Contrive FIRO User manual

© 2020 CONTRIVE • B1444|FIRO.EN 1020 1www.contrive.it
AUTOMATIC BURNER CONTROL SYSTEM
The burner control unit FIRO is suitable for the control
of industrial burners up to 350 kW, pursuant to EN
746-2, for intermittent or continuous operation.
Flame control by means of ionization rod (even shared
with ignition).
Advanced self-diagnostic system provides the display
of either the cycle status, the causes that produced
lockouts or the immediate diagnostic of the failures
that affect the equipment or the burner.
Firo provides lockout output and remote reset input.
Times and operating cycle are configurable: the same
device can be used to control different types of gas
burners, meeting all relevant requirements.
The pull-out terminal blocks allow the control device
to be easily replaced during maintenance operations.
SAFETY INFORMATION
Read and understand this manual before installing, operating, or servicing this unit. This unit must be installed
according to this manual and local regulations. The drawings may show units without covers or safety shields to
illustrate details. Disconnect power supply and follow all usual safety precautions before carrying out any operation
on the device. Be sure to reinstall covers or shields before operating any devices.
The device is not user serviceable, a faulty device must be put out of order and sent back for servicing.
CONTRIVE manufactures products used as components in a wide variety of industrial systems and equipment. The
selection and application of products remain the responsibility of the equipment manufacturer or end user.
CONTRIVE accepts no responsibility for the way its products are incorporated into the final system design. All
systems or equipment designed to incorporate a product manufactured by CONTRIVE must be supplied to the end
user with appropriate warnings and instructions as to the safe use and operation of that part.
Any warnings provided by CONTRIVE must be promptly provided to the end user.
CONTRIVE guarantees for two years from the date of manufacture of its product to replace, or, at its option, to
repair any product or part thereof (except fuses and with some limitations for tubes and photocells) which is found
defective in material or workmanship or which otherwise fails to conform to the description of its sales order.
CONTRIVE makes no warranty of merchantability or any other warranty express or implied. CONTRIVE assumes no
liability for any personal injury, property damage, losses, or claims arising from misapplication of its products.
CERTIFICATION
Gas Equipment Directive (2009/142/EC)
Low Voltage Equipment Directive (2014/35/EC)
EMC Directive (2014/30/EC)
IN CONJUNCTION WITH:
EN298 – EN746-2 – EN60730-1 – EN13611

© 2020 CONTRIVE • B1444|FIRO.EN 1020 2www.contrive.it
Please perform the following tasks after receiving the product:
•Inspect the unit for damage. If the product appears damaged upon receipt, contact the shipper immediately.
•Verify receipt of the correct unit by checking the label.
•If you have received the wrong model or the device does not function properly, contact your supplier.
FRONT PANEL
INTERNAL
FITTING SCREWS
1
5
TERMINAL BOARD
FLAME PRESENCE INDICATOR – RED
2
6
POWER SUPPLY FUSE 1
RESET / SHUTOFF BUTTON
3
1 ULTIMATE PROTECTION AGAINST DANGEROUS
CONDITIONS BY MEANS OF INTERNAL, NON
REPLACEABLE 5A SAFETY FUSE
STATUS DISPLAY
4
USE POWER, SIGNAL AND CONTROL CABLE SUITABLE FOR THE TYPE OF OPERATION AND COMPLYING WITH ALL REGULATIONS
DO NOT ROUTE CONNECTIONS TOGETHER WITH FREQUENCY CONVERTER CABLES OR CABLES EMITTING STRONG FIELDS
PROVIDE RELIABLE CONNECTION TO PE (PROTECTION EARTH) AND BURNER FRAME, RECOMMENDED WIRE GAUGE > 4 mm2
ALL ELECTRONIC SYSTEMS MUST BE SUPPLIED BY A DEDICATED TRANSFORMER IN A TN-S EARTHING SYSTEM
USE UNSCREENED HIGH-VOLTAGE CABLE FOR IGNITION AND IONIZATION ROD LINES, LAYING CABLES INDIVIDUALLY, AVOIDING
METAL CONDUITS. KEEP HIGH VOLTAGE IGNITION CABLES AS SHORT AS POSSIBLE, AVOIDING LOOPS AND KEEP ALL OTHER
CABLES, ESPECIALLY THOSE OF IONIZATION ROD, AS FAR APART AS POSSIBLE
DEVICE DATA
QR CODE
SERIAL NUMBER
CONFIGURATION

