Honeywell DBC2000 Series User manual

ENS7003R0 KO06 2010
DIGITALBURNERCONTROLLER
DBC2000 SERIES
APPLICATION
The Honeywell DB2000Eisamicroprocessor-based
integrated burnercontrolforautomaticallyfired gas,
oil orcombination fuelindustrialsingleburnerpower
burnerapplications. The DBC2000Esystemconsists
ofthe relaymoduleand wiring subbase. The
DBC2000EStandardModelprovidesthe minimum
requrementstocontrolan industrialburnersystem,
suchasautomaticburnersequencing, flame
supervision, systemstatusindication, systemorself-
diagnosticsand troubleshooting. The DBC2000E
Enhanced Modelincludesan integrated Valve
Proofing System, aswell asbuscommunication.
The DBC2000Eisprogrammed toprovide alevelof
safety, functionalcapabilityand featuresbeyond the
capacityofconventionalcontrols.
FEATURES
•Employsaplug-inmounting method
•Usesamicroprocessortoimproveperformance
•The progress ofthe sequencecan be easily
determined bystatusindicatorLEDs
•All modelshavea4-wirefiring rateswitching
circuit tocontrolan airdamperorotherauxiliary
equipment during startup ofthe burner.
•Safestart check beforeand during pre-purge
•Safetyshutdownoccurson
-malfunction ofthe burnercontroller
-failuretoignitethe pilot burnerormainburner
-loss offlameduring run period
-opening ofairflowswitchduring pre-purge,
start-up, run and post-purge period.
-flamesignaldetection during standbyorpre-
purge period
•Remotecommunication (Enhanced modelonly)
•ValveProving System(Enhanced modelonly)
Contents
Application ...................................................................1
Features.......................................................................1
Specifications...............................................................2
Dimensions..................................................................3
Installation and wiring ...................................................4
Operation .....................................................................8
PRODUCTHANDBOOK

SPECIFICATIONS
Table1: ModelSelection Guide
Model Description / Application Supplyvoltage
DBC2000E1xxx Standard model 115 or 230Vac
DBC2000E2xxx Enhanced model 115 or 230Vac
The Enhanced Model includes remote bus communication and a Valve Proofing System.
Table2: Sequencetiming
Waiting
forAFS Waiting forHF Pre-purge Ignition trial Pilot- only Main trial Main stabilized Post purge Flamefailure response
5m max 5m max 35sec 3sec 3sec 3sec* 4 sec* 15 sec** Max. 1sec
*set to0secif DBI function isenabled
** set to0secif no postpurgefeatureisenabled
Sequenceat flamefailure: immediatelock out
Table3: Contact ratings
Terminal Load Contactrating
3 Blower / Fan 3A @ cos =0.6
4 Ignition transformer 3A @ cos =0.6
5 Intermittent pilot or main (DBI) valves 3A @ cos =0.6
6 Interrupted Pilot 3A @ cos =0.6
7 Main (PI) valves 3A @ cos =0.6
8, 9, 10, 11 Control motor 0.5A @ cos =0.6
21 Alarm 0.5A @ cos =0.6
Totalload (basedon set): Max8A(InternalFuse: 10A)
Totalload (basedon terminal4,5,6,7): Max5A(InternalFuse: 6.3A)
Table4: Flamedetection systems
Detectortype Flame detectormodel No. Standard flame current
UV detector C7027A, C7035A, C7044A 4 min.
Flame Rod Rectification type Flame rod, or C7012A/G 18 max.

