FCE60 Ignition Box. User Manual

Transcription

1 FCE60 Ignton Box User Manual

2 FCE60 Ignton Box User Manual Kratbjerg DK 3480 Fredensborg - Denmark - Phone: Emal: sales@tf-technologes.com 3

3 About FCE60 User Manual Content and structure Ths user manual for the FCE60 Ignton Box has been developed to provde the necessary nformaton to nstall and operate the FCE60 Ignton Box. Ths Englsh verson of ths manual consttutes the orgnal verson, and can therefore be used as a reference n case of doubt regardng use or msuse of the system. The user manual s a practcal gude for setup, mountng, operatng and mantanng the FCE60. The user manual has been dvded nto colour-coded sectons, enablng the user to easly look up the potental subjects of the nterest. Safe use Read the nstructons before use. The FCE60 Ignton Box shall be nstalled n accordance wth the rules n force. Partcularly the secton Safety Instructon p. [16] should be read thoroughly before use. Gettng thoroughly acquanted wth the manual furthermore ensures the operator the full value of the system, as the user manual contans a multtude of practcal dos and don ts, as well as useful gudance on mantenance and troubleshootng. The user manual should always be stored together wth the system. To ensure safe use of the FCE60 Ignton Box, the operator s advsed to perform an ndvdual rsk assessment of the use of the Ignton Box n combnaton wth the relevant gas burner system. Copyrght Ths manual has been developed exclusvely for users of the FCE60 Ignton Box to provde the necessary nformaton to nstall and operate the FCE60 Ignton Box, and may only be used for ths partcular purpose. All nformaton, text and pctures are the ntellectual property of, and copyrghted materal of TF-Technologes A/S. All rghts are reserved. The manual may not be coped, dsplayed, quoted, publshed, sold, modfed, or dstrbuted wthout the wrtten consent of TF-Technologes A/S. Dsclamer TF-Technologes A/S and ts dstrbutors may not be held lable for potental edtoral errors, omssons or falure effects. Suggestons regardng updates or correcton of potental errors are apprecated. Contact nformaton TF-Technologes A/S Kratbjerg Fredensborg Denmark T: E: sales@tf-technologes.com User manual nformaton Document name: FCE60 User Manual Document number: G Publcaton date: 14. March 2016 FCE60 Ignton Box The FCE60 Ignton Box contans a model number/name, seral number and a part number, so that each unt s easly dentfed and traceable. All relevant numbers should be stated, when contactng TF-Technologes regardng your product: Example Model number/name: FCE60 Seral number: TF Part number: S Symbol overvew Ths user manual uses a range of symbols and warnng notfcatons throughout the manual to make the operator aware of mportant safety measures or nformaton regardng nstallaton or operaton. The followng symbols are used n ths manual: Warnng Indcates mportant nformaton the operator must be aware of to avod dangerous stuatons that can result n death or serous personal njury Cauton Indcates mportant nformaton the operator must be aware of to avod dangerous stuatons whch can result n materal damages Tp Indcates nformaton regardng effcent and falure-free operaton of the Mn-Lne Grade and Slope Control System Step-by-step nstructons Indcates a step-by-step nstructon, where a partcular order of actons s requred The FCE60 s CE-marked and comply wth regulatons for securty and relablty. 4 5

4 Table of Contents Introducton About the FCE60 Ignton Box... 7 Why use the FCE60 for your gas burner system... 8 How the FCE60 Ignton Box works... 9 Why the FCE60 s better than other gnton controllers...10 Where can the FCE60 Ignton Box be used...14 Backwards compatblty...15 Operaton Operatng the FCE60 Ignton Box...16 Operatng the FCE60 Ignton Box...17 Confguraton System Confguratons...18 Ignton Control System wthout Temperature Controller (stand-alone)...19 Temperature Control System wth Temperature Controller...25 Installaton Essental components for nstallaton...36 Installng the FCE60 Ignton Box...40 Safety Instructons Requrements for the gas burner system...45 Correct use...47 Incorrect Use...49 Warnngs and Dangerous Stuatons...50 About the FCE60 Ignton Box The FCE60 Ignton Box s an gnton controller desgned for use n gas burner systems for controllng the gas flow and gas gnton. When used correctly, t prevents gas accdents and secures a smooth operaton of the gas system. The FCE60 Ignton Box s certfed to the standard EN 298:2012 Automatc burner control systems for burners and applances burnng gaseous or lqud fuels. Ths certfcaton ensures that the FCE60 has been developed to the hghest safety standards for electrcal desgn of control devces for gas systems, and comply wth the European gas safety requrements. The FCE60 s a smple plug n play gnton controller operatng automatcally when suppled. The development of the FCE60 Ignton Box bulds on more than 30 years of experence wth the development of gnton Introducton controllers for gas systems n hghly durable applcatons, such as n road machnes. The FCE60 s ft for ntegraton n gas systems on machnery as well as consumer applances, but s partcularly sutable for machne ntegraton, as t s hghly resstant to electronc dsturbance from surroundng electronc products and tested to EN13309:2010 Constructon Machnery - Electromagnetc Compatblty of Machnes wth Internal Power Supply. The FCE60 Ignton Box can be used as a stand-alone gnton controller n systems desgned for contnuous burnng for up to 24 hours, or wth a temperature controller that mantans a specfc temperature level. It s applcable n sngle-burner systems as well as mult-burner systems, and can be connected to both 12V and 24V DC power supply. Mantenance Servce and Repar...51 Transport...51 Storage...52 Cleanng...52 Dsposal...53 Appendx Troubleshootng...54 Local Assembly of Hgh Tenson Cord...55 Techncal Specfcatons (data sheet)...57 Certfcate...63 Declaraton of Conformty /24 12V VDC / 24V 5 Amp. Flame error Fg. 1 - FCE60 Ignton Box n stand-alone confguraton wth one gas burner Fg. 2 - FCE60 Ignton Box n confguraton wth temperature controller and one gas burner 6 7

5 Introducton Introducton Why use the FCE60 for your gas burner system A gas burner system conssts of a gas supply, gas ppes, a gas solenod valve, a gas burner and a gas gnton devce. A smple example of a gas burner system s dsplayed below. How the FCE60 Ignton Box works The FCE60 Ignton Box controls the gas supply by openng and closng an electronc gas solenod valve, and uses a spark plug to nstantly gnte the gas, when suppled. It contnues to montor the flame throughout operaton, and any accdental blow-out of the flame mmedately trggers automatc re-gnton. In case of re-gnton falure, the FCE60 wll close the gas valve as a safety measure to prevent accdents caused by gas seepage. Gas solenod valve Gas gnton devce ILLUSTRATIVE Not for wrng purposes Gas ppe Gas ppe Gas burner Gas supply Fg. 3 - Gas burner system wth gas supply, gas ppes, gas solenod valve, gas burner and gas gnton devce Provded the burner s functonal and gas ppes are tght, the basc functonalty of the gas system s to open and close the gas valve and gnte the gas. The key to a smooth and safe operaton of the gas system s to make sure the gas s gnted when suppled and remans lt throughout operaton, so that no gas seepage takes place. Because the use of gas as a heatng soluton s combned wth the danger of explosons due to excessve seepage of gas, gntng the gas and makng sure that t remans lt s not somethng to be done safely by a person. Instead, an gnton controller such as the FCE60 Ignton Box ensures just that. Fg. 4 - Gas burner system wth FCE60 Ignton Box The FCE60 gntes the gas wth an electronc dscharge n a spark plug connected wth a hgh tenson cable. The electronc gnton makes t far easer and safer to gnte the gas, compared to a person manually gntng the gas, and at the same tme the electrode s used for automatc flame control. Montorng the flame s a major advantage, as t greatly mnmzes the rsk of gas explosons due to flame falure. To montor the flame, the FCE60 uses the concept of onzaton. The combuston of the gas creates chemcal reactons and an elevated temperature that creates local onzaton n the flame. By applyng voltage to the spark plug between the sparks, the onzed gas forms a current known as onzaton current that the FCE60 Ignton Box s able to measure. It s by measurng ths onzaton current that the FCE60 s able to know whether a flame s present. 8 9

