6.1.1.5 Edition 10.09
Technical Information · GB
• 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..I with
integrated ignition
• Display for program status and flame signal intensity
Automatic burner control unit IFD 258
Technical Information · GB
IFD 258 · Edition 10.09
2
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1.2 Two-stage-controlled burner . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.3 Modulating-controlled burner . . . . . . . . . . . . . . . . . . . . . . . 8
2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 EC type-tested and certified . . . . . . . . . . . . . . . . . . . . . . 9
2.2 AGA approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 FM approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 CSA approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Approval for Russia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1.1 IFD258 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.1.2 IFD 258..I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Program sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Animation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Program status and fault messages . . . . . . . . . . . . . . 15
3.4.1 Reading off the flame signal . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Scanning the parameters . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Flame control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.1 Burner flame signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.2 Switch-off threshold of the flame amplifier . . . . . . . . . . . . 18
4.3 Behaviour during start-up . . . . . . . . . . . . . . . . . . . . . . 19
4.3.1 Normal start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3.2 Start-up without flame signal . . . . . . . . . . . . . . . . . . . . . . . 19
4.3.3 Flame simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Behaviour during operation . . . . . . . . . . . . . . . . . . . . . 21
4.4.1 Safety time during operation tSB for V1 and V2 . . . . . . . . . . 21
4.4.2 Fault lock-out or restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Replacement possibilities . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Determining the safety time t
SA. . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.1 Calculating the safety time tSA . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Project planning information. . . . . . . . . . . . . . . . . . . . . . 26
7.1 Cable selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Star electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.3 Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4 Emergency stop in the event of fire or electric shock . 27
7.5 Emergency stop triggered by safety interlock . . . . . . . 27
7.6 Overload protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.7 Parallel reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.8 Remote reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.9 Behaviour in the event of flame failure . . . . . . . . . . . . 27
7.10 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.11 Note on EC type-examination . . . . . . . . . . . . . . . . . . . 28
7.12 Installation of solenoid valves for gas . . . . . . . . . . . . 28
7.13 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.13.1 With ionisation sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.13.2 With UV sensor UVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.14 Flame signal cut-off point . . . . . . . . . . . . . . . . . . . . . . 28
7.15 Two-stage burner control with two solenoid valves . 29
7.16 Short-circuit fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.1 High-voltage cable . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.2 Radio interference suppressed electrode adapters. . 30
9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.1 Operating controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 Maintenance cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
IFD 258 · Edition 10.09
3
Contents
11 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.1 Waiting time
t
W
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.2 Safety time on start-up t
SA
. . . . . . . . . . . . . . . . . . . . . 34
12.3 Ignition time t
Z
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.4 Flame simulation/Flame simulation delay time t
LV
. 34
12.5 Safety time during operation t
SB
. . . . . . . . . . . . . . 35
12.6 Flame signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.7 Flame detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.8 Fault lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.9 Safety interlocks (Limits) . . . . . . . . . . . . . . . . . . . . . . . . 35
12.10 Gas valve V1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.11 Continuous operation . . . . . . . . . . . . . . . . . . . . . . . . . 35
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
IFD 258 · Edition 10.09
4
IFD 258
1 Application
Automatic burner control unit IFD258 ignites and monitors
directly ignited industrial gas burners of unlimited capacity.
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 atmospheric burners or forced draught burners in multiple burner applications, where a central control
system is used for pre-purge and for monitoring. The burners
may be modulating or stage-controlled.
The program status and the level of the flame signal can be
read directly from the unit. The cut-off point can be set using
a potentiometer.
The behaviour in the event of flame failure during operation
can be selected using a switch. Either an immediate fault
lock-out or a restart occurs.
IFD 258 · Edition 10.09
5
Intermittent shuttle
kiln in the ceramics
industry
Bogie hearth
furnace
Application
Roller hearth kiln
1.1 Examples of application
IFD 258 · Edition 10.09
6
Application > Examples of application
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.
IFD 258
10
L1, N, PE
3
µC
ZMI
VR..R
11
8
9
13
14
4
5
VAS..L
BMS
IFD 258 · Edition 10.09
7
Application > Examples of application
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 IFD258 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.
IFD 258
10
L1, N, PE
3
µC
BIO/
BIC
VR..R
11
8
9
13
14
4
5
GIK..B
VAS
BMS
IFD 258 · Edition 10.09
8
Application > Examples of application
1.1.3 Modulating-controlled burner
Control: ON/OFF/continuous
The PLC uses the actuator IC20 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 IC20
and the air butterfly valve BVA to control the burner capacity.
