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Preferred FlexFit 110 Instruction Manual

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Linkageless Control
PREFERRED
FlexFit 110 Linkageless Control
Instruction Manual
PREFERRED
UTILITIES MFG CORPORATION
Copyright © 2018 Preferred Instruments – All Rights Reserved Worldwide
Revision 1.0
31-35 South Street, Danbury, CT 06810 | www.PREFERRED-MFG.com | (203) 743-6741

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Summary of Contents for Preferred FlexFit 110

  • Page 1 Linkageless Control PREFERRED FlexFit 110 Linkageless Control Instruction Manual PREFERRED UTILITIES MFG CORPORATION Copyright © 2018 Preferred Instruments – All Rights Reserved Worldwide Revision 1.0 31-35 South Street, Danbury, CT 06810 | www.PREFERRED-MFG.com | (203) 743-6741...
  • Page 2 The information contained herein is provided in good faith but is subject to change without notice. It is supplied with no warranty whatsoever and does not represent a commitment on the part of Preferred Instruments. Companies, names, and data used as examples herein are fictitious unless otherwise stated.

  • Page 3: Table Of Contents

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 FlexFit 110 Linkageless Control UTILITIES MFG CORPORATION User Guide Contents Combustion Control Installation ..............2-18 Specifications Variable Speed Drive Installation ..............2-20 FlexFit Specifications ..................vi Servo Installation ..................2-21 Safety Cautions and Warnings ................vii Servo Description and Operation ............2-21...
  • Page 4 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Servo Setup Step 5 – Configure the Servos' Span by Seeking Limits Call for Heat (Option) ..............4-72 ................... 3-49 Firing Rate > LFH-DHW-Warm Standby ..........4-75 Servo Setup Troubleshooting ............. 3-49 Firing Rate >...
  • Page 5 FlexFit 110 Timing Diagram ..........1-6 Figure 2 – 21 Detector Measuring Principle ..........2-31 Figure 1 – 4 FlexFit 110 Flex Sequence Timing Diagram ......1-7 Figure 2 – 22 Nernst Equation ..............2-31 Figure 1 – 5 FlexFit Parallel Positioning Example ......... 1-10 Figure 2 –...

  • Page 6: Specifications

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Specifications FlexFit Specifications Mechanical Specifications Flame Safeguard Size ....................7.2" Length; 5.7" Width"; 3.995" Height Combustion Control Size ..................9.880" Height; 5.054 Width; 1.6" Deep Panel Cutout ......................9.375" Height; 4.5" Width; See "Figure 2 – 4 LCD Cutout Dimensions"...

  • Page 7: Safety Cautions And Warnings

    Remote Reset Input 120 VAC, 5 mA Flame Intensity Input 4-20 mA Flame Signal Input 120 VAC, 5 mA Table A FlexFit 110 Flame Safeguard Terminal Ratings Pilot Valve/Igni- Pilot/Downstream Main Fuel Valve Combination # Ignition (TW) tion (T5) Fuel Valve (T6)
  • Page 8 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION This page intentionally left blank viii Specifications – Safety Cautions and Warnings...

  • Page 9: Section 1 - Description

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Section 1 – Description Section Contents Overview ......................1-2 Boot ....................1-8 Features ......................1-2 Standby ..................1-8 Safety Relay ..................1-2 Safe Start Checks .................1-8 Field Selectable Flex Sequence Option ..........1-3 Prestart ..................1-8 Servo Checks ..................1-3...

  • Page 10: Overview

    Commissioning is done using the FlexFit's LCD display. The FlexFit 110 is UL/CSA 60730-1, 2-5 recognized, having both fuel/air ratio control and flame safeguard capabilities. Along with all other requirements, NFPA 85 compliance is met by having total separation of the fuel/air ratio control and flame safeguard hardware.

  • Page 11: Field Selectable Flex Sequence Option

    120 VAC flame-on/flame-off output. The FlexFit provides a power supply and the analog inputs for the flame intensity relay display. Preferred Instruments flame scanners are intended for monitoring all gas, oil, and waste gas fired burners.

  • Page 12: Tandem Oil/Gas Valve Servo

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION E.g. due to fuel valve and air damper non-linearity, a 10-degree air damper change might correlate to a 5-degree fuel valve change. In this example, the fuel servo must run at one-half the speed of the air servo to remain "on the curve" during a load change.

  • Page 13: Integrated Draft Control

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION or parameter "P3.5.3 Low Fire Hold, Override Seconds" on page 4-75 times out. This cycle occurs only once per boiler start-up. The cold start warm-up cycle option overrides the burner light-off low fire hold.
  • Page 14 Low Fire Hz (with FB) Figure 1 – 3 FlexFit 110 Timing Diagram TIMING DIAGRAM NOTES: If using call for heat, safe start checks will begin once both the start limits (13) input and the call for heat are made.

  • Page 15: Figure

    (with FB) Figure 1 – 4 FlexFit 110 Flex Sequence Timing Diagram FLEX SEQUENCE TIMING DIAGRAM NOTES: If using call for heat, safe start checks will begin once both the start limits (13) input and the call for heat are made.

  • Page 16: Description Of Bms Sates

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Description of BMS Sates Note The descriptions of each Boot state to follow assumes When power is initially applied to the FlexFit, it will perform initial self-checks on itself and boot into either the standby state or default parameter values the lockout state, depending on its state prior to losing power.

