SIAD ESA Pyronics ESTRO-PO E7014P User manual

Electronics
Permanent Operation
Microprocessor Burner Control
ESA ESTRO-PO (E7014P rev. 02 - 03/05/2017)

ESA ESTRO - E7014P rev. 02 - 03/05/17
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ESA ESTRO conforms to the EN298 regulation according to the KIP-
16422/G certificate issued by notified body 0476. ESA ESTRO con-
forms to the European Directives: Gas Regulation 2016/426/EC, Low
voltage directive 2014/35/EC, Electromagnetic immunity 2014/30/EC, in
conjunction with the EN298 and EN746-2. The products conform to the
requests for the Euroasia market (Russia, Belarus and Kazakhstan).
CERTIFICATIONS:
GENERA WARNINGS: GENERA NOTES:
¾
¾All installation, maintenance, ignition and setting must
be performed by qualified staff, respecting the norms
present at the time and place of the installation.
¾
¾To avoid damage to people and things, it is essential
to observe all the points indicated in this handbook. The
reported indications do not exonerate the Client/User
from observing general or specific laws concerning acci-
dents and environmental safeguarding.
¾
¾The operator must wear proper DPI clothing (shoes,
helmets...) and respect the general safety, prevention
and precaution norms.
¾
¾To avoid the risks of burns or high voltage electrocu-
tion, the operator must avoid all contact with the burner
and its control devices during the ignition phase and
while it is running at high temperatures.
¾
¾All ordinary and extraordinary maintenance must be
performed when the system is stopped.
¾
¾To assure correct and safe use of the combustion
plant, it is of extreme importance that the contents of this
document be brought to the attention of and be meticu-
lously observed by all personnel in charge of controlling
and working the devices.
¾
¾The functioning of a combustion plant can be dange-
rous and cause injuries to persons or damage to equip-
ment. Every burner must be provided with certified com-
bustion safety and supervision devices.
¾
¾The burner must be installed correctly to prevent any
type of accidental/undesired heat transmission from the
flame to the operator or the equipment.
¾
¾The performances indicated in this technical docu-
ment regarding the range of products are a result of
experimental tests carried out at ESA-PYRONICS. The
tests have been performed using ignition systems, flame
detectors and supervisors developed by ESA-PYRO-
NICS. The respect of the above mentioned functioning
conditions cannot be guaranteed if equipment, which is
not present in the ESA-PYRONICS catalogue, is used.
To dispose of the product, abide by the local legislations
regarding it.
DISPOSA :
ASSISTANCE/CONTACTS:
Esa S.p.A.
Via Enrico ermi 40
24035 Curno (BG) - Italy
Tel [phone]
ax +39.035.6227499
[email protected]
ESA Belgium
Zoning Industriel, 4ème rue
B-6040 Jumet - Belgium
Tel [phone]
ax +32.71.256979
[email protected]
www.esapyronics.com
¾
¾In accordance to the internal policy of constant quali-
ty improvement, ESA-PYRONICS reserves the right to
modify the technical characteristics of the present docu-
ment at any time and without warning.
¾
¾It is possible to download technical sheets which
have been updated to the latest revision from the
www.esapyronics.com website.
¾
¾The products manufactured by ESA-PYRONICS
have been created in conformity to the UNI EN 746-
2:2010 Norms: Equipment for industrial thermal process
- Part 2: Safety requirements for combustion and the
movement and treatment of combustible elements. This
norm is in harmony with the Machine Directive
2006/42/CE. It is certified that the products in question
respect all the requirements prescribed by the above
mentioned Norms and Directives.
¾
¾Certified in conformity with the UNI EN ISO 9001
Norm by DNV GL.

ESA ESTRO - E7014P rev. 02 - 03/05/17
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APP ICATIONS
ESA ESTRO is a microprocessor operated flame control
device that controls gas and oil fired burners for conti-
nuous operation. This device safely controls one or two
stage burners (pilot and main), combustion air, and is
able to detect the flame signal via ionization sensors
(electrodes) or UV radiation (UV-scan), continuously per-
forming a periodic check of the flame sensor. The flame
control device is equipped with a serial communication
which allows remote burner control. The case is robust
allowing the application of the control device near the
burner.
¾
¾One or two stage gas and oil burners (pilot or main),
with any type of capacity, with permanent or non-perma-
nent operation.
¾
¾Burners with electrode, unirod and UV detection (also
combined).
¾
¾Permanent operation by electrode detenction or by
UV scanner and shutter.
¾
¾Package burners with complete ignition cycle control
(blower, air regulation valve, pressure switch and air flow
switch).
¾
¾Burners with air valve control for chamber purge, bur-
ner ignition and temperature regulation (heating/cooling)
via external regulator command.
¾
¾Plants with burner control via digital signals or ECS
serial communication.
¾
¾Personalized burner control via optional configuration
cards.
CHARACTERISTICS
GENERA :
¾
¾Voltage supply: 115 Vac or 230 Vac +10 ÷ -15%
¾
¾requency supply: 45÷65 Hz
¾
¾Type of supply: phase-neutral,
not appropriate for phase-phase systems
¾
¾Neutral: suitable for ground and
non ground neutral systems
¾
¾No-load absorption: 5 VA max
¾
¾Working temperature: 0÷60 °C
¾
¾Storage temperature: -20÷80 °C
¾
¾Protection degree:IP54 (for wiring use specific glands)
¾
¾Mounting position: any
¾
¾Working environment: not suitable for explosive or
corrosive environments
¾
¾Container: Thermosetting glass fiber
¾
¾Size: 200×120×93 mm
¾
¾Mass: 1.300 g
7014PI03
7014PI04

