ERA ERIS GC.2 User manual

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ERA - ERİS®
Controller for Gas Burners GC.2
ERA ENDÜSTRİYEL RÖLE İMALAT
SANAYİ VE TİCARET LTD.ŞTİ.
Koşuyolu Mahallesi Asmadalı Sk.
No: 15
Koşuyolu 34718 Kadıköy – İstanbul / TÜRKİYE
Tel : 0216 340 80 85
Fax : 0216 340 80 57
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info@eraendustriyel.com.tr
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ERA - ERİS®
INDEX
1. INTRODUCTION
1.1 DECLARATIONS AND CONSIDERATIONS 4
1.2 WARRANTY 5
1.3 ABOUT THIS MANUAL 6
1.4 SIGNS AND SYMBOLS 6
2. CONTENTS
2.1 CONTENTS OF THE MANUAL 7
2.2 GENERAL WARNINGS 7
3. INTRODUCTORY BASIC INFORMATION
3.1 INTENDED USE AND PRONCIPLES OF OPERATION 8
3.2 ERİS-GC.2 Intended use 8
3.3 SPECIFICATIONS 8
3.4 PARTS OF ERİS – GC.2 CONTROLLER 9
3.5 ERİS – GC.2 Standard circuit diagram 9
3.6 CIRCUIT DIAGRAM EXPLANATIONS 10
4. PROGRAM SELECTION EXAMPLES
4.1 PROGRAM SELECTION EXAMPLE FOR BURNERS WITH AND WITHOUT BLOWERS 11
5. ERİS – GC.2 INSTALLATION AND USE
5.1 INSTALLATION OF PARTS AND ACCESSORIES 12
5.2 TECHNICAL DATA 13
5.3 CONNECTION EXAMPLES 14
5.4 ERİS – GC.2 CONNECTION INPUT OUTPUT NUMBERS 15
5.5 CABLE CONNECTIONS 15
5.6 CONNECTION EXAMPLES FOR IGNITION TRANSFORMER 16
5.7 ULTRAVIOLET FLAME DETECTOR CONNECTION EXAMPLE 16
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6. PRERUN CHECK
6.1 FLAMELESS TRIAL RUN (AFTER INSTALLATION IS COMPLETED) 17
6.2 CONTROLLED PRE-TEST ATTEMPT (WITH THE GAS VALVE SHUT OFF) 17
6.3 FAILURE CODES FOR THE FIRST TEST 18
7. PROGRAM SEQUENCES
7.1 PROGRAM SEQUENCE AND DURATIONS FOR BURNERS WITHOUT BLOWERS 19
7.2 PROGRAM SEQUENCE AND DURATIONS FOR BURNERS WITH BLOWERS 20
8. FLAWLESS RUNNING
8.1 BURNER START 21
8.2 DISPLAY STATUS AND SYMBOLS 21
9. MESSAGE CODES
9.1 COMMON MESSAGE CODES 22
9.2 FAILURE MESSAGES AND EXPLANATIONS 23
10. ERİS-GC.2 FLAME MONITORING
10.1 FLAME MONITORING BY IONIZATION ELECTRODE 24
10.2 QUICK INFORMATION ABOUT IONIZATION ELECTRODE 24
11. ERİS-GC.2 DIMENSIONS 25
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1.1 INTRODUCTION
Copyright :
Target :
audience
The manual thereof has been prepared for an audience of engineers and
technicians who would work on this product and install this product. Such
persons are required to have prior experience with this sort of equipment.
ERİS Burner Controllers’ production and brand rights are owned by ERA
LTD.ŞTİ since 2015. All rights reserved throughout Turkey. The publication
thereof cannot be copied, distributed, adapted or translated into a machine
or human language without prior written consent from ERA LTD ŞTİ.
Disclaimer :
notice
GC.2xxx burner controllers which are registered under “ERA-ERİS” brand, as
per the continuous improvement policy of ERA Ltd.Şti. have been designed in
light of the state of the art technological advancements. Without any
obligation of prior notice, the specifications of the product therein can be
subject to change, within the limits permitted by international standards!
Guidelines of use presented in this manual have been arranged to comply
with corresponding international standards. If such are to be used outside its
mentioned context, a validity and conformance approval must be acquired
first.
ERA LTD.ŞTİ. guarantees that ERİS GC.2 xxx burner control relays under the
brand ERA-ERİS do not violate any patent rights of any other product within
Turkey.
Due diligence and attention have been given in preparation of the manual
thereof. However, if you happen to discover any neglected points or errors
please inform us so that we can correct. We are expecting to keep updating
our documentation this way, in order to present to our clients. Please send
your correction inquiries to info@eraendustriyel.com.tr
ADVICE
!
1.1 DECLARATIONS AND CONSIDERATIONS
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1.2 Warranty
