Dear Customer

Thank you for selecting the BurnerMax O2 / Combustion Controller. It’s user-friendly

BurnerMax2
operation and extensive features will assist you that your furnace or burner will continuously
operate efficiently and environmentally friendly.

Please take the time to read this manual carefully and make sure you become familiar with the
unit’s operation before using it. If there are any problems, please contact our Customer Service
Department or your nearest distributor. We will help you quickly and competently in order to
enable you to use the BurnerMax O2 / Combustion Controller to its full potential.

We trust the BurnerMax O2 / Combustion Controller will serve you well.

O2 / Combustion Controller
 General information

Warnings and other important information relating to BurnerMax O2 / Combustion

Instruction Manual Controller are highlighted as follows in this instruction manual:

Warnings

Warnings are highlighted by a pictogram. The accompanying Text indicates the degree of
danger:

Danger

Danger means: Physical injury or damage to property may occur if the

specified safety measures are not implemented.

Please read all warnings carefully and carry out safety measures as
specified to avoid risks.

Important information

Measurement errors!

An exclamation sign highlights information, which has to be observed in

order to achieve correct measured results.

Notes

Notes which should help you to work better with the

BurnerMax O2 / Combustion Controller are highlighted in this way.

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Contents
1 Basic safety information
1 Basic safety information................................................................................... 4 Please read the following safety information carefully!
1.1 Supply voltage ............................................................................................. 4
1.2 Electrical shock............................................................................................ 4 1.1 Supply voltage
1.3 Sensor hazards ........................................................................................... 4
2 Product description........................................................................................... 5 The BurnerMax O2 / Combustion controller can be operated at voltages from
90 to 230 Volt AC. The supply voltage will be set to 110 or 220 Volt during
2.1 The BurnerMax O2 / Combustion Controller ............................................... 5
manufacturing. If a voltage higher than 130 Volt AC is supplied to a unit set to 110
2.2 Function description .................................................................................... 5 Volt, permanent damage can result!
2.3 Efficiency in fuel burning ............................................................................. 6
2.4 Efficiency and environmental performance................................................. 7 Change of accepted supply voltage can only be done at the manufacturers work.
2.5 Electronics of the BurnerMax ...................................................................... 7
2.6 In- and outputs............................................................................................. 8 1.2 Electrical shock
2.7 Special features........................................................................................... 9
The BurnerMax O2 / Combustion controller is manufactured in accordance
2.7.1 Data logging..........................................................................................................9
with European norm EN 61010 to eliminate hazards of electrical shock. It is not
2.7.2 Controller action....................................................................................................9
allowed to open the main unit compartment by opening the four sealed screws. All
2.7.3 PC communication................................................................................................9
warranty will be void if the main compartment is opened by the client or if the
3 Installation and commissioning .................................................................... 11 screw seals are damaged!
3.1 Scope of supply ......................................................................................... 11
3.2 Mechanical installation .............................................................................. 12 The terminal compartment, locked by two screws, should only be opened by a qualified
3.3 Electrical installation.................................................................................. 13 electrician for the installation and setting up of the unit. The normal power consumtion of the
3.4 Pre-commissioning.................................................................................... 14 unit at 230 V AC supply voltage is less than 500 mA. It is required that the power supply is
3.5 Commissioning & calibration..................................................................... 14 protected by a circuit breaker of 1 Amp capacity which should be switched off whenever the
3.6 The keyboard menu .................................................................................. 15 termination compartment is opened.
3.7 Communication with a PC & software....................................................... 21
The termination compartment has small holes for the insertion of lead seals, which should be
4 Maintenance ..................................................................................................... 21 used to prevent unauthorised access.
4.1 Routine maintenance ................................................................................ 21
4.1.1 External cleaning ................................................................................................21 1.3 Sensor hazards
4.1.2 Sensor cleaning ..................................................................................................21
4.2 Function checks......................................................................................... 22 The sensor is heated while in operation to a temperature in excess of 600 °C.
4.3 Troubleshooting......................................................................................... 22 When the unit is switched on, the sensor should not be touched as injuries and
4.3.1 LED indication.....................................................................................................22 burns can be sustained.
4.3.2 Error messages ..................................................................................................22
4.3.3 The fuses ............................................................................................................22 To prevent fires, the sensor should never be brought in contact with inflammable
4.3.4 The LCD display .................................................................................................22 gases, liquids or solid material.
4.3.5 Sensor heating....................................................................................................23
5 Technical data.................................................................................................. 24 The sensor and unit is not for use in areas classified as EX explosion hazard.
5.1 Measuring ranges and accuracies ............................................................ 24
5.2 Additional instrument data......................................................................... 25
Product safety:
5.3 Calculation fundamentals .......................................................................... 25
6 Accessories / spare parts............................................................................... 26
The BurnerMax O2 / Combustion controller should only be operated within the
7 Warranty ........................................................................................................... 27 parameters specified in the technical data.
8 Appendix .......................................................................................................... 27
8.1 Keypad Menue .......................................................................................... 27 Please use the BurnerMax O2 / Combustion controller appropriately and according to
8.2 Terminal Drawing ...................................................................................... 30 instructions.
8.3 Control wiring: 3 Point / Add on Controller................................................ 31
Never use force!

