Digital Burner Controller: Product Handbook
Digital Burner Controller: Product Handbook
Digital Burner Controller: Product Handbook
DBC2000 SERIES
PRODUCT HANDBOOK
2. FEATURES
• Employs a plug-in mounting method
• Uses a microprocessor to improve performance
• Status and fault indication by indicator LEDs
• A 4-wire firing rate switching circuit controls an air
damper motor or other auxiliary equipment during
start-up of the burner.
• Safe start check before and during pre-purge
• Dual flame amplifier for UV, IR or flame rod sensor
• Automatic recycle once per 24h of uninterrupted
heat demand.
• Frontal jack plug (Ø 3.5mm) to read the flame
signal with a microampere meter.
Contents
1. Application 1
2. Features 1
3. Specifications 2
Important note:
4. Dimensions 5
Subject to changes without notice.
5. Installation and wiring 6
Please check our web site 6. Operation 12
http://hic.emea.honeywell.com 7. Trouble shooting 14
for the most recent version of this document. 8. Approvals and Maintenance 23
All rights reserved. Appendix: VPS calculation and diagrams 25
Flame
Waiting for Waiting for Pre- Pilot- Main Main Post-
Ignition failure
AFS HF purge only trial stabilization purge
response
300s (max) 300s (max) 35s1) 3s 5s 3s2) 4s2) 15s3) 1s (max)
1)
Default pre-purge time is 35s. Other timings on request, by OS number selection.
2)
Set to 0s. when DBI function is enabled (terminal 22 jumpered to line voltage).
3)
Set to 0s. when “no post-purge” feature is enabled (terminal 12 jumpered to line voltage).
Sequence at flame failure: immediate lock out
Flame
Waiting for Waiting for Pre- Pilot- Main Main Post-
Ignition failure
AFS HF purge only trial stabilization purge
response
300s (max) 300s (max) 35s1) 3s 5s 3s2) 4s2) 15s3) 1s (max)
1)
Default pre-purge time is 35s. Other timings on request, by OS number selection.
2)
Set to 0s. when DBI function is enabled using the DIP-switches on the front, at the bottom left corner (Fig 4-5).
3)
Set to 0s. when “no post-purge” feature is enabled using the DIP-switches on the front, at the bottom left corner (Fig 4-5).
Sequence at flame failure: immediate lock out
Flame detector leads are colour coded. The blue lead wire must be connected to the F terminal (T23) and the
white lead wire to the G terminal (T24). The UV sensing tube is polarity sensitive. Reversing the lead wires
even momentarily will destroy the UV sensing tube.
Fig. 3-2: Example of wiring to external equipment (see fig 3-3 for more)
Fig. 4-2: Real flame current versus reading on frontal jack plug.
Note:
The flame signal strength on the flame current jack plug is only for reference and can vary between different
DBC2000 devices.
When measuring the flame signal current directly in the flame sensor wiring whilst:
1. Using a flame rod, the (multi-)meter will show the real flame current in µA.
2. Using a UV sensor (C7027, C7035 or C7044), the current in the sensor lead wires will be in the range of
20…25mA (inverted values).
Fig. 4-3: Measuring flame signal with multi meter (µA range selection) using a jack plug.
STD & ENH Models (flame detector select only) ULT Model (bus connector and address switches)
Fig. 4-4: Position of flame sensor selection jumpers and bus connector on the back of the DBC2000.
Fig 4-5 Configuration DIP switches (VPS) on the front of the DBC2000E (ENH/ULT only)
HEAT DEMAND SW OFF The power supply voltage is applied across Terminal 1 and
2. When no flame signal is present, the combustion airflow
AIR FLOW SW OFF switch is opened (T14=OFF) and safety lockout circuit is
●○○○○○○○
SAFETY LIMIT SW ON closed (ON), it is possible to start.
HEAT DEMAND SW ON The blower is energized (T3). Firing rate goes to PURGE
START Pos SW ON position. Air flow switch closes (T14=ON) as soon as air flow
is present.
PURGE Pos SW OFF
AIR FLOW SW ON The pre-purge timer starts counting as soon as PURGE
START Pos SW OFF interlock is closed (T16=ON).
●●○○○○○○
PURGE Pos SW ON
After the completion of pre-purge timing, firing rate goes to
PURGE Pos SW OFF
START position.
The ignition wait timer starts counting as soon as the START
position interlock is closed (T17=ON).
After completion of the ignition wait timing, the Ignition ●○●○○○○○
START Pos SW ON sequence starts. The Ignition transformer is energized. The
Intermittent and Interrupted pilot valve outputs are energized
(T5 and T6). ●○●○○○●○
When a flame is detected after the ignition trial has ended
FLAME ON ●○○●○○●○
(Safety1), the pilot stabilization time starts.
After completion of the pilot-stabilization time, the Main
valves are energized (T7=ON). Note: Enhanced Model: also
(T12=ON). ●○○○●○●○
If a critical error related to safety operation (such as a loss of flame, opening of the air flow switch during the
ignition trial and run sequence) is detected, the DBC2000 instantly goes into lock-out and goes to pre-purge status.
