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RATIOTRONIC™ 6000 SERIES – INTEGRATED BURNER

CONTROLLER.

Commissioning Manual Issue 1.21

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Safety information

WARNING

When this equipment is fitted to an appliance due regard must also be given to the requirements of that appliance. Before attempting to install, commission or operate this equipment all relevant sections of this document must be read and fully understood. If in doubt about any requirements consult the supplier. Repairs to the controller must only be carried out by the manufacturer or their appointed agents. Installation, commissioning or adjustment of this product MUST only be carried out by suitably trained engineers or personnel qualified by training and experience. After installation or modifications to the installation all functions of the equipment MUST be checked to ensure safe and reliable operation of the controller. The manufacturer of this equipment accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation, commissioning or adjustment of operating parameters of the equipment. This equipment must only be fitted to burners as detailed in the contract specification. The supplier must approve any change to the specification in writing. Control panels must not be left uncovered while power is on. If it is essential to do so while rectifying faults only personnel qualified by training and experience should be involved. The time any covers are off must be kept to a minimum and warning notices must be posted. Before attempting any work on this equipment or any equipment connected to this equipment, the electrical supplies must be isolated. Safety interlocks must not be removed or over-ridden. Any faults, once detected, must be corrected before the controller is operated.

CAUTION – SOME VERSIONS OF THIS EQUIPMENT CONTAIN A LITHIUM BATTERY IN

THE DISPLAY UNIT

NOTE The manufacturer of this equipment has a policy of continual product improvement and reserves the right to change the specification of the equipment and the contents of this manual without notice.

The equipment described in this manual is capable of causing property damage, severe injury, or death. It is the responsibility of the owner or user to ensure that the equipment described herein is installed, operated and commissioned in compliance with the requirements of all national and local legislation, which may prevail.

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Table of contents This manual describes the installation, commissioning, operation and maintenance of the RATIOTRONIC 6000 series integrated burner controllers. Please read the safety information at the front of this manual before proceeding.

1. Introduction. 7

1.1 Basic System 7 1.2 Variants 7 1.3 RATIOTRONIC 6000 Inverter interface additional information 7

2. Description of operation. 8

2.1 The Display / Keypad 8 2.2 Start-up sequence 9 2.3 Gas safety valve proving (VPS) using the RATIOTRONIC1021 sensor. 13 2.4 Gas safety valve proving sequence using pressure switch. 14 2.5 Modulation 15 2.6 Non-volatile lockout 16 2.7 RATIOTRONIC 6000 Inverter interface additional information 16 2.8 Post Purge Operation 16

3. Installation. 17

3.1 Mechanical fixing details for the main RATIOTRONIC 6000 series controllers. 18 3.2 Mechanical fixing details for the display module. 19 3.3 Mechanical fixing details for optional Oxygen Probe Interface unit. 20 3.4 Mounting arrangements for Temperature, Gas pressure and Steam pressure sensors. 21 3.5 Option link selection (main controller) 23 3.6 Wiring 26 3.7 Final checks 48

4. Servo drawings 49

4.1 Type 1 servos 49 4.2 Type 2 servos 51 4.3 Type 3 servos 52

5. Servo motor selection and calibration. 53

5.1 Servo-motor selection 53 5.2 Locking the servo-motor to the valve shaft 54 5.3 Valve Control direction 54 5.4 Feedback potentiometer 54 5.5 Adjusting microswitch positions. 55 5.6 Servo movement limiters 55 5.7 Servo Movement 56

6. Commissioning the controller. 58

6.1 General 58 6.2 Commissioning data 59

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6.3 The Commissioning process. 59 6.4 Using option set mode 60 6.5 Option parameter list 61 6.6 Commission ratio mode 112 6.7 Adjust ratio mode 114 6.8 Interrogating the software issue 116

7. Inverter (variable speed) drives. 117

7.1 System configuration 117 7.2 Description of control method 117 7.3 Setting up the inverter for use with the RATIOTRONIC 6000 series. 118 7.4 Setting up the RATIOTRONIC 6000 series for use with a inverter drive 119 7.5 Encoder Wheel design. 120

8. The oxygen trim option 121

8.1 Oxygen probe description 121 8.2 Installation of oxygen probe 121 8.3 Calibrating and servicing the oxygen probe 125 8.4 Oxygen trim operation 128 8.5 Commissioning Oxygen trim 128

9. Faults and fault finding. 134

9.1 The fault display 134 9.2 What to do when a fault occurs 134 9.3 Non-volatile lockout 135 9.4 Fault subsets 135 9.5 Fault listing 135 9.6 The Engineer's Key 144 9.7 Troubleshooting 155