.
IFD 258
L1, N, PE
mA
BIO/
BIC
VAS
IC 20
BVA
GIK
µC
M
10
3
11
8
9
13
14
4
5
BMS
IFD 258 · Edition 10.09
9
2 Certification
The automatic burner control unit IFD258 is designed for ap-
plications pursuant to the Machinery Directive (98/37/EC).
2.1 EC type-tested and certified
pursuant to
– Gas Appliances Directive (90/396/EEC) in conjunction with
EN 298
– Low Voltage Directive (2006/95/EC)
– Electromagnetic Compatibility Directive (2004/108/EC)
2.2 AGA approval
Australian Gas Association, Approval No.: 4230
http://www.aga.asn.au/product_directory
2.3 FM approval
Factory Mutual Research Class: 7610 “Combustion Safeguards
and Flame Sensing Systems”.
Suitable for applications pursuant to NFPA86.
www.fmglobal.com -> Products and Services -> Product Cer-
tification -> Approval Guide
2.4 CSA approval
Certified to CAN/CSA – C 22.2 No. 199-M89 (R 2004), Canadian
Standards Association Class: 3335-01 and 3335-81 “Systems
(Gas)-Automatic Ignition and Components”
http://directories.csa-international.org
2.5 Approval for Russia
Certified by Gosstandart pursuant to GOST-R.
Approved by Rostekhnadzor (RTN).
IFD 258 · Edition 10.09
10
I
Z
c
PE
max. 2 A,
253 V~
ϑ
1 2 3 4 5 6 7 8 9 10 11 12
230V
L1 (L1)
N (L2)
s1
s2
v2v1
F1
13 14
max.
2 A,
253 V~
IFD 258
c
PE
max. 2 A,
253 V~
ϑ
1 2 3 4 5 6 7 8 9 10 11 12
230V
L1 (L1)
N (L2)
s1
s2
v2v1
F1
13 14
max.
2 A,
253 V~
IFD 258
3 Function
3.1 Connection diagrams
For the explanation of symbols, see [Legend – p.33].
For cable selection and wiring, see [Project planning infor-
mation – p.26].
3.1.1 IFD258
Ionisation control in double-electrode operation
Ionisation control in single-electrode operation
IFD 258 · Edition 10.09
11
UVS
1
2
3
c
PE
max. 2 A,
253 V~
ϑ
1 2 3 4 5 6 7 8 9 10 11 12
230V
L1 (L1)
N (L2)
s1
s2
v2v1
F1
13 14
max.
2 A,
253 V~
IFD 258
Function > Connection diagrams > IFD258
UV control
In the case of UV control, only intermittent operation is
possible.
IFD 258 · Edition 10.09
12
c
..I
UVS
1
2
3
PE
max. 2 A,
253 V~
ϑ
1 2 3 4 5 6 7 8 9 10 11 12
230V
L1 (L1)
N (L2)
s1
s2
v2v1
F1
13 14
max.
2 A,
253 V~
IFD 258
I
Z
c
..I
PE
max. 2 A,
253 V~
ϑ
1 2 3 4 5 6 7 8 9 10 11 12
230V
L1 (L1)
N (L2)
s1
s2
v2v1
F1
13 14
max.
2 A,
253 V~
IFD 258
Function > Connection diagrams
UV control
In the case of UV control, only intermittent operation is
possible.
3.1.2 IFD 258..I
The IFD258..I is suitable for double-electrode operation and
for UV control. Single-electrode operation is not possible.
Ionisation control in double-electrode operation
IFD 258 · Edition 10.09
13
Connect voltage
Safety interlocks (Li)
In the event of fault signal: reset
Flame fails: Safety time during operation t
SB
starts to elapse,
restart or fault lock-out
Start-up position/standby
Normal shut-down
via ϑ signal
Flame detected:
Operation signalling contact closes
Flame simulation check
Safety time on start-up t
SA
running,
gas valve opens, ignition in process
Operation signalling contact opens,
gas valve closes
No flame detected:
fault lock-out
Waiting time t
W
running,
start-up with ϑ signal
01
04
00
00
02
04
Function
3.2 Program sequence
Normal start-up
If, after applying voltage, an “old” fault is still being signalled,
it will be necessary to reset this first. The safety interlocks
are closed, the IFD reverts to start-up position/standby and
conducts a self-test.
