Unifire SUPERVISOR I User manual

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SUPERVISOR I
Installation and Operation Manual

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Contents
1HOW TO USE THIS MANUAL .................................................................................................................. 3
2LIMITED PRODUCT WARRANTY ............................................................................................................. 4
3SERVICE SUPPORT AND RETURNS.......................................................................................................... 5
4GENERAL PRODUCT INFORMATION....................................................................................................... 6
5SPECIFICATION AND RATINGS................................................................................................................ 7
6FACTORY CONFIGURATION.................................................................................................................... 8
6.1 PILOT MODE OF OPERATION [CONTINUOUS/INTERRUPTED].................................................................. 8
6.2 DIRECT IGNITION [ENABLE/DISABLE] ............................................................................................... 8
6.3 PURGE DURATION [0:1:1800SECONDS]........................................................................................... 8
6.4 PILOT FLAME DETECTION SOURCE [TC/FR/DI3] ................................................................................ 8
6.5 PILOT TRIAL FOR IGNITION DURATION (PTFI) [0:1:15 SECONDS] ........................................................... 8
6.6 PILOT STABILIZATION PERIOD [0:1:10 SECONDS]................................................................................ 8
6.7 MAIN FLAME DETECTION SOURCE [TC/FR/DI3]................................................................................ 8
6.8 MAIN TRIAL FOR IGNITION PERIOD [0:1:15SECONDS] ......................................................................... 9
6.9 MAIN FLAME STABILIZATION PERIOD [0:1:10SECONDS] ...................................................................... 9
6.10 PILOT FLAME FAILURE RESPONSE TIME [0:1:4SECONDS] ...................................................................... 9
6.11 MAIN FLAME FAILURE RESPONSE TIME [0:1:4 SECONDS] ..................................................................... 9
6.12 PILOT RECYCLE/RETRIAL NUMBER [0-255] ....................................................................................... 9
6.13 PILOT INTERPURGE DURATION [0:1:1800SECONDS] ........................................................................... 9
6.14 MAIN RECYCLE/RETRIAL NUMBER [0-255]....................................................................................... 9
6.15 MAIN INTERPURGE DURATION [0:1:1800SECONDS]........................................................................... 9
6.16 THERMOCOUPLE HIGH TEMPERATURE TRIP ENABLE/DISABLE .............................................................. 10
6.17 THERMOCOUPLE SETPOINT [0:1:1200°C] ...................................................................................... 10
6.18 4-20MAANALOGUE INPUT ENABLE/DISABLE .................................................................................. 10
6.19 4-20MAPRESSURE TRANSMITTER ENABLE/DISABLE ......................................................................... 10
6.20 4-20MATRANSMITTER HIGH HIGH/LOW LOW TRIP SETPOINTS [0:0.1:20MA]...................................... 10
6.21 LOW POWER OUTPUT SETTINGS.................................................................................................... 10
6.22 END USER EQUIPMENT TAG ......................................................................................................... 10
7INSTALLATION...................................................................................................................................... 11
7.1 FUSES...................................................................................................................................... 14
8TYPICAL WIRING................................................................................................................................... 15
9SYSTEM OPERATION ............................................................................................................................ 16
9.1 TYPICAL STARTUP FOR CONTINUOUS PILOT (OR MAIN DIRECT IGNITION) ............................................... 16
9.2 INTERRUPTED PILOT ................................................................................................................... 17
9.3 LOCKOUT ................................................................................................................................. 19
10 TROUBLESHOOTING............................................................................................................................. 21

0014_Installation_Operation_Manual
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1How to Use This Manual
The following symbols appear throughout Unifire installation and operation manuals.
HAZARD
A specific hazard is brought to the attention of the reader. Failure to observe these instructions may
result in injury or other high severity consequence.
CAUTION
Important information that when not followed so may result in premature failure of the product or
system malfunction.
INFORMATION
Important details relating to correct function and reliable operation of the product.