ERİS GC.2 xxx type burner controllers manufactured under ERA-ERİS brand are under liability of Era Endüstriyel
Röle İmalat San.ve Tic.Ltd.Şti as the producing firm. ERA LTD. ŞTİ’s liabilities for ERİS brand burner controllers
is limited to servicing and spare parts even when the reason is negligence or warranty breach. Accordingly, ERA
LTD.ŞTİ.is not liable for any cost and expenses, loss and damages, loss of use which may directly or indirectly
arise from the sales, installation, use or non-use of the product or from any other reason.
Every function of ERİS burner controllers is tested before sale. If end user wishes to make a
functionality check, this must be done in supervision of a qualified staff member who is specialized
in that particular type of system.
ERİS burner control relays are under ERA LTD.ŞTİ warranty for a duration of 1 year from the date
of production. ERA LTD.ŞTİ. accepts possible production defects upon technical review of the
item. However, for any failures which may arise later, it accepts no responsibility.
Improper opening of the ERİS burner control unit housing, might result in product failure. ERA
LTD. Co.is not responsible for any mechanical or electrical mistakes which might be made during
installation.
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WARNING
!
ERA - ERİS®
1.3 About this manual
Before starting the installation, please read this manual carefully!
ERİS-GC.2 xxx burner controllers’ installation must be implemented
by staff members who are particularly trained in commissioning of
burner systems and authorized for gas safety.
This manual basically mentions how to install, use, handle the ERİS
GC.2 xxx burner controller and other considerations for you on how to
stay safe.
This manual will help you during initial installation and commissioning
of the ERİS GC.2 xxx burner controller, for you to implement correct
methods and proper use.
In the meanwhile, you must make sure that the ERİS GC.2 xxx product
you have purchased is a match for your burner type, fuel type and
capacity specifications.
If you need advice and assistance during the purchase or use of ERİS-
GC.2 xxx burner controller, please do not hesitate to call the producing
company which is ERA END.LTD.ŞTİ. [email protected]r
1.4 Signs and symbols
DANGER
!
ADVICE
!
ATTENTION
!
It is beneficial to use this!
In cases of active electricity supply line, gas leak, open fire; do not
begin the installation. It may cause fire or electric shock. Please fol-
low legal regulations!
Follow all instructions carefully! Otherwise, you may be subject to
electric shock, fire or end up with improper installation as well as
unit failure!!
Lack of required attention can be very dangerous!
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2.1 Contents of the Manual
Introduction to manual – Installation guideline
Types of application/implementation
Product specifications
Principle of operation
Hazards
1.5 General Warnings
This product is a microprocessor controlled gas ignition automat which is meant to be used with single or
multi stage atmospheric burners or other burners which work with an air fan.
Please do not start the installation without reading the user manual!
Follow the accident prevention guidelines!
If there are ongoing gas or electric welding works in your work site, do not proceed.
Install the item so that it won’t be subject to heat or flame! Follow the commonly accepted work
safety rules and accident prevention guidelines. Take necessary precautions for installation staff
as well as other workers.
WARNING!
Make sure that you duly understand the content of the manual!
Strictly adhere to all safety rules! Without written consent of ERA LTD.ŞTİ, do not implement any
other practice or operational limits, than those suggested thereby.
If there is a section which you don’t understand, do not proceed. Contact ERA LTD.ŞTİ.
engineering department.
Contact address: info@eraendustriyel.com.tr
2CONTENTS

