Automatic burner control unit IFD 258

Technical Information · GB
6.1.1.5 Edition 03.12

AGA

• For directly ignited burners of unlimited capacity in

continuous operation pursuant to EN 746-2
• Continuous self-testing for faults
• Immediate fault lock-out or restart following flame failure
available as a switchable function
• Flame control with UV sensor or ionization sensor
• Diverse installation possibilities via holes or snap
mechanism for DIN rail
• Space-saving installation on site with IFD 258..I with
integrated ignition
• Display for program status and flame signal intensity

www.kromschroeder.com
 2

Contents
Automatic burner control unit IFD 258 . . . . . . . . . . . . . . . . . 1 5 Replacement possibilities . . . . . . . . . . . . . . . . . . . . . . . 23
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6.4.1 Calculating the safety time tSA . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Examples of application . . . . . . . . . . . . . . . . . . . . . . . . . 5 6.1 Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.1.1 Forced draught burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6.1.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.1.2 Two-stage-controlled burner . . . . . . . . . . . . . . . . . . . . . . . . 7 7 Project planning information . . . . . . . . . . . . . . . . . . . . . 26
1.1.3 Modulating-controlled burner . . . . . . . . . . . . . . . . . . . . . . . . 8 7.1 Cable selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.2 Star electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 EC type-tested and certified . . . . . . . . . . . . . . . . . . . . . . 9 7.3 Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 AGA approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.4 Emergency stop in the event of fire or electric shock . . 27
2.3 FM approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.5 Emergency stop triggered by safety interlock . . . . . . . 27
2.4 CSA approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.6 Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.5 Approval for Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.7 Parallel reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7.8 Remote reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7.9 Behaviour in the event of flame failure . . . . . . . . . . . . . 27
3.1.1 IFD 258 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7.10 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.2 IFD 258..I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 7.11 Note on EC type-examination . . . . . . . . . . . . . . . . . . . 28
3.2 Program sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 7.12 Installation of solenoid valves for gas . . . . . . . . . . . . 28
3.3 Animation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7.13 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4 Program status and fault messages . . . . . . . . . . . . . . 15 7.13.1 With ionization sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4.1 Reading off the flame signal . . . . . . . . . . . . . . . . . . . . . . . . 16 7.13.2 With UV sensor UVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 7.14 Flame signal switch-off threshold . . . . . . . . . . . . . . . 28
4.1 Scanning the parameters . . . . . . . . . . . . . . . . . . . . . . . . 17 7.15 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 7.16 Two-stage burner control with two solenoid valves . 29
4.2.1 Burner flame signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 7.17 Short-circuit fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.2 Switch-off threshold of the flame amplifier . . . . . . . . . . . . 18
8 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Behaviour during start-up . . . . . . . . . . . . . . . . . . . . . . . 19
4.3.1 Normal start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 8.1 High-voltage cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3.2 Start-up without flame signal . . . . . . . . . . . . . . . . . . . . . . . 19 8.2 Radio interference suppressed electrode adapters . 30
4.3.3 Flame simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4 Behaviour during operation . . . . . . . . . . . . . . . . . . . . . 21 9.1 Operating controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4.1 Safety time during operation tSB for V1 and V2 . . . . . . . . . 21
4.4.2 Fault lock-out or restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 9.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 Maintenance cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

IFD 258 · Edition 03.12 t = To be continued

Contents 3

11 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.1 Waiting time tW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.2 Safety time on start-up tSA . . . . . . . . . . . . . . . . . . . . . 34
12.3 Ignition time tZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.4 Flame simulation/Flame simulation delay time tLV . 34
12.5 Safety time during operation tSB . . . . . . . . . . . . . . . 35
12.6 Flame signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.7 Flame detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.8 Fault lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.9 Safety interlocks (Limits) . . . . . . . . . . . . . . . . . . . . . . . 35
12.10 Gas valve V1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.11 Continuous operation . . . . . . . . . . . . . . . . . . . . . . . . 35
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

IFD 258 · Edition 03.12

 4

1 Application
Automatic burner control unit IFD 258 ignites and monitors
directly ignited industrial gas burners of unlimited capacity.
As a result of its fully electronic design it reacts quickly to vari-
ous process requirements and is therefore also suitable for
frequent cycling operation.
It can be used for atmospheric burners or forced draught burn-
ers in multiple burner applications, where a central control
system is used for pre-purge and for monitoring. The burners
may be modulating or stage-controlled. The automatic burner
control is suitable for operation in grounded and ungrounded
systems.
The program status and the level of the flame signal can be
read directly from the unit. The switch-off threshold can be
IFD 258
set using a potentiometer.
The behaviour in the event of flame failure during operation
can be selected using a switch. Either an immediate fault
lock-out or a restart occurs.