If it does not determine a malfunction of the internal electronic
circuitry or of the flame sensor, the flame simulation check
then commences. This takes place in start-up position during
the waiting time tW.
If no flame simulation is detected during that period, the safety
time on start-up tSA then starts to elapse. Voltage is supplied
to the gas valve and ignition transformer. The burner starts.
After the safety time on start-up tSA has elapsed, the operation
signalling contact closes. This completes start-up.
Start-up without flame signal
If, after the gas valve has opened and the ignition has been
activated, no flame is detected during the safety time on startup tSA, a fault lock-out will then occur.
Behaviour in the event of flame failure during operation
If the flame fails during operation, the IFD258 will perform
a fault lock-out within the safety time during operation tSB.
Depending on the setting of the program selector switch, the
valves will be closed immediately or the burner will be restarted
once. If the burner does not function, a fault lock-out occurs.
IFD 258 · Edition 10.09
14
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).
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.
If the animation does not start to play, you can download
it from the document library (Docuthek) as an independent
application.
Function
IFD 258 · Edition 10.09
15
Function
3.4 Program status and fault messages
A
B
C
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.
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.
Program status
DISPLAY
Fault message (blinking)
Unit is switched off
––
Start-up position/standby
00
Waiting time/Pause time
01
Flame simulation
Safety time on start-up t
SA
02
Start-up without flame signal
Operation
04
Flame failure during operation
09
Oscillating thermostat signal
10
Too many remote resets
52
Permanent remote reset
53
Time between two start-ups is too short
IFD 258 · Edition 10.09
16
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 25µA
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 10.09
17
4 Parameters
Description Parameter Value range Factory default settings Adjustable*
Burner flame signal 01 0 – 25 μA
Burner switch-off threshold 04 2 – 20 µA 2 µA
1)
Burner restart 12 0; 1 0
2)
Safety time during operation for V1 and V2 t
SB
14 1; 2 s
3)
Burner safety time on start-up t
SA
22 3; 5; 10 s
3)
Last fault 81
Second to last occurring fault 82
Third to last occurring fault 83
…
Tenth to last occurring fault 90
1) Via potentiometer in lower section of housing.
2) Via switch in lower section of housing.
3) 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.
4.1 Scanning the parameters
During operation, the 7-segment display shows the, see [Pro-
gram status and fault messages – p.15].
The flame signal and all following parameters of the IFD can
be scanned one after the other by repeatedly pressing the
Reset/Information button (for 2s).
In the event of a fault, the IFD halts the program run, the dis-
play blinks and it then displays the cause of the fault in coded
form.
IFD 258 · Edition 10.09
18
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 20µA.
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.
The set value can be increased via a potentiometer in the lower
section of the housing so that only the flame of the system’s
“own” burner is detected.
The measured flame signal of the system’s “own” burner should
be at least 3µA (empirical value) higher than the set switch-
off threshold.
IFD 258 · Edition 10.09
19
Parameters
4.3 Behaviour during start-up
4.3.1 Normal start-up
The safety time tSA can be read on the type label (parameter22).
t
W
t
1
3
10
11
5
8-9
13-14
ϑ
L1
t
Z
t
SA
88
04
0201
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. If no flame simulation is detected
during that period, the safety time on start-up tSA (3, 5 or 10s)
then starts to elapse. This forms the minimum operating time
of the automatic burner control unit and the burner. Voltage is
supplied to the gas valve and ignition transformer. After the
safety time on start-up tSA has elapsed and the flame signal
has been received, the operation signalling contact between
terminals 13 and 14 closes. The display indicates the current
program status
04
.
4.3.2 Start-up without flame signal
t
W
t
1
3
10
11
5
13–14
8–9
L1
t
Z
t
SA
ϑ
01
02
88
02
If, after a successful burner start, the automatic burner control
unit does not detect a flame signal during the safety period on
start-up tSA, a fault lock-out will occur (fault signalling contact
between terminals 8 and 9 closes). During the entire safety
time on start-up tSA, the gas valve V1 is open. The display
blinks and indicates
02
.