6 Introducton Why the FCE60 s better than other gnton controllers The FCE60 Ignton Box has been developed adherng to the hghest safety standards for electrcal desgn. When usng the FCE60 as prescrbed n ths manual, the manufacturer can rest assured that hs gas burner system n hs machne or consumer applance meets the hghest standards for gas safety. Specfcally desgned to comply wth strct safety regulatons for desgn of gas systems The FCE60 Ignton Box was bult specfcally to comply wth nternatonal strct regulatons for the desgn of safe gas burner systems. In the European Unon, the gas safety requrements are specfed n the 2009/142/ EC Gas Applances Drectve and 2006/42/ EC Machnery Drectve for consumer applances and machnery respectvely. The FCE60 s EN 298 certfed wth full complance to 2009/142/EC Gas Applances Drectve 2006/42/EC Machnery Drectve Because gnton controllers lke the FCE60 control the gas flow and montor the gnton, they are characterzed n these Drectves as safety devces, whch entals that when used n a gas system on a machne or n a consumer applance, they must be desgned, so that a potental falure of the devce does not result n an unsafe stuaton. Ths sets very hgh demands on the electrcal desgn as specfed n the harmonzed standard EN 298, and also entals that a certfcaton that all these demands have been met s mandatory. The FCE60 Ignton Box s fully certfed to the standard EN 298:2012 Automatc Burner Control Systems for Burners and Applances Burnng Gaseous Fuels. Ths s your guarantee for a falure-safe gnton controller n full complance wth the European legslaton. Please refer to the certfcate n the Appendx of ths manual. In the US, Canada and Australa the legslaton s very smlar, and the EN 298 certfcaton wll typcally correspond to the gas safety requrements n these regons. EN 298 certfed - your guarantee for a falure-safe gnton controller The EN 298 certfcaton of the FCE60 entals hgh demands to the functonalty and the electrcal desgn, as t s requred to mantan a safe electrcal control of a gas burner system, even n the face of several nternal falures. The FCE60 therefore has several bult-n redundances, ncludng double relay, an nternal fuse and three control crcuts that ndvdually control the flame detecton performed by the FCE60. Ths means the FCE60 Ignton Box wll mantan a safe gas system even n cases of overcurrent, a permanent short crcut of the gas solenod valves, or up to two ndvdual component falures, all of whch could otherwse result n a dangerous gas leakage. The desgn of the FCE60 Ignton Box certfed to the EN 298 standard s therefore your guarantee for a falure-safe gnton controller that mantans gas safety even under adverse condtons. The FCE60 mantans gas safety even n cases of Overcurrent Short crcut of gas solenod valves Up to two component falures Certan other demands for confguraton and nstallaton are requred under the 2009/142/EC Gas Applances Drectve and 2006/42/EC Machnery Drectve, please refer to the relevant sectons of ths manual. Non-certfed gnton controllers offer false sense of safety There are stll many outdated non-certfed gnton controllers avalable n the market that do not comply wth the current gas safety requrements, offerng a false sense of safety for the user, as well as the manufacturer of the machne or consumer applance wth the gas system n whch the gnton controller has been ncorporated. Such non-certfed gnton controllers are outdated and not sutable for ther applcaton, as they wll not have the requred bultn redundancy. Ther smple electrcal desgn s not sutable for a safety devce such as an gnton controller and do not provde for a safe gas system. Introducton For example, a sngle component falure due to overheatng or product ageng could lead to false flame detecton or nablty to control the gas solenod valve output, whch can result n a dangerous gas leakage. Lkewse, a short crcut of the gas solenod valve could leave the gnton controller unable to shut off any gas solenod valves, also resultng n a hghly unsafe gas system. A non-certfed gnton controller can result n serous personal njury and makes the manufacturer open to product lablty clams So not only do these non-certfed, outdated gnton controllers not comply wth the current gas legslaton n most parts of the world n the EU makng t llegal to CE mark the machne or applance they are ncorporated n these outdated models also put the manufacturer of the machne or applance wth the gas system n queston at great rsk of product lablty clams n case of accdents. The manufacturer of the gas system s n a very bad poston n the face of such allegatons of unsafe equpment, as the lack of EN 298 certfcaton of the gnton controller makes t s very easy to prove that the proper gas legslaton has been gnored

7 Introducton Introducton Fg. 5 - Examples of non-certfed outdated gnton controllers not sutable for the EU, US and Australan markets Years of experence provdng relable and durable desgn The development of the FCE60 Ignton Box bulds on more than 30 years of experence wth the development of gnton controllers for gas systems n hghly durable applcatons, such as n road machnes. Ths tred and true technology has now been appled n a new verson developed to comply wth the hgh safety requrements of today s strct gas regulatons. The electroncs s fully encapsulated n a flame retardant housng, makng the FCE60 partcularly robust even n rough envronmental condtons. The hardy cable connectng the spark plug to the FCE60 can endure many years of contnuous use. Ths ensures an extremely robust controller and more 50,000 unts of the FCE60 and ts predecessors have already operated successfully n the feld n a vast array of tough applcatons. Resstant to electronc dsturbance The electronc sgnals of the FCE60 Ignton Box are hghly resstant to electronc dsturbance from surroundng electronc products, and the FCE60 s tested to the standard EN 13309:2010 Constructon Machnery - Electromagnetc Compatblty of Machnes wth Internal Power Supply for full complance to the 2014/30/EU Electromagnetc Compatblty Drectve. Smple plug n play soluton wth compact desgn The FCE60 Ignton Box s very compact n sze allowng for nstallatons even where space s lmted, as s often the case on machnery or n applances, and partcularly relevant n confguratons wth multple burners. It s easy to nstall wth no settngs or requred software setup. Flexble soluton that can be used n many dfferent gas systems Gas burner systems n varous applcatons and machnes by dfferent manufacturers come n many forms and shapes, whch entals that the desgn of the gnton control secton dffers greatly. The FCE60 Ignton Box s a flexble soluton that can be used n a wde array of these systems, as t can be ncorporated n a broad range of confguratons. It s applcable n sngle-burner systems as well as mult-burner systems, and can be connected to both 12V and 24V DC power supply. It can be used both as a stand-alone gnton controller n systems desgned for contnuous burnng for up to 24 hours or wth a temperature control module that mantans a specfc temperature level. Other Advantages of FCE60 Relable and durable desgn Resstant to electronc dsturbance Tested to EN 13309:2010 Compact, smple plug n play soluton No settngs or software setup For sngle- or multburner system Connects to 12V and 24V DC For use wth or wthout thermostat ILLUSTRATIVE Not for wrng purposes Fg. 6 - Gas burner system wth FCE60 Ignton Box and Temperature Controller 12 13

8 Introducton Introducton Where can the FCE60 Ignton Box be used The FCE60 Ignton Box can be used for controllng the gas flow and gas gnton n any gas burner system wth a maxmum burner output of 360kW per burner, where the FCE60 can be connected to a 12V or 24V DC system, and has a valve output of maxmum of 2.5A. The FCE60 Ignton Box can be utlzed n systems desgned for permanent operaton, but the Ignton Box should be shut off and restarted once every 24 hours as a safety measure, to allow the FCE60 to perform a start-up check and to ensure all functons are workng. The gas burner system and any ndvdual components heren, ncludng gas valves, fttngs, hoses, and regulators must be constructed n accordance wth general statutory gas safety regulatons. Backwards compatblty The FCE60 Ignton Box s backwards compatble wth the former non-certfed FCE24 Ignton Box. The FCB24 Ignton Box only dfferng from the FCE24 n ts physcal dmensons, wll not become avalable n a new EN 298 certfed verson, as the housng does not leave room for a crcut board that can contan the requred components to satsfy the safety requrements. Smlartes and dfferences of the FCE60 and FCE24 Ignton Boxes FCE24 Ignton Box (old verson) FCE60 Ignton Box (new verson) When the FCE60 Ignton Box s nstalled n a gas system on a machne, there are certan other requrements for the safe operaton, please refer to Safety Instructon p. 45 and Confguraton p. 18. What s the EN 298 standard and why s t mportant? The 2009/142/EC Gas Applances Drectve (GAD) specfes mandatory gas safety regulaton for gas burner systems n applances marketed n the EU, whereas the 2006/42/EC Machnery Drectve (MD) specfes mandatory gas safety regulaton for gas burner systems n machnery. more ndrectly to GAD. In effect, ths entals that any gas burner system marketed n the EU s requred under EU law to comply wth GAD, and where the gas burner system ncludes an automatc control system, such as an gnton box, t shall comply specfcally wth the EN 298 standard. Commonaltes Identcal housng Actvaton (GND) Yellow flame dode Max. 2.5A (gas) Mn. 10 Hz spark frequency Length of hgh tenson cords m CE marked (EMC drectve) Functons Manufacturers as well as dstrbutors are drectly lable n cases of gas safety ssues or accdents, where these Drectves have not been compled wth. Complance s therefore essental from both a moral and a legal perspectve. Both GAD and MD refer drectly to the harmonzed standard EN 298 for complance for automatc burner control systems, and addtonally MD (n Artcle III) refer Where complance to harmonzed standards s normally voluntary, the serous nature of gas-related accdents entals that GAD has a mandatory requrement for a notfed body certfcaton to document complance to the EN 298 standard. Ths means that usng a non-en 298-certfed gnton box n a gas burner system n an applance or a machne makes t llegal to mark the applance or machnery wth the CE mark and sell t on the EU market. Red error dode Drect spark (constant) VDC C App. 7 sec. safety tme 1 relay 2-layer crcutboard 90 components 4 transstors Specfcatons Desgn Red/green status dode 1 sec. start-up check 3 gas control crcuts 12/24 VDC system C <10 sec. safety tme 2 relays + nternal fuse 4-layer HDI crcutboard 400+ coponents 100 transstors 14 15