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CHARACTERISTICS
INPUTS AND OUTPUTS:
¾
¾Voltage to the flame detection probe: max 300 Vac
¾
¾Minimum ionization current: 2,4 µA ± 0,3 µA
¾
¾Current limits to the probe: 1 mA
¾
¾lame signal display: 0 ÷ 90 µA
¾
¾Detection probe type: electrode or scanner ESA UV-2
¾
¾Probe line length to electrode or UV-2 detection: < 30 m
¾
¾Insulation between the probe conductors: > 50 MΩ(cables with double insulation or double protection)
¾
¾HV cable length from ignition transformer: maximum 2 m
¾
¾Distance between ignition electrode and burner mass: 3 mm ± 0,5
¾
¾Digital input voltage: the same as the supply voltage
¾
¾Digital input absorption: max 5mA
¾
¾ilter for digital input: RC 100 Ω- 0,47 µ - 250 Vac
¾
¾Output voltage: the same as the supply voltage
¾
¾Maximum current per single output: 1,5 A (2 A for ignition transformer)
¾
¾Total maximum current for all outputs: 3.15A per 10 second / minute
¾
¾Output protection fuse: 3.15A rapid (*) replaceable
¾
¾Internal relay protection fuse: 4 A not replaceable
¾
¾Instrument protection fuse: 1 A not replaceable
¾
¾Minimum voltage supply to maintain output: 70Vac (version 115Vac) and
140Vac (version 230Vac)
¾
¾EXP-2, EXP-4 and EXP5 expansion card input voltage: 24 Vac/Vdc, 115 Vac, 230 Vac
¾
¾EXP-2, EXP-4 e EXP5 expansion card input absorption: max 5mA
¾
¾EXP-2, EXP-4 e EXP5 expansion card output voltage: the same as the supply voltage
¾
¾EXP-2, EXP-4 e EXP5 expansion card output maximum current: 2A (not protected by internal fuse)
(*) On request it is possible to implement a fast fuse 4A.
PARAMETERS:
¾
¾Purging or waiting time before ignition: 0 ÷ 99 sec or 2 ÷ 20 min
¾
¾1st gas stage safety time*: 1 ÷ 25 sec
¾
¾Regulation delay time or 2nd gas stage safety time*: 0 ÷ 25 sec
¾
¾Reaction time*: 1 ÷ 20 sec
¾
¾Shut off purging or waiting time: 0 ÷ 99 sec or 2 ÷ 4 min
¾
¾Accepted remote unlocks: max 5 in 15 minutes
¾
¾lame sensor check on permanent operation: in 1 hour
¾
¾Auto shut down for test with non permanent operation: in 24 hours
¾
¾Behaviour at flame loss: configurable
¾
¾1st gas stage burner functioning: configurable
¾
¾Air valve functioning: configurable
* These parameters must be set according to the norm that is applicable at the time of installation.

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DESCRIPTION
¾
¾ESA ESTRO-A: to be used for single stage burners with air valve control. Via the configuration software it is possi-
ble to chose the air valve behaviour.
¾
¾ESA ESTRO-B: to be used for double stage burners: 1st stage (pilot), 2nd stage (main). Via the configuration soft-
ware it is possible to choose between the interrupted or continuous 1st stage burner functioning.
¾
¾ESA ESTRO-C: to be used for single gas stage burners with burner running output available (volt free contact SPST)
ESA ESTRO is a microprocessor flame control device
equipped with inputs and outputs for controlling and
supervising burners with permanent functioning, fit for
ESA
ESTRO
A
IGNITION
TRANSFORMER
DIGITAL INPUT
GAS VALVE
REMOTE
CONTROL
AIR VALVE
FLAME SIGNAL
DIGITAL OUTPUT
ESA
ESTRO
B
IGNITION
TRANSFORMER
DIGITAL INPUT
1ST STAGE
GAS VALVE
REMOTE
CONTROL 2ND STAGE
GAS VALVE
FLAME SIGNAL
DIGITAL OUTPUT
ESA
ESTRO
C
IGNITION
TRANSFORMER
DIGITAL INPUT
GAS VALVE
REMOTE
CONTROL
BURNER ON
FLAME SIGNAL
DIGITAL OUTPUT
D7014PI01
applications in which the burners remain running for more
than 24 hours. The instrument has four different versions:
D7014PI02
D7014PI03