IFD 258 · Edition 03.12

Application 5

1.1 Examples of application

Intermittent shuttle
kiln in the ceramics
industry

Roller hearth kiln

Bogie hearth
­furnace

IFD 258 · Edition 03.12

Application > Examples of application 6

1.1.1 Forced draught burners

Control: ON/OFF
Gas valve and air valve are activated simultaneously. The
burner is ignited and monitored by a single electrode. In the
event of a flame failure, an immediate fault lock-out occurs.

L1, N, PE

BMS

4 3 IFD 258
8
9
µC
13
14

11 10 5

VAS..L ZMI

VR..R

IFD 258 · Edition 03.12

Application > Examples of application 7

1.1.2 Two-stage-controlled burner

Control: ON/OFF or ON/HIGH/LOW/OFF
The burner BIO/BIC starts at low-fire rate. Once the normal
operating state is reached, the automatic burner control unit
for continuous operation IFD 258 will release control.
The PLC can now pulse the air solenoid valve VR..R in order to
L1, N, PE control the capacity between high and low fire.

BMS

4 3 IFD 258
8
9
µC
13
14

11 10 5

GIK..B

VAS BIO/
BIC
VR..R

IFD 258 · Edition 03.12

Application > Examples of application 8

1.1.3 Modulating-controlled burner

Control: ON/OFF/continuous
The PLC uses the actuator IC 20 to move the air butterfly valve
BVA to ignition position.
The burner BIO/BIC starts at low-fire rate. Once the normal
operating state is reached, the PLC uses the actuator IC 20
L1, N, PE and the air butterfly valve BVA to control the burner capacity.

mA BMS

4 3 IFD 258
8
9
µC

13
14

11 10 5

VAS

GIK

BIO/
BIC
IC 20
M

BVA

IFD 258 · Edition 03.12

 9

2 Certification
The automatic burner control unit IFD 258 is designed for ap-
plications pursuant to the Machinery Directive (2006/42/EC).

2.1 EC type-tested and certified

pursuant to
– Gas Appliances Directive (90/396/EEC) in conjunction with
EN 298
– Low Voltage Directive (2006/95/EC)
AGA
– Electromagnetic Compatibility Directive (2004/108/EC)
2.2 AGA approval
Australian Gas Association, Approval No.: 4230
http://www.aga.asn.au/product_directory

2.3 FM approval
Factory Mutual Research Class: 7610 “Combustion Safeguards
and Flame Sensing Systems”.
Suitable for applications pursuant to NFPA 86.
www.fmglobal.com  Products and Services  Product Cer-
tification  Approval Guide

2.4 CSA approval

Certified to CAN/CSA – C 22.2 No. 199-M 89 (R 2004), Canadian
Standards Association Class: 3335-01 and 3335-81 “Systems
(Gas)-Automatic Ignition and Components”
http://directories.csa-international.org

2.5 Approval for Russia

Certified by Gosstandart pursuant to GOST-R.
Approved by Rostekhnadzor (RTN).

IFD 258 · Edition 03.12

 10

IFD 258 3 Function

3.1 Connection diagrams
s1
For the explanation of symbols, see page 33 (Legend).
F1 For cable selection and wiring, see page 26 (Project plan-
ning information).
230V s2 c v1 v2
3.1.1 IFD 258
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Ionization control in double-electrode operation
max.
max. 2 A, 2 A,
253 V AC 253 V AC

Z ϑ
I

L1 (L1)
N (L2)
PE

IFD 258
Ionization control in single-electrode operation

s1 t
F1
230V

s2 c v1 v2

1 2 3 4 5 6 7 8 9 10 11 12 13 14
max.
max. 2 A, 2 A,
253 V AC 253 V AC
ϑ

L1 (L1)
N (L2)
PE

IFD 258 · Edition 03.12

Function > Connection diagrams > IFD 258 11

IFD 258
UV control
In the case of UV control, only intermittent operation is ­possible.

s1

F1

230V s2 c v1 v2

1 2 3 4 5 6 7 8 9 10 11 12 13 14
max.
1 max. 2 A, 2 A,
UVS 2 253 V AC
3 253 V AC
ϑ

L1 (L1)
N (L2)
PE

IFD 258 · Edition 03.12

Function > Connection diagrams 12

IFD 258..I
3.1.2 IFD 258..I
The IFD 258..I is suitable for double-electrode operation and
for UV control. Single-electrode operation is not possible.
s1 c
Ionization control in double-electrode operation
F1

230V
s2 v1 v2

1 2 3 4 5 6 7 8 9 10 11 12 13 14
max.
max. 2 A, 2 A,
253 V AC 253 V AC

Z ϑ
I

L1 (L1)
N (L2)
PE

IFD 258..I
UV control
In the case of UV control, only intermittent operation is ­possible.

s1 c

F1
230V

s2 v1 v2

1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 max.
max. 2 A, 2 A,
UVS 2 253 V AC
3 253 V AC
ϑ