9 Operaton Operaton Operatng the FCE60 Ignton Box Safe use Before the FCE60 Ignton Box s nstalled and operated, t s mportant that the nstaller and operator have been nformed and understand the secton Safety Instructon, p. 45. Operatng the FCE60 Ignton Box Lght ndcators The FCE60 Ignton Box features two LEDs that dsplay the status of operaton. One LED ndcates the burner mode and one LED ndcates whether the unt s on or n fault mode. General operaton The FCE60 Ignton Box automatcally starts operaton when power s appled. ON / FAULT BURNER The operaton begns wth a bref one second safety check, where functonalty and gas solenod valve power s tested. Once confrmed, the FCE60 Ignton Box opens the gas supply and starts the gnton. When the FCE60 detects a flame, the Ignton Box wll cease sparkng. After ths, the FCE60 wll contnue to montor the flame. If no flame s detected or n case the flame dsappears later, the FCE60 Ignton Box wll ntate sparkng to attempt re-gnton. If a flame s stll not detected wthn a safety tme of max 10 seconds, the FCE60 stops sparkng, and turns off the gas supply by closng the gas solenod valves. When the Ignton Box closes the gas solenod valves, a red lamp wll ndcate a fault mode. The gas solenod valves wll reman closed untl a power-down and power-up s performed for the FCE60 Ignton Box. Dsplay Operaton mode Descrpton Gas Valve Power OFF FCE60 Ignton Box has no power supply Closed 1 flash Start-up check FCE60 Ignton Box s suppled, and checks gas valve power and no flame presence Closed Igntng FCE60 Ignton Box s tryng to gnte the suppled gas, ether followng start-up mode or flame loss Open Runnng FCE60 Ignton Box montors flame presence Open Flame falure FCE60 Ignton Box dd not succeed gntng the gas and s n flame falure mode Closed Fg. 6 - General operaton of the FCE60 Ignton Box 16 17

10 Confguraton System Confguratons The FCE60 Ignton Box can be used n two overall system confguratons: An gnton control system, where the FCE60 Ignton Box operates on a stand-alone bass and a temperature control system confguraton, where the FCE60 Ignton Box s ntegrated n a temperature control system wth a temperature controller. Both of these overall confguratons can be appled for a sngle-burner setup and a mult-burner setup, but the setup vares wth the overall confguraton. The two overall system confguratons are therefore descrbed separately, but the requrements that apply to both types of overall system confguratons, rrespectve of the number of burners, are outlned below. The gas solenod valves must be EN 161 approved to comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/ EC Machnery Drectve The hgh tenson cord connectng the spark plug to the FCE60 Ignton Box must feature a nose resstor In the Ignton Control System confguraton, the FCE60 s used as a stand-alone gnton controller n a gas system desgned for contnuous burnng. In ths system, the FCE60 Ignton Box wll mantan the gas lt throughout operaton, from system power-up to system power-down. Confguraton Ignton Control System wthout Temperature Controller (stand-alone) The operator must ensure that the Ignton Control System does not run for more than 24 consecutve hours, as the FCE60 s not desgned for contnuous operaton beyond 24 hours. An Ignton Control System wth the FCE60 Ignton Box can be set up wth one or multple burners. The maxmum contnuous operaton tme for the FCE60 Ignton Box s 24 hours Pn 1 (orange wre) on the FCE60 Ignton Box can be connected to a lamp to ndcate flame falure The FCE60 Ignton Box, temperature controller, temperature sensor, hgh tenson cords and all other system accessores must only be nstalled n confguratons where they operate wthn ther specfcatons 18 19

11 Confguraton Ignton Control System (stand-alone) wth a sngle burner The most basc confguraton wth the FCE60 Ignton Box s the Ignton Control System confguraton wth one sngle burner. Ths confguraton s dsplayed n fgure 7. Confguraton Ignton Control System (stand-alone) wth up to four burners The Ignton Control system wth the FCE60 Ignton Box n a confguraton wth multple burners up to a total of four burners s dsplayed n fgure 8. One FCE60 Ignton Box per burner s requred and they must be serally suppled to ensure the safety of the gas system n case any one of the FCE60 detects a flame error. Serally suppled entals that the frst FCE60 Ignton Box s connected to the power supply, the next FCE60 s suppled va the gas valve output of the frst FCE60 and so on. The last FCE60 n the seres supples the two gas valves that are connected to ths FCE60 n parallel. Fg. 7 - FCE60 Ignton Box n stand-alone Ignton Control System confguraton wth one sngle burner The Ignton Control System must be desgned wth two gas solenod valves connected serally to the gas supply to comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve A fuse of mnmum 5A for overcurrent protecton must be nstalled between the power supply and the FCE60 Ignton Box Fg. 8 - FCE60 Ignton Box n stand-alone Ignton Control System confguraton wth up to four burners Because the FCE60 Ignton Box performs a one second safety check upon start-up, when connected serally, there wll be a delay of one second per FCE60 connected n the seres, before the last FCE60 s powered up and the gas solenod valves are opened. After the last FCE60 has opened the gas solenod valves, we need to allow suffcent tme for the frst FCE60 to gnte the gas and detect the flame, before ts safety tme,.e. the amount of tme the FCE60 wll check for flame presence before t closes the gas solenod valves, has tmed out and the frst FCE60 closes the gas solenod valves. Snce the safety tme s < 10 seconds, and each FCE60 n the seres adds a delay of 1 second, n order to allow suffcent tme for the frst FCE60 to gnte the gas and detect the flame, no more than four FCE60 Ignton Boxes should be connected serally

12 Confguraton The Ignton Control System should be confgured so that no more than four FCE60 Ignton Boxes are connected serally to the gas solenod valves The amount of tme requred for the FCE60 Ignton Box to detect the flame depends heavly on the burner n queston and the qualty of the flame produced, as well as the exact postonng of the spark plug correctly n the mddle of the flame. In some cases, t may be possble to connect more than four FCE60 serally to the gas valves and mantan system functonalty, n other cases t may be less than four FCE60 Ignton Boxes. If you have problems mantanng functonalty wth less than four serally connected FCE60, we frst recommend tryng to optmze the spark plug poston, please refer to p. 41. If t s stll not possble to obtan a functonal system, the system must be reconfgured as an Ignton Control System wth more than four burners, but wth fewer FCE60 n each seres. Confguraton Ignton Control System (stand-alone) wth more than four burners Because the maxmum number of FCE60 Ignton Boxes that can be connected serally to the gas solenod valves s four, a system confguraton wth more than four burners, requres one more seres of FCE60 Ignton Boxes. Each seres must stll be connected to two gas solenod valves, and all gas solenod valves must be serally connected to the gas supply before all burners to ensure the safety of the gas system n case any one of the FCE60 detects a flame error. Fgure 9 dsplays an Ignton Control System wth the FCE60 Ignton Boxes n a confguraton wth up to eght burners. Just as n the sngle-burner confguraton, two gas valves must be connected serally to the gas supply for a suffcently safe gas system. The Ignton Control System must be desgned wth two gas solenod valves connected serally to the gas supply to comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve A fuse of mnmum 5A for overcurrent protecton must be nstalled between the power supply and the FCE60 Ignton Boxes If an ndcaton of flame error s requred, pn 1 (orange wre) on all the FCE60 Ignton Boxes must be connected to a flame falure ndcator n parallel. Fg. 9 - FCE60 Ignton Box n stand-alone Ignton Control System confguraton wth more than four burners 22 23