0014_Installation_Operation_Manual
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Copyright 2017 Unifire
2Limited Product Warranty
Unifire warranty covers the product against defects in workmanship and materials, only if the product is
installed and used according to the installation instructions. The warranty is valid for a period of twelve
(12) months starting from the date of purchase.
At the sole discretion of Unifire; the liability of Unifire shall be limited to the costs of the parts to be
repaired in the defective product or to the exchange of the defective product for a replacement product.
Unifire is not responsible, in contract, tort or strict product liability for any losses, damages, costs,
inconveniences and expenses, direct or indirect arising from the use of the product, or from defects in
workmanship or materials.
This warranty applies only to those products returned to Unifire during the warranty period.
This warranty does not cover the costs of the parts or labor incurred for the removal and transportation
of the defective product, or the reinstallation of the repaired or replaced product.
This warranty does not apply if the product has been damaged due to negligence by person, accident,
fire, Act of God, abuse or misuse; or has been damaged by modification, alterations or attachments
made subsequent to the purchase which have not been authorized by Unifire; or if the product was not
installed in compliance with Unifire instructions and the local codes and standards.

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3Service Support and Returns
For service and support please contact the Unifire support team using your preferred method below.
Please include the serial number on the label of the Supervisor I module in your communications to
allow us to help you as quickly as possible.
Telephone:
[phone]
Email:
[email protected]
Returns:
Unifire (A division of CSI Group)
207 –Discovery Way
Squamish
V6B 0E5
BC
Canada

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4General Product Information
SUPERVISOR I provides all necessary functions for the safe start-up and shutdown of industrial,
natural draft gas fired appliances. Approved to the latest IEC/CSA 60730-2-5 standard the control
module provides factory configured purge, pilot trial for ignition and main trial for ignition
periods, multiple recycle/retrials on flameout, varied flame safeguard options (Ionization rod,
UV/IR scanner, thermocouple), interrupted pilot and direct main ignition options. 24VDC power
supply and low power consumption allows for remote off-the-grid field operation with
aftermarket solar panels or thermoelectric power sources. The module is approved and ready for
use in Class I Zone/Div 2 Hazardous locations.
Designed to be safe, simple and flexible; the module allows the end user to integrate BMS
functionality to natural draft gas fired appliances; quickly, easily and safely. The design of the
module allows for process trips to be wired in series to a permissive input that will prevent
startup of the burners until all permissive inputs are proven. During light-off and once the
burner(s) are in operation the permissive inputs continue to provide a trip mechanism for safe
shutdown of the appliance. With all permissive inputs proven a factory configured timed purge is
invoked either automatically via remote commands or by pressing the front mounted start/reset
button. A completed purge is followed with trial for ignition on either the pilot burner or, in the
case of direct ignition, main burner. On completion of the trial for ignition the module will
energize two status outputs that can be connected to a controlling PLC or direct to the solenoids
of a main burner fuel train.
Beyond the basic startup and shutdown of typical appliances SUPERVISOR I is extended to
include multiple options for flame safeguard. Conventional flame (Ionization) rods are
supplemented with options for Thermocouple based flame detection and use of third party
UV/IR flame scanners. Other options during runtime include configurations for interrupted pilot
ignition and recycles or retrials of ignition on a loss of flame.
The complete sequence of operation and control is clearly indicated on the front panel with 4
simple LED’s and started automatically or manually via the front mounted START/RESET button.
CAUTION
Prior to powering up the SUPERVISOR I module please ensure that all safety and code
compliance information within this manual is observed.

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5Specification and Ratings
Enclosure
Polycarbonate (10% Fiberglass reinforced cover)
Hinged Door
IP67, NEMA 4X UL-508
12.142" L x 7.874" W x 5.906” H
(308.40mm x 200.00mm x 150.00mm)
Flammability UL94-V0
Min Operating Temperature
-45°C
Max Operating Temperature
60°C
Power Supply
24VDC
Quiescent Current
TBD
Inputs
AI
TC
DI1
DI2
DI3
DO2+
DO3+
4-20mA Analogue Process Input
Thermocouple Type K -50°C –1200°C
12-24VDC (Process Permissive)
12-24VDC (Start/Reset)
12-24VDC (Flame Scanner)
0-24VDC Source power for DO2
0-24VDC Source power for DO3
Outputs
DO1
DO2
DO3
IGN
FR
24VDC, 3A (Pilot Solenoid)
Switched to DO2+, 3A (Status/Main Solenoid 1)
Switched to DO3+, 3A (Status/Main Solenoid 2)
24VDC, 3A
150VAC, mA
Communications
COMM1±
COMM2±
(Reserved)
(Reserved)
Approvals
IEC/CSA 60730-2-5
Class I Zone/Div 2 Ex ‘nA’
NEMA 4X, IP67 (Enclosure)
cULus File #######