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¾
¾ESA ESTRO-Q: to be used for single stage burners in which control is done via serial line.
ESA
ESTRO
Q
IGNITION
TRANSFORMER
GAS VALVE
REMOTE
CONTROL
FLAME SIGNAL
The ESA ESTRO-A, B and C versions also have a digital
configurable input and output, in particular the digital
input is necessary in high temperature applications to
activate specific functioning (see Norm EN746-2), whilst
the digital output is used to check the UV-2 sensor during
permanent operation. Depending on the working time and
on the type of burner flame detection, it is possible to defi-
ne the sensor’s check method by selecting from the inter-
nal check of the ionization probe every hour, external
check of the UV-2 sensor via the dimming shutter every
FIELDBUS
PLC
GAS
ESTRO-B
25
6
3
4
+1 A-
8 97 B
10
GAS 2
1
GAS
ESTRO-A
N
N
5
6
3
4
+
+
L
L
1
-
-
8 97 2
10
AIR A
1GAS
ESTRO-C
25
6
3
4
+1 A-
8 97 B
10
1GAS
ESTRO-Q
N+
-
V
N
+L *-
N FT *
G
1
ECS BUS
POWER LINE
POWER
SUPPLY
SAFETY
LIMITS
D7014PI04
D7014PI05
On the front panel, ESA ESTRO has a configurable local
button, a phase indication display, a bargraph flame
signal indicator as well as the infrared port for the confi-
guration of certain parameters via a hand held program-
mer. Via the special programming software, the instru-
ment allows the configuration of parameters and functio-
ning modes according to the application needs. It is pos-
sible to personalize the air valve command or the digital
output, select the digital input or front button behavior or
change timers of certain phases, provided that the appli-
hour or shut down every 24 hours for non permanent
operation with UV-2. All the ESA ESTRO versions are
equipped with the ESA ECS serial interface that allows to
completely control the burner from remote, communica-
ting via the ECS or Modbus-RTU protocols, both imple-
mented as standard in the instrument. Via serial commu-
nication a complete check of the burner is possible: igni-
tion and shut down, pilot and main burner control, air
valve control, information on the status and value of the
flame signal.
cable norm at the time of installation is respected. ESA
ESTRO runs the burner ignition cycle count, storing the
number of activations of the first stage gas valve and then
the second stage gas valve or air valve. Via the program-
ming software or hand held (portable) programmer you
can read the numbers of the cycles performed following
maintenance of the valves and reset the meters. All the
ESA ESTRO versions are equipped with a replaceable
protection fuse that blows in case of failures in the con-
nected devices. urthermore there is a non replaceable

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¾
¾ESA EXP-2: expansion that allows to control a package type burner, able to activate the air valve or blower, check
the air pressure switch status and control the air damper during the prepurge and burner ignition phases. The EXP-2
expansion card can also be used only to control the air valve (for versions that are different from ESTRO-A).
¾
¾ESA EXP-3: expansion allowing to interface the flame control with the most common field bus. or detailed informa-
tion refer to specific data sheet E7015.
ESA
EXP-3
PROFIBUS-DP
DEVICE-NET
ETHERNET
PROFINET
¾
¾ESA EXP-4: expansion having four digital inputs and four digital outputs as well as an analogical input and output,
and a serial interface that allows to control the card from remote. or detailed information refer to specific data sheet
E7016.
¾
¾ESA EXP-5: expansion that has four digital inputs and four digital outputs with predefined functions. or detailed
information refer to the specific data sheet E7017.
ESA
EXP-4
DIGITAL
OUTPUT 1
DIGITAL
OUTPUT 2
DIGITAL
OUTPUT 3
DIGITAL
OUTPUT 4
DIGITAL
INPUT 1
DIGITAL
INPUT 2
DIGITAL
INPUT 3
DIGITAL
INPUT 4
ANALOGIC
INPUT ANALOGIC
OUTPUT
ESA
EXP-2
AIR VALVE OR
BLOWER
THERMOSTAT
OPEN AIR
DAMPER
AIR PRESSURE
SWITCH
CLOSE AIR
DAMPER
PURGE AIR FLOW
OR DAMPER OPENED
IGNITION AIR FLOW
OR DAMPER CLOSED REGOLATION
ENABLED
D7014PI06
D7014PI07
D7014PI08
internal relay protection fuse that blows only in case of
malfunctioning of the first. ESA ESTRO is supplied in a
robust case in thermoset material, predisposed for the
housing of the ignition transformer and for the outputs of
the various connecting cables with external users.
Expansion cards that allow further control of the burner
devices or specific serial communication can be applied
to all the versions. The installation of the expansion cards
precludes the possibility of mounting the ignition transfor-
mer inside the instrument.The available expansions are
indicated below:

DISP AY STATUS DESCRIPTION
FIXED
Auto diagnosis phase in which the instrument checks the effciency of its inter-
nal components. This phase is carried out each time the device is powered or
every time the burner is reignited (duration of about 2s).
F ASHING
Waiting phase in which the instrument waits for the condition to be unlocked by
the operator. It can be unlocked by the local button, remote button or by serial
communication. This phase only occurs at power on when the “Cycle start”
parameter is programmed on “Stand-by”.
FIXED
Stopping phase for adjustment requested by the thermostat. The instrument
keeps the burner off and waits for the ignition command, forces the air damper
to close and deactivates the other outputs.
FIXED
Air pressure switch waiting phase after having activated the air valve (or com-
bustion blower), or burner stop waiting for the air pressure switch during nor-
mal operation regime. This last behaviour occurs when the “Air pressure
switch” parameter is programmed on “Waiting”.
FIXED
Air damper opening phase waiting for the limit switch of the maximum position
reached or for the minimum purge flow switch ( SL) consent, to purge with
maximum air flow. This phase occurs with expansion cards when the “Air flow
or damper switch control” parameter is programmed on “Local, Remote or SL
enable purge”, or if the function assigned to the digital input is “ SL enable
purge”.
FIXED
Chamber purging or waiting phase before burner ignition. In applications with
controlled cooling, this status indicates the phase in which only the air valve is
on. During this phase flame absence is checked otherwise lockout is determi-
ned due to illegal flame.
FIXED
Air shutter closing phase waiting for the limit switch of the minimum position
reached or for the consent from the maximum ignition flow switch ( SH) con-
sent, to carry out ignition at minimum power. This phase only occurs with
expansion cards when the “Air flow or damper switch control” parameter is pro-
grammed on “Local, Remote or SH enable ignition”, or if the function assi-
gned to the digital input is “ SH enable ignition”.
FIXED
Check or waiting phase for signal presence from the ZSL limit switch indicating
the 1st stage gas valve closed. This phase is present just before burner igni-
tion.
FIXED
1st stage burner ignition phase, lasting the same amount of time as the first
safety time. The instrument activates the ignition transformer and 1st gas stage
solenoid valve, then at the end, deactivates the transformer and checks the
flame formation.
FIXED
1st stage burner flame stability check phase: at the end of this the instrument
checks the efficiency of the flame amplifier. This phase also occurs following a
shut down command of the 2nd stage burner.
FIXED
Regime phase for ESTRO-A, ESTRO-C and ESTRO-Q versions. or ESTRO-
B it is the 2nd stage burner ignition phase, lasting the same amount of time as
the second safety time. The instrument activates the 2nd gas stage solenoid
valve keeping the 1st gas stage on. This is a regime condition for the ESTRO-
B when the “1st stage gas outlet type” is programmed on “Intermittent”.
ESA ESTRO - E7014P rev. 02 - 03/05/17
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DISP AY AND OCA BUTTON SECTION
DISP AY
ESA ESTRO displays different codes to indicate the flame control functioning and lockout statuses.
ixed symbols indicate normal operating conditions or certain non resettable faults, whilst lock or resettable fault con-
ditions are indicated by flashing symbols.
Normal operation phases