IFD 258 · Edition 10.09
20
Parameters > Behaviour during start-up
4.3.3 Flame simulation
t
88 00 02 . . . 01
t
W
V1
The flame simulation check is conducted after applying the
start-up signal (J) during the waiting time tW.
t
1
3
10
11
5
L1
t
W
t
LV
8–9
13–14
ϑ
0101
If flame simulation is signalled during start-up, the flame simu-
lation delay time tLV starts to elapse. If the flame simulation
is discontinued during the flame simulation delay time tLV
(max.25s), the burner will start up. Otherwise, a fault lock-out
occurs. The display blinks and indicates
01
.
Start-up signal, safety interlock
The start-up signal is the same as the signal in the safety
interlock.
If the start-up/safety interlock signal drops more than four
times in succession during start-up, an inadmissible quantity
of non-combusted gas can reach the combustion chamber
during the safety time via open gas valves. Therefore, a fault
lock-out is performed on the automatic burner control unit
IFD258 following three consecutive drops of the start-up/
safety interlock signal (blinking
09
).
IFD 258 · Edition 10.09
21
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 t
SB
for valves
V1 and V2. The default in accordance with EN298 is 1s. The
IFD is also available with a safety time during operation tSB of
2s. Prolonging the time increases the installation availability
in the case of brief-duration signal fades (e.g. fades of the
flame signal). In accordance with EN746-2, the safety time
of the installation during operation (including closing time of
the valves) may not exceed 3 seconds (note the requirements
of the Standards).
4.4.2 Fault lock-out or restart
Parameter 12
A switch in the lower section of the housing determines whether
the IFD starts a one-off restart or performs an immediate fault
lock-out for the burner after a flame failure, see [Behaviour in
the event of flame failure – p.27].
Immediate fault lock-out following flame failure
Parameter 12 = 0,
Switch in fault lock-out position
:
t
SB
t
1
3
10
11
5
L1
04 04
88
13–14
8–9
ϑ
< 2 s
After a flame failure during operation, the IFD258 will perform
a fault lock-out within the safety time during operation tSB (the
safety time during operation tSB is 1 second. The IFD258 is
available with a safety time of 2seconds upon request). At
the same time, the gas valve is closed. The fault signalling
contact closes and the display blinks and indicates
04
, see
[Program status and fault messages – p.15].
After a fault lock-out, the IFD258 can be reset, either by using
the button on the front panel or an external button. Several
automatic burner control units can be reset in parallel using
the external button. The IFD258 cannot be reset by mains
failure. The fault signalling contact does, however, open as
soon as the mains voltage fails.
IFD 258 · Edition 10.09
22
Parameters > Behaviour during operation
Restart following flame failure
Parameter 12 = 1,
Switch in restart position :
t
Z
t
SA
t
W
t
SB
t
1
3
10
11
5
13–14
8–9
ϑ
L1
02 01 04 04
1x
88
> 2 s
If the IFD detects a flame failure after a minimum operating
time of 2s, 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. If the burner does not function, a fault lock-out
occurs. The display blinks and indicates
02
.
If, on restart, the automatic burner control unit detects a flame
signal within the safety time on start-up tSA, the operation
signalling contact closes. The display indicates the current
program status
04
.
In accordance with EN746-2, a restart may be conducted
only if the safety of the installation is not impaired. Restart is
recommended for burners which occasionally display unstable
behaviour during operation.
The precondition for a restart is that activation of the restart
allows the burner to restart as intended (in all operating
phases). It must be ensured in this case that the program
sequence started by the IFD matches the application.
IFD 258 · Edition 10.09
23
5 Replacement possibilities
The new automatic burner control unit IFD258 is interchangeable with the IFS258 and provides almost all of the previous
functions of the IFS258.
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”).
IFS 258 IFD 258
D-49018 Osnabrück, Germany
IFS 258
CE-0063AT1088
230 VAC
50/60 Hz
-20/+60 °C
ts
IP 40 (30)
D-49018 Osnabrück, Germany
IFD 258
CE-0063BXXXXX
230 VAC
50/60 Hz
-20/+60 °C
-4/+140 °F
ts 5/1s
IP 54/NEMA 3
Signalling contact for fault and operating signals Signalling contact for fault and operating signals
Flame signal called up via test jacks in upper section of housing
using external measuring instrument
The fl ame signal can be called up on the 2-digit 7-segment display.