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The BurnerMax O2 / Combustion Controller should not be opened except if expressly
described in this instruction manual for maintenance or installation purposes. 2.3 Efficiency in fuel burning

Only maintenance and repair work, which is described in the instruction manual, should be With raising fuel prices, the efficiency of fuel burning equipment becomes an important issue in
carried out. We suggest, that for these purposes, you keep this manual. Only original spare industry and commerce. The operation of fuel burning appliances at the correct excess air
parts from BurnerMax are permitted for use. level is important to maintain the optimum efficiency. It has been shown, that the setting of
burners during commissioning is not sufficient to maintain a satisfactory air to fuel ratio. If too
Only authorised, trained personnel should carry out any work, which may be required. much air is supplied to the system, energy will be wasted, due to increased amount of flue gas.
Otherwise, the responsibility for the correct functioning of the instrument and the validity of If not enough air is provided for the combustion, smoke and other harmful compounds are
guarantee will be released from BurnerMax. generated, and energy is again wasted through incomplete combustion of the fuel. The
following background information on combustion technology should be considered:
2 Product description
Combustion control & energy efficiency
2.1 The BurnerMax O2 / Combustion Controller
Every combustion process requires air for the burning of fuel. If the exact amount of air
The BurnerMax flue gas oxygen analyser and controller offers many features to ensure necessary for the combustion chemical reaction is provided, stochiometric conditions are
that your combustion process can be maintained to optimum conditions at all times. present. When the combustion air is reduced, at sub-stochiometric conditions, combustion is
incomplete, excessive smoke and harmful gases are generated and fuel is wasted.
2.2 Function description
The BurnerMax combustion controller has the following main properties: If too much air is mixed with the fuel, the flue gas volume increases and the amount of energy
wasted through the chimney also increases.
• Microprocessor based “embedded” controller
The following table shows the typical energy loss (as % of total fuel cost) for an oil fired boiler
operated at 210 ˚ C flue gas temperature.
• Measurement of oxygen (vol %) and flue gas temperature in combustion
processes. (boilers, furnaces etc.) Oxygen in flue Excess air Energy loss
• Calculation of flue gas CO2 (vol %) and flue heat loss
4% 125 % 8.9 %
• Reliable and robust BOSCH zircon sensor for in situe gas analysis (no sampling) 8% 167 % 11.7 %
• Data storage for approximately 4 weeks operation at 60 sec. storage intervals 12 % 247 % 16.8 %
16 % 470 % 31.4 %
• LED indication of unit status
Savings of 5 – 10 % fuel cost are achievable if the combustion is controlled to maintain the
• Fail save error relay to indicate unit function and to generate fail save controller
optimum excess air level. This can, however, only be done if oxygen in the flue is measured
output signal.
and adjusted continuously, as the following typical factors change the excess air level.
• Keypad interface for programming, set-up and calibration Liquid and gas fuels:
• PC communication for data download, online trending and unit programming
Factor Possible change of excess air
• RS 232 or RS 485 port for up to 1000 m communication with PC
Ambient air pressure ± 15 %
• Interlock alarms (high and low) for oxygen, CO2 and temperature Ambient air temperature ± 10 %
Fuel supply pressure ± 10 %
• 0 – 20 mA / 4 – 20 mA / 0 – 10 V output for Oxygen / CO2 or combustion control
Fuel temperature & viscosity ± 25 %
• 3 point controller and PI controller Fuel heating value ± 5%
Fuel filter blockage ± 25 %
• 0 – 20 mA / 4 – 20 mA / 0 – 10 V input to generate trim signal

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Additional factors with solid fuels:

2.6 In- and outputs

Factor Possible change of excess air

The electrical terminations for
the connections of the unit are
Fuel moisture content & heating value ± 10 % shown on the photo on the left.
Fuel bulk density ± 10 %
An electrical termination drawing
can be found in the cover of the
With a combination of the above factors, excess air level can easily vary to the extent that termination compartment.
10 % fuel or more is wasted. If a boiler is set up manually for high efficiency operation, then,
with the variables above, operation with air starvation can occur. For additional copies of these
drawings, please contact us.
Most modern industrial boilers and furnaces, lack continuous flue gas oxygen control and often
produce heavy smoke. Large amounts of energy are also wasted due to high excess air
operation.

