Kromschroeder IFD 258 Manual

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 IFD258..........................................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 tSA.........................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 tW ..............................34
12.2 Safety time on start-up tSA .....................34
12.3 Ignition time tZ ...............................34
12.4 Flame simulation/Flame simulation delay time tLV . 34
12.5 Safety time during operation tSB .............. 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 IFD258 ignites and monitors
directly ignited industrial gas burners of unlimited capacity.
As a result of its fully electronic design it reacts quickly to vari-
ous process requirements and is therefore also suitable for
frequent cycling operation.
It can be used for atmospheric burners or forced draught burn-
ers 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 IFD258 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 IC20 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 IC20
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 IFD258 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 NFPA86.
www.fmglobal.com -> Products and Services -> Product Cer-
tification -> Approval Guide
2.4 CSA approval
Certified to CAN/CSA – C 22.2 No. 199-M89 (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 IFD258
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 > IFD258
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 IFD258..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 tSB
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 tSA running,
gas valve opens, ignition in process
Operation signalling contact opens,
gas valve closes
No flame detected:
fault lock-out
Waiting time tW 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 t
SA
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 start-
up tSA, a fault lock-out will then occur.
Behaviour in the event of flame failure during operation
If the flame fails during operation, the IFD258 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
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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 tSA 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
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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 25µA
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 tSB 14 1; 2 s 3)
Burner safety time on start-up tSA 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 2s).
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 20µA.
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 3µA (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 t
SA
can be read on the type label (parameter22).
tWt
1
3
10
11
5
8-9
13-14
ϑ
L1
tZ
tSA
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 10s)
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
tWt
1
3
10
11
5
13–14
8–9
L1
tZ
tSA
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
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Parameters > Behaviour during start-up
4.3.3 Flame simulation
t
88 02 . . . 00
t
88 00 02 . . . 01
t
W
V1
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
tW
tLV
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.25s), 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
IFD258 following three consecutive drops of the start-up/
safety interlock signal (blinking 09 ).