13 Confguraton To comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve, the Ignton Control System wth more than four burners must be desgned, so that each seres of up to four FCE60 connect to two gas solenod valves connected serally to the gas supply A fuse of mnmum 8A for overcurrent protecton must be nstalled between the power supply and the gnton control system confguraton As long as the system s confgured wth a maxmum of four FCE60 Ignton Boxes n each seres, t s possble to expand the system ndefntely wth more seres of Ignton Boxes. The number of seres possble s lmted only by the battery capacty, but the fuse for overcurrent protecton should be adjusted accordngly. Confguraton Temperature Control System wth Temperature Controller In the Temperature Control System confguraton, the FCE60 Ignton Box s ntegrated n a temperature control system wth a temperature controller. Ths type of gas system s desgned to mantan a specfc materal temperature, and a temperature sensor wll be connected to the temperature controller that compares the temperature measurements to a user specfed temperature settng. The FCE60 Ignton Box wll be controlled by the temperature controller that wll turn the FCE60 on and off to mantan the specfed temperature. A Temperature Control System wth the FCE60 Ignton Box can be set up for one or multple burners. TF-Technologes can delver a complete Temperature Control System to one or more gas burners. The system s fully ntegrated n a closed cabnet wth all connectons assembled n a central termnal and desgned specfcally to the specfcatons of the ndvdual manufacturer, whle ensurng full complance to the European gas safety regulatons. Ths s the easest soluton to ensure a safe and correctly confgured system, and offers the beneft of a practcal plug n play soluton, ready for quck nstallaton on the relevant machnery or applance. Due to the complex nature of the European safety regulatons, t s not recommended for manufacturers wthout extensve knowledge of ths area to perform the confguraton of these systems themselves. If an ndcaton of flame error s requred, pn 1 (orange wre) on all the FCE60 Ignton Boxes must be connected to a flame falure ndcator n parallel. Insde cabnet Fg Example of complete Temperature Control System fully ntegrated n closed cabnet desgned specfcally to the specfcatons of the manufacturer, ready for delvery from TF-Technologes 24 25

14 Confguraton TF-Technologes offers three dfferent temperature controllers that can be ntegrated n such a Temperature Control System wth FCE60. Confguraton descrbed n ths manual must be used and the system must only be confgured and nstalled as descrbed n the followng sectons. The alternatve temperature controller must comply wth the followng safety specfcatons. If an alternatve temperature controller s used t may not allow automatc re-start of the FCE60 Ignton Box(es) from ts flame falure mode Temp. range C or C 1 Burner 1 Temperature sensor No manual overrde TC101 SC5-96 STC1600 Key specfcatons Temp. range C 4-8 Burners 1 Temperature sensor Manual overrde Temp. range C 8 Burners 4 Temperature sensors Manual overrde For a complete gude to functonalty of the temperature controllers, please refer to ther ndvdual user manual The temperature controllers from TF-Technologes can only be used n Temperature Control Systems, where the temperature controller tself s not desgned to work as a safety devce. Ths s the case, where the Temperature Control System s desgned to prevent explosons by mantanng materal temperature below a certan threshold (e.g. mantanng temperature of a btumnous materal to prevent exploson). Note that only specfc versons of the TC101, SC5-96 and STC1600 comply wth the 009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve. Contact TF-Technologes for nformaton, or refer to the data sheet of the ndvdual part numbers for ths specfcaton The temperature controllers from TF-Technologes can only be used n systems where the temperature controller tself s not desgned to work as a safety devce For such an applcaton, t s possble to use an alternatve temperature controller approved specfcally to such an applcaton and assemble the Temperature Control System locally. If an alternatve temperature controller s used, the temperature controller must be able to handle an error sgnal The Temperature Control System must also be confgured so that t s the FCE60 that controls the gas solenod valves, and not the temperature controller. If an alternatve temperature controller s used wth a turnng knob, the turnng knob must have a lockng functon The Temperature Control System must be confgured so that the FCE60 controls the gas solenod valves drectly Temperature Control System wth a sngle burner The most basc confguraton wth the FCE60 Ignton Box n a Temperature Control System s a confguraton wth one sngle burner. Ths confguraton s dsplayed n fgure 11 for an NPN controlled temperature controller and n fgure 12 for a PNP controlled controller. The dfference from the Ignton Control System wth a sngle burner s that the temperature controller controls when and for how long the FCE60 s turned on, whch determnes the frequency and duraton of the flame presence. For the gas burner system to comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve, only approved components as 26 27

15 Confguraton Confguraton Temperature Control System wth a sngle burner The most basc confguraton wth the FCE60 Ignton Box n a Temperature Control System s a confguraton wth one sngle burner. Ths confguraton s dsplayed n fgure 11 for an NPN controlled temperature controller and n fgure 12 for a PNP controlled controller. The dfference from the Ignton Control System wth a sngle burner s that the temperature controller controls when and for how long the FCE60 s turned on, whch determnes the frequency and duraton of the flame presence. Temperature Control System wth up to four burners The Temperature Control System wth the FCE60 n a confguraton wth multple burners up to a total of four burners s dsplayed n fgure 13 for an NPN controlled temperature controller and n fgure 14 for a PNP controlled controller. One FCE60 Ignton Box per burner s requred and they must be serally suppled to ensure the safety of the gas system n case any one of the FCE60 detects a flame error. Serally suppled entals that the frst FCE60 Ignton Box s connected to the power supply, the next FCE60 s suppled va the gas valve output of the frst FCE60 and so on. The last FCE60 n the seres supples the two gas valves that are connected to ths FCE60 n parallel. All flame error outputs of the FCE60 Ignton Boxes must be connected to the flame error nput of the controller n parallel. Fg FCE60 Ignton Box n Temperature Control System confguraton wth one sngle burner and a NPN controlled temperature controller, e.g. TC101 or SC5-95 Fg FCE60 Ignton Box n Temperature Control System confguraton wth one sngle burner and a PNP controlled temperature controller The Temperature Control System must be desgned wth two gas solenod valves connected serally to the gas supply to comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve A fuse of mnmum 5A for overcurrent protecton must be nstalled between the power supply and the FCE60 Ignton Box Fg Temperature Control System confguraton wth FCE60 Ignton Boxes and up to four burners, and a NPN controlled temperature controller, e.g. SC5-95 The TC101 and SC5-95 Controllers are applcable n the NPN confguraton 28 29

16 Confguraton Confguraton Check wth the manual of the temperature controller that the total calculated power consumpton of the confguraton fall wthn the specfcatons of the temperature controller The TC101 and SC5-95 Temperature Controllers are applcable n confguratons wth up to four FCE60 Ignton Boxes n one seres (to one burner output), the STC1600 s lmted to two FCE60 Ignton Boxes per seres (burner output) Fg Temperature Control System confguraton wth FCE60 Ignton Boxes and up to four burners, and a PNP controlled temperature controller In order to allow suffcent tme for the frst FCE60 to gnte the gas and detect the flame, no more than four FCE60 Ignton Boxes should be connected serally. For more nformaton, refer to p. 21, Ignton Control System (stand-alone) wth up to four burners. The Temperature Control System should be confgured so that no more than four FCE60 Ignton Boxes are connected serally to the gas solenod valves Just as n the sngle-burner confguraton, two gas valves must be connected serally to the gas supply for a suffcently safe gas system. The Temperature Control System must be desgned wth two gas solenod valves connected serally to the gas supply to comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve A fuse of mnmum 5A for overcurrent protecton must be nstalled between the power supply and the FCE60 Ignton Boxes If you have problems mantanng functonalty wth less than four serally connected FCE60, we frst recommend tryng to optmze the spark plug poston, please refer to secton [x]. If t s stll not possble to obtan a functonal system, the system must be reconfgured as a Temperature Control System wth more than four burners, but wth fewer FCE60 n each seres. Be aware that the number of gas burners and FCE60 Ignton Boxes that can be connected n a seres to a burner output of a temperature controller can be further lmted by the maxmum power consumpton of the burner output. Temperature Control System wth more than four burners Because the number of FCE60 Ignton Boxes that can be connected serally to the gas solenod valves s lmted to four by the FCE60 or fewer by the temperature controller, a temperature control system confguraton wth more burners, requres an addtonal seres of FCE60 Ignton Boxes. Each seres must stll be connected to two gas solenod valves, and all gas solenod valves must be serally connected to the gas supply before all burners to ensure the safety of the gas system n case any one of the FCE60 detects a flame error. All flame error outputs of the FCE60 Ignton Boxes must be connected to the flame error nput of the controller n parallel. A Temperature Control System wth FCE60 Ignton Boxes n a confguraton wth up to eght burners, s dsplayed n fgure 15 for an NPN controlled temperature controller, and fgure 16 for a PNP controlled controller

17 PT100 Confguraton Confguraton To comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve, each seres of FCE60 n a Temperature Control System must connect to two gas solenod valves connected serally to the gas supply A fuse of mnmum 8A for overcurrent protecton must be nstalled between the power supply and the temperature control system confguraton Fg Temperature Control System wth FCE60 Ignton Boxes n a confguraton wth up to eght burners, and an NPN controlled temperature controller, e.g. an SC5-96 wth two burner outputs Be aware that the number of seres of FCE60 Ignton Boxes that can be connected to a temperature controller s lmted by the number of burner outputs avalable on the temperature controller, and the maxmum power consumpton of each ndvdual burner output. The total number of FCE60 Ignton Boxes that can be connected to a temperature controller s also lmted by the total maxmum power consumpton of the controller and the battery capacty. How many seres of FCE60 that can be connected to a temperature controller s lmted by the number of burner outputs on the controller and the max power consumpton of each ndvdual burner output 8 Amp. 12V / 24V Check wth the manual of the temperature controller that the total calculated power consumpton of the confguraton fall wthn the specfcatons of the temperature controller Check that the battery capacty s suffcent for the Temperature Control System confguraton Fg Temperature Control System wth FCE60 Ignton Boxes n a confguraton wth up to eght burners, and an PNP controlled temperature controller The SC5-95 Temperature Controller wth two burner outputs from TF-Technologes s applcable n ths confguraton wth up to eght FCE60 Ignton Boxes 32 33