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DISP AY STATUS DESCRIPTION
FIXED
Regime phase for ESA ESTRO-B with only 2nd stage burner on. The instru-
ment intercepts the 1st stage solenoid valve. This phase occurs only when the
“1st stage gas outlet type” parameter is programmed on “Interrupted”.
FIXED
Regime phase with air valve on. In case the “Air pressure switch parameter” is
programmed on “Lockout o Waiting" the instrument waits for the pressure
switch signal before indicating this phase, whilst if “Disable” is programmed the
transition to this phase corresponds with the activation of the air valve . This
phase occurs only when the “Air flow control mode” parameter is programmed
on “Discontinue or Pulse”.
FIXED
Detection system check phase in which the instrument verifies that the flame is
extinguished in a maximum time of 20 seconds after burner shut down, other-
wise there is lockout for illegal flame.
FIXED
Chamber cooling phase with maximum air flow. In applications with three-posi-
tion air valve, the air valve is brought to maximum opening . During this phase
flame absence is checked otherwise lockout is determined due to illegal flame.
FIXED
Chamber cooling phase with minimum air flow. In applications with three-posi-
tion air valve, the air valve is driven to the minimum opening . During this phase
flame absence is checked otherwise lockout is determined due to illegal flame.
FIXED
DOT
Chamber purging or waiting phase following burner shut down. During this
phase the instrument does not accept any command and displays the phase or
lockout code that caused shut down, besides the fixed decimal point.
FIXED
Stop phase for regulation requested by serial communication. The instrument
keeps the burner off, waits for an ignition command, forces the air shutter to
close and deactivates all the other outputs.
F ASHING
DOT
High temperature functioning on. During this operation the instrument displays
the lockout or phase code, besides the flashing decimal point. If the high tem-
perature function provides only the prepurge exclusion, this indication is pre-
sent in all the phases prior to the ignition of the burner.
DISP AY STATUS DESCRIPTION
F ASHING
Manual stop generated by the operator via the local or remote button when the
burner is in a normal operation phase. The instrument keeps the burner off and
waits for the unlock that can be given by local button, remote button or serial
communication.
F ASHING
Lockout due to the detection of an illegal flame, during the phases before the
burner ignition phase or after the shut down phase. The causes can be found
in the detection system (broken probe or presence of humidity in UV-2) or in a
gas leakage from the solenoid safety valve that allows the burner to remain on.
F ASHING
Lockout due to the missing flame formation during 1st gas stage burner igni-
tion. The causes can be found in the ignition system (no spark from the elec-
trodes or broken transformers), in the bad flow regulation of fuel and combu-
stion agents, or in the detection system (broken probe, interrupted cables,
ground not connected). Specifically, in the first two cases the flame does not
ignite, whilst in the last case the flame forms but ESA ESTRO is unable to
detect it.
F ASHING
Lockout due to the flame signal loss during normal burner operation. The cau-
ses can be found in the flow regulation of combustion air and fuel (rapid flow
variations, regulation out of allowed range). urthermore, this lockout condition
is due to malfunctioning of the sensibility probe dimming shutter when perma-
nent operation is on with UV detection, if this does not open after the hourly
check.
ockout or failure

