CONTROL UNIT FOR GAS BURNERS

For Atmospheric Burners and Power Burners with Blowers

( Intermittent Operation )
03P1-03P2

Application
03P1 is designed for combustion programming and flame monitoring of single or dual staged gas/oil burners full
automatically, and atmospheric burners and burners with blowers which are shut down manually or automatically
at least once every 24 hours (03P2)
The most distinctive feature that makes 03P Series stand apart from its competitives is , its elegant design and
the gathered signalization system on the front side. 03P1-03P2 burner control units can be mounted on the
control panels. With the measurements of 48 x 96 mm. They comply with DIN 43700 Standards.
It can detect the flame by ionisation electrode or UV detector.
V1 Output ( constant ) can be used as pilot flame or 1. stage valve, V2 output can be used as the main valve in
03P1-03P2.
It has been manufactured with semi-conductives , timing and logic circuits are controlled by microprocessors.

The Structure of Control Unit 03P1 and 03P2

Within the shock and heat resistant ABS plastic case , there are:
A PCB Card with the following components:
• Flame detector logic circuit and amplifier,
• Flame detector relay,
• Programme and main logic circuit,
• Power Circuit,
• Certified parts for alarm relay and burner impulsion.
• Related outputs and connections which are used to start the burner.
Case consists of the following:
• IP 54 panel (Leksan),
• Bargraph monitor entegrated to flame intensity ,
• Reset button,
• Easy mounting connector at the backside of the case,
• There are 3 alarm lights which are:FAULT ,FLAME , MV.VALVE ( Main fuel valve ).

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03P1-03P2 INTERNAL DIAGRAM

AL : External Alarm lamp K4 : Alarm Relay

BR : Burner L : 220 VAC. supply
EK : External Reset Button LS : Internal Reset Button
F1 : UV flame detector M : Air Blower Motor ( In 03P2 Models )
F2 : Detector electrode MV : Main Flame Signal Lamp
Fault : Fault signal lamp N : Neutral
Flame : Flame signal lamp P : Air Pressure Switch (In 03P2 Models)
K1 : Ignition Relay V1 : 1. Solenoid valve
K2 : 1. Solenoid valve relay V2 : 2. Solenoid valve
K3 : 2. Solenoid valve relay Z : Ignition Transformer

Features :
• Lockdown if flame fault has been detected during pre-purge or standby sequence.
• Stability of time
• Option for resetting the alarm via remote button.
• Output for 2 solenoid valves.
• Output for 1 ignition transformer
• Output for external alarm lamp
• 3 different coloured state indicating lamps ( Fault – Main Flame – Flame Signal )
• 48 x 96 mm dimensions for mounting on the control panel
• 0 – 150 uA scaled bargraph display entegrated to the flame signal
• Can be used with either ionisation electrode or UV detector (ER-3B)
• Dynamic air test in 03P2 Models

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Attention
The Device should not be opened or modified under any
circumstances!
03P Series control units should be installed and operated by authorized staff only.
The power supply should be cut prior to removing the device from its socket.
Connectors should be checked after the wiring is complete.
In case a problem occurs with the device, please contact our technical department before
interfering.

Application Notes
• Detector connection cable should not be longer than 20m.
• Detector cable should be wired away from high voltage ( ignition transformer) and control cables.
• Cables with high conductivity and resistance should be prefered for the detector wiring.
• The resistance between the detector’s rod and the isolation ceramic should not be less than 50 MΩ.
• The isolation ceramic of the rod should be kept clean and without any cracks. Dirt or steam can fill these
cracks and may cause reduction in the resistance value of isolation and distorts flame signal value.
• Burner adjustments should be made properly since excess air would sweep the electrons on the electrode
and insufficent air would prevent the electrones to form up in the combustion process.
• In the cases that the flame does not contact the flame tube sufficently, ionisation electrode cannot be
used.( In these cases the conductivity between the flame and the flame tube is insufficent) In the
burners with refractory blocks, grounding electrode should be used in addition to the detector
electrode.The surface area of the electrode which will be used for grounding of the flame should be
bigger than the ionisation electrode.