L1 (L1)
N (L2)
PE

IFD 258 · Edition 03.12

Function 13

Connect voltage 3.2 Program sequence

Normal start-up
In the event of fault signal: reset
If, after applying voltage, an “old” fault is still being signalled,
it will be necessary to reset this first. The safety interlocks
00 Safety interlocks (Li) are closed, the IFD reverts to start-up position/standby and
conducts a self-test.
Start-up position/standby If it does not determine a malfunction of the internal electronic
circuitry or of the flame sensor, the flame simulation check
01 Waiting time tW running, then commences. This takes place in start-up position during
start-up with ϑ signal the waiting time tW.
If no flame simulation is detected during that period, the safety
Flame simulation check
time on start-up tSA then starts to elapse. Voltage is supplied
to the gas valve and ignition transformer. The burner starts.
02 Safety time on start-up tSA running, After the safety time on start-up tSA has elapsed, the operation
gas valve opens, ignition in process signalling contact closes. This completes start-up.
Start-up without flame signal
No flame detected:
fault lock-out If, after the gas valve has opened and the ignition has been
activated, no flame is detected during the safety time on start-
up tSA, a fault lock-out will then occur.
04 Flame detected:
operation signalling contact closes Behaviour in the event of flame failure during operation
If the flame fails during operation, the IFD 258 will perform
Flame fails: a fault lock-out within the safety time during operation t SB.
safety time during operation tSB Depending on the setting of the program selector switch, the
starts to elapse, restart or fault lock-out valves will be closed immediately or the burner will be restarted
once. If the burner does not function, a fault lock-out occurs.
04 Normal shut-down
via ϑ signal

00 Operation signalling contact opens,

gas valve closes

IFD 258 · Edition 03.12

Function 14

3.3 Animation click on “Adobe Reader” in the “Download” section and follow
The interactive animation shows the function of the automatic the instructions.
burner control unit IFD. If the animation does not start to play, you can download it
Click on the picture. The animation can be controlled using the from the document library www.docuthek.com as an inde-
control bar at the bottom of the window (as on a DVD player). pendent application.
To play the animation, you will need Adobe Reader 9 or a ­newer
version. If you do not have Adobe Reader on your system, you
can download it from the Internet. Go to www.adobe.com,

IFD 258 · Edition 03.12

Function 15

3.4 Program status and fault messages Operating controls

A: 2-digit 7-segment display for indicating program status
and flame signal.
B: Reset/Information button to reset the system after a fault
or to call up the flame signal on the display.
A C: Mains On/Off button.

The 7-segment display (A) shows the program status. In the event of a fault, the IFD halts the program run and the display
starts to blink. The program status and cause of the fault are displayed in coded form.
Program status DISPLAY Fault message (blinking)
Unit can be switched off ––
Start-up position/standby 00
Waiting time/Pause time 01 Flame simulation
Safety time on start-up tSA 02 Start-up without flame signal
Operation 04 Flame failure during operation
09 Oscillating thermostat signal
10 Too many remote resets
52 Permanent remote reset
53 Time between two start-ups is too short

IFD 258 · Edition 03.12

Function > Program status and fault messages 16

3.4.1 Reading off the flame signal

Internally:
The flame signal can be called up on the display by pressing
the Reset/Information button (for 2 seconds). The flame signal
of the burner is indicated in µA. A value between 0 and 25 µA
is displayed.
Important!
When using an external µ-ammeter, you must make sure
that this µ-ammeter cannot trigger an incorrect flame signal.

IFD 258 · Edition 03.12

 17

4 Parameters
Description Parameter Value range Factory default settings Adjustable*
Burner flame signal 01 0 – 25 μA
Burner switch-off threshold 04 2 – 20 µA 2 µA  1)
Burner restart 12 0; 1 0  2)
Safety time during operation for V1 and V2 tSB 14 1; 2 s 3)
Burner safety time on start-up tSA 22 3; 5; 10 s 3)
Last fault 81
Second to last occurring fault 82
Third to last occurring fault 83
…
Tenth to last occurring fault 90
1) Via potentiometer in lower section of housing.
2) Via switch in lower section of housing.
3) Quote in your order.

On parameterization, ensure that the program sequence

matches the application. Select the parameters so that the
burner can be operated as intended in all operating p
­ hases.

4.1 Scanning the parameters

During operation, the 7-segment display shows the program
status, see page 15 (Program status and fault messages).
The flame signal and all following parameters of the IFD can
be scanned one after the other by repeatedly pressing the
Reset/Information button (for 2 s).
In the event of a fault, the IFD halts the program run, the display
blinks and it then displays the cause of the fault in coded form.

IFD 258 · Edition 03.12

Parameters 18

4.2 Flame control

4.2.1 Burner flame signal
Parameter 01
Flame signal of the burner, display in µA, measuring range:
0 – 25 µA.
4.2.2 Switch-off threshold of the flame amplifier
Parameter 04
The sensitivity at which the burner control unit still detects a
flame can be set between 2 and 20 µA.
Example: In the case of UV control with the UV sensor UVS,
the signal of the burner to be monitored is influenced by other
burners.
The set value can be increased via a potentiometer in the lower
section of the housing so that only the flame of the system’s
“own” burner is detected.
The measured flame signal of the system’s “own” burner should
be at least 3 µA (empirical value) higher than the set switch-
off threshold.