ENS7003R0 KO06 2010
Mainsinput: Supplyvoltage
220 to240Vac-15%+10%50/60Hzor
110 to120Vac-15%+10%50/60Hz
AllowableambientTemperature&Humidity
-10 C; +60 C
90%RH max. at 40 C(non condensing)
Approvals
CEcertification tostandardEN298:2003
CEcertification tostandardEN230:2005
Additional approvals:
Lloyds(planned)
EN746-2compliant
PED(planned)
SIL2 (planned)
Apave(planned)
Powerconsumption
9VA
Protection class
IP40
Vibration
0.5G
Mounting
Plug-inmounting method using sub-base
Dimensions
103mm x103mm x124mm (WxDxH)incl. sub base.
StatusindicatorLEDs
-Standby
-Purge
-Ignition
-Pilot
-Main
-Modulate
-FlameOn
-Alarm
TheLEDswill shortlyblinkassoon aspowerisappliedto
theDBC2000Eand thenassoon thereisaheat demand ,
indicatetheburnersequence.
TheLED’sarealsousedtoindicatefaults. Forexample, if
aloss of flamesignaloccursduring RUN, theLED’sfor
Alarm, Flameand Mainwill blinkthefault code.
Resetswitch
WhentheDBC2000 isinlock out condition and thealarm
LEDblinks, press reset button onetimetoreset the
DBC2000 and stop thealarm. If theheat demand isstill
present, theDBC2000ewill performthestart sequence
normallyif thefault condition hasbeenresolved,
otherwisethelock out will repeat.
If during thelock out condition theDBC2000Eis
deenergizedand powerisreappliedafterwards, the
DBC2000 will remaininlock out (non-volatilelock out).
Aremotereset pushbutton switchcan beconnected
betweenterminals15 and 19. Thefunctionalityof the
remotereset isthesameastheredpushbutton on the
front of thedevice, withoneexception:.
Theremotereset mayoccuronly5timesduring 15
minutesof operation, whiletheinternalreset buton is
unlimited.
Remotecommunication
-Communication protocol: ProfibusorModbus(future)
-Availabilityof:
Sequencestatus
Fault information
Flamesignalstrength
Remotereset (max5xper15mins)
Remoteheat demand
-Transmission speed: 9600bps
-Interfacetype: RS485 (M+, M-, COM)
-Address select : 1~99 encoderswitch

DIMENSIONS
Fig. 1: ExternalDimensions(inmm)
Fig. 2: Mounting dimensionsofsub-baseand terminallayout

ENS7003R0 KO06 2010
INSTALLATIONAND WIRING
CAUTION
INSTALLATION
When Installing thisProduct
1.Read theseinstructionscarefully. Failuretofollow
themcoulddamagetheproduct orcausea
hazardouscondition.
2.Check theratingsgivenintheinstructionsand
markedon theproduct tomakesuretheproduct is
suitablefortheapplication.
3.Installermust beatrained, experienced, flame
safeguardservicetechnician.
4.Afterinstallation iscomplete, check out theproduct
operation asprovidedintheseinstructions.
WARNING
Fire orExplosion Hazard.
Can cause propertydamage,
severe injury, ordeath.
Carefullyfollowsafetyrequirementswheninstalling a
burnercontrol.
CAUTION
Electrical Shock Hazard orEquipment/
Control Damage.
Can cause electrical shock orequipment
damage.
Disconnect powersupplybeforebeginning
installation.
IMPORTANT
1.Wiring connectionsfortherelaymodulesareunique;
refertoFig. 3-2ortheappropriateSpecificationsfor
individualsubbasewiring.
2.Wiring must complywithall applicablecodes,
ordinancesand regulations.
3.Wiring must complywithNECClass 1
(LineVoltage)wiring.
4.LoadsconnectedtotheDBC2000Emust not exceed
thoselistedon therelaymodulelabelorthe
Specifications; see Table3.
5.Limitsand interlocks must beratedtosimultaneously
carryand breakcurrent totheignition transformerand
fuelvalve(s).
6.All externaltimersmust belistedor
componentrecognizedbyauthoritieswho haveproper
jurisdiction.
7.Foron-off gas-firedsystems, someauthoritieswho
havejurisdiction prohibit thewiring of anylimit or
operating contactsinseriesbetweentheflame
safeguardcontroland themainfuelvalve(s).
8.TwoUVflamedetectorscan beconnectedinparallel.
9.Thisequipment generates, usesand can radiate
radiofrequency energyand, if not installedand used
inaccordancewiththeinstructions, can cause
interferencewithradiocommunications. It hasbeen
testedand found tocomplywiththelimitsforaClass
Bcomputing deviceof Part 15 of FCC rules, which
aredesignedtoprovidereasonableprotection
against suchinterferencewhenoperatedinan
industrialorcommercialenvironment. Operation of
thisequipment inaresidentialareacan cause
interference, inwhichcase, theusers, at theirown
expense, mayberequiredtotakewhatevermeasures
arerequiredtocorrect thisinterference.
10.Thisdigitalapparatuscomplieswiththerequirements
asstatedintheEN298:2003.
11.Donot install theBurnerControllerunderany
circumstancesinthefollowing locations.
Wherechemicalsorcorrosivegasesarepresent,
suchasammonia, sulfur, chlorine, ethylene
compounds, acids, etc.
②Install therelaymodulewheretherelative
humidityneverreachesthesaturation point. The
relaymoduleisdesignedtooperateina
maximum85%relativehumiditycontinuous,
noncondensing, moistureenvironment.
Condensing moisturecan causeasafety
shutdownordamagethedevice.
③Wheretemperaturesexceedthemaximum
specification forthisdevice.
④Wherevibration exceeds0,5G continuous
vibration.
12.Donot bundlepowerwiring and high voltageignition
cablewiththeflamedetectorwiring, orrun themin
parallelwithinthesameconduit. High voltagecables
must bekept separatedat least 10 cmfromthe
BurnerController.
13.Usepropergrounding workinaccordancewiththe
engineering standardsforelectricalequipment
14.Connect thehigh voltagecableof theignition
transformerproperlytotheignition electrode. Apoor
connection can causean electricalshock ordamage
theequipment. Additionallytheignition transformer
must beproperlygroundedaccording thestandards.

