ratings giv en in the instructions and
marked on the product t o m ake sure the produc t
is suitable for the application.

3. Installer must be a trained, experienced, fl ame
safeguard service technician.

4. After installation is completed, check out the
product operation as provided in these
instructions.

WARNING

Fire or Explosion Hazard.
Can cause property damage,
severe injury, o r death.

Carefully f ollow safety requirements when installing a
burner control .

CAUTION

Electrical Shock Hazard or Equipment/
Control Damage.

Disconnect power supply before beginning installation,
to avoid electrical shock or equipment damage..

IMPORTANT

1. Wiring connections for the relay modules are

unique; refer to Fig. 3-2 or the appropriate
Specifications for individual subbase wiri ng.

2. Wiring must comply with all appli c able c odes,

ordinances and regulat ions.

3. Wiring must comply with NEC Class 1

(Line Voltage) wiri ng.

4. Loads connected to the DBC2000E must not

exceed those listed on the relay module label or the
Specificati ons; see Table 3.

5. Limits and interlock s must be rated t o

simultaneously c ar r y and break c ur r ent t o the
ignition transformer and fuel valve(s).

6. All external timer s must be listed or component
recognized by aut hori ties who have proper
jurisdiction.

7. For on-off gas-fired systems, some authorities
who have jurisdicti on pr ohibit the wiring of any
limit or operating contacts in series between the
flame safeguard control and the mai n fuel
valve(s).

8. Two UV flame detect or s can be connec ted in
parallel.

9. This equipment generat es, use s and can radiate
radio frequency ener gy and, if not installed and
used in accordance with the instructions, can
cause interfer enc e with radio communications. It
has been tested and found to comply with the
limits for a Class B computing device of Part 15 of
FCC rules, which are designed t o pr ov ide
reasonable protec tion against such interference
when operated in an industrial or commercial
environment. O per ation of this equipment in a
residential area c an c ause interference, in which
case, the users, at t heir own expense, may be
required to take whatever measures are required
to correct this interference.

10. T his digital apparatus complies with the
requirements as stated in the EN298 standard.

11. Do not install the Burner Controll er under any
circumstances in the following locations.

① Where chemicals or corrosiv e gases are

present, such as ammonia, sulfur, chlorine,
ethylene compounds, ac ids, etc.

② Install the relay module where the relative

humidity never reaches the satur ation point.
The relay module is designed t o oper ate in a
maximum 85% relative humi dity continuous,
noncondensing, moisture environment.
Condensing moistur e c an c ause a saf ety
shutdown or damage the devic e.

③ Where temperatures exceed the maximum

specificat ion for thi s device.

④ Where excessive continuous vi br ation exists.

12. Do not bundle power wiring and high voltage
ignition cable with the flame detector wiring, or run
them in parallel wit hin the same conduit. High
voltage cables must be k ept separated at least 10
cm from the Burner Controller.

13. Use proper grounding work in accor danc e with
the engineeri ng standar ds for electrical equipment

14. Connect the high voltage cabl e of t he ignition
transformer pr operl y to t he ignition electrode. A
poor connection c an c ause an el ectr ic al shock or
damage the equipment . Additionally the ignition
transformer must be properly grounded according
the standards.

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REMOVE THE RELAY MODULE FRO M ITS
SUB BASE AND FIX THE SUB BASE

1. Loosen the M3 fixing screw as shown in F ig. 1 by
about eight turns using a Phili ps head screwdriver.

2. Take the subbase and cover with both hands and
unfold them gently. Fold the relay module
upwards, the turni ng point is on the top. Do not
apply excessive force, otherwise damage may
occur.

3. Punch out the needed conduit knockout holes for
the wiring as shown i n Figs 1 and 2, and install the
wiring conduit (s).

4. Using the fixing screws, mount the subbase in the
specified position.

Avoid to overtighten the fixat io n screw on the

front of the device, to avoid damaging the
(Phillips) head o f the screw.