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6Factory Configuration
The SUPERVISOR I module is shipped factory configured for the end-user application. Configuration
parameters are detailed below. The Unifire engineering team will assist in the correct configuration of
the module for the end user appliance. The flexibility offered by the module configuration permits the
use of SUPERVISOR I on numerous end-user industrial fired appliances.
6.1 Pilot Mode of Operation [Continuous/Interrupted]
Both interrupted and continuous pilot is supported. Interrupted pilot will de-energize the DO1 output on
detection of a main flame and maintain the de-energized state if the main trial for ignition is successful.
6.2 Direct Ignition [Enable/Disable]
Using only the DO1 output the system can support direct ignition of the main burner. In this
configuration the pilot trial for ignition timings will adopt the settings for the main burner and the main
flame detection source shall be used. When configured for direct ignition the pilot mode of operation is
ignored.
6.3 Purge Duration [0:1:1800seconds]
Prior to commencing the trial for ignition a preconfigured purge shall be executed during which time all
outputs are maintained in the de-energized state. A maximum purge time of 30 minutes is supported.
6.4 Pilot Flame Detection Source [TC/FR/DI3]
If not configured for direct ignition the input to use for the pilot flame safeguard is selected from the
TC/thermocouple, FR/Flame Rod or DI3/Flame Scanner inputs.
6.5 Pilot Trial for Ignition Duration (PTFI) [0:1:15 seconds]
Up to 15 seconds may be configured for pilot trial for ignition. This time should be selected to meet the
requirements of the governing codes in the end users jurisdiction. On completion of purge the IGN
output shall be energized for a period of time up to a maximum of the PTFI. During this time the pilot
flame detection source (or main if configured for direct ignition) shall be monitored. The IGN output
shall de-energize on detection of a flame to allow detection of flame stability and energizing of the
status (DO2, DO3) outputs.
6.6 Pilot Stabilization Period [0:1:10 seconds]
On detection of a flame an additional timer is ran to ensure pilot flame stability prior to energizing
status outputs DO2 and DO3.
6.7 Main Flame Detection Source [TC/FR/DI3]
If configured for Interrupted pilot or direct ignition the source of the main flame detection must be
configured to use either the TC/Thermocouple, FR/Flame Rod or DI3/Flame Scanner input. For systems
configured with a continuous pilot a main flame detection source may also be configured. When
configured a main trial for ignition period is executed during which time the main flame detection
source must be proven. For direct ignition systems DO1 will de-energize when main flame is lost, on
continuous and interrupted systems the DO2 and DO3 outputs will de-energize when the main flame is
lost.