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DISP AY STATUS DESCRIPTION
F ASHING
Lockout due to the extended absence of serial commands by the remote super-
visor, for a longer period of time than the period programmed in the
“Communication timeout” parameter.
FIXED
Malfunctioning is due to the presence of the air pressure switch signal before
the instrument has activated the combustion blower. The causes can be found
in the incorrect wiring or in a fault in the air pressure switch. During normal ope-
ration, this indication appears for a few seconds during the air pressure signal
test.
F ASHING
Lockout due to the presence of the air pressure switch signal before the instru-
ment has activated the combustion blower over the time limit or due to the mal-
functioning of the internal circuit related to the air pressure switch input. The
causes can be found in the incorrect wiring or in a fault in the air pressure
switch.
F ASHING
Lockout due to the missing air pressure switch signal after having activated the
air valve or during normal burner operation. The causes can be found in the
combustion air flow (blocked filters, blower off) or in a pressure switch failure.
F ASHING
Lockout due to the presence of the maximum position limit switch signal or
minimum purge flow switch ( SL), before the instrument has commanded the
air damper to open. urthermore, this lockout can occur when the prepurge
SL check is on, but when the signal is received the input test result is negati-
ve. The causes can be found in the incorrect wiring or regulation of the air shut-
ter limit or flow switch.
F ASHING
Lockout due to the presence of the minimum position limit switch signal or
maximum ignition flow switch ( SH), before the instrument has commanded the
air damper to close. urthermore, this lockout can occur when only the SH
ignition check is on, but when the signal is received the input test result is nega-
tive. The causes can be found in the incorrect wiring or regulation of the air
shutter limit or flow switch.
F ASHING
Lockout due to the failure of the air damper to close at the end of purging. The
instrument waits for the minimum position limit switch signal for a maximum of
150 seconds from the closing command. The causes can be found in the incor-
rect wiring or regulation of the air damper limit or flow switch.
F ASHING
Lockout due to failed power consumption by the electric devices connected to
the instrument (ignition transformer or solenoid valves). The causes can be
found in the breaking of one of the ignition devices, output protection fuse, in
an interrupted electric connection or if the non resettable protection fuse of the
internal relays is broken. In the last case the instrument must be sent to the
manufacturer.
F ASHING
Lockout due to a failure in the flame detection probe. The causes can be found
in the breaking of the probe, a short circuit of the probe or in its ground connec-
tion (burner body), in the inverted connection of the ESA UV-2 sensibility probe,
in the incorrect ground connection of the instrument or in the strong currents on
the furnace mass (welding machines operating, etc).
F ASHING
Lockout due to malfunctioning of the internal flame amplifier detected after igni-
tion or during the periodic check or the flame amplifier sensor. urthermore this
lockout is due to the malfunctioning of the dimming shutter probe when the per-
manent operation with UV detection is running. The causes can be found in the
incorrect wiring or in the functioning of the UV-2 shutter. Otherwise, if after an
attempt to reset the problem reoccurs, the instrument must be sent back to the
manufacturer.
F ASHING
Lockout due to the malfunctioning of the internal circuit related to the thermo-
stat input. If after an attempt to reset the problem reoccurs, the instrument must
be sent back to the manufacturer.

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DISP AY STATUS DESCRIPTION
F ASHING
Lockout due to an error in the internal memory reading. The failure can be tem-
porary or final. The causes can be found in the incorrect connection to ground
of the instrument or of the connected ignition devices, in the missing suppres-
sion filter in the ignition electrode connector, or else in the strong electromagne-
tic disturbances in the atmosphere or in the power supply. If after an attempt to
reset the problem reoccurs, the instrument must be sent back to the manufac-
turer.
F ASHING
Lock out due if the ZSL gas valve limit switch signal is missing for more than 5
seconds prior to ignition or if the actual limit switch has not been released after
10 seconds following the ignition phase. The causes can be found in possible
incorrect wiring or in the adjustment of the limit switch of the valve.
F ASHING
Lockout due to missing communication with the optional card, if the presence of
the expansion card has been configured. The causes can be found in the incor-
rect programming or in a card failure; in the first case check the programming,
whilst in the second case if after an attempt to reset the problem reoccurs, the
instrument must be sent back to the manufacturer.
F ASHING
Lockout due to a short circuit in the internal command relay. If after an attempt
to reset the problem reoccurs, the instrument must be sent back to the manu-
facturer.
FIXED (1)
Malfunctioning due to the front button or the digital input button (if the reset/stop
function from remote is on) that are blocked as if pressed during the auto dia-
gnosis of the instrument. The causes can be found in the connection and con-
trol of the remote reset, in the possible absence of the RC filter, or front button
failure. To reset the alarm, cut off the power to the instrument for a few seconds.
FIXED (1)
Malfunctioning due to memory corruption or a failure in the safety system. The
failure can be temporary or final. The causes can be found in the incorrect
ground connection of the instrument or of the connected devices, in the missing
suppression filter in the ignition electrode connector, or else in the strong elec-
tromagnetic disturbances in the atmosphere or in the power supply. To reset the
alarm, cut off the power to the instrument for a few seconds. If the problem
reoccurs, the instrument must be sent back to the manufacturer.
FIXED (1)
Malfunctioning due to a short circuit in the internal safety relay. To reset the
alarm, cut off the power to the instrument for a few seconds. If the problem
reoccurs, the instrument must be sent back to the manufacturer.
FIXED (1) Malfunctioning due to a short circuit between the pins and the microprocessor.
If the problem reoccurs, the instrument must be sent back to the manufacturer.
FIXED (1)
Malfunctioning due to a gap in the program. The causes can be found in the
incorrect ground connection of the instrument or of the connected ignition devi-
ces, in the missing suppression filter in the ignition electrode connector, or else
in the strong electromagnetic disturbances in the atmosphere or in the power
supply. To reset the alarm, cut off the power to the instrument for a few seconds.
If the problem reoccurs, the instrument must be sent back to the manufacture
F ASHING
DISP AY
AND BARGRAPH
Mlafunctioning due to excessive ambient temperature that does not allow the
instrument to work. When this malfunctioning occurs the instrument continues
to switch on and off displaying only the beginning of the auto diagnosis phase.
(1) (1) The indication of these failures or lockout conditions starts flashing when power is supplied again, indicating
that alarm reset is possible.