Operation Principle of 03P1 – 03P2

When terminal 1 of 03P1 control unit is energized with 220V phase, and if control unit is not in fault
stage when neutral is connected to terminal 2 , then terminal 3 will have phase output.Terminals 3 and 4 must
be short circuited or a pressure switch should be connected to them.Control unit starts the primary test
sequence* when the phase output of terminal 3 returns to the terminal 4 serially over auxillary control devices.In
03P2 models, alongside primary test sequence, there is also a pre-purge sequence** (t1). In 03P2 models, a
pressure switch should be connected to terminal 3 and 4. Since 03P2 executes dynamic air test, it can’t be
operated by short circuiting.If detector fault signal reaches terminal 10 and 11 for any reason during primary test
sequence of both models, after a period of time that is equivalent to the t2 time, control unit switches to “fault
state”, and all outputs are closed except AL output at terminal no.9.If air pressure switch is not connected to
03P2 models, or pressure switch’s contact alters position even though no air exists at that moment ,after a
period of time that is equivalent to the t2 time, a system lockdown occurs.
If tw and t1 sequences are completed without any errors, terminal 5 (Z: ignition transformer) and terminal 6
are both energized at the same time and gives way to first fuel valve (V1).Thus safety sequence starts.If “Flame
ON” signal , (which comes from flame detector to terminal no. 10 and 11), can be formed within the limits of
duration of t2 and terms of standard currents, ignition command ends and V1 is stabilized. (In burner types
which use ionisation electrodes, it should be considered that there can be a possible jolt of alternate current from
high voltage spark of ignition transformer to the ionisation electrode over the flame, and therefore ignition
sequence ends 1 second before time set for t2.)
After a period of time that is adressed in program descriptions, main fuel valve V2 is activated. If ignition couldn’t
successfuly be established during t2 period, main fuel valve is not activated and control unit, shuts down all the
outgoing signals except AL signal and switches to fault state.After the main fuel valve is activated, in case of a
drop of flame signal to a level below the stated one, control unit shuts down the fuel valves and switches to fault
state.
During the operation of the control unit, in case of removal of bridges at terminals 3 and 4 , or switching to on
state of gas pressure switch contacts (or air pressure switch contacts for 03P2 models) depending on the
preffered connection, all the outputs are shut down including alarm output.

*Primary test sequence tw : is the time that flame detector detects a fault in the flame and sends an error signal
to the logic circuit in case of existance of flame because of any reason even though first valve is not energized by
the control unit.

**Pre-purge time t1 : is the time that passes from the control unit is energized to the ignition transformer is
activated.

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 03P1-P2 Sequential Programme Diagram

A – B : Start Position A1 : Open –Close Switch

B – B” : Flame detection duration AL : External Alarm Led
B”- C : Stabilization duration for both valves BR : Burner
C – D : Burner start with T/C control EK : External Reset Button
D–E : Period of time the flame signal is not FS1 : UV. Detector ( ER-3B / ER – 3F )
detected whilst main valve is active FS2 : Ionisation Electrode
t1-tw : Pre-Purge and Waiting time M : Air Blower ( In 03P2 Models )
t2 : Safety Time P : Air Pressure Switch (In 03P2 Models )
t3 : Ignition Time R1 : Control Fuse
t4 : V1 – V2 opening range Z : Ignition Transformer
TC : Limit Control Device

* : Air Pressure Switch (In 03P2 Models) V1-V2 : Fuel Valves

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 Technical Information:

Supply Voltage : 220 VAC +10-15 %

Frequency : 50 – 60 Hz.
Power Consumption : 5VA Max.
Operating Temperature : 0 – 60 Degrees

Drawing : 2 Detector connection Contact Currents : 4 A 220 V. Cos=1

1st drawing indicates the connection with ionisation 2 A.220 V. Cos=0,5

electrode , 2nd drawing indicates the connection Fuse : 4 Amp.

with UV detector (ER-3B or ER – 3F). External start : 5 mA. Max.

Detector Voltage : 200 VAC. For ER-3B

Minimum Flame Current : 1 uA.
Bargraph Display : 0 – 150
Safety Time : 5 “ or 10” *
Main Valve Closing Time : < 1”
Detector Cable Length : 30 metres Max.
Protection Class : IP 54 (Front Panel )
Detector Cable Isolation : 50 Mohm.

Drawing 4 : Mounting (on control panel) and case conductivity between the flame and the flame tube
dimensions. is not sufficient) ionisation electrode cannot be used.
In case of composite combustion when ionisation
current reaches the maximum level , the air being
Circumstances that ionisation
detection is not advised: insufficent or excess can cause negative effects.
Excess air sweeps the electrons on the electrode
In some industrial combustion processes , in case of surface while insufficent air prevents the ions to
high temperatures in the combustion room ( higher form up sufficently.
than 1000 degrees Celcius) ionisation currents may
cause interference so as a result of these high
temperatures the loss of the flame cannot be
detected instantly. Therefore it is suggested to use
UV detectors in such cases.
In some burners that the flame does not contact the
flame tube sufficiently like in silicon carbide or the
burners that have ceramic flame tubes (where the

Drawing 3 : Ionisation current measuring circuit

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