WIRING TH E RELAY MODULE BOTTOM
TERMINALS

1. For applications with a UV detector, remov e the
jumper terminal located at the t erminal block on
the bo ttom of the relay module.

2. For applications using remote communicati on,
connect communication cable to “BUS” terminal
located at the terminal block on the bottom of the
relay module. In addition, set the communic ation
address uring the rotary switches at the bo ttom of
the relay module.

WIRING THE SUB BASE

1. Fig. 2 shows the lay out of the terminals on the
subbase, and Figs. 3-1 to 3-3 show examples of
connections to external equipment. Regarding the
wiring to the flame detector, refer to Fig. 4.

2. When using Intermittent Pilot, connect the pilot
valve to Terminal 5. Connect the main valves to
Terminal 7 (Enhanced and Ultimate models:
connect main valve 1 to Terminal 7 and main valve
2 to Terminal 12 for the VPS function)

3. When using Interrupted Pilot, connect the pilot
valve to Terminal 6. Connect the main valv es to
Terminal 7 (Enhanced and Ultimate models:
connect main valve 1 to Terminal 7 and main valve
2 to Terminal 12 for the VPS function)

4. When using direct ignition (DBI), jumper Terminals
15 and 22. And connect the Main(DB I) valves to
Terminal 5.

5. When not using purge positi on interlock, jumper
Terminals 15 and 16.

6. When not using start posi tion interlock, jumper
Terminals 13 and 17.

7. When not purge and start posi tion interlocks,
jumper Terminal s 15 and 16 as well as Termi nals
13 and 17 simultaneously.

8. Connect the safety switc h ci r c uit (lockout
interlocks) bet ween Terminals 15 and 18. The
safety switch cir c uit must be cl osed al way s,
otherwise a lockout oc c ur s immediately.

9. For non-floating mains power grids (Neutral to
Ground), connec t t he Line-L to Terminal 1 and t he
Line-N to Terminal 2. Use a corr ect fuse: 10A fast
bl ow maximum.

10. Check all wiring circuits and assure that the
correct fuse is installed. Check the correct voltage.

11. F inally plug the relay module on to its sub base
and fix it with the M3 fixing screw. Do not overtight
the screw.

12. When using a surge absorber, connect it between
Terminal 2 and application ground.

13. Connect the mains supply volt age usi ng 0.75mm

2

or larger lead wire.

14. Never connect blank stripped wir es to the wiring
sub base. Loose wire strands may c ause short
circuits to elec tric ally safe contacts which may
cause an electri c al shock haz ar d.

Always use cable lugs to attach the wires to th e

sub base.

See Fig 2-1 for do’s and don’ts about wiring.

Fig. 2-1: Wiring the sub base terminals

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Note: terminals 18 and 19 are swapped for the Standard and Enhanced/Ultimate models.
This is to prevent that a Standard model can be used by mistake in a system that is wired for an Enhanced or Ultimate model.

Fig. 3-1: Terminal layout

Fig. 3-2: Example of wiring to external equipment (see fig 3-3 for more)

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Fig. 3-3: More examples of wiring to external equipment

Fig. 4-1: Wiring a flam e detector

CAUTION

There is line voltage on fl am e sensor inputs. Don’t touch the lead wires of the UV detector or the flame sensing
electrode t o avoi d an electri c al shock.

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Flame signal monitoring

Fig. 4-2: Real flame current versus reading on frontal jack plug.

Note:
The flame signal strengt h on the flame current jack plug is only for reference

and can vary between differ ent
DBC2000 devices.
When measuring the fl am e signal c ur r ent direc tly in the flame sensor wiring whilst:

1. Using a flame rod, the (multi -)meter will show the real flame current in µA.

2. Using a UV sensor (C7027, C7035 or C7044), the current in the sensor lead wires will be in the range of
20…25mA (inverted values).

Fig. 4-3: Measuring flame signal with multi meter (µA range selection) using a jack plug.