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6.8 Main Trial for Ignition Period [0:1:15seconds]
Up to 15 seconds may be configured for main trial for ignition. This time should be selected to meet the
requirements of the governing codes in the end users jurisdiction. This time will be used in direct
ignition mode, interrupted pilot and continuous pilot if a main flame detection source is configured.
During MTFI the main flame must be proven. If not proven, direct ignition systems shall have all outputs
de-energized, interrupted and continuous pilot systems shall have DO2 and DO3 de-energized. If the
system is not configured to retrial/recycle this results in lock out requiring a reset.
6.9 Main Flame Stabilization Period [0:1:10seconds]
During MTFI, on detection of a flame the main flame stabilizastion timer shall be executed. On expiry of
this timer, if the flame remains proven the MTFI is successful.
6.10 Pilot Flame Failure Response Time [0:1:4seconds]
On loss of pilot flame a flame failure response timer may be configured during which the IGN output
shall re-energize to recover the pilot flame. If successful the DO2 and DO3 status outputs remain
energized, if not successful the module will adopt the lock-out state unless recycle/retrials are
configured.
6.11 Main Flame Failure Response Time [0:1:4 seconds]
On loss of main flame a flame failure response timer may be configured during which the IGN output
shall re-energize to recover the main flame. If successful the DO2 and DO3 status outputs remain
energized, if not successful the module will adopt the lock-out state unless recycle/retrials are
configured.
6.12 Pilot Recycle/Retrial Number [0-255]
If permitted by the governing codes of the end-user jurisdiction the module may be configured to
recycle/retry for ignition on a loss of flame. If configured all outputs shall be de-energized on loss of
flame and interpurge timer executed prior to re-attempting ignition. If flame is successfully recovered
the recycle/retrial counts reset. If not successful the number of retrials/recycles executed shall
increment up to the configured maximum before adopting the lock out state.
6.13 Pilot Interpurge Duration [0:1:1800seconds]
Pilot interpurge is executed during recycle/retrial for ignition of the pilot flame (or main during direct
ignition). All outputs are de-energized to allow the purging of combustible mixture from the appliance.
6.14 Main Recycle/Retrial Number [0-255]
If permitted by the governing codes of the end-user jurisdiction the module may be configured to
recycle/retry for ignition of the main on a loss of main flame. If configured DO2 and DO3 outputs shall
be de-energized on loss of flame and the main interpurge timer executed prior to re-attempting ignition.
If flame is successfully recovered the recycle/retrial counts reset. If not successful the number of
retrials/recycles executed shall increment up to the configured maximum before adopting the lock out
state. This option is valid on continuous or interrupted pilot systems where a main flame detection
source has been configured.
6.15 Main Interpurge Duration [0:1:1800seconds]
Main interpurge is executed during recycle/retrial for ignition of the main flame DO2 and DO3 outputs
are de-energized to allow the purging of combustible mixture from the appliance.

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6.16 Thermocouple High Temperature Trip Enable/Disable
The TC input can be used as a high temperature trip on the appliance. For example bath heaters may use
a thermocouple for a high bath temperature trip or it may be used for a stack temperature trip. The TC
input can only be used with a Type K thermocouple. If set as a high temperature trip the TC input cannot
be used as a flame detection source.
6.17 Thermocouple Setpoint [0:1:1200°C]
The thermocouple setpoint is either set to the process temperature at which high temperature trip is to
be detected or to a flame temperature when used as a flame detection source.
6.18 4-20mA Analogue Input Enable/Disable
The AI input can be configured as a process transmitter trip. If enabled the configured high and low trip
set points shall result in de-energizing of all outputs and the module will enter the lock-out state. The
transmitter scaling/transfer function will be required for factory configuration.
6.19 4-20mA Pressure Transmitter Enable/Disable
The AI input may be used as a fuel pressure transmitter. When enabled the transmitter high and low trip
setpoints shall be monitored during light-off. Typically the transmitter will be located between the
double block valves of the main valve train. The trip is automatically bypassed until 2 seconds after the
DO2 and DO3 solenoids are energized. Then high or low pressure conditions shall result in de-energizing
of all outputs and the module will enter the lock-out state.
6.20 4-20mA Transmitter High High/Low Low Trip Setpoints [0:0.1:20mA]
When the AI input is enabled for use the High and Low trip setpoints must be configured. Low may be
set artificially high and vice versa to deliver only Low or High process trips respectively.
6.21 Low Power Output Settings
The output drivers DO1, DO2 and DO3 are possible to configure for PWM operation. If required the duty
cycle and frequency of the appliance valves/solenoids is configured individually for each output. For
solenoids that required a peak and hold drive waveform the pull-in or peak duration is also configured.
Duty Cycle 0:1:100%
Frequency 0:1:500MHz
Pull-in/Peak Period 0:1:4000ms
6.22 End User Equipment Tag
A twelve character alphanumeric equipment tag may be pre-programmed in the device.