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BARGRAPH
ESA ESTRO has a bargraph with five leds indicating the
flame value detected in a range of 0µA to 90µA. If the
detection current is greater than 90µA the upper led is
kept on. The flame detection signals generated by elec-
trodes (ionization) are sensibly lower that compared with
the signals generated by the UV probe, however, in both
cases the stability of the indication on the bargraph is
related to the stability of the signal detected by the bur-
ner flame.
DISP AY STATUS DESCRIPTION
FIXED Programming phase from serial input via the special configuration software.
During this phase it is not possible to carry out any other operation.
FIXED
Programming phase from infrared input via the special programmer. ase di
programmazione da ingresso infrarosso tramite l’apposito programmatore.
During this phase it is not possible to carry out any other operation.
Configuration
OCA BUTTON
ESA ESTRO allows the configuration of the local button
according to the application needs (see Configuration
Parameter paragraph). The button can carry out the lock
and manual stop functions as well as only lock or only
manual stop or else it can be disabled with the possibility
of being activated by serial communication.
The button action differs depending on the function:
¾
¾Unlock: the local button must be kept pressed for 1 to
3 seconds and when released ESA ESTRO unlocks the
condition. If pressed for less or longer than specified, the
command is not accepted.
¾
¾Halt in manual stop: as soon as the local button is
pressed, ESA ESTRO activates the halt.

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FUNCTIONING
ESA ESTRO is a configurable device for burner control
that, depending on the set parameters, can assume diffe-
rent behaviour or determine different actions (see
Configuration parameters). Below there is a description
of the main functions or locks.
D7014PI09
BURNER IGNITION CYC E
The following diagram indicates an ignition cycle when
the EXP-2 expansion card has been installed to control a
package burner with first gas stage output interrupted.

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BURNER IGNITION CYC E
The following diagram indicates an ignition cycle of ESA ESTRO-B version without EXP-2 expansion card with first
gas stage output interrupted.
IGNITION BEHAVIOUR
The following diagrams indicate the behaviour at instrument powering according to the “Cycle start” parameter if con-
figured on “Autostart” or “Standby”.
D7014PI10
D7014PI11
COMP ETE CYC E
AUTOSTART

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STANDBY
In the following diagram we have indicated the ESA ESTRO-B ignition cycle without EXP-2 expansion card.
I EGA F AME
The following diagram indicates the behaviour in the presence of an illegal flame at burner ignition or shut down
D7014PI12
D7014PI13
STAND-BY
IN FAU T “d”

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FAI ED IGNITION
The following diagram indicates the behaviour in case of 1st gas stage ignition failure.
F AME SIGNA OSS
The following diagram indicates the behaviour if the flame signal is lost with burner in regime phase and with the
“Behaviour at flame loss” parameter configured on “Lockout stop”.
D7014P14
D7014P15
IN FAU T “U”
IN FAU T “F”

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CONFIGURATION PARAMETERS
The configuration defines the ESA ESTRO functioning
mode, adapting it to the needs of the plant. Certain confi-
guration parameters are defined and blocked by the fac-
tory in conformity to the related application norms. Others
instead, can be altered by the user with the aid of suitable
equipment. The modification of the parameters is accep-
ted by the ESA ESTRO when it is in the manual stop con-
dition and can be done with a portable programmer or
dedicated software via a serial interface card. The porta-
ble programmer communicates via infrared interface and
allows the serial communication parameters to be altered.
Non blocked parameters
PARAMETER VA UE DESCRIPTION
N° NAME
/Address
Segment
0 ÷ 9 and
A ÷ Z
capital letters
With “Address Segment” the device is indentified for serial communica-
tion. The ECS protocol identifies the zone or the group to which it
belongs. With Modbus-RTU protocol the address tens are defined (0÷
for 0÷16 tens).
/ Address Node
0 ÷ 9 and
A ÷ Z
capital letters
With “Address Node” the device is indentified for serial communication.
The ECS protocol identifies the unit inside the zone or group. With
Modbus-RTU protocol the address units are defined (0÷9 units).
2 Cycle start
Automatic ignition
Autostart
When powered the instrument automatically starts the ignition cycle, at
less than one block before shut down. This configuration is useful when
controlling the burner through the power of the instrument.
Standby
At power on the instrument does not start the ignition cycle but waits for
the local or remote ignition command. This configuration is useful when
controlling the the burner through serial communication to avoid simulta-
neous ignitions or for applications that require operator action every time.
3 Prepurge time 0 ÷ 99 sec
2 ÷20 min
Chamber purge or waiting time before burner ignition. In applications
with air shutter or flow control, the timing starts at maximum opening or
with target purge flow ( SL).
5
Regulation
delay time
2°safety time
0 ÷ 25 sec
Waiting time following the stability check phase of the 1st gas stage, after
which air valve regulation is allowed (ESTRO-A and expansions). or the
ESA ESTRO-B version this time corresponds to the second safety time
(2nd gas stage ignition), for which the parameter is blocked and cannot
be changed. urthermore, when this time has expired, the 1st gas stage
shuts down when it is interrupted.
7Behaviour at
flame failure
Lockout
The instrument determines shut down in burner lockout, caused by flame
signal extinction for longer than the time set in the “Reaction time” para-
meter (reset is required).
Recycle
The instrument performs a sequence of complete ignition (including pre-
purge) after the flame signal has disappeared. When burner ignition has
taken place correctly, at the next flame extinction, the instrument per-
forms another ignition sequence.
The software installed on the pc instead, communicates
via the ECS serial interface and allows all the non bloc-
ked parameters to be altered. With the aid of the softwa-
re, the user can block other parameters, with the restric-
tion that the blocks can only be removed by the manufac-
turer or by the person who entered them. Configuration
via the ECS serial interface is allowed for one instrument
at a time, and it is compulsory to disconnect the network
on field and connect it directly to the ECS interface card
connected to the PC.