Only the use of suitable equipment for the measurement and continuous control of flue gas
oxygen can rectify this problem.
The BurnerMax has the following terminations and connections:

2.4 Efficiency and environmental performance • Power 90-110V/ 220-250V at 50 – 60 Hz (change from 200 to 110 V to be done by
authorised service station only)
Efficiency and environmentally friendly operation go “hand in hand”. Combustion equipment
which operates on low efficiency often generates excessive smoke - in case of solid fuel firing, • Fail save relay (240 V AC – 10 Amp) to indicate functioning of BurnerMax and
the emission of small particulate is increased. Secondary gas clean up equipment such as wet vital alarms
scrubbers, electrostatic precipitators, bag house filters or high efficiency cyclones all have
reduced performance when large amounts of sub-micron particles are emitted. If insufficient • Two switch over relays (as 3 point controller) controlled by the oxygen setpoint and
air is provided for the combustion of fuel, unburned hydrocarbons, excess carbon mono oxide the control band, which can be entered with the keypad.
and other harmful compounds leave the combustion process.
• The connections for sensor heater and sensor signal.

2.5 Electronics of the BurnerMax • The connection of the K type thermocouple for measuring the flue gas temperature

• Analogue input for trim control.

The BurnerMax is based on an embedded microprocessor solution utilising the Atmel
AT89S8252 microcontroller with integrated watchdog function. The digital circuits are • Analogue output set as Forced Value, PI- or PI trim controller.
completely separated from the analogue in- and outputs as well as from the communication
connections by optocouplers. These ensure that the digital service is not subjected to noise or
spikes, which might be generated in the field cabling.
Please note that the power supply for the analogue output is internal in the
The analogue circuits are further protected by “Tranzorp” high voltage earth connections to BurnerMax and power only has to be provided for the analogue input
protect the in- and output circuits. circuit NOT the output circuit.

The design of the BurnerMax satisfies the requirements of the European CE certification
and the enclosure is rated to IP 65. • Two wire RS 485 communication for PC connection of up to 1000 m.

• Standard 9 pin RS 232 connector for PC communication.

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2.7 Special features for the PC are available as options. The RS 485 communication can run up to 1000 m and
can address up to 32 separate BurnerMax units on one twisted bear communication line in
Over and above the measurement of flue gas oxygen, temperature and the indication of the series.
efficiency of combustion, the BurnerMax combustion controller has special features, which
are normally not found in comparable equipment. These features are described below. The WINDOWS based software includes a comprehensive help file and also learning
programs, which allow the operator to become fully familiar with the many features which are
2.7.1 Data logging included in the software such as:

The BurnerMax is equipped with a memory chip which allows the storage for measurement • Online trending of process variables
data at selectable intervals. At 60 second interval the stored data will cover approximately 4
weeks of operation. If shorter or longer intervals are selected, the storage period changes • Download and display of historical data
accordingly. The stored data can be retrieved with a PC through the RS 232 or RS 485
communication connection. It is possible to download the complete stored information or • Calibration of BurnerMax sensors
select specific days and limit the download of data to these periods. The data storage can be
erased either with the BurnerMax keyboard menu or with the appropriate commands from • Troubleshooting and fault finding
the PC software.
The program CD also includes copies of the wiring diagrams and general information about the
2.7.2 Controller action BurnerMax unit such as this manual, Keypad menu etc.
The BurnerMax has integral controlling functions, which are described as follows:
To install the BurnerMax software enter the CD in your PC and follow the instruction on the
screen.
The three-point controller activating the two switchover relays (marked control), which compare
the oxygen set points selected in the BurnerMax keyboard menu with the actual measured
Normally the installation of the software and the connection with the BurnerMax unit is
value. According to the band selected, these relays will switch over if the actual flue gas
selfexplanatory. Should there be any questions, you can contact us under:
oxygen is outside the selected band. The three-point controller can be used for a simple
oxygen trim or it can also be used for indication and alarm purposes. One example how to
[email protected]
operate a three light indicator is shown in the wiring diagram shown at the back cover inside.
Or on our website under
To slow down control action, the relays can be configured with an ON and OFF time by setting
T1 (ON) and T2 (OFF) so for example at T1 = 001 and T2 = 010 the relay will switch on for 1
www.burnermax.com/english/E_Kontakt.htm
second and switch off for 10 second intervals as long as the measured value is outside the
alowable band.
When doing so please state the dealer from whom you have bought the unit.
The three-point controller works continuously, but the relay operation can be switched off by
setting T1 to 000.

The PI controller consists of an analogue control unit integral to the BurnerMax which, if
selected, will either generate a controller output on the 4-20 (0-20) mA output or it can, in
conjunction with the analogue input also be used as a trim control. The trim control will add a
controlling current to the input current and in this way an existing control signal can be trimmed
to adjust the air to fuel ratio in a burning appliance. The controlling parameters can be set-up
with the BurnerMax control menu and a “trim max” variable allows to limit the add on trim
control to a certain percentage of total output to ensure that overswings in the control are not
disturbing normal operation. The action of the controller can be set forward or reverse to cater
for different actuator systems.