Complies with requirements in accordance with EN 1993 Complies with requirements in accordance with EN 2003
Fault signal with no mains voltage supplied Fault signal with mains voltage supplied
Flame simulation indicated by yellow LED
Flame simulation indicated on 7-segment display =
01
Operation indicated by yellow and green LEDs
Operation indicated on 7-segment display =
04
Mains voltage = 100, 115, 200, 230 V Mains voltage = 100, 120, 200, 230 V
No protection against frequent remote resets
Protection against frequent remote resets (blinking
10
)
No protection against frequent switch-off during t
SA
Protection against frequent switch-off during tSA (blinking
09
)
IFD 258 · Edition 10.09
24
Burner with mechanical combustion
air supply
Burner capacity
Natural draught burner with direct ignition
Natural draught burner with pilot burner
kW
Safety time
on start-up t
SA
s
6 Selection
6.1 Determining the safety time t
SA
The safety time on start-up tSA = 3 s, 5 s or 10s should be
indicated when ordering.
The details are based on the 1997 edition of EN746-2.
� 70 kW
> 70 kW*
5 s
3 s
� 350 kW
> 350 kW**
10 s
10 s
5 s
EN 746-2
0 ➔ ∞*
P
N
t
SA
* PZ 0,1 × PN, P
Zmax
= 350 kW
** P
Z
0,33 × PN, P
Zmax
= 350 kW
PN = rated capacity
P
Z
= Pilot burner capacity (this is defined via the
gas valve V1)
The safety time on start-up tSA depends on the burner type,
the burner capacity and the respective application.
6.1.1 Calculating the safety time t
SA
IFD 258 · Edition 10.09
25
Selection
6.2 Selection table
2 5 8 -3 -5
-10
/1 /2 Y Q P W I*
IFD
● ● ● ● ● ● ● ● ● ● ● ●
* Only available for IFD 258..Q and IFD 258..W.
=
standard
, =
available
Order example
IFD 258-5/1W
6.2.1 Type code
Code Description
IFD Automatic burner control unit
2 Series 200
5 With ionisation or UV control
8 Immediate fault lock-out or restart, switchable
-3
-5
-10
Safety time on start-up t
SA
: 3 s
5 s
10 s
/1
/2
Safety time during operation t
SB
: 1 s
2 s
W
Q
Y
P
Mains voltage: 230 V~, 50/60 Hz
120 V~, 50/60 Hz
200 V~, 50/60 Hz
100 V~, 50/60 Hz
I* Integrated electronic ignition
* if “none”, this specifi cation is omitted.
IFD 258 · Edition 10.09
26
7 Project planning information
7.1 Cable selection
Use mains cable suitable for the type of operation and com-
plying with local regulations.
Signal and control line: max. 2.5mm
2
.
Cable for burner earth/PE wire: 4mm
2
.
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 – p.30].
Recommended cable length:
Ionisation cable – max. 75m,
Ignition cable:
IFD258: max. 5m, recommended <1m (with TZI/TGI),
IFD258..I: max. 1m, recommended <0.7m.
The longer the ignition cable, the lower the ignition capacity.
Avoid external electrical interference.
Lay cables individually and not in a metal conduit, if
possible.
Lay the ignition cable and UV cable/ionisation cable as far
apart as possible.
Screw the ignition cable securely into the ignition transformer
TGI/TZI and feed it out of the unit on the shortest possible
route (no loops).
Only use radio interference suppressed electrode adapters
(with 1kΩ resistor) for ignition electrodes, see [Accessories –
p.30].
UV cable
The UV cable should be no longer than 100m and should be
laid as far as possible from the ignition cable.
7.2 Star electrodes
We recommend using 7.5kV ignition transformers on burners
with star electrodes.
7.3 Purge
In the case of multiple burner applications, burners with forced
air supply are used. The air for combustion and pre-purge is
supplied by a central fan controlled by a separate logic. This
logic determines the purging time and controls an external
relay that switches the air valve to purge.
The automatic burner control unit must not be activated during
purging. This is achieved by interrupting the safety interlock,
amongst other methods.
IFS 258
10
L1, N, PE
3
µC
BIO/
BIC
VR..R
11
8
9
13
14
4
5
GIK..B
VAS
SPS
N
Purge
IFD 258 · Edition 10.09
27
Project planning information
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!
7.5 Emergency stop triggered by safety interlock
The safety interlock turns off the power to the input 3 (start-up/
safety interlock signal), such as in the event of air deficiency
or similar.