© 2020 CONTRIVE • B1444|FIRO.EN 1020 3www.contrive.it
WIRING DIAGRAM
LEXTERNAL LIMITS
V FUEL VALVE
01 POWER SUPPLY – PHASE
02 POWER SUPPLY – NEUTRAL N
03 OUTPUT BURNER LOCKOUT
04 INPUT REMOTE RESET
05 FUEL VALVE – NEUTRAL N
06 FUEL VALVE – PHASE V
07 IGNITION TRANSFORMER – NEUTRAL N
08 IGNITION TRANSFORMER – PHASE
09 GROUND GND
10 FLAME DETECTOR INPUT ROD
FLAME DETECTED ONLY IF THE NEUTRAL IS WIRED
TO TERMINAL 2 AND CONNECTED TO GROUND
RESET
A reset action is supposed to be a clear defined manual action. An automatic reset is not allowed by EN 13611:2015.
FIRO limits the maximum number of remote resets (input terminal 4) to 5 actions within a span of 15 minutes.
Lockout (resettable only from local button) exceeding this limit.
STATUS DISPLAY
The STATUS DISPLAY [4] gives, at any time, a clear indication about the working conditions of both the burner and
the equipment, making it easier to detect any failure occurring in the system or the device.
LOCKOUTS
STANDBY
WAITING FOR RESET WH
EN PROGRAMMED
FOR STANDBY MODE AT
POWER-ON.
IGNITION FAILURE
NO FLAME DETECTED AT
THE END OF
SAFETY TIME (IGNITIO
N TRIAL).
FLAME SIMULATION
FLAME DETECTION DURI
NG PREPURGE OR
POSTPURGE (AFTER POS
TCOMBUSTION).
FLAME FAILURE
FLAME QUENCHING DURI
NG NORMAL
BURNER OPERATION.
RESET / COMMAND ERRO
R
TOO MANY
REMOTE RESETS
(MORE THAN 5 WITH
IN 15 MIN).
CYCLE
MANUAL SHUTDOWN
UNIT
HAS BEEN PUT OUT OF SERVICE FROM
PUSH BUTTON. PUSH AG
AIN TO RESTORE.
BURNER ON
FUEL VALVE IS O
PEN, OPERATING POSITION
FOR SINGLE STAGE BUR
NERS.
PREPURGE
PURGE OF COMBUSTION
CHAMBER OR MIN
TIME FOR IL
LEGAL FLAME PROVING.
POSTCOMBUSTION
WAITING FOR FLAME QU
ENCHING AFTER
LOCKOUT OR SHUTDOWN
REQUEST.
IGNITION
SAFETY TIME. BURNER
IGNITION TRIAL
WITH PILOT FUEL VALV
E OPEN.
POSTPURGE
PURGE OF COMBUSTION
CHAMBER, SHOWN
TOGETHER WITH ASSOCI
ATED CODE.

© 2020 CONTRIVE • B1444|FIRO.EN 1020 4www.contrive.it
FAILURES
IGNITION OUTPUT FAIL
URE
IGNITION DEVICE OUTP
UT REMAINS
INACTIVE.
PROGRAM ERROR
WRONG PROGRAM SEQUEN
CE.
UNSAFE OPERATION
STOPPED.
FUEL VALVE OUTPUT FA
ILURE
FUEL VALVE OUTPUT
REMAINS INACTIVE.
MEMORY ERROR
DATA CORRUPTION.
CONFIGUR
ATION ERROR.
OUTPUT RELAYS FAILUR
E 1
SHORT CIRCUIT ON OUT
PUT RELAY CONTACT
LOADS DISCONNECTED B
Y SAFETY RELAY.
TIMEBASE ERROR
MISMATCH BETWEEN 1
ST AND 2ND INTERNAL
TIMEBASE GENERATORS.
UNDERVOLTAGE
P
OWER SUPPLY VOLTAGE TOO LOW
SYSTEM REMAINS ACTI
VE.
SYSTEM ERROR
MICROPROCESSOR IS NO
T OPERATING
PROPERLY.
OVERVOLTAGE
P
OWER SUPPLY VOLTAGE TOO HIGH
FUSE INTENTIONALLY B
ROKEN AFTER 5”.
FLAME INPUT FAILURE
FLAME SENSOR REVERSE
D POLARITY OR
UNRELIABLE FLAME AMP
LIFIER.
MASTER SAFETY RELAY
FAILURE 1
SHORT CIRCUIT ON SAF
ETY RELAY CONTACT.
OUTPUTS RELEASED.
RESET
FAILURE
PUSH BUTTON
OR REMOTE RESET ACTIVE
FOR LONG TIME (MORE
THAN 10 SECONDS).
1A PREMANENT FAILURE TO THE RELAY CONTACT MAY CAUSE THE MAIN FUSE TO BLOWN, AS A SAFETY MEASURE TO
PREVENT DANGEROUS CONDITIONS. IN SUCH CASE THE UNIT MUST BE RETURNED TO FACTORY FOR SERVICING.
WARNINGS
SELF
-TEST
VERIFICAT
ION AND INITIALIZATION OF
SYSTEM COMPONENTS AT
POWER-ON.
CONFIGURATION
UNIT IN CONFIGURATIO
N MODE THROUGH
INFRARED
COMMUNICATION LINK.
CONFIGURATION
The device is fully configurable using the free software
F|tool and the infrared adapter Q|beam.USB.
1Press the button to put the unit in
MANUAL SHUTDOWN
2Point and keep Q|beam.USB toward the device
push button at a distance of 30 to 60 cm
Display shows a horizontal dash while linked. Some
parameters are password protected and can be modified
only by authorized users or by factory.
Configuration parameters and usage log can be retrieved
also by free APP running on Android devices.
Correct reception is confirmed by a green blink of LED 2.