ENS7003R0 KO06 2010
REMOVE THERELAYMODULEFROM
ITSSUB BASE AND FIXTHESUB BASE
1.LoosentheM3fixing screwasshowninFig. 1by
about eight turnsusing aPhilipshead screwdriver.
2.Takethesubbaseand coverwithbothhandsand
unfoldthemgently. Foldtherelaymoduleupwards,
theturning point ison thetop. Donot applyexcessive
force, otherwisedamagemayoccur.
3.Punchout theneededconduit knockout holesforthe
wiring asshowninFigs1and 2, and install thewiring
conduit(s).
4.Using thefixing screws, mount thesubbaseinthe
specifiedposition.
WIRING THERELAYMODULEBOTTOM
TERMINALS
1.ForapplicationswithaUVdetector, removethe
jumperterminallocatedat theterminalblock on the
bottomof therelaymodule.
2.Forapplicationsusing remotecommunication,
connect communication cableto “BUS”terminal
locatedat theterminalblock on thebottomof the
relaymodule. Inaddition, set thecommunication
address uring therotaryswitchesat thebottomof the
relaymodule.
WIRING THESUB BASE
1.Fig.2showsthelayout of theterminalson the
subbase, and Figs.3-1to3-3showexamplesof
connectionstoexternalequipment. Regarding the
wiring totheflamedetector, refertoFig.4.
2.Whenusing Intermittent Pilot, connect thepilot valve
toTerminal5. Connect themainvalvestoTerminal7
(EnhancedModel: connect mainvalve1toTerminal7
and mainvalve2toTerminal12 fortheVPS function)
3.Whenusing InterruptedPilot, connect thepilot valve
toTerminal6. Connect themainvalvestoTerminal7
(EnhancedModel: connect mainvalve1toTerminal7
and mainvalve2toTerminal12 fortheVPS function)
4.Whenusing direct ignition (DBI), jumperTerminals15
and 22. And connect theMain(DBI)valvestoTerminal
5.
5.Whennot using purgeposition interlock, jumper
Terminals15 and 16.
6.Whennot using start position interlock, jumper
Terminals13 and 17.
7.Whennot purgeand start position interlocks, jumper
Terminals15 and 16 aswell asTerminals13 and 17
simultaneously.
8.Connect thesafetyswitchcircuit (lockout interlocks)
betweenTerminals15 and 18. Thesafetyswitch
circuit must beclosedalways, otherwisealockout
occursimmediately.
9.Fornon-floating mainspowergrids(Neutralto
Ground), connect theLine-LtoTerminal1and the
Line-NtoTerminal2. Useacorrect fuse: 10Afast
blowmaximum.
10.Check all wiring circuitsand assurethat thecorrect
fuseisinstalled. Check thecorrect voltage.
11.Finallyplugltherelaymoduleon toitssub baseand
fixit withtheM3fixing screw. Donot overtight the
screw.
12.Whenusing asurgeabsorber, connect it between
Terminal2and application ground.
13. Connect themainssupplyvoltageusing 0.75㎟or
largerlead wire.