7.6 Overload protection
To protect the unit against overload by frequent cycling, only a
specific number of start-up attempts can be carried out by the
IFD. The maximum number of start-up attempts per minute
depends on the safety time tSA and the ignition unit.
t
SA
[s]
t
Z
[s]
Type of ignition Cycle lock
[s]
3 1,8 External TZI 10
5 3 External TZI 12
10 6 External TZI 15
3 1,8 IFD..I 36
5 3 IFD..I 60
10 6 IFD..I 120
If too many start-up attempts are made,
53
flashes on the
display to indicate a fault.
7.7 Parallel reset
Several automatic burner control units can be reset in parallel
using the external button. The IFD258 cannot be reset by mains
failure. The fault signalling contact does, however, open as
soon as the mains voltage fails.
7.8 Remote reset
Permanent
The unit can no longer be reset by permanent remote reset: If
a remote reset signal is permanently applied to terminal 4,
52
flashes on the display as a warning signal. The IFD continues
operation until it locks off.
Automatic (PLC)
Check whether automatic remote reset (PLC) complies with
standards (reset for no longer than 1 second).
If a fault is acknowledged by remote reset too often,
10
flashes
on the display to indicate a fault (too many remote resets). The
error can only be acknowledged with the Reset/Information
button on the unit.
The burner malfunction must be remedied. The malfunction
can not be remedied by changing the method of activation.
7.9 Behaviour in the event of flame failure
In the event of a flame failure, either a restart or an immediate
fault lock-out can be selected using a switch in the upper section of the automatic burner control unit IFD258.
Restart
Select for burners that occasionally demonstrate unstable
flame behaviour.
Immediate fault lock-out
Select an immediate fault lock-out when using the unit with
slow-closing air control valves or continuous control, if the
burner may not be started at maximum capacity, for burners
with a capacity of over 120kW in accordance with EN676 and
in the case of On/Off intermittent operation.
IFD 258 · Edition 10.09
28
Project planning information
7.10 Wiring
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 out-
puts.
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).
The burner should be adequately earthed. Incorrect wiring
and an insufficient earth connection can cause damage to
the equipment during single-electrode operation.
In the case of single-electrode operation, only ignition trans-
formers of type TZI or TGI may be used. The use of pulse-spark
or high-frequency ignition devices is not permitted.
7.11 Note on EC type-examination
Since EN 298 (1993) does not describe all functions of the IFD,
the operator is responsible for ensuring that all parameters
and functions are matched to the respective application.
7.12 Installation of solenoid valves for gas
During the safety time on start-up tSA, the burner must be
supplied with gas and ignited. For this reason, the gas so-
lenoid valve should be installed as close as possible to the
burner itself.
7.13 Flame control
7.13.1 With ionisation sensor
The IFD generates an alternating voltage (230VAC) between
the sensing electrode and burner earth. The flame rectifies
this voltage. Only the DC signal (>2µA) is recognised by the
automatic burner control unit as a flame.
A flame cannot be simulated by a short-circuit.
Ignition and monitoring with a single electrode are possible,
see [Connection diagrams – p.10].
7.13.2 With UV sensor UVS
A UV tube inside the UV sensor detects the ultraviolet light of
a flame. It does not respond to sunlight, incandescent bulb
light or infrared radiation emitted by hot workpieces or redhot furnace walls.
In the event of incident UV radiation the UV sensor rectifies
the supplied alternating voltage. As with ionisation control, the
automatic burner control unit only detects this DC signal.
In the case of flame control with the UV sensor UVS, only
intermittent operation is allowed (a flame simulation check
must be carried out once every 24hours).
7.14 Flame signal cut-off point
The cut-off point can be set between 2 and 20µA using a po-
tentiometer in the upper section of the housing. The automatic
burner control unit IFD is set to 2µA at the factory.
If a flame is detected during the burner start,
01
flashes on
the display to indicate a fault.
IFD 258 · Edition 10.09
29
7.15 Two-stage burner control with two solenoid
valves
The IFD is equipped with two signalling contacts for operating
and fault signals. For controlling two-stage burners, a bridge
must be installed in the lower section of the housing between
terminals 12 and 13. Valve V2 is connected to terminal 14.
I
Z
c
V1
V2
13 14
PE
max. 2 A,
253 V~
ϑ
1 2 3 4 5 6 7 8 9 10 11 12
230V
L1 (L1)
N (L2)
s1
s2
v2v1
F1
13 14
max.