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3.1 ERİS-GC.2 xxx Intended use
ERİS - GC.2 xxx controllers are designed for flame control on mid-scale atmospheric or blast-sweeping
gas burners with 1 or 2 stages. It is suitable for use with gas burners which are manually stopped or
have automated thermostat which stops, at least once in every 24 hours.
Product Introduction:
Manufacturer Co. :ERA END.Röle İML.SAN.ve TİC.LTD.ŞTİ.
Brand :ERA-ERİS
Model : GC.2 xxx (micro-processor controlled)
Intended use : Gas burner flame controller
Control system : 2 staged structure
PCB Structure : UL 94 – V0 + Protective Coating
Operating voltage : 230 VAC. 50/60 Hz.
Operation principle : Electronic controller which utilizes ionization electrode or
UV photo-detector for 1 or 2 stage burners
Outer casing : PC+ABS
Connection socket : PC+ABS
3.3 Specifications
Front panel displays failure codes “in letters and numbers”,
In case of a flame failure prior to program, initiates lock phase and gives a failure notice,
Remote reset is available
2 outputs for solenoid valves
1 output for ignition transformer,
1 output for ignition transformer,
A two color status lamp on controller unit, (Red – Green)
Can work with ionization electrode or ERİS-3 UV photocell with rectification output
Detection and ignition via single electrode (with TAR-10 transformer, see Picture 7)
Low voltage detection,
Microprocessor controlled
During the production, product can be custom-programmed as per customer requirements upon
request (See program examples, Figure 3 and Figure 4)
3.2 Structure of Controllers
3. INTRODUCTORY BASIC INFORMATION

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3.4 Parts of ERİS - GC.2 xxx Controller
1. Outer casing (PC+ABS)
2. Casing fixing screws
3. PCB fixing part
4. PCB (mainboard) (UL94-V0)
5. PCB fixing screws
6. Protective cover (UL94-V0)
7. Mounting socket (PC+ABS)
8. Failure and operation notifications
display
9. Reset button
10. Failure/Operation indicator light
(Failure: Red – Functioning: Gr een)
Figure:1 ERİS - GC2 Parts
Figure 2 : ERİ S - GC.2 xxx Electric circuit diagram
3.5 ERİS – GC.2 xxx Standard circuit diagram

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K1 : Main Relay
K2/1 : Failure output contact
K2/2 : Ignition output contact
K3 : 1. Valve relay
K4 : 2. Valve relay
K5 : Protective relay (1)
FE : Functional Ground
N: Neutral
L: Phase (220 – 230 VAC. 50-60Hz.)
MS : Main switch (ON-OFF)
Si : External protective fuse
Pg : Gas pressurestat
T: Thermostat
M: Air blower
B: Bridge between 4 – 5 (DI not connected)
DI : Air pressurestat (B and DI not connected)
IT : Ignition Transformer
V1 : 1. Solenoid valve
V2 : 2. Solenoid valve
ER : External reset
AL : External alarm light
EK1 : Internal reset
IE : Ionization electrode
BR : Burner
(1) Protective relay stands for protecting the flame detector circuit from ignition transformer’s spark
3.6 Circuit Diagram Explanations (Figure : 2)

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0
60
1
10
0
10
S
K
/
H
/
1...3
T
Min. Seconds
Max. Seconds
Min. Seconds
Max. Seconds
Min. Seconds
Max. Seconds
CONTINUDUS
INTERMITTEN
BRIDGE
AIR SWITCH
NONE
NUMBER OF REPETITIONS
TERMOSTATE INPUT
PRE. SWEPING
SAFETY DURATION
V1 TYPE OF OPERATION
DIGITAL INPUT FUNCTION
AUTO - REPEATDURATION BETWEEN V1 - V2
4.1 Program Durations Selection Examples for Burners
with and without Blowers (Customer should choose.)
BURNERS WITHOUT BLOWERS
ORDERING CODE ( 1 )
05 10 //S
PRODUCT CODE
ERİS-GC.2 05
BURNERS WITH BLOWERS
ORDERING CODE ( 2 )
0
60
1
10
0
10
S
K
/
H
/
1...3
T
Min. Seconds
Max. Seconds
Min. Seconds
Max. Seconds
Min. Seconds
Max. Seconds
CONTINUDUS
INTERMITTEN
BRIDGE
AIR SWITCH
NONE
NUMBER OF REPETITIONS
TERMOSTATE INPUT
PRE. SWEPING
SAFETY DURATION
V1 TYPE OF OPERATION
DIGITAL INPUT FUNCTION
AUTO - REPEATDURATION BETWEEN V1 - V2
05 10 /HS
PRODUCT CODE
ERİS-GC.2 30
Figure 3 : Duration options for
burners without blowers
Time durations of GC.2 xxx unit will be adjusted during production as per customer requirements, as shown in table.
Alphanumerical characters are timing values and together they form the model number.
4. ERİS-GC.2 PROGRAM SELECTION EXAMPLES
Figure 4 : Duration options for
burners with blowers