10. Technical specification 160

10.1 General 160 10.2 Servo motor control 160 10.3 Digital (Relay) outputs (main unit and display module) 161 10.4 Digital inputs 161 10.5 Pressure/temperature input 162 10.6 Auxiliary Analogue Inputs 162 10.7 Gas pressure input 162 10.8 Flame sensing devices 163 10.9 Communications interface 163 10.10 RATIOTRONIC 1021 gas pressure sensor 163 10.11 RATIOTRONIC 1030 steam pressure sensors 164 10.12 RATIOTRONIC 1034 pressure sensors 164 10.13 RATIOTRONIC 1040 and RATIOTRONIC 1044 boiler temperature sensors 165 10.14 RATIOTRONIC 6021, 6022, 6023 & 6024 Servo Motors 166 10.15 RATIOTRONIC 6026, 6027 & 6028 Servo Motors 166 10.16 RATIOTRONIC 6032 & 6033 Servo Motors 167 10.17 RATIOTRONIC 6080 Oxygen Probe Interface (optional) 168 10.18 RATIOTRONIC 6086 Ambiant Air Temperature Sensor Unit (optional) 168 10.19 RATIOTRONIC 6000 Daughter Board (optional) 169 10.20 Approvals 170

11. RATIOTRONIC 6000 terminal layout 171

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1. Introduction.

1.1 Basic System The controls described in this manual provide a fully integrated burner control system for industrial burners, providing a PID function to control the pressure / temperature of the boiler by modulating the fire rate, and a full burner management functions including flame and air pressure monitoring and fuel valve shut-off control.

1.2 Variants This manual covers the basic model with additional information on variant models at the end of each chapter. The RATIOTRONIC 6000 series is available in several models, which have different operating characteristics. These characteristics are shown briefly in the following table

Model

Characteristics

RATIOTRONIC 6000 Standard controller.

The RATIOTRONIC 6000 series controllers are complemented with a range of boiler temperature and pressure sensors, servo motors, optional interface boards which facilitates Inverter control, analogue input / output channels and Oxygen Trim functions (with an RATIOTRONIC 2012 Oxygen probe). Some of the models in the table above require the functions of an interface board and/or an expansion module for correct operation.

1.3 RATIOTRONIC 6000 Inverter interface additional information The RATIOTRONIC 6000 can accommodate a daughter board within the main enclosure to allow control of 1 or 2 inverter drives. The daughter board provides for inverter feedback as a current signal or pulse signal from an encoder measuring the speed of the relevant motor, fan or pump shaft. The daughter board has provision for monitoring a rotary cup speed via encoder input.

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2. Description of operation.

2.1 The Display / Keypad The display is a 2 line, 20 character per line, dot matrix vacuum fluorescent type allowing the use of plain text messages for display parameters. The keypad is a membrane construction with tactile keys to give a positive feedback of the actuation.

Key Function

EK Selects Engineers Key mode.

LOW FIRE Pressing this key will force the burner to Low fire until the key is pressed again to release the burner to modulate.

FUEL SELECT Changes Fuel/Profile. If the fuel is changed when the burner is firing, the burner will go off then restart firing the new fuel selection.

BURNER O-I Sets the burner On or Off. When setting ON the modulation mode, normal or local operation is selected. Note: Terminal PE9 must be ON for this switch to start the burner. When the burner is ON this button will set the burner OFF when pushed.

MUTE / RESET Press this key to mute (open) the alarm relays, then hold the key down for approximately three seconds to reset the cleared faults.

AUTO / HAND Selects auto or manual burner modulation. In manual mode the UP/DOWN keys are used to alter the fire rate.

DATA Selects different data types on the display window. Pressing this button for several seconds allows selection of the modulation mode – see 2.5 following.

COM Changes operation to commission mode via a passcode.

The UP/DOWN keys are

used to adjust the fire rate in

manual modulation mode.

In commission mode, they

are used for data value

selection.

The SCROLL keys are used to

view boiler and burner status

data during normal running

conditions.

In commission mode, these

keys select option parameters,

which are adjusted by the

UP/DOWN keys.

Alternate key functions

when in commission

mode.

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2.2 Start-up sequence When a fuel selection is made and the ‘burner select’ signal is given to start up the burner, the controller performs the sequence described below. If a gas profile is selected and the safety valve proving function is selected, the controller will perform safety valve pressure proving concurrently with the start-up sequence.