IFD 258 · Edition 03.12

Parameters 19

4.3 Behaviour during start-up 4.3.2 Start-up without flame signal

4.3.1 Normal start-up 01 02 02 88
The safety time tSA can be read on the type label (parameter 22). 1 L1
3 ϑ
10
11
01 02 04 88 5
1 L1
3 ϑ 13–14
10 8–9
11 tW tZ t
5
13-14 tSA
8-9
tW tZ t
tSA If, after a successful burner start, the automatic burner control
unit does not detect a flame signal during the safety time on
start-up tSA, a fault lock-out will occur (fault signalling contact
Once the start-up signal (J) has been applied, the automatic between terminals 8 and 9 closes). During the entire safety
burner control unit checks the burner for flame simulation time on start-up tSA, the gas valve V1 is open. The display
during the waiting time tW. If no flame simulation is detected blinks and indicates 02 .
during that period, the safety time on start-up tSA (3, 5 or 10 s)
then starts to elapse. This forms the minimum operating time
of the automatic burner control unit and the burner. Voltage is
supplied to the gas valve and ignition transformer. After the
safety time on start-up tSA has elapsed and the flame signal
has been received, the operation signalling contact between
terminals 13 and 14 closes. The display indicates the current
program status 04 .

IFD 258 · Edition 03.12

Parameters > Behaviour during start-up 20

4.3.3 Flame simulation Start-up signal, safety interlock

The start-up signal is the same as the signal in the safety
00 01 02 . . . 88
interlock.
V1
t
If the start-up/safety interlock signal drops more than four
tW
times in succession during start-up, an inadmissible quantity
of non-combusted gas can reach the combustion chamber
The flame simulation check is conducted after applying the during the safety time via open gas valves. Therefore, a fault
start-up signal
00 (J) during the waiting time
02 . . . tW.88 lock-out is performed on the automatic burner control unit
V1 IFD 258 following three consecutive drops of the start-up/
01 01
1 L1 t safety interlock signal (blinking 09 ).
3 ϑ
10
11
5
13–14
8–9
tW t
tLV

If flame simulation is signalled during start-up, the flame simu-

lation delay time tLV starts to elapse. If the flame simulation
is discontinued during the flame simulation delay time t LV
(max. 25 s), the burner will start up. Otherwise, a fault lock-out
occurs. The display blinks and indicates 01 .

IFD 258 · Edition 03.12

Parameters 21

4.4 Behaviour during operation safety time during operation tSB is 1 second. The IFD 258 is
available with a safety time of 2 seconds upon request). At
4.4.1 Safety time during operation tSB for V1 and V2 the same time, the gas valve is closed. The fault signalling
Parameter 14 contact closes and the display blinks and indicates 04 , see
This indicates the safety time during operation tSB for valves page 15 (Program status and fault messages).
V1 and V2. The default in accordance with EN 298 is 1 s. The After a fault lock-out, the IFD 258 can be reset, either by using
IFD is also available with a safety time during operation tSB of the button on the front panel or an external button. Several
2 s. Prolonging the time increases the installation availability automatic burner control units can be reset in parallel using
in the case of brief-duration signal fades (e.g. fades of the the external button. The IFD 258 cannot be reset by mains
flame signal). In accordance with EN 746-2, the safety time failure. The fault signalling contact does, however, open as
of the installation during operation (including closing time of soon as the mains voltage fails.
the valves) may not exceed 3 seconds (note the requirements
of the Standards). t
4.4.2 Fault lock-out or restart
Parameter 12
A switch on the underside of the upper section of the housing
determines whether the IFD starts a one-off restart or performs
an immediate fault lock-out for the burner after a flame failure,
see page 27 (Behaviour in the event of flame failure).
Immediate fault lock-out following flame failure
Parameter 12 = 0,
Switch in fault lock-out position :

04 04 88
1 L1
3 ϑ
10
11
5
13–14
<2 s 8–9
tSB t

After a flame failure during operation, the IFD 258 will perform

a fault lock-out within the safety time during operation tSB (the

IFD 258 · Edition 03.12

Parameters > Behaviour during operation 22

Restart following flame failure

Parameter 12 = 1,
Switch in restart position :
1x
04 01 02 04 88
1 L1
3 ϑ
10
11
5
13–14
>2 s 8–9
tSB tW tZ t
tSA

If the IFD detects a flame failure after a minimum operating

time of 2 s, the valves are closed and the operation signalling
contact (terminals 13 and 14) is opened within time tSB.
The automatic burner control unit now attempts to restart the
burner once. If the burner does not function, a fault lock-out
occurs. The display blinks and indicates 02 .
If, on restart, the automatic burner control unit detects a flame
signal within the safety time on start-up t SA, the operation
signalling contact closes. The display indicates the current
program status 04 .
In accordance with EN 746-2, a restart may be conducted
only if the safety of the installation is not impaired. Restart is
recommended for burners which occasionally display unstable
behaviour during operation.
The precondition for a restart is that activation of the restart
­allows the burner to restart as intended (in all operating
­phases). It must be ensured in this case that the program
sequence started by the IFD matches the application.