18 Confguraton Temperature Control System wth more than one temperature sensor and up to eght burners A Temperature Control System wth FCE60 Ignton Box can be confgured wth more than one temperature sensor. Ths s advantageous f envronmental factors can affect the temperature of the measured area dfferently, e.g. dfferent sectons of a screed are mpacted dfferently by a draft wnd. To mantan a stable temperature n the total measured area, a temperature controller wth several temperature sensors can be appled n a Temperature Control System wth FCE60 Ignton Boxes. The STC1600 Temperature Controller from TF-Technologes can be used n such a confguraton, and wll typcally be delvered as a complete Temperature Control System fully ntegrated n a closed cabnet wth all connectons assembled n a central termnal and desgned specfcally to the specfcatons of the ndvdual manufacturer. A Temperature Control System confguraton wth a STC1600 Temperature Controller wth four temperature sensors and FCE60 Ignton Boxes for up to eght burners s dsplayed n fgure 17. Confguraton The STC1600 Temperature Control System should be confgured so that no more than two FCE60 Ignton Boxes are connected serally to the gas solenod valves To comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve, each seres of FCE60 n a Temperature Control System must connect to two gas solenod valves connected serally to the gas supply A fuse of mnmum 10A for overcurrent protecton must be nstalled between the power supply and the temperature control system confguraton Check that the battery capacty s suffcent for the Temperature Control System confguraton Fg Temperature Control System wth STC1600 Temperature Controller wth four temperature sensors and FCE60 Ignton Boxes for up to eght burners 34 35

19 Installaton Essental components for nstallaton For the nstallaton of the FCE60 Ignton Box the followng key components are requred. The components are avalable from TF-Technologes wth the part numbers specfed. See data sheets n Appendx. For the gas burner system to comply wth the gas regulatons of the 2009/142/EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve, only components approved as descrbed here can be used. Gas Solenod Valves Gas valves wth a sutable voltage and pressure specfcaton to the gas burner system n queston must be used. EN 161 certfed gas valves are requred for systems wth a gas pressure up to 5 bar. The followng EN 161 certfed gas valves are avalable from TF-Technologes. Part number S Gas Solenod Valve 0-5 bar, 12V Installaton Gas Spark Plugs One or more Spark Plugs s requred for gntng the gas and measurng the onzaton current to montor flame presence. To comply wth the dmensons of dfferent gas burner systems, three lengths are avalable from TF-Technologes. Part number S Gas Spark Plug 35mm S Gas Spark Plug 50mm S Gas Spark Plug 100mm Accessores The Thread Mount s used to mount the Spark Plug and ensure sold ground. Part number S Thread Mount Ø18mm / 0.71n S Gas Solenod Valve 0-5 bar, 24V S Gas Solenod Valve 0-3 bar, 12V S Gas Solenod Valve 0-3 bar, 24V For systems wth a gas pressure >5 bar, the gas valves must comply wth EN Contact TF-Technologes for nformaton on avalablty. Hgh Tenson Cords One or more Hgh Tenson Cords s requred to connect the FCE60 to the Spark Plug(s). The hgh tenson cord must feature a nose resstor and comply wth general safety prncples for wrng and conductors as descrbed n EN The Hgh Tenson Cords from TF-Technologes are avalable n varous cable lengths and can be used n all the system confguratons llustrated n ths manual. For larger systems, cablng must be reconfgured as descrbed n EN Part number S-50007/x,x Hgh Tenson Cord Wth ceramc cap, nose resstor, BMW connector and rubber cap x,x s cable length Cable components for local assembly are also avalable from TF-Technologes. See Appendx for part numbers and gude to assembly

20 Installaton Installaton Connector wth Gasket The Connector wth Gasket s used for settng up the nterface to the gas burner system. Part number S Connector wth Gasket 4-Pn Connector Part number S TC101 Temperature Controller 50 to 175 C / 122 to 347 F S TC101 Temperature Controller 20 to 90 C / 68 to 194 F Wrng colour codes Pn number Wre colour Functon 1 Orange Flame error 2 Purple Gas valves 3 Red Supply (12/24VVDC) 4 Green Ground Wrng colour codes Pn number Wre colour Functon 0 Orange Flame error 1 Grey Pt-100 (pn 1) 2 Whte Pt-100 (pn 2) 3 Green Burner output 4 - Not connected 5 Red Supply (12/24VDC) Extra components for Temperature Control Systems When the FCE60 s ntegrated n a Temperature Control System, the system s typcally delvered fully assembled and ntegrated n a closed cabnet from TF-Technologes to ensure full complance to the European gas safety regulatons. If, however, the system s confgured locally, the followng addtonal essental components are avalable from TF-Technologes. Pt-100 Temperature Sensor The Pt-100 Temperature Sensor(s) s requred to supply the Temperature Controller wth temperature nputs 6 Black Ground Note that other versons of the TC101 Temperature Controller wth dfferent part numbers than those stated above may not comply wth the 2009/142/ EC Gas Applances Drectve and the 2006/42/EC Machnery Drectve. Refer to the data sheet for the specfc part number for clarfcaton. Part number S-50019/0,7 S-50019/3,0 S-50019/5,0 S-50019/6,5 Pt-100 Temperature Sensor -25 to 200 C / -13 to 392 F Avalable n 0,7m, 3m, 5m, 6,5m cable lengths Temperature Controller The Temperature Controller s requred to control the frequency and duraton of the supply to the connected FCE60 Ignton Box(es). The TC101 Temperature Controller s avalable from TF-Technologes n two versons wth dfferent temperature ntervals. For SC5-96 and STC1600 Temperature Controllers wth addtonal functonalty, contact TF-Technologes

21 Installaton Installng the FCE60 Ignton Box The followng nstructon for nstallaton should be observed for nstallaton of the FCE60 Ignton Box, regardless of whether the Ignton Control System/Temperature Control System s confgured locally or delvered fully assembled and ntegrated n a closed cabnet from TF-Technologes. When nstallng an Ignton Control System or Temperature Control System, ensure that the system s nstalled n such a way that any moveable parts and hgh temperature areas of the machne or applance wll not harm the system When nstallng an Ignton Control System or Temperature Control System, take ergonomcal aspects related to daly use, mantenance and servce nto account Turn off power supply before commencng nstallaton Ensure that the Ignton Control System or Temperature Control System s connected to a swtched power supply, so that the system powers up wth the machne or applance. The system must not be connected drectly to the battery. Alternatvely, nstall a swtch before the system to turn t on and off 2 Installaton 1 Weld Thread Mount onto system If the gas burner system does not already contan a sutable thread for mountng the Spark Plug, the Thread Mount should be welded onto the system n a sutable locaton. The thread used for mountng must be welded soldly onto the system, as t s vtal that the Spark Plug s properly grounded to control the sparkng The thread Mount must be postoned to ensure that the tp of the Spark Plug s postoned n the hottest part of the flame,.e. the center of the blue part of the flame Mount Spark Plug Mount the Spark Plug n the Thread Mount. Ensure that the Spark Plug s postoned correctly. It s mportant that the Spark Plug s postoned correctly to be able to perform flame detecton. The correct poston s wth the tp of the Spark Plug n the center of the blue part of the flame. To optmse the response tme of the FCE60, t s mportant to get the maxmum onzaton current possble from the Spark Plug. The best result s accomplshed by measurng the onzaton current for dfferent adjustments of the Spark Plug poston, when the system s confgured for the frst tme. Ths can be done safely wth a Spark Plug Poston Test Box avalable from TF-Technologes. Contact us for more nformaton