2.7.3 PC communication
A comprehensive WINDOWS based software package is delivered with the BurnerMax,
which allows online communication with the BurnerMax combustion controller. The
communication can be either effected through a RS 232 computer connection or can also be
installed with a RS 485 two wired twisted pair communication. Special non-powered adapters

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3 Installation and commissioning
3.1 Scope of supply 3.2 Mechanical installation
The standard BurnerMax package comprises of the following items: To ensure correct operation of the BurnerMax, some care needs to be given to the
installation.
Part description Part Number
Mount the BurnerMax in at least 2 meter distance from variable speed drives and other
361.001 high frequency emitting devices.
BurnerMax main electronic unit
Lambda sensor 361.002 The unit is fixed to a wall or plate with 3 bolts, two of which are introduced through holes in the
20 m of special sensor cable 361.20.003 termination compartment. The third bolt is located at the back of the casing, and can be
Sensor welding adaptor 361.004 hooked in after the bolt is located in the wall. The distance of the mounting bolt centres is 177
mm vertically and 242 mm horizontally and is shown on the back of the enclosure. The main
K Type thermocouple 361.007 enclosure must not be opened.
20 m thermocouple cable 361.009
RS 232 communication cable (9 / 9 pin) 361.022 Do not drill additional holes in the BurnerMax casing, as this will invalidate the IP 65
PC software & data CD 361.E.025 rating of the enclosure, and in turn void the guarantee.
Instruction manual 361.E.026
Sensor:
Calibration certificate 361.E.027

The items are shown on the following photograph:

The BurnerMax package has been

carefully checked. In the unlikely event
that the supply is not complete or
damaged during transport please notify us
immediately.

The adapter supplied for the gas sensor must be welded airtight into the side or the top of the
flue duct. The adapter shall be welded to the flue gas duct on the collar so that the extended
part is advancing into the duct by about 80 mm. This ensures, that the sensor is not picking up
streams of air, which can travel along the duct inside wall in the case of, for example, duct
flange leakages.

The sensor is screwed into the adapter after zero calibration with approximately 11 Nm
moment. Use only correct size spanner (22 mm) for tightening the gas sensor. To fit the
sensor with any other tool, such as an adjustable
spanner, can damage the sensor casing and the
sensor.

The thermocouple is installed near to the Oxygen

sensor, preferably downstream to ensure air
leakages not to influence the oxygen measurement.
The thermocouple is fitted with the supplied weld in
socket.

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3.3 Electrical installation Thermocouple connections colour code:

Red T/C -
A single line wiring drawing for the electrical Yellow T/C +
installation can be found inside the cover of the
termination compartment of the BurnerMax unit Analogue in- and outputs
or in the Appendix of this document For additional
copies of these drawings, please contact us under The analogue output provides a 4 – 20 mA (0 – 20 mA selectable) with 12 V DC power supply.
[email protected] or visit our website under: (Maximum Impedance= 600 Ohm)

www.burnermax.com The analogue input has an impedance of 60 Ohm.

Please note that the power supply for the analogue output is internal in the

select the English version of the “ BurnerMax the combustion controller” link and go to the BurnerMax and power only has to be provided for the analogue input circuit,
NOT the output circuit.
section Documents

Power supply
Communication
The BurnerMax can be set up for AC power (mains) supply of 220 V or 110 V. The supply
voltage is preset to 220V at the factory. Please ensure that the required voltage is requested The BurnerMax can communicate with a PC using either a dedicated RS 232 connection
in the order, should the equipment be supplied to a country with a supply voltage other than or a RS 485 two wire twisted pair cable, where up to 32 units can be connected to one PC. If
220 – 250 V AC! Frequencies of 50 or 60 Hz are acceptable. RS 485 communication is used, please ensure that the communication cable is routed in
separate instrumentation cable trays with sufficient distance from high voltage, power or
Sensor frequency cables and equipment.

The cabling of the Sensor is colour coded as follows

3.4 Pre-commissioning
Sensor Connector Extension Cable
White Heater 12V Pin 1 of connector Green/yellow After the completion of the installation of the BurnerMax combustion controller, it is
White Heater 0V Pin 2 of connector Brown recommended to conduct a number of pre-commissioning tests to ensure the proper
Grey Sensor – (Ox-) Pin 3 of connector Blue functioning of the unit. At this time the oxygen sensor is still located outside of the flue gas
Black Sensor + (Ox+) Pin 4 of connector Black duct hanging in fresh air. Before the unit is connected to the power mains, please ensure that
all terminations are wired correctly.