IFD 258 · Edition 03.12

 23

5 Replacement possibilities
The new automatic burner control unit IFD 258 is interchangeable with the IFS 258 and provides almost all of the previous
functions of the IFS 258.
The housing dimensions and hole pattern are unchanged.
The new upper section of the housing will fit on the existing lower section (for further information see operating instructions
“Automatic burner control unit for continuous operation IFD 258”).
IFS 258 IFD 258
D-49018 Osnabrück, Germany
D-49018 Osnabrück, Germany
IFD 258
IFS 258 230 VAC
50/60 Hz
-20/+60 °C CE-0063BXXXXX
CE-0063AT1088 ts 230 VAC
50/60 Hz
IP 40 (30) -20/+60 °C
-4/+140 °F
ts 5/1s
IP 54/NEMA 3

Signalling contact for fault and operating signals Signalling contact for fault and operating signals
Flame signal called up via test jacks in upper section of housing The flame signal can be called up on the 2-digit 7-segment display.
using external measuring instrument
Complies with requirements in accordance with EN 1993 Complies with requirements in accordance with EN 2003
Fault signal with no mains voltage supplied Fault signal with mains voltage supplied
Flame simulation indicated by yellow LED Flame simulation indicated on 7-segment display = 01
Operation indicated by yellow and green LEDs Operation indicated on 7-segment display = 04
Mains voltage = 100, 115, 200, 230 V Mains voltage = 100, 120, 200, 230 V
No protection against frequent remote resets Protection against frequent remote resets (blinking 10 )
No protection against frequent switch-off during tSA Protection against frequent switch-off during tSA (blinking 09 )

IFD 258 · Edition 03.12

 24

6 Selection
6.4.1 Calculating the safety time tSA

IFD 258 · Edition 03.12

Selection 25

6.1 Selection table 6.1.1 Type code

2 5 8 -3 -5 -10 /1 /2 Y Q P W I* Code Description
IFD ● ● ● ● ● ● ● ● ● ● ● ●  IFD Automatic burner control unit
* Only available for IFD 258..Q and IFD 258..W. 2 Series 200
 = standard,  = available 5 With ionization or UV control
8 Immediate fault lock-out or restart, switchable
Order example
-3 Safety time on start-up tSA: 3 s
IFD 258-5/1W
-5 5s
-10 10 s
/1 Safety time during operation tSB: 1 s
/2 2s
W Mains voltage: 230 V AC, 50/60 Hz
Q 120 V AC, 50/60 Hz
Y 200 V AC, 50/60 Hz
P 100 V AC, 50/60 Hz
I* Integrated electronic ignition
* If “none”, this specification is omitted.

IFD 258 · Edition 03.12

 26

7 Project planning information UV cable

The UV cable should be no longer than 100 m and should be
7.1 Cable selection laid as far as possible from the ignition cable.
Use mains cable suitable for the type of operation and com-
plying with local regulations. 7.2 Star electrodes
Signal and control line: max. 2.5 mm2. We recommend using 7.5 kV ignition transformers on burners
with star electrodes.
Cable for burner ground/PE wire: 4 mm2.
Do not route IFD cables in the same cable duct as frequency 7.3 Purge
L1, N, PE
converter cables or other cables emitting strong fields. In the case of multiple burner applications, burners with forced
Ionization cable and ignition cable air supply are used. The air for combustion and pre-purge is
Use unscreened high-voltage cable for both lines, see page supplied by a central SPS
fan controlled by a separate logic. This
30 (Accessories). logic determines the purging time and controls an external
relay that switches the air valve to purge.
Recommended cable length:
Ionization cable – max. 75 m, The automatic burner control unit must not be activated during
4 is achieved 3by interrupting
purging. This IFS 258 the safety interlock,
Ignition cable: 8
IFD 258: max. 5 m, recommended < 1 m (with TZI/TGI), amongst other methods.µC 9

IFD 258..I: max. 1 m, recommended < 0.7 m. 13

14
The longer the ignition cable, the lower the ignition capacity.
Avoid external electrical interference. 11 10 5

Lay cables individually and not in a metal conduit, if ­possible.

Lay the ignition cable and UV cable/ionization cable as far
apart as possible.
Screw the ignition cable securely into the ignition transformer GIK..B
TGI/TZI and feed it out of the unit on the shortest possible Purge
route (no loops). VAS BIO/
BIC
Only use radio interference suppressed electrode adapters VR..R N
(with 1  kΩ resistor) for ignition electrodes, see page 30
(Accessories).