22 Installaton 3 4 Mount FCE60 Ignton Box Mount the FCE60 Ignton Box on a plane surface, preferably so that the two LEDs dsplayng operaton modes are vsble. The FCE60 can be mounted n a cabnet to sheld t from heat, dust and condensaton. Ambent temperature must not exceed 70 C / 158 F Alternatvely, mount fully-ftted cabnet wth Ignton Control System or Temperature Control system as delvered by TF-Technologes n a sutable locaton Connect Hgh Tenson Cord Push the ceramc spark plug cap of the cable onto the Spark Plug, and the BMW Connector n the other end onto the FCE60 n the bottom, and pull up the rubber cap to provde the solaton requred at the hgh voltage output of the FCE60 (FCE60 already connected n fully-ftted cabnet). 6 7 Installaton Mount Gas Valves Mount the Gas Solenod Valves on the gas ppes, whle observng best practce for nstallaton, ensurng that gas ppes are completely tght and no gas seepage s possble. Perform wrng as descrbed for the relevant confguraton Perform all wrng of the system for the relevant confguraton, as descrbed n the secton Confguraton p. 18. The wrng and nstallaton of the FCE60 n an Ignton Control System or Temperature Control System must be undertaken n complance wth best practce for nstallaton as descrbed n EN All cablng n the nstallaton of the Ignton Control System or Temperature Control System must comply wth EN Use the Connector wth Gasket to connect wres to the FCE60. Refer to colour-codes on p. 38. For pn 2, one wre for each Gas Valve s requred. For pn 1, t s possble to connect a lamp, f an error ndcaton s desred apart from the red LED on the FCE60 Ignton Box. 5 Organze the cable so that t can reach the FCE60 or cabnet wthout beng n the way of any moveable parts. Mount Pt-100 Sensor (f applcable) If the confguraton s a Temperature Control System, the Pt-100 Temperature Sensor should be mounted n a sutable poston. Organze the cable so that t s not n the way of any moveable parts. Ensure that the Pt-100 Temperature Sensor s nstalled n a poston, where t s able to measure the correct, relevant temperature, wthout exceedng ts temperature specfcaton. Maxmum ambent temperature s 200 C / 392 F The current consumpton from the gas solenod valve output of the FCE60 Ignton Box must not exceed 2.5 Amp. If usng other gas valves than those on p. 36, the current consumpton must be checked pror to nstallaton to avod damagng the FCE60 Ignton Box The current consumpton drawn from the flame error output must not exceed 1 Amp

23 Installaton 8 Refer to colour-codes on p. 39 for nstallaton of TC101 Temperature Controller. The nterfacng between the FCE60 Ignton Box and TC101 Temperaturel Controller should be set up as the followng: TC101 Temperature Controller FCE60 Ignton Box Pn number Wre colour Pn number Wre colour Interface functon 0 Orange 1 Orange Flame error nput from FCE60 to TC101 1 Grey TC101 measures Pt-100 varable temperature 2 Whte resstor value 3 Green Green TC101 supples ground to FCE Red 3 Red Supply (12/24 VDC) 6 Black Ground from gas burner system 2 Purple Gas valve supply from FCE60 (12/24 VDC) If an alternatve temperature controller s used, refer to ts manual for correct wrng. Alternatvely, f a fully-ftted cabnet wth an Ignton Control System or Temperature Control System wth FCE60 delvered by TF-Technologes s nstalled, t wll already comply wth all of the above standards, and all wrng as descrbed n ths step 7 s not requred. Mount fuse as descrbed for the relevant confguraton Before the system s connected to the power supply, mount a fuse as specfed for the relevant confguraton n the secton Confguraton on p. 18. Any fully-ftted cabnet wth an Ignton Control System or Temperature Control System wth FCE60 delvered by TF-Technologes does not nclude ths fuse. The fuse must be mounted separately outsde the cabnet Safety Instructon Requrements for the gas burner system It s a pre-condton for the safe use of the FCE60 Ignton Box n accordance wth applcable safety regulatons that the FCE60 s only used n gas burner systems that comply wth statutory safety regulaton. There are two categores of key safety requrements for gas burner systems that have an nfluence on the safe use of the FCE60 Ignton Box. Gas burner systems n general must meet the safety requrements specfed n 2009/142/EC Gas Applances Drectve (GAD). Gas burner systems nstalled on machnery must meet the requrements specfed n 2006/42/EC Machnery Drectve (MD) n addton to the requrements under the frst category. Key safety requrements for gas burner systems n general for safe use and nstallaton of the FCE60 Ignton Box The gas burner system and any ndvdual components heren, ncludng gas applances, fttngs, gas connectng hoses, gas valves and regulators must comply wth the relevant requrements of GAD. Inapproprate equpment may gve rse to dangerous stuatons and serous personal njury due to gas leaks. Combuston emssons such as CO and CO 2 must be kept below a level that ensures no danger for personnel. Ths should be done by ether ventlaton or proper safety devces 9 Connect system to swtched power supply and check functonalty Connect the system to the power supply and turn on power to check functonalty. The yellow LED of the FCE60 should flash once, and the other LED should turn green. Refer to Troubleshootng secton on p. 54 n case of problems. The FCE60 Ignton Box must be nstalled, mounted and connected n accordance wth the nstructons n ths user manual For Temperature Control Systems remember to also turn on the temperature controller. Temperature controllers from TF-Technologes wll start up n off mode. The FCE60 Ignton Box must be nstalled so that t s accessble and protected aganst harmful effects 44 45

24 Safety Instructon A fuse for overcurrent protecton must be nstalled between the power supply of the gas burner system and the FCE60 Ignton Box(es). Ths should be checked pror to the connecton of the system. The short crcut breakng capacty must be adapted to the total maxmum power consumpton of all the FCE60 Ignton Boxes and gas valves n the confguraton, or equal the prospectve fault current n case of short-crcutng. Addtonal key safety requrements for gas burner systems on machnery for safe use and nstallaton of the FCE60 Ignton Box The machnery must comply wth the relevant requrements of MD, specfcally the requrements descrbed n EN Safety on Machnery - Electrcal Equpment on Machnes The machnery must be equpped wth an emergency stop that can stop all potentally dangerous parts of the machne, ncludng swtchng off the power supply to the FCE60 Ignton Box Correct use The FCE60 Ignton Box s an gnton controller desgned for use n gas burner systems for controllng and montorng the gas flow and gas gnton. Correct use therefore entals that the Ignton Box s used for ths purpose. Safety Instructon The FCE60 Ignton Box must only be nstalled by electrcally traned personnel wth tranng n gas safety, so that personal njury and damaged equpment s avoded. Read and understand the user manual. In case of questons, contact your local representatve Be aware of the stuatons descrbed under Examples of Incorrect Use p. 49, Warnngs and Dangerous Stuatons p. 50 and be able to avod them Be aware of the techncal specfcatons of the FCE60 Ignton Box and ensure t s nstalled correctly and only wthn ts techncal specfcatons FCE60 Ignton Box s desgned for use on machnery wth a 12V DC or a 24V DC system. The machnery must be able to delver a stable power supply, for nstance va the machne battery. Such a battery power supply must avod power loss for more than 5 ms and mantan a supply wthn 0.85 to 1.15 tmes the nomnal voltage (0.7 to 1.2 tmes the nomnal voltage for battery powered vehcles) After nstallng the FCE60 Ignton Box, t must be tested that the emergency stop covers the power supply to the FCE60 Ignton Box so that t s swtched off, when the emergency stop s actvated Make sure a total rsk assessment of the gas burner system s made accessble to everyone who wll be workng wth and around the gas system, so they are made aware of how to avod the dangerous stuatons dentfed Investgate local health and safety regulaton concernng the operaton of the gas burner system, and ncorporate any rsks nvolved n the use of hot surfaces n the total rsk assessment of the system. Partcular attenton needs to be pad to any gas rsks that components of the system may ntroduce separately or n combnaton wth other parts 46 47

25 Safety Instructon Safety Instructon Make sure all personnel who wll be workng wth and around the gas burner system are made aware of how the FCE60 Ignton Box affects the system Inform the operator of the gas system of all the relevant safety nstructons contaned n ths manual Incorrect Use The FCE60 Ignton Box should only be used for the purpose t s constructed to, and most examples of ncorrect use are self-explanatory and not descrbed. However, certan key examples of msuse or napproprate behavour are outlned below, and should be avoded. Do not use unauthorsed system confguratons, as ths can damage the FCE60 Ignton Box and lead to unpredctable flame and gas control, whch may result n serous personal njury or materal damage. Ensure the FCE60 Ignton Box s not damaged Inform TF-Technologes or your local representatve, f the FCE60 Ignton Box for any reason s not safe to use Avod contact wth the hgh tenson cable, spark plug or hgh voltage output thread of the FCE60 Ignton Box, when the system s powered on No parts of the FCE60 Ignton Box must be rebult or refurbshed, as TF-Technologes wll no longer be able to vouch for the qualty, and rebuldng unts may cause serous personal njury or materal damage Do not use unauthorsed cables or unauthorsed spare parts, as ths can damage the FCE60 Ignton Box and lead to unpredctable flame control and montorng, whch may result n serous personal njury or materal damage Do not connect the FCE60 Ignton Box, when power s already appled, as t can lead to serous personal njury The FCE60 Ignton Box s only for use on gas burner systems. Do not use the FCE60 on other types of burner systems 48 49