The BurnerMax Sensor, when connected, becomes very HOT (> 600 °C) After all the connections are checked to be correct and a visual inspection shows that the
mechanical and electrical installation is without fault (all cables are undamaged etc.) a unit can
.Do not run any cables directly on hot surfaces. be connected to the mains. As soon as power is connected to the BurnerMax a beep can
be heard and BurnerMax followed by the software version number will be seen on the units
display. On completion of this step the commissioning of the unit can commence.
A sensor cable with maximum length of 20 meter is supplied with the unit. The 3.5 Commissioning & calibration
cable length cannot be increased but the cable can be shortened as necessary.
No other cable can be used. If a PC connection is utilised it is recommended to first establish communication between the
PC and the BurnerMax unit. Further instructions with regard to the PC software can be
found in the software help files and the tutor program in the PC. WINDOWS based
Thermocouple BurnerMax software will guide the user through the commissioning of communication
between the BurnerMax and the PC. Problems with the communication can be solved as
The type K thermocouple has to be connected with the correct compensating described under debugging in the software’s help file.
cable. Do not extend the compensating cable with any other type of cable.

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The commissioning can be continued with the calibration of the sensor and it is recommended The keypad menu structure is documented in a spreadsheet, which is supplied with the
that this is done with the BurnerMax keyboard, as action on the place of measurement is hardware and at the end of this document. For additional copies please contact us.
required.
The main items of the keypad menu are shown in the following graphical display:
Although the sensor is calibrated before it leaves the manufacturing facility, it is recommended
to recalibrate the sensor to ensure high accuracy measurement. 1 Password - Enter password to access the units keyboard menu

First of all a zero calibration shall be conducted during which the sensor should still be hanging 2 Error Log – Displays or clears the last 5-recorded errors
outside in fresh air. Sensor calibration should only be conducted after the sensor was in
operation for at least 15 minutes to ensure that the sensor has reached its operational 
temperature. 3 Display Mode – Selects and sets the units display mode

Span calibration is necessary if measurement values better than 0.4 % oxygen are required 4 Log setting – Sets the units data logging parameters
and it is necessary to have a auxiliary hand held oxygen test equipment available against
which the span calibration can be effected. The span calibration done on the final checks of 
the unit before it leaves the manufacturing facility are based on long term average values of all 5 Control settings – Setting of controller mode and input and output variables
sensors supplied and therefore the span calibration represents a historical value and the 
accuracy of oxygen will be better than ± 0.4 % oxygen. The span calibration can also be done 6 Alarm settings – Settings for the main alarm relay
after the sensor is screwed into the sensor socket in the flue gas duct and left there for
approximately 15 minutes after which the sensor can be calibrated to a manual measured 
oxygen value using the span calibration in the keyboard menu. 7 Comms settings – Setting of PC communication parameter

Please note, that the sensor accuracy can only be as good as the accuracy of the reference 8 Set fuel – Setting of fuel to calculate flue gas CO2
measurement. We offer recalibrated sensors where the sensor calibration data can be entered
numerically via the keyboard so that on site calibration is not necessary. This method is also

offered as a service for sensors which are returned to the factory for recalibration. Service fees 9 Calibration – Zero and span calibration of O2 sensor
for recalibration are available on request. 
10 Set password – Change of access password
3.6 The keyboard menu 
11 Diagnostics – Function checks and troubleshooting
The keypad of the BurnerMax makes the controller independent of a PC, as all functions 
and selections can be entered into the BurnerMax via the keypad.
At the menu items of the keypad menu are described in detail as follows:
It is recommended to carry out the calibration and set up of the BurnerMax with the
keypad, as it is easier to evaluate the effects on the plant than by setting up from a remote 1 Password
control room. With the keypad available we recommend, that the PC software is primarily
used for online trending or historical data download. The default password of the factory-supplied unit is 1234. Should the password be changed
manually and the new password be forgotten, the unit has to be returned to the manufacturer
The keypad has 4 entry keys as shown on the photo left. Their function is as follows: for resetting of the password; therefore please ensure that the password is stored in a safe
place.
C = Cancel To erase entered values, clear inputs, go one level up in the
menu and exit the menu. 2 Error log

Arrow up To go back in the menu and to decrease numerical input The Error key allows the following functions:
values. (When outside the menu, this key will send a data string to the
PC communication for checking.) To view the last 5 errors with description and time
To clear the error log
Arrow down To go forward in the menu and to increase numerical input
values

E = Enter To enter numerical values and to confirm entries.