2 A,
253 V~
IFD 258
Program sequence
t
W
t
1
3
10
11
5
8-9
14
ϑ
L1
t
Z
t
SA
88
04
0201
V1
V2
During the waiting time tW after heat demand, checks are
made for flame simulation and fail-safe operation. If no flame
simulation is detected, the IFD258 opens the gas valve V1 and
ignites the burner. The ignition time tZ is constant. The safety
time tSA starts with the ignition time tZ. If a flame is detected
during the safety time, the operation signalling contact closes
and valve 2 is opened once the safety time tSA has elapsed.
If no flame is detected, the fault signalling contact closes once
the safety time tSA has elapsed.
Example of application
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
IFD258 opens the air valve. The burner switches to high-fire
operation.
IFD 258
10
µC
BIO/
BIC
VR..R
11
8
9
13
14
5
GIK..B
VAS
12
7.16 Short-circuit fuse
In accordance with EN298, all safety outputs for gas valves are
fitted with an internal fuse, which may no longer be replaced.
In the event that the internal fuse blows, the unit must be sent
to the manufacturer for inspection.
Project planning information
IFD 258 · Edition 10.09
30
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, 4mm (0.16inch), interference-suppressed,
Order No. 04115308.
Straight adapter, 4mm (0.16inch), interference-suppressed,
Order No. 04115307.
Straight adapter, 6 mm (0.2inch), interference-suppressed,
Order No. 04115306.
IFD 258 · Edition 10.09
31
9 Technical data
Mains voltage for grounded and ungrounded mains:
200VAC, -15/+10%, 50/60Hz,
120VAC, -15/+10%, 50/60Hz,
100VAC, -15/+10%, 50/60Hz,
230VAC, -15/+10%, 50/60Hz.
Safety time on start-up t
SA
: 3, 5 or 10s.
Safety time during operation t
SB
: <1s, <2s.
Ignition time t
Z
: approx. 2, 3 or 6s.
Power consumption:
IFD258: approx. 9VA,
IFD258..I: approx. 9VA + 25VA during ignition.
Output voltage for valves and ignition transformer = mains
voltage.
Contact rating:
Ignition output: max. 2A, cosj = 0.2,
Valve output: max. 1A, cosj = 1,
Signalling contacts: max. 2A, 253VAC,
Max. number of operating cycles: 250,000.
Max. number of operating cycles:
Reset button: 1000,
Mains button: 1000.
Signal inputs:
Input voltage 100/120 V AC 200/230 V AC
Signal “1” 80 – 132 V 160 – 253 V
Signal “0” 0 – 20 V 0 – 40 V
Frequency 50/60 Hz
Input current signal inputs: Signal “1”: typ. 2mA.
Flame control:
sensor voltage: approx. 230VAC,
length of sensor cable:
max. 75m for ionisation control,
max. 100m for UV control,
sensor current: >2µA,
cut-off point can be adjusted between 2 and 20µA,
max. sensor current for ionisation control <25µA.
Permissible UV sensors:
Elster Kromschröder models UVS1, 5 and 6 for ambient
temperatures from -40 to +80°C (-40 to 176°F).
Valve connections: 1.
IFD258..I: ignition voltage: 22kVpp,
ignition current 25mA,
spark gap: ≤2mm.
Ignition cable:
IFD258: max. 5 m, recommended <1m (with TZI/TGI),
IFD258..I: max. 1 m, recommended <0.7m.
Fuse in unit: F1: T3.15A H250 V pursuant to IEC127-2/5.
Ambient temperature: -20 to +60°C (-4 to +140°F).
Relative humidity: no condensation permitted.
Enclosure: IP54 pursuant to IEC529.
Overvoltage category III pursuant to EN60730.
Cable gland: M16.
Installation position: any.
Weight:
IFD258: 610g,
IFD258..I: 770g.
IFD 258 · Edition 10.09
32
A
B
C
75,5
(2.97")
85,5
35
(3.36")
(1.38")
112,8
(4.44")
35
(1.38")
M5
70
(2.75")
M16
M5
Technical data
9.1 Operating controls
A: 2-digit 7-segment display to dis-
play 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.
9.2 Installation
The unit can be installed in any position.
The installation position should however
be selected carefully in order to ensure
that the display can easily be read.
The housing is made of impact-resistant
plastic. The upper section containing the
detection circuitry is a push connection
fit into the lower section. The connection terminals, earthing strip and neutral
bus are located in the lower section. The
upper section of the housing is attached
to the lower section using two screws.