IFD 258 · Edition 03.12

Project planning information 27

7.4 Emergency stop in the event of fire or electric 7.8 Remote reset
shock Permanent
If there is a risk of fire, electric shock or similar, inputs The unit can no longer be reset by permanent remote reset: if
L1, N and 3 (start-up/safety interlock signal) of the IFD a remote reset signal is permanently applied to terminal 4, 52
should be disconnected from the electrical power supply. flashes on the display as a warning signal. The IFD continues
Important! This should be reflected in the wiring on site! operation until it locks off.

7.5 Emergency stop triggered by safety interlock Automatic (PLC)

Check whether automatic remote reset (PLC) complies with
The safety interlock turns off the power to the input 3 (start-up/
standards (reset for no longer than 1 second).
safety interlock signal), such as in the event of air deficiency
or similar. If a fault is acknowledged by remote reset too often, 10 flashes
on the display to indicate a fault (too many remote resets). The
7.6 Overload protection error can only be acknowledged with the Reset/Information
To protect the unit against overload by frequent cycling, only a button on the unit.
specific number of start-up attempts can be carried out by the The burner malfunction must be remedied. The malfunction
IFD. The maximum number of start-up attempts per minute cannot be remedied by changing the method of activation.
depends on the safety time tSA and the ignition unit.
7.9 Behaviour in the event of flame failure
tSA tZ Type of ignition Cycle lock
[s] [s] [s] In the event of a flame failure, either a restart or an ­immediate
3 1.8 External TZI 10 fault lock-out can be selected using a switch in the upper sec-
5 3 External TZI 12 tion of the automatic burner control unit IFD 258.
10 6 External TZI 15 Restart
3 1.8 IFD..I 36 Select for burners that occasionally demonstrate unstable
5 3 IFD..I 60 flame behaviour.
10 6 IFD..I 120
Immediate fault lock-out
If too many start-up attempts are made, 53 flashes on the Select an immediate fault lock-out when using the unit with
display to indicate a fault. slow-closing air control valves or continuous control, if the
burner may not be started at maximum capacity, for burners
7.7 Parallel reset with a capacity of over 120 kW in accordance with EN 676 and
Several automatic burner control units can be reset in p­ arallel in the case of On/Off intermittent operation.
using the external button. The IFD 258 cannot be reset by mains
failure. The fault signalling contact does, however, open as
soon as the mains voltage fails.
IFD 258 · Edition 03.12
Project planning information 28

7.10 Wiring 7.13 Flame control

The IFD is suitable for hard wiring only. Do not reverse phase 7.13.1 With ionization sensor
and neutral conductor. Different phases of a three-phase The IFD generates an alternating voltage (230 V AC) between
current system must not be installed at the IFD. the sensing electrode and burner ground. The flame rectifies
No voltage may be connected to the valve and ignition outputs. this voltage. Only the DC signal (> 2 µA) is recognized by the
Do not use unused terminals as support terminals. automatic burner control unit as a flame.
The signalling contacts for operating and fault signals do not A flame cannot be simulated by a short-circuit.
meet the requirements for safety extra low voltage (SELV/PELV). Ignition and monitoring with a single electrode are possible,
The burner should be adequately grounded. Incorrect wiring see page 10 (Connection diagrams).
and an insufficient ground connection can cause damage to 7.13.2 With UV sensor UVS
the equipment during single-electrode operation. A UV tube inside the UV sensor detects the ultraviolet light of
In the case of single-electrode operation, only ignition trans- a flame. It does not respond to sunlight, incandescent bulb
formers of type TZI or TGI may be used. The use of pulse-spark light or infrared radiation emitted by hot workpieces or red-
or high-frequency ignition devices is not permitted. hot furnace walls.
In the event of incident UV radiation, the UV sensor rectifies
7.11 Note on EC type-examination the supplied alternating voltage. As with ionization control,
Since EN 298 (1993) does not describe all functions of the IFD, the automatic burner control unit only detects this DC signal.
the operator is responsible for ensuring that all parameters
In the case of flame control with the UV sensor UVS, only
and functions are matched to the respective application.
intermittent operation is allowed (a flame simulation check
7.12 Installation of solenoid valves for gas must be carried out once every 24 hours).
During the safety time on start-up tSA, the burner must be 7.14 Flame signal switch-off threshold
supplied with gas and ignited. For this reason, the gas so-
The switch-off threshold can be set between 2 and 20 µA us-
lenoid valve should be installed as close as possible to the
ing a potentiometer in the upper section of the housing. The
burner itself.
automatic burner control unit IFD is set to 2 µA at the factory.
If a flame is detected during the burner start, 01 flashes on
the display to indicate a fault.