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WARNING
!
5. ERİS – GC.2 xxx Installation and Use
5.1 Installation of parts and accessories
Before starting the installation, check whether your gas burner capacity and working
principles match with those of ERİS GC.2 xxx control unit data sheet. See page 12,
technical data. ERİS-GC.2 xxx control unit can perform flame control in two different
ways depending on the user preference and burner structure.
a) With ionization electrode
b) With ERİS - 3 Ultraviolet photocell.
Ionization and ignition electrodes are often integrated into the gas burners. If you need
to use UV detector in gas burner system, you can use ERİS-3 UV Photocell for ERİS –
GC.2 xxx controller. See Picture 6
For ionization electrode and UV photocell guidelines of use, please see page 24.
ERİS-GC.2 xxx Auxiliary components for flame control :
Picture 5 :
ERA - 402 Connection socket
Picture 6 :
ERİS-3 UV.Photocell
Picture 7 :
Ignition transformer (TAR-10)
* Picture 5 : Connection socket consists of 11 pcs energy input-output terminals and 3 pcs neutral
(N), 2 pcs ground (FE) terminals located just underside of the terminals.
ADVICE
!

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5.2 TECHNICAL DATA
Technical Data :
Supply voltage : 230 VAC. +%10 - %15
Minimum operation voltage : 185 VAC. (During operation <175 VAC. Stop)
Maximum operation voltage : 265 VAC. (Short term)
Frequency : 50 / 60 Hz.
Maximum power drawn from control unit : 3 Watt. Max.
Remote reset : 100 Pf/m 20m. Non-shielded cable (If laid separately
from other cables)
Flame control with ionization electrode : Voltage between chassis and ionization electrode
( Ri <10 MΩ) AC 153V.
Current when there is flame : > 1,5 uA. (Minimum)
Current when there is no flame : < 1 uA. (Maksimum)
Regular operating current : 3 ± uA.
Short circuit current between ion/chassis (Ri<10 MΩ): AC. 60 uA.
Flame control with UV detector : (with ERİS-3 detector)
Flame detection with a 1 m.cable (candle flame) : 8,6 uA. (Detector Current)
Flame detection with a 20 m.cable (candle flame) : 7,9 uA. (Detector Current)
Max.current drawn from control outputs
Terminal 6,7,8 : 1.0 Amp.
Terminal 10 : 0.5 Amp.
Terminal 4 : 2.5 Amp
Max.current drawn from terminals : 5.0 Amp. 10 seconds 1 minute Max.
Cable lengths
Terminal 11 (GC… dedektör arası kablo mesafesi : 10 Mt. Max. (With an ignition rod cable laid separately from other cables)
Terminal 1 – 3 – 4 : <20 mt. 1,5 mm2 max.
Terminal 5 – 6 – 7 – 8 – 9 –10 : <20 mt. 1,5 mm2 max.
Other information
Protection class : IP 40
Operable ambient temperature : -20 / + 60 °C Max.
Mounting position : Optional
Weight
Control relay( Without Connection Socket) : 177 gr.
Connection socket : 95 gr.