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PARAMETER VA UE DESCRIPTION
N° NAME
7Behaviour at
flame failure
Respark
The instrument performs burner reignition (excluding prepurge) after the
flame signal has disappeared. When burner ignition has taken place cor-
rectly, at the next flame extinction, the instrument performs another rei-
gnition sequence.
Only one
recycle
The instrument performs a sequence of complete ignition (including pre-
purge) after the flame signal has disappeared. When burner ignition has
taken place correctly, at the next flame extinction, the instrument per-
forms burner lockout halt (reset is required).
Only one
respark
The instrument performs burner reignition (excluding prepurge) after the
flame signal has disappeared. When burner ignition has taken place cor-
rectly, at the next flame extinction, the instrument performs burner loc-
kout halt (reset is required).
9 Postpurge flex
Inhibited The instrument begins timing of the “Post purge time” from burner shut
down due to a shut down request or lockout.
Enable
The instrument begins timing of the “Post purge time” from the burner
ignition phase. When this configuration is present, the “Postpurge time”
becomes the minimum time between one burner ignition and the next.
10 Postpurge time 0 ÷ 99 sec
2 ÷4 min
Chamber purge or waiting time before another ignition after burner shut
down. During the postpurge phase the instrument does not accept any
other command; whilst in applications with air damper control, during this
phase the damper is commanded to open. Enabling the “Postpurge flex”
function this time becomes the minimum time between one burner igni-
tion and the next.
12 Air flow
control type
Continue
The instrument activates the air valve (or blower) from the ignition
request and keeps it on until burner shut down due a request or lockout.
This selection is necessary when the output has to be on for the entire
prepurge cycle and burner operation because it controls the combustion
blower or air interception valve. When this configuration is present, the
“Air on “ and “Air off” commands have no effect.
Discontinue
delayed 0 sec
The instrument activates the air valve from the ignition request until the
end of the purging phase. It deactivates the valve by passing instantane-
ously to the ignition phase and then activates it from the end of the
“Regulation delay time” until the burner shuts off due to a shut down
request or lockout. This selection is useful in applications having an air
partializing valve that must be activated for controlled prepurge or coo-
ling.When there is this configuration, the “Air on” and “Air off” commands
have effect from the end of the “regulation delay time”.
Pulse
The instrument activates the air valve from the end of the “regulation
delay time” until the burner shuts off due to a shut down request or loc-
kout. This selection is useful in applications having an air partializing
valve but that don’t need to be activated for controlled prepurge or coo-
ling. When there is this configuration, the “Air on” and “Air off” commands
have effect for air valve control purposes.
Remote
The instrument activates the air valve output only from the ignition phase
until the end of the “regulation delay time”. This configuration is used
when the EXP-2 expansion card is present and via the negated blower
output (NC contact), to interrupt the air valve remote command allowing
minimum burner ignition.
Discontinue
delayed 3 sec
The instrument maintains the same behaviour as when “Discontinue
delayed 0 sec” is selected, with the difference being that from the valve
closing command, it waits for 3 seconds before moving onto burner igni-
tion, giving the valve time to close.

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PARAMETER VA UE DESCRIPTION
N° NAME
12 Air flow
control type
Discontinue
delayed 5 sec
The instrument maintains the same behaviour as when “Discontinue
delayed 0 sec” is selected, with the difference being that from the valve
closing command, it waits for 5 seconds before moving onto burner igni-
tion, giving the valve time to close.
Discontinue
delayed 10 sec
The instrument maintains the same behaviour as when “Discontinue
delayed 0 sec” is selected, with the difference being that from the valve
closing command, it waits for 10 seconds before moving onto burner igni-
tion, giving the valve time to close.
13 Digital input
function
Inhibited The state of the digital input is not checked by the instrument.
Reset / Stop
The digital input has a dual function: with burner on as soon as it activa-
ted it leads to manual stop; whilst with burner in stop or lockout, if activa-
ted from 1 to 3 seconds when released, burner lockout is activated. The
instrument accepts 5 reset commands from remote in 15 minutes.
Only stop The digital input is checked by the instrument only with burner running:
as soon as it is activated it leads to burner manual stop.
Only reset
The digital input is checked by the instrument only with burner in stop or
lockout: if activated from 1 to 3 seconds, when released burner lockout
is activated. The instrument accepts 5 reset commands from remote in
15 minutes.
Thermostat
The digital input works as a thermostat alternatively at the expansion
input: with input on, the instrument switches the burner on, whilst when
the input is not on, it determines shut down. This configuration is possi-
ble if the EXP-2 expansion card is not installed.
High
temperature
The digital input is used to activate high temperature functioning. This
selection is possible only for certain industrial applications where it is
allowed according to the EN746-2 and in the “High temperature function”
parameter, the instrument behavior is defined when this configuration is
present.
Main burner
on / off
The digital input controls the 2nd gas stage as an alternative to the serial
commands: with input on and 1st gas stage burner running, the instru-
ment switches on the 2nd gas stage burner; whilst with input off, it deter-
mines second gas stage burner shut down.
Air valve
on / off
The digital input controls the air as an alternative to the serial commands:
with input on and 1st gas stage burner running the instrument activates
the air; whilst with input deactivated, it determines shut down. This fun-
ction is valid only when the type of air control is discontinuous or impul-
sive.
SL
enable purge
Via the flow switch ( SL) the digital input checks the presence of the
minimum air flow needed to time purging, as an alternative to the expan-
sion input. This configuration avoids the EXP-2 expansion card as it is
necessary to check just this command. The appropriately programmed
digital output, will supply the phase to the flow switch.
SH
enable ignition
Via the flow switch ( SH) the digital input checks the correct air flow for
burner ignition, as an alternative to the expansion input. This configura-
tion avoids the EXP-2 expansion card as it is necessary to check just this
command. The appropriately programmed digital output, will supply the
phase to the flow switch.
Air pressure
switch
The digital input functions as an air pressure switch as an alternative to
the expansion input. This configuration avoids the EXP-2 expansion card
as it is necessary to check just this command. The instrument behavior
depending on the pressure status, is always defined in the “Air pressure
switch” parameter (parameter n° 27). The appropriately programmed
digital output, will supply the phase to the pressure switch.
ZSL Gas valve
Before carrying out ignition the instrument checks the presence of the
closed gas valve limit switch signal via the digital input. After the ignition
phase the device checks that the signal disappears. The digital output
programmed appropriately, will supply the phase to the limit switch.