7.15 Commissioning
The IFD retains its switch position (On/Off) when the voltage
is removed from terminal 1.

IFD 258 · Edition 03.12

Project planning information 29

7.16 Two-stage
IFD 258
burner control with two solenoid and valve 2 is opened once the safety time tSA has elapsed.
valves If no flame is detected, the fault signalling contact closes once
the safety time tSA has elapsed.
The IFD is equipped with two signallings1contacts for operating
and fault signals. For controlling two-stage burners, a bridge Example of application
must be installed
F1 in the lower section of the housing between Control: ON/OFF or ON/HIGH/LOW/OFF
terminals 12 and 13. Valve V2 is connected to terminal 14.
230V The burner BIO/BIC starts at low-fire rate. Once the normal
s2 c v1 v2
operating state is reached, the automatic burner control unit
1 2 3 4 5 6 7 8 9 10 11 12 13 14 IFD 258 opens the air valve. The burner switches to high-fire
max. operation.
max. 2 A, 2 A,
253 V AC 253 V AC

Z ϑ IFD 258
I 8
9
µC
13
14
L1 (L1)
N (L2) 12 11 10 5

PE

Program sequence
GIK..B

01 02 04 88 VAS BIO/
1 L1 BIC
3 ϑ VR..R
10
11 V1
5
14 V2
8-9
tW tZ t 7.17 Short-circuit fuse
tSA In accordance with EN 298, all safety outputs for gas valves are
fitted with an internal fuse, which may no longer be replaced.
During the waiting time tW after heat demand, checks are In the event that the internal fuse blows, the unit must be sent
made for flame simulation and fail-safe operation. If no flame to the manufacturer for inspection.
simulation is detected, the IFD 258 opens the gas valve V1 and
ignites the burner. The ignition time tZ is constant. The safety
time tSA starts with the ignition time tZ. If a flame is detected
during the safety time, the operation signalling contact closes

IFD 258 · Edition 03.12

 30

8 Accessories
8.1 High-voltage cable
FZLSi 1/7 -50°C (-58°F) to 180°C (356°F),
Order No.: 04250410,
FZLK 1/7 -5°C (23°F) to 80°C (176°F),
Order No.: 04250409.

8.2 Radio interference suppressed electrode

adapters
Plug cap, 4 mm (0.16 inch), interference-suppressed,
Order No. 04115308.
Straight adapter, 4 mm (0.16 inch), interference-suppressed,
Order No. 04115307.
Straight adapter, 6 mm (0.2 inch), interference-suppressed,
Order No. 04115306.

IFD 258 · Edition 03.12

 31

9 Technical data Flame control:

Mains voltage for grounded and ungrounded mains: sensor voltage: approx. 230 V AC,
200 V AC, -15/+10%, 50/60 Hz, length of sensor cable:
120 V AC, -15/+10%, 50/60 Hz, max. 75 m for ionization control,
100 V AC, -15/+10%, 50/60 Hz, max. 100 m for UV control,
230 V AC, -15/+10%, 50/60 Hz. sensor current: > 2 µA,
switch-off threshold can be adjusted between 2 and 20 µA,
Safety time on start-up tSA: 3, 5 or 10 s.
max. sensor current for ionization control < 25 µA.
Safety time during operation tSB: < 1 s, < 2 s.
Permissible UV sensors:
Ignition time tZ: approx. 2, 3 or 6 s. Elster Kromschröder models UVS 1, 5, 6 and 10 for ambient
Power consumption: temperatures from -40 to +80°C (-40 to 176°F).
IFD 258: approx. 9 VA, Valve connections: 1.
IFD 258..I: approx. 9 VA + 25 VA during ignition.
IFD 258..I: ignition voltage: 22 kVpp,
Output voltage for valves and ignition transformer = mains ignition current: 25 mA,
voltage. spark gap: ≤ 2 mm.
Contact rating: Ignition cable:
ignition output: max. 2 A, cos j = 0.2, IFD 258: max. 5 m, recommended < 1 m (with TZI/TGI),
valve output: max. 1 A, cos j = 1, IFD 258..I: max. 1 m, recommended < 0.7 m.
signalling contacts: max. 2 A, 253 V AC,
Fuse in unit: F1: T 3.15A H 250 V pursuant to IEC 127-2/5.
max. number of operating cycles: 250,000.
Ambient temperature: -20 to +60°C (-4 to +140°F).
Max. number of operating cycles:
reset button: 1000, Relative humidity: no condensation permitted.
mains button: 1000. Enclosure: IP 54 pursuant to IEC 529.
Signal inputs: Overvoltage category III pursuant to EN 60730.
Input voltage 100/120 V AC 200/230 V AC Cable gland: M16.
Signal “1” 80 – 132 V 160 – 253 V Installation position: any.
Signal “0” 0 – 20 V 0 – 40 V Weight:
Frequency 50/60 Hz IFD 258: 610 g,
IFD 258..I: 770 g.
Input current signal inputs: signal “1”: typ. 2 mA.

IFD 258 · Edition 03.12

Technical data 32

112,8 9.1 Operating controls

)
(4.44"
A: 2-digit 7-segment display to dis-
play program status and flame
A signal.