ENS7003R0 KO06 2010
Fig. 3-1: Terminallayout
Fig. 3-2: Example1 ofwiring toexternalequipment

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Fig. 3-3: Example2 ofwiring toexternalequipment
Fig. 4: Connection toflamedetector

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OPERATION
1. NORMALOPERATION
PowerSWand Controllers
Operation ofBC2000 and device IndicatorLED*
Power SW ON,
Limit SW OM
The power supply voltage is applied across Terminal 1, and 2.
When no flame signal is present, the combustion airflow switch
is
opened (T14=OFF) and safety lockout circuit is closed (ON)
, it is
possible to start.
●○○○○○○○
Controller ON The blower is energized (T3). Firing rate goes to PURGE position.
Air flow switch closes (T14=ON) as soon as air flow is present.
●●○○○○○○
The pre-purge timer starts counting as soon as PURGE interlock is
closed (T16=ON).
After the completion of pre-purge timing, firing rate goes to
START position.
The ignition wait timer starts counting as soon as the START
position interlock is closed (T17=ON).
After completion of the ignition wait timing, the Ignition sequence
starts. The Ignition transformer is energized. The Intermittent and
Interrupted pilot valve outputs are energized (T5 and T6).
●○●○○○●○
When a flame is detected after the ignition trial has ended
(Safety1), the pilot stabilization time starts.
●○○●○○●○
After completion of the pilot-stabilization time, the Main valves
are energized (T7=ON). Note: Enhanced Model: also (T12=ON).
The Main trial for ignition takes place (Safety2).
●○○○●○●○
After completion of the main trial time, Interrupted pilot valve is
deenergized (t5=OFF). The Main stabilization time starts.
●○○○●○●○
After completion of the main stabilization time, the firing rate
goes to modulation position and releases control to an external
modulation device.
●○○○○●●○
Controller OFF The intermittent pilot valve and main valves are deenergized
(T6=OFF and T7=OFF). Note: Enhanced Model: also (12=OFF)”.
Firing rate moves to PURGE position.
The post-purge timing takes place.
●●○○○○○○
After the completion of the postpurge time, the blower is
deenergized and firing rate moves to START position.
●○○○○○○○
After the air flow switch goes OFF, DBC2000E returns to the
STANDBY condition, waiting for the next heat demand.
*ForLEDindication, ○means ‘off’●means ‘illuminated’◐means ‘blinking’.
*TheLEDsarearrangedinthefollowing order: Standby, Purge, Ignition, Pilot, Main, Modulate, Flameand Alarmattheleft
front sideof theDBC2000E.

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Pre-Purge IgnitionWait
Ignition Trial
Pilot-Only
MainTrial
Main Stabilized
Modulating
High
Interlock ON Low Interlock ON
CONTROLLER ON
Limit/PowerSwitchON
Post-Purge
CONTROLLER OFF
BLOWER
IGNITIONTR
PILOTVALVE
MAINVALVE
ALARM
HIGH
LOW
DAMPER
AIRFLOWSW
FLAMESIGNAL
POWER
PRE/POST-PURGE
IGNITIONTRIAL
PILOTONLY
M-TRI/M-STA
RUN
FLAME
ALARM
I
N
D
I
C
A
T
I
O
N
L
O
A
D
Fig. 5: Normaloperation