© 2020 CONTRIVE • B1444|FIRO.EN 1020 5www.contrive.it
PARAMETERS
101 START-UP MODE AUTOSTART A
STANDBY S
303 PREPURGE (WAITING) TIME 0” … 000
DEFAULT 1”… 250” 250
401 PRE-IGNITION TIME 10,5”
402 SAFETY TIME 2” … 02
DEFAULT 3” … 25” 25
403 BURNER STARTUP ATTEMPTS 1 1
2 2
3 3
44
504 FLAME FAILURE LOCKOUT L
RECYCLE C
IGNITION RESTORATION K
505 FLAME FAILURE RESPONSE TIME 1” … 01
DEFAULT 1”… 12” 12
602 POSTPURGE (WAITING) TIME 0” … 000
DEFAULT 1”… 250” 250
ENCLOSURE PLASTIC FRP
ALUMINIUM FRA
1 NON-CONFIGURABLE PARAMETER
101 – START-UP MODE
At power-on, once the self-test has been successfully completed, the unit waits in
STANDBY mode until a reset operation is performed from push button, input or
through a fieldbus remote command. Setting AUTOSTART mode, the cycle starts
automatically, unless the units has been turned off while in lockout.
303 – PREPURGE TIME
EN298 § 3.124.1 - § 3.124.2 - § 3.124.3 - § 3.124.4
Set pre-purge time in forced draught burners according to applicable and relevant
standards (EN 676). During this time the flame simulation test is carried out.
This is a merely waiting time if there is no air control.
401 – PRE-IGNITION TIME
EN298 § 3.135.3
The ignition transformer is turned on 500 ms before the pilot fuel valve to check
the correct operation before supplying the fuel.
This is a fixed time and can not be changed.
402 – SAFETY TIME
EN298 § 3.116
Set the correct time following EN 746-2 (or other relevant) requirements:
Natural draught burners ≤ 350 kW → 10” > 350 kW → 5”
IGNITION POWER ≤33% NOMINAL POWER WITH MAXIMUM OF 350 KW
Forced draught burners ≤ 70 kW → 5” > 70kW →3”
IGNITION POWER ≤ 10% NOMINAL POWER WITH MAXIMUM OF 350 KW
403 – BURNER STARTUP ATTEMPTS
EN746-2 -EN676
When the flame is not detected at the end of startup safety time, it is possible to
make up to 4 startup attempts (including the first one), if the safety of the
application is not impaired, repeating the cycle from the beginning.
A lockout will occur if no flame has formed within programmed attempts.