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3 Display mode In the same menu the following constants can also be set

The Display menu allows the selection of the following display types: Select either oxygen or CO2 for control
Set the oxygen and CO2 set points
Flue gas temperature – Flue gas oxygen P1 = % Oxygen Value below which the set point floats (increases)
Flue gas loss – Flue gas oxygen P2 = Addition to setpoint at 0% Oxygen (linear increase from P1 downwards to 0%)
Flue gas temperature – Flue gas CO2 (calculated) Band for 3 point controller
Flue gas loss – Flue gas CO2 (calculated) T1 = active time of 3 point controller relay
Analogue input mA – Analogue output mA T2 = inactive time (sec) of 3 point controller relay
PP Proportional for PI or PI Add controller
4 Log settings IP Integral amplification for PI or PI Add controller
Integral value for PI or PI Add controller (larger values will make controller faster)
The BurnerMax log stores date, time, flue gas temperature, oxygen or CO2 TrimMax maximum add on value of full scale
Control action foreward or reverse
At 60 sec storage interval (preset), approximately 4 weeks of data are stored. Analogue In mode (4 – 20 mA or 0 – 20 mA)
Analogue out mode (4 – 20 mA or 0 – 20 mA)
In the log settings menu the following parameters and actions can be chosen:
6 Alarm – set-up
Log mode (to store oxygen or CO2)
Log interval (recommended 60 sec) If any of the alarms are triggered, the following actions will be executed:

Show log statistics (Log size, first entry, last entry) The vital alarm relay will switch
The alarm is logged in the error log
Erase the log The “BurnerMax ok” LED on the facia will switch off

5 Control settings The LED will also switch off and an error is logged, if other malfunctions occur, such
as a sensor short, disconnected sensor or thermocouple or a system reset.
The controller menu allows the following settings:
The following alarms can be set up in the menu:
To force the analogue output to 4 mA
To force the analogue output to 20 mA Minimum flue gas oxygen value
To force the analogue output to represent the measured oxygen Maximum flue gas oxygen value
To force the analogue output to represent the calculated CO2 Maximum sensor heating current
To force the analogue output to supply the controller output Minimum flue gas temperature
To force the analogue output to represent the analogue input Maximum flue gas temperature

To force the analogue output to represent the analogue input with added controller 7 Comms settings
output
The communication between the BurnerMax and the PC must be configured, so
The BurnerMax controller can be set up to provide: that the parameters match the PC settings. The following can be set:

To force the analogue output to 4 or 20 mA or to a process value PC Port (protocol as RS 232 or RS 485)
PI control Baud rate (The PC program only supports 9600 or 19200 bps)
PI Add control – the control signal is added to the analogue input signal Address (For RS 485 communication, the PC can communicate with BurnerMax on
addresses 1-32 over one serial cable)

Only one of the above functions can be selected at any time! For setting up the PC, please refer to the software menu communications.

The three point controller driving the two control switch over relays work For troubleshooting the communication connection please use the keyboard Arrow Up key to
continuously. To stop the 3 point controller to switch the control relays, send data from the BurnerMax to the PC and use the BurnerMax software Setup – Options –
select T1 = 000 (active switching time in sec.) in the controller constants set ComCheck menu to look at received data and send data from the PC to the BurnerMax. See
up. also 11 Diagnostics below.

- 17 – - 18 –
8 Set fuel 11 Diagnostics

In this menu, the fuel used in the combustion process is selected. The fuel selection is used to The BurnerMax keypad allows for extensive diagnosis and the following functions can be
determine the maximum CO2 necessary for the calculation of the CO2 content in the flue gas. used in this menu. The diagnostic functions are only available through the keyboard not the
A number of fuels are given in the menu, but the CO2 max can also be selected for a custom PC.
fuel.
Show Date and Time
9 Calibration
Set Date and Time
The sensor calibration allows:
ComCheck: When this function is selected it will show any incoming communication
Zero calibration by pressing one key (when sensor is in still air and heating has stabilised)
received by the BurnerMax. The settings have to be equal in the PC
Span calibration (with the use of an independent flue gas analyser) and the BurnerMax. The communication is displayed as an ANSI
character and normal character, allowing the operator to determine the
The span calibration constant is set in the factory to a long term average complete details of the communication string received by the
value, which already will result in measurements with + / - 5 % accuracy BurnerMax. At the end of the communication, the data is evaluated
(of full span) if a zero calibration was performed on the individual sensor. and will be displayed as valid or not.

