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FlexFit 110
Preferred FlexFit 110 User Manual
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Fl
ex
Fi
t
11
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Linkag
el
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ss
Co
nt
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l
Inst
r
uc
tion
Manual
Copyr
ight © 2018 Preferre
d Instrum
ents – All R
ights Reser
ved Wor
ldwide
Linkageless Control
PREFERRED
PREFERRED
UTILITIES MFG CORPORA
TION
31
-3
5 South St
reet, D
anbur
y
, CT 06
810 |
ww
w.PREFERR
ED
-
M
FG.com
| (203) 7
43
-
67
4
1
Revision 1
.0
2
Table of Contents
Default Chapter
3
Table of Contents
3
Fi
6
Flexfit Specifications
6
Specifications
6
Safety Cautions and Warnings
7
Section 1 - Description
9
Overview
10
Features
10
Safety Relay
10
Field Selectable Flex Sequence Option
11
Servo Checks
11
Automatic Fuel SSOV Leak Test
11
Lockout and Alarm History
11
MAF and PAF Safe Start Checks
11
High Flue Gas Temperature Shutdown
11
Fuel Selection and Flexibility
11
FD VSD to VSD Bypass Changeover
11
Pilot Test Hold
11
Flame Scanner/Relay
11
Tandem Oil/Gas Valve Servo
12
Oxygen Trim
12
Firing Rate Setpoint and Control
12
Call for Heat
12
Domestic Hot Water Override
12
Warm Standby Option
12
Cold Start Warmup Cycle Option
12
Integrated Draft Control
13
RS485 Modulating Lead/Lag Interface
13
Burner Management System
13
Figure
15
Description of BMS Sates
16
Boot
16
Standby
16
Safe Start Checks
16
Prestart
16
Purge
16
Pilot Trial for Ignition (PTFI)
16
Main Trial for Ignition (MTFI)
16
Release to Modulate
16
Assured Low Fire Cutout (ALFCO) Option
16
Gas Valve Leak Test Option (Flex Sequence Option Only)
17
Lockout
17
Interlock Groups
17
Call for Heat
17
Recycling Limits
17
Fuel Select
17
Non-Recycling Limits
17
Purging
17
Ignition
17
False Flame
17
Parallel Positioning
18
Section 2 - Installation
19
Electrical Noise Suppression
20
General Wiring Requirements
20
Ignition Transformer Wiring / Mounting
20
VSD Wiring
20
Oxygen Analyzer Wiring
20
Flame Scanner Wiring
20
Installation Warnings and Notes
21
Flex Sequence Option
21
Burner Management System (Flame Safeguard) Installation
22
Figure 2 - 2 FF-110 BMS Standard Wiring Diagram (Typical) (Default)
24
Combustion Control Installation
26
Variable Speed Drive Installation
28
Figure 2 - 7 FF-110 VSD Wiring (Typical)
28
Servo Installation
29
Servo Description and Operation
29
Servo Control Board
30
Figure 2 - 9 Servo Control Board
30
Travel Limit Switches
31
Figure 2 - 10 Servo Travel Limit Switches
31
Servo Mechanical Installation
32
Servo Wiring
32
QD1 Quick Disconnect Cables
34
Flame Scanner/Relay
35
Flame Status
35
Figure
35
Flame Relay
36
Self-Checking
36
Flame Scanner Specifications
36
Flame Scanner Installation
36
Flame Scanner Wiring
37
Figure 2 - 17 Typical Scanner Mounting
37
Figure 2 - 18 Typical Flame Scanner Wiring
37
ZP Oxygen Sensor System Overview
38
Detector
38
Measuring Principle
38
Probe
40
ZP Oxygen Sensor Installation
40
Oxygen Probe Mounting Location
41
Mounting Oxygen Probe Nipple and Flange
41
Check Oxygen Detector Flange Temperature
41
Rotating the Probe to Lower Detector Flange Temperature
42
Oxygen Calibration Gas Tubing
42
Oxygen Sensor Wiring
43
Operation
44
Boiler Startup and Shutdown
44
Insertion into a Hot Stack or Duct
44
Powering down and Removing a ZP Oxygen Sensor
44
Maintenance
44