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2. ERRORTYPES AND SAFESHUTDOWN
If acriticalerrorrelatedtosafetyoperation (suchasaloss offlame,opening oftheairflowswitchduring theignition trial
and run sequence)isdetected, theDBC2000 instantlygoesintolock-out and goestopre-purgestatus.
If anon criticalerror(suchasopening oftheairflowswitchopening during post-purge)isdetected,DBC2000 holdsthe
sequenceforlock-out timeand thengoesintolock-out.
Forall typesof errors, thestatusLEDsindicatethestatusinformation totheoperator.
Fig.6toFig.13 showthesequenceofDBC2000 incaseofsomeerror.And Table.5showsthestatusofLEDsforeach
error.
IgnitionTrial
CONTROLLERON
POWER SWON
Post-Purge
Lockout
20SEC
BLOWER
IGNITIONTR
PILOT VALVE
MAIN VALVE
ALARM
HIGH
LOW
DAMPER
AIR FLOWSW
FLAME SIGNAL
POWER
PRE/POST-PURGE
IGNITIONTRIAL
PILOT ONLY
M-TRI/M-STA
RUN
FLAME
ALARM
I
N
D
I
C
A
T
I
O
N
L
O
A
D
Fig. 6: Failuretoignitethe pilot

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ErrorConfirmation
Flame
Failure
Post-Purge
Lockout
20SEC
RUN
BLOWER
IGNITIONTR
PILOTVALVE
MAINVALVE
ALARM
HIGH
LOW
DAMPER
AIR FLOWSW
FLAMESIGNAL
POWER
PRE/POST-PURGE
IGNITIONTRIAL
PILOTONLY
M-TRI/M-STA
RUN
FLAME
ALARM
I
N
D
I
C
A
T
I
O
N
L
O
A
D
Fig. 7: Flamefailureduring run period
Error Confirmation
Power SW ON Lockout
BLOWER
IGNITION TR
PILOT VALVE
MAINVALVE
ALARM
HIGH
LOW
DAMPER
AIRFLOW SW
FLAME SIGNAL
POWER
PRE/POST-PURGE
IGNITION TRIAL
PILOT ONLY
M-TRI/M-STA
RUN
FLAME
ALARM
I
N
D
I
C
A
T
I
O
N
L
O
A
D
Fig. 8: When falseflamesignalisgenerated during standby

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Lockout
20 SEC
ErrorConfirmation
Pre-Purge
Post-Purge
BLOWER
IGNITIONTR
PILOTVALVE
MAINVALVE
ALARM
HIGH
LOW
DAMPER
AIRFLOWSW
FLAMESIGNAL
POWER
PRE/POST-PURGE
IGNITIONTRIAL
PILOTONLY
M-TRI/M-STA
RUN
FLAME
ALARM
I
N
D
I
C
A
T
I
O
N
L
O
A
D
Fig. 9: When falseflameisgenerated during pre-purge
Lockout
LockoutTiming
ErrorConfirmation
Pre-Purge
BLOWER
IGNITION TR
PILOTVALVE
MAINVALVE
ALARM
HIGH
LOW
DAMPER
AIRFLOW SW
FLAMESIGNAL
POWER
PRE/POST-PURGE
IGNITION TRIAL
PILOTONLY
M-TRI/M-STA
RUN
FLAME
ALARM
I
N
D
I
C
A
T
I
O
N
L
O
A
D
Fig. 10: When airflowswitchgoesOFF during pre-purge, and continuesafterthe Lockout timing