The lower section can either be snapped
onto a DIN rail or secured with two M5
screws. In order to obtain enclosure
IP 54, two sealing washers must be
placed beneath the M5 screws.
The housing has 6 knock-out holes for
M16 plastic screw connectors.
.
IFD 258 · Edition 10.09
33
10 Maintenance cycles
The automatic burner control unit IFD258 requires little servicing.
11 Legend
Symbol Description
8
8
Affi chage
88
Affi chage clignotant
Chaîne de sécurité
Signal de démarrage
Transformateur d’allumage
Vanne gaz
Signal de fl amme
Indication de service / RUN
Indication de défaut
Réarmement / info
Signal d’entrée
Signal de sortie
Z
Allumage / haute tension
I Ionisation
Entrée / sortie circuit de sécurité
t
W
Temps d’attente
t
LV
Temps de temporisation de fl amme parasite
t
Z
Temps d’allumage
t
SA
Temps de sécurité au démarrage 3, 5 ou 10 s
t
SB
Temps de sécurité en service < 1 s ou < 2 s
IFD 258 · Edition 10.09
34
12 Glossary
12.1 Waiting time tW
t
W
t
1
3
10
11
5
13–14
8–9
L1
t
Z
t
SA
ϑ
01
02
88
02
Once the start-up signal J has been applied, the waiting time
tW starts to elapse. During this time, a self-test is conducted
to detect errors in internal and external circuit components. If
no malfunction is detected, the burner will start up.
12.2 Safety time on start-up tSA
t
W
t
1
3
10
11
5
8-9
13-14
ϑ
L1
t
Z
t
SA
88
04
0201
This refers to the period of time between switching on and
switching off of the gas valve V1, when no flame signal is
detected. The safety time on start-up tSA (3, 5 or 10s) is the
minimum operating time of the burner and automatic burner
control unit.
12.3 Ignition time tZ
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
6seconds, see [Technical data – p.31].
t
W
t
1
3
10
11
5
8-9
13-14
ϑ
L1
t
Z
t
SA
88
04
0201
12.4 Flame simulation/Flame simulation delay
time t
LV
t
1
3
10
11
5
L1
t
W
t
LV
8–9
13–14
ϑ
0101
Flame simulation is an incorrect flame signal. If flame simulation is detected during start-up, the flame simulation delay
time tLV (max.25s) starts to elapse. If the flame simulation is
discontinued during the flame simulation delay time tLV, startup can be initiated or operation continued. Otherwise, a fault
lock-out occurs.
IFD 258 · Edition 10.09
35
Glossary
12.5 Safety time during operation t
SB
t
SB
t
1
3
10
11
5
L1
04 04
88
13–14
8–9
ϑ
If the flame fails during operation, the valves are closed within
the safety time tSB.
The default safety time during operation tSB in accordance with
EN 298 is 1 second. In accordance with EN 746-2, the safety
time of the installation during operation (including closing time
of the valves) may not exceed 3 seconds, see [Project planning
information – p.26]. Note the requirements of the Standards!
12.6 Flame signal
If a flame is detected, the flame detector will supply a flame
signal.
12.7 Flame detector
The flame detector detects and signals the presence of a flame.
The flame detector usually consists of a flame sensor, an ampli-
fier and a relay to produce the signal. These components, with
the exception of the flame sensor itself, are accommodated
within a single housing (IFW 50).
12.8 Fault lock-out
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.
12.9 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), Gas
min
,
Gas
max
...) must isolate input 3 from the voltage supply.
12.10 Gas valve V1
The start fuel flow rate is released by gas valve V1. The gas
valve V1 opens at the start of the safety time on start-up tSA.
It remains open until the burner is switched off again by a
controlled shut-down or fault lock-out.
12.11 Continuous operation
The gas burner has been running for longer than 24hours
and was not switched off during that time.
IFD 258 · Edition 10.09
36
Kromschröder, a product
brand of the Elster Group
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1
Elster Kromschröder GmbH
Postfach 2809 · 49018 Osnabrück
Strotheweg 1 · 49504 Lotte (Büren)
Germany
T +49 541 1214-0
F +49 541 1214-370
info@kromschroeder.com
www.kromschroeder.com
www.elster.com
The current addresses of our international
agents are available on the Internet:
www.kromschroeder.com Sales
We reserve the right to make technical
modifications in the interests of progress.
Copyright © 2007 Elster Group
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