State no.

State name Description

0.

Non-volatile lockout

All fuel valve outputs are OFF and the Alarm output is ON until muted. The burner is held in this state until all faults are removed.

1.

Burner off

The burner is checked to make sure that it has switched off completely. Testing includes - main fuel safety valves closed, no flame signal, and no air pressure’ signal. The controller will remain in this state until there is a call for heat from the PID system.

2. Wait for start The controller waits for both a burner select (PE9 ON) and a fuel/air profile to be selected. Progression to stage 3 or 5 maybe held off by external influences, e.g. Digital Communications control or digital input controlled by an external circuit.

3. Open fuel valve If gas firing and safety valve proving are selected, the gas valve servo motor is moved ‘open’ for five seconds to allow any gas in the test section to be vented easily during the proving sequence.

4. Hold fuel valve The fuel motor is held in position until step 1 of the safety valve proving sequence (open main valve 2, or vent valve) is completed.

5. Prove closed positions

If gas is selected, the gas valve proving sequence begins (see section 2.3). The fuel and air motors are moved to closed position until they stop. The final positions are compared with the closed positions stored in memory when the profile is commissioned.

6. Prove air pressure The burner motor output is set ON and air pressure prove time (t1) is initiated. The selected motors are moved ‘open’ towards the purge position. If the ‘fan start early’ option parameter has been set then the motors will not move until the option time has expired.

7. Prove purge positions

When the air pressure prove time has elapsed, the air pressure switch must give a ‘pressure’ signal or the controller will lockout the burner and move to stage 0. If primary air is selected, then both primary and secondary air pressure signals must be ON to prove air pressure. The selected motors are driven ‘open’ until they reach their commissioned purge position.

8. Pre-purge Once the servo motors are at their purge positions the controller starts the pre-purge (t2) timer.

9. Move to ignition positions

When t2 has elapsed, the fuel and the air motors are moved to the ignition position for the selected profile. The controller will wait at the ignition positions while the gas valve proving sequence finishes before progressing to stage 10

10. Pre-ignition Once the fuel and air motors are at their ignition positions, the ignition transformer output is energized and pre-ignition time (t3) is starts.

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State no.

State name Description

11. Pilot ignition

Once t3 has elapsed the ignition transformer remains on, first main valve if required for pilot flame gas, and pilot valve outputs are energised and the first safety time (t4) is started. If firing on oil and ignition selected to be with both pilot and main valve, use timing in the startup sequence table for main valve 1. If firing on oil and ignition with main valve is not selected the pilot ignition will occur with only the pilot valve, use timing in the startup sequence table for main valve 2.

12. Pilot ignition interval

When t4 is complete, a flame must be detected or the controller will lockout the burner and move to stage 0. The ignition transformer may optionally be on or off (See option parameter 14.6).

13.

Main ignition Once the pilot interval time (t5) has elapsed, the second (and first if not already open) main valve output(s) for gas, or main oil valve output for oil is energized and the second safety time (t6) is started. If firing on oil and ignition with main valve was selected the main oil valve will have already opened for pilot ignition. The ignition transformer may optionally be on or off (See option parameter 14.6). A flame and air pressure signal must be detected or the controller will lockout the burner and move to stage 0.

14. Wait for Main flame established

When t6 has expired, the pilot valve output is turned off. If permanent pilot is selected and the burner is firing on gas, then the pilot will remain open with the main valves. Main flame interval time (t7) is started. A flame and air pressure signal must be detected or the controller will lockout the burner and move to stage 0.

15. Moving to low fire When t7 has elapsed, the flame is considered established and the fuel and air motors are moved from their ignition positions to their low fire positions and held at those positions for the duration of the Low Fire Hold Time (t8). A flame and air pressure signal must be detected or the controller will lockout the burner and move to stage 0.

16. Modulation When t8 has elapsed the fuel and air motors are modulated according to the demand placed on the burner. If the fuel selection is changed or the ‘burner on’ signal (PE9) is removed, the main valve output(s) are turned off. A flame and air pressure signal must be detected or the controller will lockout the burner and move to stage 0.

17. Move to post-purge

If Post Purge is not selected then the controller returns to state 1 to wait for another startup. If Post Purge has been selected then the fuel servo motor is moved to its closed position, and the selected air motor(s) are moved to their post purge position(s).

18. Post-purge When the air drive(s) have reached their post purge positions then the Post Purge Time (t9) is started. When t9 has elapsed, the burner motor is turned off and the controller returns to state 1 to wait for another startup.