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5.3 CONNECTION EXAMPLES
For a burner without a blower
EXAMPLE CONNECTION DIAGRAM
For a burner with a blower
Figure 8 : Connection diagram for a burner without a blower
Figure 9 : Connection diagram for a burner with a blower

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WARNING
!
Input
1. 230 VAC. 50/60 Hz. Supply voltage
2. FE – Functional ground
3. Neutral (For neutral conductives use 12-13-14)
5. Start input 220/230 VAC.
9. External reset input
11.Ionization electrode input
Output
4. 220 VAC. Control output
6. Ignition transformer output
7. 1. Solenoid valve output
8. 2. Solenoid valve output
10.External failure lamp output
5.4 ERİS – GC.2 xxx Connection input output numbers
Terminal : 1 – 3 – 4 : <20 mt. 1,5 mm. max.
Terminal : 2: Functional ground
Terminal : 5 – 6 – 7 – 8 – 9 –10 : <20 mt. 1,5 mm. max.
Terminal : 11 – (Between the detector – GC.2) : 10 Mt. Max. (With a spark plug cable which is
laid separately from other
cables)
5.5 Cable Connections
Connection lines must be compliant to at least 70 °C of ambient temperature.
ERİS – GC.2 xxx control unit connection cables are according to Picture 5 connection socket num-
bers. Cable sections and lengths must comply with below specifications.
Picture 8 You must apply either B or DI mark!
a) For IT transformer connection and choice, please see Figure 10.1 – 10.2 !
b) For standard ignition transformer connection, please see Figure 10.3 !
ADVICE
!

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5.6 CONNECTION EXAMPLES FOR IGNITION TRANSFORMER
Ignion transformer must be chosen according to the electrode, which is to be used with the ERİS - GC.2
burner controller. Ignion and detecon through single electrode, as shown on Figure 10.1, requires
special transformer TAR -10 or any other ignion transformer of the same category. On Figure 10.2,
ignion and detecon are separate. As for Figure 10.3 the system requires a standard transformer along
with two or single ignion electrode and one ionizaon electrode.
Figure 10.1: Ignition and detection via
single electrode
5.7 ULTRAVIOLET FLAME DETECTOR CONNECTION EXAMPLE
Controllers must be selected according to process structure. You might need to use a UV detector for flame
detection. Ionization electrodes work with gas burners. They don’t work with diesel, fuel-oil and other liquid fuel
burners. Loss of flame cannot be detected immediately due to ionization currents interference above 1000°C. For
these reasons ultraviolet photocell monitoring is recommended. ERİS-3 UV. Detector can be connected to
ERİS-GC.2 xxx controller as shown on Figure 11.
Figure 10.2: Ignition and detection via
separate electrodes
Figure 11 : ERİS - 3 UV. Detector Connection Figure 10.3: With standard transformer and
two electrodes. Ignition and
detection electrode sare separate.

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6.1 Flameless Trial Run (after installation is completed)
Gas valve is shut off!
Flameless trial run
Fixing screw
Reset
Button
After checking the electric connections, place the
upper case onto the socket vertically, as shown in
the Picture!
With a matching screwdriver, screw in the fixing
screws into the lower socket!
See. Figure 12
ERİS - GC.2 xxx control unit and burners to be
commissioned must be disconnected from mains from
both directions.
Otherwise, electric shocks might occur!
Shut the burner gas input off!
Do the connections match with controller input/output
information?
Do cable section and specifications match with
required specifications?
During the installation or at any other time, if you drop the unit to the floor; do not operate it. A
visible or invisible damage might have occurred to its elements. In this case, please send the unit to our technical
service for a fault check
Contact address : [email protected]
ERİS - GC.2 xxx is in “failure” mode, right after
production.
Failure lamp is lit red. Message display shows the most
recent failure code. Figure 13
Turn the burner start switch “on”!
Push the “Reset” button with your finger!
Do not use a sharp tool to push Reset button. Electric
shock might occur or the unit can be damaged.
Reset is done.
Red light disappears. GC.2 xxx becomes active.
Message display
6.2 Controlled pre-test attempt
Please check failure codes on Page 17.
(with the gas valve shut off ) Reset Button Failure lamp
Figure 12 : ERİS - GC.2
Fixing of the lower/upper case
Connection Socket
Figure 13 : GC.2 in Failure state
6. Prerun Check
ADVICE
!
ATTENTION
!
WARNING
!