This menu further allows the reading of all set up constants K1 – K7, which can be used for To check the communication from the BurnerMax to the PC, it is
evaluation and troubleshooting. If any of the following constants have changed, the possible to send a string of current measurement data manually from the
BurnerMax must be reset: BurnerMax to the PC. To do this, exit the keypad program and press
the arrow up key. The display will acknowledge the sending with “Data
K1 = 1090 Sent” and a string in the format:
K2 = 0.26
K4 = 0.0 (for future use) “MM,DD,hh,mm,ss,tttt,c.c,Koo.o” will be send
K6 = 0.041 (TC calibration value)
MM = month
The constants can also be read with the PC software configuration command. DD = day
hh = hour
Although it is preferred to calibrate the sensor at the BurnerMax installation to mm = minute
have better supervision, it is also possible to calibrate remotely through the PC ss = second
software. tttt = temperature
c.c = heater current
K = C for CO2 or O for Oxygen
The sensor calibration can also be performed by entering numerical calibration values supplied oo.o = Oxygen or CO2 value
with replacement sensors.
This string can be received by a standard terminal program for analysis.
10 Set password Or with the BurnerMax software in the menu Setup – Options –
ComCheck. Data in the receive buffer will be shownin normal letters and
The keypad menu is protected by a password, consisting of four digits, which can be ANSI code when pressing “Built Test String”
configured by the authorised user. If the password is forgotten, the BurnerMax has to be
returned to the service station for resetting of a valid password. Reset Settings: This feature clears all settings in the BurnerMax and resets all
variables to the factory values. Therefore any specific set ups including
The default password as delivered ex works is “1234” sensor calibration will be lost and the unit has to be completely re-
configured. The reset function should only be used when all other actions
fail.
.
After a 30 second time out, as a safety measure, the menu will disable and can be DEBUG: This function allows the check on analogue input and outputs. Each
re-activated by re-entering the password. display shows the analogue value received by the AD converter and the
digital value sent to the micro controller from the AD converter (toggled
with the arrow keys). With this function, it is possible to determine if an
error is related to the sensing device, the cabling or internal in the

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 BurnerMax. The following checks are available.

Test Temp: The analogue values and the AD digital values are displayed to check Never use high-pressure water or compressed air on the sensor
thermocouple functioning and wiring for cleaning.

Test Current: The analogue values and the AD digital values are displayed to check
sensor heating functioning and wiring
4.2 Function checks
Test Oxygen: The analogue values and the AD digital values are displayed to check
sensor signal functioning and wiring The function of the BurnerMax unit can be checked by using the analytical program
included in the unit, as described under item 11- Diagnostics in the menu above. Further to
Test Analogue The analogue values and the AD digital values are displayed to check the diagnostic possibilities, the following should be noted:
in: analogue input functioning and wiring

The debug mode further allows the creation of an analogue output over the full selected range 4.3 Troubleshooting
where 0 (bits) will be minimum and 255 (bits) will be the maximum.

3.7 Communication with a PC & software 4.3.1 LED indication

With the supplied WINDOWS based software, it is possible to connect up to 32 units to one PC The LED indication on the front plate of the BurnerMax shows, if the operation of the unit is
(via RS 485) and use the following features: within its prescribed limits. The ok indication will switch off if vital errors occur such as a
sensor shortage etc. or if one of the alarm values is exceeded. When the ok LED goes off, at
• Online trending of measured values the same time the main alarm on relay no. 1 is also de-energised.
• Downloading of historical data
• Set-up and calibration 4.3.2 Error messages
The BurnerMax stores the last 5 errors giving the error as well as the time it last occurred.
A comprehensive help and tutorial is included in the software supplied with the BurnerMax Error messages can be accessed through the keyboard menu as described above under item
unit. 2- Diagnostics in the menu.
4 Maintenance
4.3.3 The fuses
The BurnerMax 02 combustion controller has been designed as a robust unit, which Fuses safeguard the power supplies as well as the relay outputs. If the unit does not start up
requires very little, if any maintenance. However, extensive features are included in the unit to please check first, if any of these fuses have blown. Before replacing these fuses, investigate
allow the operator to check the function of the controller and to optimise its operation, as well the cause for the high current and rectify the problem before re-starting the unit. The fuse
as to conduct fault finding and troubleshooting. rating is printed next to the fuse location Never use the unit with unsuitable fuses and never
bridge the fuses with metal.
4.1 Routine maintenance
The routine maintenance of the unit is limited to cleaning exercises. 4.3.4 The LCD display

4.1.1 External cleaning The LCD display can be used to show process variables such as
O2, calculated CO2, flue gas temperature, combustion efficiency
If the unit has to be cleaned externally, please use a soft cloth with a mild cleaning agent.
or analogue input and/or output values. If the LCD display is not
indicating any messages after the BurnerMax unit is switched
4.1.2 Sensor cleaning on and the LED lights are shown then a wrong contrast setting of
The sensor should only be removed and cleaned while the unit is non operational the LCD display might be the case. The variable resistor to
and the sensor has cooled down completely. Attempts to clean the sensor during adjust the LCD display contrast is located on the right hand
operation or when the sensor is still hot can result in thermal stresses and corner next to the RS 232 connector in the BurnerMax
destruction of the sensor. If the sensor is dirtied by soot or carbon deposits, it is termination box.
advised to leave the sensor in air and switch on for some 24 to 48 hours. This will give the
sensor the opportunity to burn off the excessive carbon and return to normal operation.
Otherwise the sensor can be cleaned with a dry cloth when it is cold and dust can be wiped off
the sensor.