© 2020 CONTRIVE • B1444|FIRO.EN 1020 6www.contrive.it
504 – FLAME FAILURE
EN298 § 7.101.2.3
Determines the behavior at flame loss during normal burner operation.
For burners with occasionally unstable flame signal a single recycle (including pre-
purge) or direct ignition restoration can be attempted.
The setting is to be
determined on the basis of burner capacity and relevant application standard.
505 – FLAME FAILURE RESPONSE TIME
EN298 § 3.105.1- § 7.101.3.4.3 - § 7.101.3.7
If the flame fails during operation, gas valves are switched off within this safety
time that must be in accordance with relevant application standards (default for
EN 298 is 1” and must not exceed 5”, including valves closing time for EN 746-2).
509 – ALLOWED POST-COMBUSTION TIME
Flame signal allowed for 20” once fuel valves has been closed.
Lockout occurs when the flame is detected after this post-combustion time.
Useful when fuel valves are distant from the burner.
602 – POSTPURGE TIME
EN298 § 3.124.6
Set post-purge time in forced draught burners according to standards (EN 676).
The flame simulation test is carried out during this time.
This is a merely waiting time if there is no air control.
CONFIGURATION CODE
FRP = PLASTIC | FRA = ALUMINUM
START-UP MODE . 101
PREPURGE TIME . 303
SAFETY TIME . 402
START-UP ATTEMPTS . 403
FLAME FAILURE BEHAVIOR . 504
FLAME FAILURE RESPONSE TIME . 505
POSTPURGE TIME . 602
FRP
A
001
03
1
L
01
001

© 2020 CONTRIVE • B1444|FIRO.EN 1020 7www.contrive.it
ENCLOSURE
According to European Standard EN60529 a minimum protection degree IP40 must be guaranteed, raised to IP54 for
open air application.
1EXTERNAL FITTING HOLES (4) 106 x 186 mm
4.2 mm SELF TAPPING OR M5 THREAD FORMING SCREW
2 BREAKABLE FITTING HOLES (4) 77 x 182 mm
4,0 mm DIAMETER
3 BREAKABLE HOLES FOR WIRING (4) Ø 19,0 mm
SUITABLE FOR PG11 CABLE GLAND
4BREAKABLE HOLES FOR WIRING (4) Ø 15,5 mm
SUITABLE FOR PG9 CABLE GLANDS
FRA - CAST ALUMINUM ALLOY EN AB 46100 IP64
OVERALL DIMENSION: 200 x 120 x 71 mm WEIGHT: ≈ 850 g
ELECTROSTATIC POLYESTER POWDER COATING RAL9006
FRP - THERMOPLASTIC POLYMER BLEND UL-V0 IP64
OVERALL DIMENSION: 200 x 120 x 71 mm WEIGHT: ≈ 550 g
GLOSSY SURFACE FINISH RAL9006
IGNITION TRANSFORMER
The ignition transformer could be mounted inside the device or fixed on the back of the unit.
TRE820
EXTERNAL FITTING HOLES
4.2mm SELF TAPPING SCREW
TRE820
EXTERNAL FITTING HOLES
4.2mm SELF TAPPING SCREW
TRK2
ASSEMBLY INSIDE
WITH SILICON GLUE
TRK2
EXTERNAL FITTING HOLES
4.2mm SELF TAPPING SCREW
ALUMINUM ENCLOSURES MUST BE
CONNECTED TO PROTECTIVE EARTH

© 2020 CONTRIVE • B1433|FIRO.EN 1020 8www.contrive.it
GAS BURNER
The burner is turned ON/OFF together with device power supply.
A flame simulation test is carried out during pre-purge (waiting time).
The fuel valve [V] will be activated only if the ignition output is detected during pre-ignition time.
The fuel valve remains open during the programmed safety time, if a valid flame signal is detected within the safety
time, the valve is kept open: the burner is ON. If no flame is detected the system will lockout.
In accordance with EN746-2 and EN676, up to 4 ignition attempts are allowed if the safety is not impaired.
Push the front panel button to reset from lockout (will take place at release).
Flame quenching during burner operation will force the system to lockout, recycle or ignition restoration.
To put the burner out of service (manual shutdown) push the front panel button during the operating cycle.
A post-combustion time (max 20 seconds) is allowed after a lockout or shutdown request, followed by post-purge.
It is possible to share a single rod for ignition and flame detection using special ignition transformers.
THERMOSTAT GAS VALVE
KPOWER RELAY
SINGLE ROD CIRCUIT
MBLOWER DUAL ROD CIRCUIT
LOW AIR PRESSURE SWITCH BURNER LOCKOUT
RESET INPUT
ALL SAFETY SWITCHES SHOULD BE APPROVED AS LIMIT CONTROLS
THE USE OF ELECTRONIC SWITCHES MAY CAUSE ERRATIC OPERATIONS