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ERİS - GC.2 xxx
Controller Display status
Pre-test started
Pre-sweeping started
Pre-ignition started
Valve 1 activated
“No flame !”
Led light is lit red
GC2… in failure status
Internal tests,
Pre-test or pre-sweeping, Pressurestat
Ignition system
1. valve is activated. (For trial, gas is shut off.)
Detector cannot detect a flame.
4.3 Failure Codes for the First Test
During flameless trial, GC.2 xxx has performed below checks, respectively.

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0
60
1
10
0
10
S
K
/
H
/
1...3
T
Min. Seconds
Max. Seconds
Min. Seconds
Max. Seconds
Min. Seconds
Max. Seconds
CONTINUDUS
INTERMITTEN
BRIDGE
AIR SWITCH
NONE
NUMBER OF REPETITIONS
TERMOSTATE INPUT
PRE. SWEPING
SAFETY DURATION
V1 TYPE OF OPERATION
DIGITAL INPUT FUNCTION
AUTO - REPEATDURATION BETWEEN V1 - V2
05 05 10 //S
7.1 Program sequence and durations for burners without blowers
ORDER CODE (1) (See.Page 11 - Figure: 3)
Figure 14 : GC.2 xxx P rogram sequence
GC.2 xxx program sequence and durations
A—B : Pre-test duration = tw : 2.0 s.
B—C : Waiting duration = t1 : 5.0 s. Apporx.
C—D : Pre-ignition = t3 : 2.0 s.
D—E : Final ignition = t3a : 4.0 s.
D—F : Safety duration = t2 : 5.0 s. Max.
E—F : Flame occurring duration = t3b : 0.5 s.
F—G : Duration between V1–V2 = t4 : 10.0 s. Approx.
G—H : Burner operation =
Controlled operation
Symbol explanations
Pg/T : Gas pressurestat / thermostat
B: Bridge
DI : Digital input
IT : Ignition transformer
V1 : 1. Solenoid valve
V2 : 2. Solenoid valve
AL : Failure message
IE : Ionization Electrode , or
UV.Detector (ERİS-3)
7PROGRAM SEQUENCES
Example sequence and durations for burners without blowers
I/O Signal off
I/O Signal on
I/O Signal is on or off

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15 : GC.2 xxx PrograProgram sequence
0
60
1
10
0
10
S
K
/
H
/
1...3
T
Min. Seconds
Max. Seconds
Min. Seconds
Max. Seconds
Min. Seconds
Max. Seconds
CONTINUDUS
INTERMITTEN
BRIDGE
AIR SWITCH
NONE
NUMBER OF REPETITIONS
TERMOSTATE INPUT
PRE. SWEPING
SAFETY DURATION
V1 TYPE OF OPERATION
DIGITAL INPUT FUNCTION
AUTO - REPEATDURATION BETWEEN V1 - V2
05 10 /30 KH
7.2 Program sequence and durations for burners with blowers
ORDER CODE (2) (See.Page 11 - Figure: 3)
Example sequence and durations for burners with blowers
GC.2 xxx program sequence and durations
A—B : Pre-test duration = tw : 2.0 s.
B—C : Waiting duration = t1 : 5.0 s. Yaklaşık
C—D : Pre-ignition = t3 : 2.0 s.
D—E : Final ignition = t3a : 4.0 s.
D—F : Safety duration = t2 : 5.0 s. Max.
E—F : Flame occurring duration = t3b : 0.5 s.
F—G : Duration between V1–V2 = t4 : 10.0 s. Yaklaşık
G—H : Burner operation =
Controlled operation
Symbol explanations
Pg/T : Gas pressurestat / thermostat
B: Blower motor
DI : Digital input
IT : Ignition transformer
V1 : 1. Solenoid valve
V2 : 2. Solenoid valve
AL : Failure message
IE : Ionization Electrode , or
UV.Detector (ERİS-3)
I/O Signal off
I/O Signal on
I/O Signal is on or off
Table of contents