STD & ENH Models (flame detector sel ec t only) ULT Model (bus connector and address switches)

Fig. 4-4: Position of flame sensor selection jumpers and bus connector on the back of the DBC2000.

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SETTING THE OPTIONAL FEATURES

1. Post-purge or no post-purge

Post-purge mode

(default for all DBC2000E
models): before going to standby after heat
demand has ended, the DBC2000E performs a
15s post-purge cycle t o ventilate the burner
chamber, with the bl ower swit c hed on and the
firing rate in low positi on to save energy.

No post-purge mode

(selectabl e option): the
DBC2000E goes to standby with the blower
switched off immediately after heat demand ends
and the firing rate goes to low position.

STD model:

To enable no post-purge, apply line voltage to
terminal 12 on the wiring base. Practically this
means that a jumper is placed bet ween term inals
1 (L) and 12.

ENH/ULT models:

To enable no-post-purge, make the correct DIP­switch setti ng on the front of t he DB C2000E .
SW1 = POSTPURGE select.
Factory set to post-purge (SW1=off).
See fig. 4-5 to locate the DIP switches.

2. Pilot Ignition (PI) or Direct main
Burner Ig nit i on (DBI)

PI mode

(default): the main burner is ignited
indirectly by usi ng an interrupted or intermittent
pilot flame. Aft er the pilot is ignited and
stabelized, the DBC2000E goes for a second trial
of ignition (2

nd

safety and main stabilization are

3s) to ignite the mai n burner.
DBI mode

(selectabl e option): the intermittent
pilot ignition cycle is used to ignite the main
burner directl y via the spark igniter. The second
trial for ignition has become redundant in this
mode. In DBI mode the 2

nd

safety and main
stabilizati on times are 0s and DBC2000E goes
straight into running/modulate after pil ot
stabilization.

STD model:

To enable DBI mode, apply li ne v oltage to
terminal 22 on the wiring base. Practically this
means that a jumper is placed bet ween term inals
1 (L) and 22.

ENH/ULT models:

To enable DBI mode, make the correct DIP-switch
setting on the front of t he DBC2000E.
SW2 = DBI/PI select. Factory set to PI (SW2=off).
See fig. 4-5 to locate the DIP switches.

3. Valve Proofing System – VPS
(ENH/ULT models only)

Connect a gas pressure switc h ( such as the
C6097A2210) to terminal 22 on the wiring base
(N.O. contact).
Rule of thumb: adjust t he pr essure switc h to 0.5x
the inlet pressure.

Table 5: VPS function:

VPS enabled
SW3 = on

VPS is being perform ed

VPS disabled
SW3 = off

VPS is not used (default)

VPS pre-config

SW4 = on
SW5 = off

The VPS test cycle i s

performed duri ng pr e-purge
cycle, right aft er the heat

demand has started.

VPS post-config

SW4 = off

SW5 = on

The VPS test cycle i s

performed ri ght after the heat

demand has ended.

VPS both config

SW4 = on

SW5 = on

The VPS test cycle i s

performed before and after

the heat demand cycle.

Table 6: VPS timing:

VPS test time
25s

SW6=on
SW7=on

VPS test time
20s

SW6=on
SW7=off

VPS test time
15s

SW6=off
SW7=on

VPS test time
10s (default)

SW6=off
SW7=off

SW1: Post-p urg e use (default: off = post-purge enabled)
SW2: DBI/PI select

(default: off = PI enabled)

SW3: VPS use

(def ault: off = dis abled)

SW4: VPS pre-config

(default: off = dis abled)

SW5: VPS post-config

(default: off = disabled)

SW6: VPS test time

(default: off = see timing table)

SW7: VPS test time

(default: off = see timing table)

SW8: Not used (for future use)

Note for DIP switches:

on = upwards
off = downwards

Fig 4-5 Configurati on DIP switc hes (VPS) on the front of the DB C2000E (ENH/ ULT only)