(2.97")
75,5
B: Reset/Information button to reset
C
the system after a fault or to call up
B the flame signal on the display.
35
(1.3 C: Mains On/Off button.
8" ) 85,
(3.3 5
6") 9.2 Installation
The unit can be installed in any position.
The installation position should however
70
(2 .75
") be selected carefully in order to ensure
M5 that the display can easily be read.
The housing is made of impact-resistant
plastic. The upper section containing the
M5
detection circuitry is a push connection
fit into the lower section. The connection
terminals, grounding strip and neutral
bus are located in the lower section. The
M16
­upper section of the housing is attached
to the lower section using two screws.
The lower section can either be snapped
onto a DIN rail or secured with two M5
screws. In order to obtain enclosure
IP  54, two sealing washers must be
placed beneath the M5 screws.
The housing has 6 knock-out holes for
(1.38")

M16 plastic cable glands.

35

IFD 258 · Edition 03.12

 33

10 Maintenance cycles 11 Legend

The automatic burner control unit IFD 258 requires little servicing. Symbol Description
88 Display

88 Blinking display

Safety interlocks (Limits)

Start-up signal
Ignition transformer
Gas valve
Flame signal
Operating signal/RUN
Fault signal
Reset/Information
Input signal
Output signal
Z Ignition/High voltage
I ionization
Input/Output safety circuit
tW Waiting time
tLV Flame simulation delay time
tZ Ignition time
tSA Safety time on start-up (3, 5 or 10 s)
tSB Safety time during operation (< 1 s or < 2 s)

IFD 258 · Edition 03.12

 34

12 Glossary 12.3 Ignition time tZ

If no malfunction is detected during the waiting time tW, the
12.1 Waiting time tW
ignition time tZ then starts to elapse. Voltage is supplied to
the gas valve V1 and the ignition transformer and the burner
01 02 02 88
1 L1 is ignited. The duration of the ignition time is either 2, 3 or
3 ϑ 6 seconds, see page 31 (Technical data).
10
11
5 01 02 04 88
13–14 1 L1
8–9 3 ϑ
tW tZ 10
t 11
tSA 5
13-14
8-9
tW tZ t
Once the start-up signal J has been applied, the waiting time
tW starts to elapse. During this time, a self-test is conducted tSA
to detect errors in internal and external circuit components. If
no malfunction is detected, the burner will start up. 12.4 Flame simulation/Flame simulation delay
12.2 Safety time on start-up tSA time tLV
01 01
01 02 04 88 1 L1
1 L1 3 ϑ
3 ϑ 10
10 11
11 5
5 13–14
13-14 8–9
8-9 tW t
tW tZ t tLV
tSA

Flame simulation is an incorrect flame signal. If flame simula-

This refers to the period of time between switching on and tion is detected, the flame simulation delay time tLV (max. 25 s)
switching off of the gas valve V1, when no flame signal is starts to elapse. If the flame simulation is discontinued during
detected. The safety time on start-up tSA (3, 5 or 10 s) is the the flame simulation delay time tLV, start-up can be initiated
minimum operating time of the burner and automatic burner or operation continued. Otherwise, a fault lock-out occurs.
control unit.

IFD 258 · Edition 03.12

Glossary 35

12.5 Safety time during operation tSB 12.8 Fault lock-out

In the event of a fault lock-out, all valves are closed and a
04 04 88 fault signalled. Resetting must take place manually following
1 L1
3 ϑ
a fault lock-out.
10
11
5
12.9 Safety interlocks (Limits)
13–14 The limiters in the safety interlock (linking of all the relevant
8–9
tSB
safety control and switching equipment for the use of the ap-
t
plication, for example STB (safety temperature limiter), Gasmin,
Gasmax ...) must isolate input 3 from the voltage supply.
If the flame fails during operation, the valves are closed within
the safety time tSB. 12.10 Gas valve V1
The default safety time during operation tSB in accordance The start fuel flow rate is released by gas valve V1. The gas
with EN 298 is 1 second. In accordance with EN 746-2, the valve V1 opens at the start of the safety time on start-up tSA.
safety time of the installation during operation (including clos- It remains open until the burner is switched off again by a
ing time of the valves) may not exceed 3 seconds, see page controlled shut-down or fault lock-out.
26 (Project planning information). Note the requirements
of the Standards!
12.11 Continuous operation
The gas burner has been running for longer than 24 hours
12.6 Flame signal and was not switched off during that time.
If a flame is detected, the flame detector will supply a flame
signal.

12.7 Flame detector

The flame detector detects and signals the presence of a flame.
The flame detector usually consists of a flame sensor, an ampli-
fier and a relay to produce the signal. These components, with
the exception of the flame sensor itself, are accommodated
within a single housing (IFW 50).

IFD 258 · Edition 03.12

 36

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Michael Rehkamp
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IFD 258 · Edition 03.12