If a non critical error is detected (such as opening of the air flow switch during post-purge), DBC2000 holds the
sequence during the lock-out time, allowing time for the error to rectify, and then goes into lock- out.
For all types of errors, the status LEDs indicate the status information to the operator.
Fig. 6 to Fig. 13 show the sequence of DBC2000 in case of some error. And Table 8 shows the status of LEDs for
each error.
The product handbook (ENS7003) shows the different scenarios for possible failures.
Indicator LED
Sequence Error condition
status (*1)
Safety limits opened at any time (no voltage present at T18 (STD model) or
All T19 (ENH/ULT model)
●○○○○○○◐
Air flow switch remains ON (closed) for more than 5 minutes, or START position ●◐○○○○○◐
interlock switch remains OFF(opened) for more than 5 minutes.
Standby (*2)
Flame signal is present ●○○○○○◐◐
Air flow switch remains OFF for more than 5 minutes after the heat demand has ●◐○○○○○◐
started.
PURGE position interlock switch remains OFF for more than 5 minutes after the heat ●◐◐◐○○○◐
demand started.
Both PURGE and START position interlocks ON at the same time during prepurge ●◐◐◐○○○◐
period
Pre-purge
START position interlock remains OFF more than 5 minutes after pre-purge has ●◐◐◐○○○◐
finished
Air flow switch goes ON within 5 minutes after the heat demand started, but air flow ●◐○○○○○◐
switch goes OFF again.
Flame signal is present. ●◐○○○○◐◐
Post-purge Flame signal is present for more than 10 seconds after heat demand has ended. ●○○○○○◐◐
Air flow switch keeps ON more than 5 minutes after post-purge. ●◐○○○○○◐
1. Line voltage out of specs for more than 2 seconds
2. Line frequency out of range for more than 2 seconds
All 3. Excessive noise on power line or in the area
●○○○○○○●
4. Internal device problem: CPU clock out of sync
*1 : For LED indication, ○ means ‘off’, ● means ‘illuminated’, ◐means ‘blinking’.
The LEDs are arranged in the following order: Standby, Purge, Ignition, Pilot, Main, Modulate, Flame and Alarm at the left
front side of the DBC2000.
*2 : If an error occurs during Standby, the DBC2000 will not lock-out but LEDs indicate the current error status.
In this case, the DBC2000 cannot start before the error is resolved.
Declaration of Conformity
Honeywell Technologies Sàrl
Z.A. La Pièce 16
1180 Rolle
Switzerland
declares under it’s sole responsibility that the following product family of burner controllers:
• in conformity with the essential requirements of the Gas Appliance Directive 2009/142/EC
based on EN 298
and in conformity with the type as described in the EC type-examination certificate issued
by DVGW CERT GmbH in Bonn with pin number 0085CM0138
• in conformity with the essential requirements of the Low Voltage Directive 2006/95/EC
based on EN 60730-2-5
• in conformity with the essential requirements of the EMC Directive 2004/108/EC on immunity
Conformity with the essential requirements of the EMC Directive 2004/108/EC on emission can only be
determined in the application.
A.Veld
We cannot assume that the product can be safely used beyond the mentioned designed lifetime. This lifetime is
based on use of the control according manufacturer’s instructions.
Regular inspection of the control by authorized personnel in accordance with guidelines of the appliance
manufacturer is required.
After reaching the designed lifetime the product has to be replaced by authorized personnel.
2 x Pi x Vp
Tp = --------------- [s]
Qm
Important
The total volume Vp has to be calculated with all volumes
between the tested valves: internal volumes of valves and all
pipes.
Calculation examples Calculation of the minimum test time (per valve) in a DN80
Example 1 flanged pipe train, where a 1” bypass valve is used.
Pi = 150 mbar
3
Qm = 100 dm /h
Gas valves used: DN80 size with 1 meter pipe (L1).
Bypass valve: 1” valve with 0.5 meter pipe (L2).
To be calculated: Tp [s]
Calculation of the minimum test time (per valve) in a 2” Calculation:
threaded pipe train. From Table a. :
3
Pi = 150 mbar DN80 @ L1=1m Vp1 = 6.9 dm
Qm = 60 dm /h
3 1” @ L2=0.5m Vp2 = 0.44 dm3
Gas valves used: 2” size with 0.5 meter pipe. There is only 1” bypass valve, that reduces the total volume
3
To be calculated: Tp [s] by 0.5x the volume @ L=0m Vp3 = 0.19 dm
Calculation: 3
From Table a. : Vp = Vp1 + Vp2 – (0.5 x Vp3) = 7.245 dm
3
2“ @ L=0.5m Vp = 2.3 dm
2 x 150 x 7.15
2 x 150 x 2.3 Tp = ------------------ [s]
Tp = ---------------- [s] 100
60
Using the formula above, the minimum test time Tp = 21.735s
Using the formula above, the minimum test time Tp = 11.5s The DBC2000E2 must be set to 25s test time (see page 11).
The DBC2000E2 must be set to 15s test time (see page 11).
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