26 Safety Instructon Warnngs and Dangerous Stuatons Do not use the FCE60 Ignton Box f t s obvously damaged Do not use the FCE60 Ignton Box f t shows sgns of unauthorzed repar Do not use the FCE60 Ignton Box f t s connected an ncompatble voltage supply, spark plug, gas valve or temperature controller Do not connect the FCE60 Ignton Box to a gas burner system that uses other types of nput than the output the FCE60 s able to delver. Servce and Repar Mantenance In case of problems wth the FCE60 Ignton Box, please refer to p. 54 Troubleshootng for answers to the most common problems. If problems persst, contact TF-Technologes or your local representatve for assstance Do not attempt to repar the equpment yourself. Replacement of connectors or any other parts must be undertaken by TF-Technologes or an apponted servce representatve of TF-Technologes. Contact your local representatve for further nformaton Servce and repars of the FCE60 Ignton Box, cables or other parts undertaken by anyone else than TF-Technologes or an apponted servce representatve of TF-Technologes can result n serous personal njures and/or damaged equpment Do not nstall or use the FCE60 Ignton Box n dangerous areas or n dangerous atmospheres or at dangerours pressure levels, as the FCE60 s not desgned to such operaton Transport Vsually nspect the the FCE60 Ignton Box, cable and accessores upon recept. Make sure all tems are ntact, and the seral number s engraved and the temperature label attached to the FCE60 Ignton Box If parts of the FCE60 Ignton Box, cable or accessores are damaged at recepton, we recommend you to: Reject the package f t s vsbly damaged (regress) Document any potental damage n the form of text and pctures Inform seller of the damages Do not use damaged products 50 51

27 Mantenance Storage Keeep the FCE60 Ignton Box, cable and accessores dry and out of drect sunlght for long term storage Store the FCE60 Ignton Box, cable and accessores wthn ther storage temperature range. Note that the storage temperature range for the FCE60 s dfferent from some of the accompanyng parts. Everythng can be stored together at a storage temperature of -40 C to 85 C / 14 F to 185 F Mantenance Never use cellulose thnner or acetone, as they dssolve pant and plastc respectvely, whch wll degrade functonalty. Other cleanng agents can also be harmful, but experence shows these two n partcular should be avoded Be careful to not remove the temperature label, as t must reman nctact or warranty wll be vod Use of benzne to clean the Hgh Tenson Cables can make the wrtng on the cables dsappear, but the cables wll not be damaged Cleanng It s not necessary to clean the the FCE60 Ignton Box to mantan functonalty, but t can be cleaned for cosmetc reasons. If cleanng the FCE60 Ignton Box or accompanyng cable and parts, t s mportant to use approprate cleanng agents. Inapproprate cleanng agents or an ncorrect cleanng method can damage the equpment and cause degradng or loss of functonalty. Dsposal When dsposng the FCE60 Ignton Box the equpment must be treated as electronc waste n complance wth the local regulatons of the country n whch the equpment s dsposed. The responsblty for safe and approprate dsposal s transferred to the buyer n the sale of the FCE60 Ignton Box. We recommend benzne (cleaner s naphta) as cleanng agent due to ts effectveness and quck evaporaton. Please note that benzne s an organc dssolvent, whch s flammable and harmful to health and envronment. Use t responsbly and wth respect for ts harmful effects. Follow the nstructons on the bottle of benzne Use as lttle as possble Avod breathng vapors and drect contact wth the skn 52 53

28 Appendx Appendx Troubleshootng Symptom Probable Cause Approprate Acton Wthn frst 4 seconds of power up: One of the FCE60 Ignton Boxes does not turn on turn on ts green LED After frst 4 seconds of power up: One of the FCE60 Ignton Boxes turns on ts red LED (shortly) Poor connecton to FCE60 Check connectons around the gven FCE60 Change faulty wrng or connectons Internal fault of FCE50 Replace faulty FCE60 Poor or empty gas supply Poor connecton to FCE60 Check for faulty gas ppes and gas connectons and change where requred Check gas contaner Check connectons around the gven FCE60 Change faulty wrng or connectons Poor connecton to external hardware Check connectons to external hardware Replace faulty external hardware Poor connecton to gas valves Check supply and ground connecton to gas valves Change faulty wrng or connectons to gas valves Internal fault of FCE60 Replace faulty FCE60 Burner problem Check burner for damage or drt Change or clear burner Defect gas valve Replace faulty gas valve Local Assembly of Hgh Tenson Cord It s possble to purchase cable components from TF-Technologes and perform a local assembly of the Hgh Tenson Cord. Requred components Part number S-50059/25 Hgh Tenson Cable 25m S BMW Connector M4-thread connector S Rubber Cap For nsulaton of BMW connector S Nose Resstor 1KΏ nose resstor S Ceramc Spark Plug Cap Woodscrew wre connecton, 50mm Poor postonng of Spark Plug not n center of blue part of the flame Optmze Spark Plug poston, e.g. usng Spark Plug Poston Test Box. Contact TF-Technologes for avalablty S Crmpng Tool For mountng BMW Connector 54 55

29 Appendx Appendx Instructon for assembly Techncal Specfcatons (data sheet) Cut the Hgh Tenson Cable n the desred length. Put the Rubber Cap on the Hgh Tenson Cable. Strp off the solaton of the Hgh Tenson Cable leavng 3mm exposed core. Push the BMW Connector onto the exposed core of the Hgh Tenson Cable. Use the Crmpng Tool to crmp the thn part of BMW Connector around the exposed core. Cut the Hgh Tenson Cable 30cm from the end wthout the BMW Connector. Reassemble the Hgh Tenson Cable wth the Nose Resstor by screwng the nose resstor nto the core center of the cable wthout strppng t. The Nose Resstor s vtal to avod nfluence on other electronc equpment nstalled close by. Screw the Ceramc Spark Plug Cap nto the core center of the open end of the Hgh Tenson Cable. It s mportant to use a ceramc cap due to the hgh temperature exposure durng the gas burn. FCE60 Ignton Box Ignton Box - EN 298:2012 certfed FCE60 for Flame Control and Montorng The FCE60 Ignton Box s a certfed gas safety component for use n any gas burner system. It controls the gnton of a gas burner and secures a contnued safe operaton. The FCE60 controls the gas supply and gntes the gas, and montors the flame throughout operaton. Any accdental blow-out of the flame s mmedately detected by the Ignton Box, and wll trgger a re-gnton. In case of re-gnton falure, the FCE60 wll shut off the gas supply to prevent accdents caused by gas seepage, and send out an error sgnal. The status of the operaton of the burner s easly vewed at all tmes wth red/green and yellow ndcator lamps. The FCE60 Ignton Box can be utlzed n systems desgned for permanent operaton, but the Ignton Box should be shut off and restarted once every 24 hours as a safety measure, to allow the FCE60 to perform a start-up check and to ensure all functons are workng. The FCE60 Ignton Box can be used n systems wth a maxmum burner output of 360kW/channel. The FCE60 Ignton Box s certfed as a safety component to the standard EN 298:2012 Automatc Burner Control Systems for Burners and Applances Burnng Gaseous Fuels. Ignton Box Specfcatons Part Number S Power Supply Power Consumpton Dmensons (LxWxH) Weght 12/24 V (DC) System Typcal at 24 VDC 120 ma Max. 400 ma 105x70x40mm / 4.1x2.8x1.6n 250g / 0.6lbs Storage Temperature -40 C to 85 C / -40 F to 185 F Operatng Temperature -10 C to 70 C / 14 F to 158 F Valve Output Flame Error Output Mn. Spark Frequency Flame Falure Response Tme Flame Falure Detecton Tme Housng Protecton Class Internal Supply Voltage Flame Detecton Max. 2.5 A Max 1 A 7 Hz <10 sec. <1 sec. IP55 11 Volt Ionzaton Current/Operaton >3 µa Swtch-off Senstvty <1 µa Ionzaton (not adjustable) Ths ensures full complance to the 2006/42/EC Machnery Drectve and 2009/142/EC Gas Applances Drectve, when used n gas burner systems on machnery or n consumer applances. Tested to EN 13309:2010 Constructon Machnery - Electromagnetc Compatblty of Machnes wth Internal Power Supply, the FCE60 s also n full complance of the 2014/30/EU EMC Drectve and CE marked. The FCE60 Ignton Box s backwards compatble wth the former noncertfed FCE24 Ignton Box. EN 298:2012 certfed The FCE60 Ignton Box Vbraton Resstance Hgh Voltage Output Cable Irreplaceable Internal Fuse Mountng Optons Connectons Hz 1 g rms Hgh tenson cord, up to 6m / 19.7ft, w. ceramc cap, nose resstor and BMW connector 6 A On plane surface, angle rrelevant 1: Flame Error Output 2: Valve Output 3: 12/24V (DC) w. extern. 5A Fuse. : Ground (GND) Ignton Box wth Hgh Tenson Cord, Nose Resstor and Spark Plug TF-Technologes reserves the rght to make changes wthout further notce. v. H Page 1/2 TF-Technologes A/S Kratbjerg 214 DK-3480 Fredensborg Phone: sales@tf-technologes.com 56 57