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PARAMETER VA UE DESCRIPTION
N° NAME
14 Digital output
function
Stop / fault
The digital output indicates that the instrument is in lockout status,
manual stop or waiting after power on (flashing display). The output is not
activated during auto diagnosis.
ault
The digital output indicates that the instrument is in lockout status. The
output is not activated during auto diagnosis, in manual stop status nor
waiting after power on.
Burner ON
The digital output indicates that the burner is on. The output is activated
from the end of the ignition phase and remains on for all the burner fun-
ctioning phases.
Regolation
consent
The digital output allows burner regulation. It activated at the end of the
“Regulation delay time” and remains on for the time that the burner is in
regime. The behavior of this output is the same as the ready output of the
EXP-2 expansion.
Command
NO shutter
The digital output controls the NO dimming UV-2 shutter, needed for
periodic check during permanent functioning. Without any command, the
shutter is normally open and the digital output is activated in the test
phase to command the closing, determining the dimming of the UV-2
probe.
Command
NC shutter
The digital output controls the NC dimming UV-2 shutter, needed for
periodic check during permanent functioning. Without any command, the
shutter is normally closed and the digital output is deactivated in the test
phase to command the closing, determining the dimming of the UV-2
probe.
Digital input
control
In the absence of the EXP-2 expansion, the digital output controls the
phase sent to the air pressure or flow switches when the digital input
takes on the “ SL enable purge”, “ SH enable ignition” or “Air pressure
switch” or “ZSL gas valve”. This selection is necessary to check the effi-
ciency of the digital input when it carries out these functions.
Minimum air
control
The digital output is activated from the ignition request until burner shut
down for controlling the minimum air flow valve. The behavior of the digi-
tal output is contemporary to the air output when it is continuous. Instead
it is independent for other types of air control (see Air flow control para-
meter type).
Minimum air in
advance
The digital output is activtated from the ignition request to the burner shut
down but two seconds earlier compared with all the other outputs. This
selection allows to anticipate the opening of the minimum flow air valve
or of the fume valve.
15 ocal
botton
Remote
enable
The front button is not checked by the instrument as the burner control
takes place via serial communication. If the specific status request com-
mand is sent, the instrument activates the local button action and it takes
on the “Reset / Stop” function to allow local maintenance operations.
Reset / stop
The front button has dual function: with burner running, as soon as it is
pressed, it determines manual stop; whilst with the burner in stop or loc-
kout, if pressed for 1 - 3 seconds, when released, it unlocks the burner.
Only stop The front button is checked by the instrument only with burner running:
as soon as it is pressed it determines burner manual stop.
Only reset
The front button is checked by the instrument only with burner in stop or
lockout: if it is pressed for 1-3 seconds, when released it unlocks the bur-
ner.
20 Communication
timeout 0 ÷ 480 sec
Time limit for serial communication absence, that can be set in ten steps
from 0 to 480 seconds, after which the instrument activates the Com-
timeout alarm, determining burner stop. Set this parameter at 0 to disa-
ble the Com-timeout alarm when serial communication is not used.
21
&
22
Communication
Baudrate
&
Communication
protocol
4800 ÷ 38400
ECS
Communication speed (4800, 9600, 19200 and 38400 Bit/s) with ECS
protocol. The hardware interface is ECS, and it requires a specific con-
verter.
4800 ÷ 38400
ModbusRTU 1
Communication speed (4800, 9600, 19200 and 38400 Bit/s) with
Modbus RTU (1 stop bit) protocol. The hardware interface is ECS, and it
requires a specific converter.
4800 ÷ 38400
ModbusRTU 2
Communication speed (4800, 9600, 19200 and 38400 Bit/s) with Modbus
RTU (2 stop bit) protocol. The hardware interface is ECS, and it requires
a specific converter.