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LockoutTiming
Pre-Purge
ErrorConfirmation
Pre-Purgerestart
Pre-Purge
BLOWER
IGNITIONTR
PILOTVALVE
MAINVALVE
ALARM
HIGH
LOW
DAMPER
AIRFLOWSW
FLAMESIGNAL
POWER
PRE/POST-PURGE
IGNITIONTRIAL
PILOTONLY
M-TRI/M-STA
RUN
FLAME
ALARM
I
N
D
I
C
A
T
I
O
N
L
O
A
D
Fig. 11: When airflowswitchgoesOFF during pre-purge, and then ONagainwithinLockout timing
Error Confirmation
CONTROLLER OFF
Post-Purge
Lockout
RUN
60SEC
BLOWER
IGNITIONTR
PILOTVALVE
MAINVALVE
ALARM
HIGH
LOW
DAMPER
AIRFLOWSW
FLAMESIGNAL
POWER
PRE/POST-PURGE
IGNITIONTRIAL
PILOTONLY
M-TRI/M-STA
RUN
FLAME
ALARM
I
N
D
I
C
A
T
I
O
N
L
O
A
D
Fig. 12: When flamesignalremainspresent afterthe end ofheat demand

ENS7003R0 KO06 2010
AirflowSW OFF
PostPurge
Lockout
ErrorConfirmation
20SEC
BLOWER
IGNITION TR
PILOTVALVE
MAINVALVE
ALARM
HIGH
LOW
DAMPER
AIRFLOW SW
FLAMESIGNAL
POWER
PRE/POST-PURGE
IGNITION TRIAL
PILOTONLY
M-TRI/M-STA
RUN
FLAME
ALARM
I
N
D
I
C
A
T
I
O
N
L
O
A
D
Fig. 13: When airflowswitchgoesOFF during Pilot stabilization
Table5: Errorcondition and LEDstatus
Sequence Errorcondition Indicator LEDstatus
*1
Air flow switch remains ON (closed) for
more than 5 minutes, or
START position interlock switch remains OFF(opened) for
more
than 5 minutes.
●◐○○○○○◐
Flame signal is present ●○○○○○◐◐
Standby *2
Blower motor is energized ●○○◐◐○○◐
Air flow switch remains OFF for more than 5 minutes. after the
heat
demand has started.
●◐○○○○○◐
PURGE position interlock switch remains OFF for more than 5
minutes. after the heat demand started.
●◐◐◐○○○◐
Both PURGE and START position interlocks ON at the same time
during prepurge period
●◐◐◐○○○◐
START position interlock remains OFF more than 5 minutes. after
pre-purge has finished
●◐◐◐○○○◐
Air flow switch goes ON within 5 minutes. after the heat demand
started, but air flow switch goes OFF again.
●◐○○○○○◐
Pre-purge
Flame signal is present. ●◐○○○○◐◐
Ignition Standby Air flow switch goes OFF ●◐○○○○○◐

ENS7003R0 KO06 2010
Flame signal is present ●◐○○○○◐◐
Air flow switch goes OFF ●◐◐○○○○◐ Ignition Trial
Ignition failure (flame signal is present during ignition-trial). ●○◐○○○○◐
Air flow switch goes OFF ●◐○◐○○○◐ Pilot
No flame signal ●○○◐○○◐◐
Air flow switch goes OFF ●◐○○◐○○◐ Main ignition Trial
No flame signal ●○○○◐○◐◐
Air flow switch goes OFF ●◐○○◐○○◐ Main ignition Stability
No flame signal ●○○○◐○◐◐
Air flow switch goes OFF ●◐○○○◐○◐ Run
No flame signal ●○○○○◐◐◐
No power is supplied to NO.3 terminal because of inter relay contact
failure.
●◐○◐◐○○◐
Flame signal is present for more than 10 seconds after heat demand
has ended.
●○○○○○◐◐
Post-purge
Air flow switch keeps ON more than 2 minutes after post-purge. ●◐○○○○○◐
*1ForLEDindication, ○means ‘off’●means ‘illuminated’◐means ‘blinking’.
TheLEDsarearrangedinthefollowing order: Standby, Purge, Ignition, Pilot, Main, Modulate, Flameand Alarmat the
left front sideof theDBC2000E
.*2If an erroroccursduring Standby, theDBC2000 will not lock-out but LEDsindicatethecurrent errorstatus.
Inthiscase, theDBC2000 cannot start beforetheerrorisresolved.

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