Cleaning the Detector and Probe
44
Table 2 - 1 ZP Sensor Maintenance Periodicity
44
ZP Oxygen Sensor Calibration
45
Section 3 - Operation & Commissioning
47
Initial Steps
48
Operating the Flexfit
48
Button Functions
48
LCD Screen Indicators
49
Alarm and Event Log
49
Menu Tree
50
Figure
50
Figure
51
Figure
52
Entering and Navigating the Main Menu
53
Lockout Data
53
Passwords
53
Figure
53
Obtaining a Temporary Password
54
Password Levels
54
Utilities
54
Date/Time and S/N
54
I/O Data Display
54
Cycle Statistics
54
Oxygen Cell Status
54
Oxygen Calibration
54
Software Versions
54
Configuring Parameters
55
Flexfit Edit
55
Servo Setup
55
Servo Setup Step 1 - Configure the Servos' Travel Limit Switches
56
Servo Setup Step 2 - Configure the Servos' Addresses
56
Servo Setup Step 3 - Configure the Servos' Functions and Feedback
56
Servo Setup Step 5 - Configure the Servos' Span by Seeking Limits
57
Servo Setup Troubleshooting
57
Commission Mode
58
Curve Points
58
Starting the Burner
58
Verifying Positions and Curve Points
58
Flame Scanner Tests
59
Pilot Test Hold
59
Pilot Flame Test (Non-DSI Burners)
59
Main Flame Test
60
Pilot Turndown Test (Non-DSI Burners)
60
Tuning the Burner
60
Fuel/Air Ratio Curves
60
Entering Additional Curve Points
61
Low Fire, High Fire, Avoid Setpoint
61
Verifying Curves
62
Tuning
63
The Proportional Function
63
The Integral Function
63
The Derivative Function
63
Recommended Procedure for Tuning a PID Loop
63
General Steps for Tuning the Flexfit PID Loop
63
Documentation
64
Section 4 - Parameters
65
Introduction
68
Flame Safety
68
Flame Safety > Basic
68
Flame Safety > Advanced
69
Flame Safety > Flex Sequences
70
Gas Valve Leak Test Option
72
Timing Calculations
72
Table 4 - 1 Total Pipe Area
72
Table 4 - 2 Gas Leak Test Timing Calculation Example Data
73
Fuel-Air
74
Fuel-Air > FD VSD
74
Fuel-Air > Aux 2
74
Fuel-Air > O2 Analyzer
75
Fuel-Air > O2 Trim
76
Fuel-Air > FGR
77
Firing Rate > Basic
78
Firing Rate > Tuning
79
Firing Rate > 24 Hour Recycle
80
Firing Rate > Local/Remote Mode
80
Call for Heat (Option)
80
Firing Rate > LFH-DHW-Warm Standby
83
Firing Rate > Cold Start Warmup
83
Firing Rate > Advanced
84
Draft Control
85
Draft Control > Basic
86
Draft Control > Tuning
87
Draft Control > Options
89
Button Sets
89
Modbus
90
Serial Number
90
Section 5 - Troubleshooting
91
General Troubleshooting Tips
92
Lockout Data
94
I/O Data Display
94
Electrical Noise
94
Table 5 - 1 Lockout Messages
94
Not at Position" Lockouts
95
Not at Position" Lockout Exceptions
95
Possible Reasons for a
95
ZP Oxygen Analyzer Troubleshooting
96
ZP Wet Measurement Vs. Dry Measurement
96
Normal Operating Values
96
Slow Response Time
97
Reading Is Lower than Expected
97
Reading Is Higher than Expected
97
Cell Can't Reach Operating Temperature
97
Low Calibration Gas Flow Rate
98
Detector Leak Test
98
LCD Messages
99
Normal Operating Messages
99
Curve Commissioning Error Messages
101
Oxygen Cell Status and Messages
102
Trip Messages
104
General Alarm, Error & Warning Messages
110
Common Problems & Solutions
112
Figure 2 - 6 FF-CC Wiring Diagram (Typical)
112
Section a - Appendix
113
Abbreviations Used in this Manual
114
Terms and Definitions
115
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Preferred FlexFit 110 Specifications
General
Brand
Preferred
Model
FlexFit 110
Category
Controller
Language
English
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