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4.3.5 Sensor heating
The power supply of the BurnerMax is fail safe and even on a short circuit sensor heating
5 Technical data
the unit will not fail, however, the heating voltage will drop to 0V. 5.1 Measuring ranges and accuracies

Type of measurement Meas. range Reading accuracy Display resolution

1
Temperature -10 to +400 °C -10to +99,9°C: ±2°C 0.1°C
> 100°C: ±2% of reading
2
Efficiency 0…99.9% - 0.1%
4
Oxygen (O2) 0 to 21 Vol.% ±0.1 (0.4) vol.% absolute 0.1%
3
Carbon dioxide (CO2) 0 to CO2max. - 0.1Vol.%

1
Sensor: Type K thermocouple (NiCr-Ni)
2
Calculated flue gas loss
3
calculated
4
0.1 % accuracy will only be reached if span calibration is performed.

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5.2 Additional instrument data 6 Accessories / spare parts

Power supply 90-110V or 220-250V at 50-60 Hz set at factory Description Part No

Operating temperature 0º - 50º

Oxygen Sensor with 1.2 m connection cable and plugs S361.002
Storage/transport -10º – 80º Exchange Oxygen Sensor recalibrated S361.018
temperature Oxygen Sensor calibration in factory S361.019
Weight app. 7kg Oxygen sensor weld-in socket S361.004
20 meter oxygen sensor cable S361.20.003
Unit housing S361.011 **
5.3 Calculation fundamentals Unit display / keyboard facia S361.012 **
These equations are used to calculate the following values. Unit printed circuit board (without transformer) S361.013 **
Transformer S361.014 **
CO2max •(21% - O2) CO2max: Maximum Carbon dioxide value specific
Carbon dioxide: CO2= -------------------------- to fuel K – type Thermocouple 300 mm insertion 361.007
21% 21 %: Oxygen level in air Thermocouple weld-in socket 361.008
O2: Measured oxygen level in %
20 m Thermocouple compensating cable 361.009
RS 232 / 485 converter for PC 361.021
RS 232 converter ( 9 / 25 pin) connection cable 361.022
Efficiency referred to Ho: A/B/C Fuel-specific factors RS 232 ( 9 / 9 pin) communication cable 361.023
21%: Oxygen level of air
A O2: Measured oxygen level in % Software CD 361.E.025
EFF GROSS = 100 –((------------+B)•(FT-AT)+C) FT: Flue gas temperature Instruction manual 361.E.026
21%-O2 AT: Ambient temperature

Efficiency referred to Hu:

EFF NET is calculated using the same formula as for EFF GROS. However, the fuel-specific
factors are different.

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7 Warranty

BurnerMax gives a 6 month warranty on this product from the date of purchase. The oxygen
sensor is considered a wear part and therefore excluded. All material and manufacturing errors
are covered by the warranty.

Any faults occurring during the warranty time will be repaired by BurnerMax, BurnerMax’s
authorised sales companies or authorised dealers in accordance with the following conditions
and without charge for working and material costs. It is left to BurnerMax’s discretion as to
whether defect parts are to be replaced by new spare parts or if the complete product is to be
replaced by a new product.

The following are excluded from the manufacturer’s warranty:

Damage caused by:

• inexpert handling or non-observance of the Instruction manual and/or safety

information,
• lack of care, accidents or normal use,
• outside influences (e.g. damage during transport, damage caused by vibration,
excess heat, water, moisture or acids),
• use of unsuitable accessories.

This warranty is void if:

• the type or serial number of the product is changed, deleted, removed or made
illegible
• any of the screw wax covers protecting the main compartment screws or the internal
calibration variable resistors are damaged, indicating unauthorised opening of the
equipment.
• repairs or modifications where undertaken by third parties or unauthorised persons.

This warranty does not cover the following:

• Regular maintenance and repair or the replacement of parts as a result of normal

wear and tear,
• Costs of packaging and transport,
• Transport risks connected directly or indirectly to this warranty,
• Costs for necessary repairs, adjustments or similar carried out outside the warranty.
• Consequential damages whatsoever.

If you have a warranty claim, please contact your local distributor or the sales company responsible for your
company. Please send a brief description of the fault and your receipt showing date of delivery and
purchase with the product. Also include your details should we need to contact you. Warranty services
rendered do not extend the warranty time. Other claims directed at BurnerMax, such as cancellation,
mitigation or compensation, regardless of type, are not admitted. If your flue gas analyser is not functioning
to your satisfaction, please contact the company who sold the equipment or contact us directly on the
address shown on the back cover of this manual.

8 Appendix
8.1 Keypad Menue

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 8.2 Terminal Drawing

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8.3 Control wiring: 3 Point / Add on Controller
BurnerMax
Otto Hahn Strasse 6
D 71364 Winnenden
GERMANY

Tel +49 (0) 7195 139 931

Fax +49 (0) 7195 139 939

www.burnermax.com
[email protected]

11.07.2005 1:51 © BurnerMax GmbH

D:\Arbeit\BMax\dokumentation\Manual\BMAX_Manual_eng_411.DOC %03'

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