30 Appendx Appendx FCE60 Ignton Box Gas Solenod Valves Program Flow Gas Solenod Valve - (0-5 bar EN161 approved) 12 or 24 Volt Electromagnetc gas valve for controllng the gas flow n a gas system. The gas valve s EN161 approved. Ths approval s requred for gas valves n automatc burner control systems requred to comply wth 2006/42/EC Machnery Drectve or 2009/142/EC Gas Applances Drectve. For 2006/42/EC or 2009/142/EC complance, two gas valves connected serally to the gas supply are requred. To comply wth these drectves, the automatc burner control system further requres an gnton controller certfed as a safety component, such as the S FCE60 Ignton Box certfed to EN 298:2012. When powerng up the FCE60, both the gas valve(s) and gnton crcut are held back for about one second whle the Start-Up Control (T SU ) s executed. Afterwards the gas valve(s) are opened, the gnton starts and a flame appears. In case of a loss of flame, the FCE60 detects ths n less than a second, whch s the Flame Falure Detecton Tme (T FFD ) and re-starts gnton. If a flame appears n less than ten seconds whch s the Flame Falure Response Tme (T FFR ), the gnton stops and the gas valve(s) remans open. If a flame does not appear wthn the Flame Falure Response Tme (T FFR ), both the gas valve(s) and the gnton are shut off, and a flame error sgnal s outputted for as long as the FCE60 s powered on. Gas Solenod Valve Wrng Dagram Status Indcators Part number Gas Input Thread Gas Output Thread S (12V) S (24V) G1/4 G1/4 12V / 24V Power consumpton Wthout power 8 W Valve closed Gas valves 12V / 24V Amp. Flame error Operaton Mode BURNER ON/FAULT Dmensons (HxLxW) 72x49x45mm / 2.8x1.9x1.8n Weght 450g / 1lbs Housng materal Brass Installaton poston Arbtrary Operatng temperature -15 C to 60 C / 5 F to 140 F 5 Amp Flame error Turned off IP Class IP 65 Max gas pressure 5 bar Start-up (One flash) Connector Valve plug A-type DIN Ignton Box Igntng The flame error output (pn 1) can be connected to a lamp or a temperature control module. The supply nput (pn 3/ GND) can be connected drectly to a 12V/24V DC system, or t can be controlled by a temperature control module. For an EN298:2012 complant system, the use of two gas valves connected n seres s requred. Runnng (flame on) Flame falure Spark Plug Example of applcaton of Gas Solenod Valves TF-Technologes reserves the rght to make changes wthout further notce. v. H Page 2/2 v. H TF-Technologes A/S Kratbjerg 214 DK-3480 Fredensborg Phone: sales@tf-technologes.com TF-Technologes A/S Kratbjerg 214 DK-3480 Fredensborg Phone: sales@tf-technologes.com 58 59

31 Appendx Appendx Gas Solenod Valves Pt-100 Temperature Sensor Gas Solenod Valve - (0-3 bar EN161 approved) 12 or 24 Volt Pt-100 Temperature Sensor for Pavng Screeds Electromagnetc gas valve for controllng the gas flow n a gas system. The gas valve s EN161 approved. Ths approval s requred for gas valves n automatc burner control systems requred to comply wth 2006/42/EC Machnery Drectve or 2009/142/EC Gas Applances Drectve. For 2006/42/EC or 2009/142/EC complance, two gas valves connected serally to the gas supply are requred. To comply wth these drectves, the automatc burner control system further requres an gnton controller certfed as a safety component, such as the S FCE60 Ignton Box certfed to EN 298:2012. The Pt-100 sensor s a temperature nput sensor for the SC5-96 and STC1600 systems. The sensor s a platnum RTD (resstance temperature detector) sensor, whch measures temperature by correlatng the resstance of the RTD element wth temperature. The advantages of platnum resstance temperature sensors nclude: Hgh accuracy Low drft Wde operatng range Sutablty for precson applcatons The unt s specfcally desgned to wthstand the tough workng condtons of the constructon ndustry. Gas Solenod Valve Part number S (12V) S (24V) Gas Input Thread G1/4 Gas Output Thread G1/4 Power consumpton 8 W Wthout power Valve closed Dmensons (HxLxW) 68x66x27mm / 2.7x2.6x1.1n Weght 250g / 0.6lbs Housng materal Brass Installaton poston Arbtrary Operatng temperature -15 C to 60 C / 5 F to 140 F Gas valves 12V / 24V 5 Amp Flame error Pt-100 Temperature Sensor Specfcatons Part number S-50019/x,x (x,x s cable length n meters) Applcaton Temperature sensor for pavng screeds Operatng temperature -25 C to +200 C Storage temperature -40 C to +200 C Sensor type Pt-100 DIN B Cable type Slcone nsulated cable 2 x 0.75 mm 2 wth galvanzed steel wre bradng Sensor house Alumnum wth 6.3mm mountng holes Connector No plug IP Class IP 54 Max gas pressure 3 bar Connector Valve plug B-type DIN Ignton Box Spark Plug Example of applcaton of Gas Solenod Valves v. H TF-Technologes reserves the rght to make changes wthout further notce. H TF-Technologes A/S Kratbjerg 214 DK-3480 Fredensborg Phone: sales@tf-technologes.com TF-Technologes A/S Kratbjerg 214 DK-3480 Fredensborg Phone: sales@tf-technologes.com 60 61

32 Appendx Appendx TC101 Temperature Controller Certfcate TC101 Temperature Controller 1 Channel Temperature Controller for Gas Heatng The TC101 Temperature Controller s the user-nterface for the TC101 temperature control systems. It s desgned to automatcally mantan the correct operatng temperature of asphalt contaners/ hotboxes or other related equpment throughout operaton wthout overheatng the btumen. The TC101 Temperature Controller provdes the ablty to adjust the temperature to the desred temperature on the turnng knob. Once the desred temperature s set, the TC101 Temperature Controller automatcally mantans ths temperature. It s not possble to manually overrde the temperature set, but the system can be turned on/off on the swtch. The TC101 Temperature Controller s a sngle channel system montorng the temperature va one connected Pt-100 temperature sensor. It regulates the temperature to the level set by the operator by turnng the connected FCE60 Ignton Box ON/OFF. The gnton box controls the gasflow to mantan the desred temperature. Ths verson wthout automatc re-gnton s specfcally desgned to comply wth the 2006/42/EC Machnery Drectve. TC101 Number 91443/01 Replaces -- Issued Scope 2009/142/EC( ) Report number Contract number E 7392 PIN EC TYPE EXAMINATION CERTIFICATE (GAD) Kwa hereby declares that the Automatc Burner Control System, type FCE60 Ignton Box manufactured by 0063CR1834 TF-Technologes A/S Fredensborg, Denmark TC101 Temperature Controller Specfcatons Part Number S S meets the essental requrements as descrbed n the Drectve 2009/142/EC relatng to applances burnng gaseous fuels. The complance s based on examnaton to EN 298:2012. Power Supply Power Consumpton Dmensons (LxWxH) Weght 12/24 Volt System (11-30 VDC) Typcal at 24 VDC 80 ma Max. 200 ma 121x90x45mm / 4.8x3.5x1.8n 350g / 0.8lbs The product has been approved for all EU and EFTA countres. A descrpton of the specfc types s gven n the appendx to ths certfcate. Storage Temperature -40 C to 85 C / -40 F to 185 F Operatng Temperature 0 C to 60 C / 32 F to 140 F Temperature Control Range 20 C to 90 C / 68 F to 194 F (S-50121) 50 C to 175 C / 122 F to 347 F (S-50122) Auto Mode Avalable Manual Mode Avalable Burner Output Input Yes No 1x Temperature Controlled Output (max 3.5A) Pt-100 Temperature Sensor Resoluton 1 C Connector BLZ 5.08/7 SN OR TC101 mounted n a cabnet TF-Technologes reserves the rght to make changes wthout further notce. v. H Kwa Nederland B.V. Wlmersdorf 50 P.O. Box AC APELDOORN The Netherlands Luc Leroy Kwa TF-Technologes A/S Kratbjerg 214 DK-3480 Fredensborg Phone: sales@tf-technologes.com 62 63