© 2020 CONTRIVE • B1433|FIRO.EN 1020 9www.contrive.it
PROGRAM SEQUENCE
ASELF TEST IS PERFORMED AT POWER-ON, ONCE
SUCCESSFULLY COMPLETED BURNER IS READY TO START.
IF THE UNIT HAS BEEN TURNED OFF WHILE IN LOCKOUT
OR PARAMETER 101 HAS BEEN SET TO STANDBY, IT WILL
BE NECESSARY TO PUSH THE LOCAL OR REMOTE BUTTON
TO EXIT FROM NON-VOLATILE LOCKOUT.
FLAME SIMULATION VERIFIED WHILE IN WAITING OR
PREPURGE.
AFTER PRESET WAITING OR PREPURGE TIME HAS
ELAPSED, IGNITION DEVICE ACTIVATED AND VERIFIED,
THEN THE GAS VALVE IS OPEN.
BURNER PROVING STARTS IF THE FLAME IS DETECTED
WITHIN THE SAFETY TIME.
IF NO FLAME IS DETECTED WITHIN THE SAFETY TIME, A
LOCKOUT OCCURS.
DEPENDING ON PARAMETER 403 THE UNIT COULD
CARRY OUT UP TO THREE FURTHER START-UP
ATTEMPTS.
AFTER THE BURNER PROVING THE IGNITION CYCLE IS
COMPLETED AND BURNER IS ON.
FLAME FAILURE DURING OPERATION LEADS TO LOCKOUT, IGNITION RESTORATION OR RECYCLE (PARAMETER 504).
MANUAL SHUTDOWN REQUEST WILL TURN OFF THE BURNER, WAITING FOR ALLOWED POSTCOMBUSTION AND OPTIONAL
POSTPURGE, BURNER CAN BE SWITCHED OFF REMOVING THE POWER SUPPLY.
TECHNICAL DATA
POWER SUPPLY
VOLTAGE 230 V +10-15%
FREQUENCY 50/60 Hz
LINE FUSE 3 A QUICK-ACTING - 5x20mm
POWER CONSUMPTION 4 VA MAX
POWER DISSIPATION 3 W MAX
OVERVOLTAGE CATEGORY II PURSUANT TO EN 60730
FLAME DETECTION
MINIMUM IONIZATION CURRENT > 1µA
CURRENT LIMITATION < 1 mA
DETECTOR LINE LENGTH < 30 m
SINGLE ROD LINE LENGTH < 2 m
DETECTOR VOLTAGE 250 Vac
DETECTOR INSULATION > 50 MΩ
ENVIRONMENT
OPERATING TEMPERATURE (-4 … 140 °F) -20 … 60 °C
STORAGE TEMPERATURE (-40 … 185 °F) -40 … 85 °C
RELATIVE HUMIDITY NO CONDENSATION ALLOWED
WEIGHT ≈ 880 g ALUMINIUM | ≈ 550 g PLASTIC
PROTECTION CLASS IP64 NEMA3
MOUNTING POSITION ANY
THIS UNIT IS NOT INTENDED FOR EXPLOSIVE OR CORROSIVE ENVIRONMENTS
OUTPUTS
MAX RATED VOLTAGE 250 Vac
MAX SWITCHING VOLTAGE 440 Vac
MAX LOAD (PER OUTPUT) 2 A cosϕ=0,7
CONTRIVE S.r.l. I-24040 SUISIO (Bergamo) via Enrico Fermi 18
ANY ILLUSTRATIONS, PHOTOGRAPHS, OR EXAMPLES USED IN THIS MANUAL ARE PROVIDED AS EXAMPLES ONLY AND MAY NOT APPLY TO ALL PRODUCTS TO
WHICH THIS MANUAL IS APPLICABLE. THE PRODUCTS AND SPECIFICATIONS DESCRIBED IN THIS MANUAL OR THE CONTENT AND PRESENTATION OF THE
MANUAL MAY BE CHANGED WITHOUT NOTICE TO IMPROVE THE PRODUCT AND/OR THE MANUAL.
PRODUCT NAMES, CORPORATE NAMES, OR TITLES USED WITHIN THIS DOCUMENT MAY BE TRADEMARKS OR REGISTERED TRADEMARKS OF OTHER COMPANIES,
AND ARE MENTIONED ONLY IN AN EXPLANATORY MANNER TO THE READERS’ BENEFIT, AND WITHOUT INTENTION TO INFRINGE.
WHILE EVERY EFFORT HAS BEEN MADE TO MAKE SURE THE INFORMATION IN THIS DOCUMENT IS CORRECT, CONTRIVE CAN NOT BE LIABLE FOR ANY DAMAGES
WHATSOEVER FOR LOSS RELATING TO THIS DOCUMENT.
© COPYRIGHT 2020 CONTRIVE SRL ITALY. ALL RIGHT RESERVED.