  • Page 17: Gas Valve Leak Test Option (Flex Sequence Option Only)

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Gas Valve Leak Test Option (Flex Sequence Option Only) If enabled, when possible, the leak test is performed after the completion of post purge. If the recycling or non-recycling trips open during the leak test, the leak test is postponed and done during the next start-up, after prestart and before purge.

  • Page 18: Parallel Positioning

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION • Oxygen Trim – compares the oxygen levels in the flue gas to a value determined during commissioning and will implement control actions to correct the error • Draft Control – maintains a constant furnace or boiler outlet draft pressure (positive or negative) as the boiler firing rate...

  • Page 19: Section 2 - Installation

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Section 2 – Installation Section Contents Electrical Noise Suppression ............... 2-12 Flame Scanner Specifications ............2-28 General Wiring Requirements ............. 2-12 Flame Scanner Installation ..............2-28 Ignition Transformer Wiring / Mounting ..........2-12 Flame Scanner Wiring .................2-29...

  • Page 20: Electrical Noise Suppression

    Flame Scanner Wiring If a Preferred Instruments flame scanner with the included cable is used, the connecting field wiring must be installed exactly as shown. The wire shield is connected to earth ground at the scanner via the prefabricated cable and must be insulated at all other locations to prevent accidental grounding.

  • Page 21: Installation Warnings And Notes

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Installation Warnings and Notes WARNING The FlexFit is a Primary Safety Controller. A qualified person must edit the FlexFit param- eters to suit the design of the burner being controlled. Qualifications include knowledge of the burner design and operation;...

  • Page 22: Burner Management System (Flame Safeguard) Installation

    17. A remote (panel mounted, etc.) reset switch may be wired to terminal 28 to reset the controller after a lockout. 18. If using a Preferred Instruments flame scanner, see section "Flame Scanner/Relay" on page 2-27, for proper flame scanner installation.
  • Page 23 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION FF-110 BMS Internal Diagram 120 VAC Flame Relay +24V Output External Flame (Flame Safeguard) Intensity Electronics 4-20mA Input Future (do not connect) Start = Tab connection to Limits existing wiring base...

  • Page 24: Figure 2 - 2 Ff-110 Bms Standard Wiring Diagram (Typical) (Default)

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION FF-110 Flame Safeguard (BMS) Standard/Default Wiring (Typical) Existing Wiring Base † Fuel Select - 2 For E110 retrofits, move Fuel 1 Interlocks Running (Lockout) this wire from D to M.
  • Page 25 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION FF-110 Flame Safeguard (BMS) Example: Fuel 1 = Gas Flex Sequence Wiring (Typical) Existing Fuel 2 = Oil Wiring Base † Fuel Select - 2 For E110 retrofits, move...

  • Page 26: Combustion Control Installation

    A 135-ohm controller and a boiler outlet sensor may not both be wired to the FlexFit at the same time. See section "Servo Installation" on page 2-21, for servo installation instructions. If using the Preferred Instruments oxygen sensor, see section "ZP Oxygen Sensor Installation" on page 2-32, for ZP Oxygen Sensor Installation.
  • Page 27 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Servo Servo Servo 6-wire Cable FlexFit Combustion Controller Address 0 Address 1 Address 2 PUMC # BMU-CABLE FF-CC Wiring (Typical) 24V+ 24V- Firing Rate 135-ohm Firing Rate Motor Comm+...

  • Page 28: Variable Speed Drive Installation

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Variable Speed Drive Installation Be sure you have read the notes in section "Electrical Noise Suppression" on page 2-12 and section "Installation Warnings and Notes" on page 2-13. Connect the blower (fan) output on the FF-BMS (terminal M) to the VSD as shown.

  • Page 29: Servo Installation

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION FD Fan Motor Variable Speed Drive Customer supplied circuit protection, input (with Bypass) Wiring (Typical) 460V–3Φ–60Hz Earth Ground power, and motor wiring must be selected in accordance with N.E.C., any applicable FD Fan VSD local codes, and the drive current rating.

  • Page 30: Servo Control Board

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION The proprietary digital communication protocol allows the servos to be daisy chained to the FlexFit chassis in any order. This allows the installing contractor to wire the servos in the best way to allow the shortest and cleanest conduit runs. The commissioning engineer assigns each servo an address and a function during the setup procedure.

  • Page 31: Travel Limit Switches

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION A 7-segment (single character) LED display continuously scrolls a message indicating the servo position (Pxx.x), the servo function (Sxx), the servo address (Axx), and any error messages for that servo (Ex). Below is the key for interpreting these messages.

  • Page 32: Servo Mechanical Installation

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Servo Mechanical Installation Mechanically connect the servo to the valve or damper such that the shaft will not slip, and the servo does not move under load. The servo stroke must be between 15 and 180 degrees and cannot stroke inside the forbidden zone. If necessary, rotate the servo mounting connection 90 or 180 degrees to avoid the forbidden zone.
  • Page 33 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Separate the bare drain wire. Mark the pink/gray wire pair "IN" if it's coming for the FlexFit or a previous servo. Mark the pink/gray wire pair "OUT" if it's going to the next servo in the daisy chain.

  • Page 34: Qd1 Quick Disconnect Cables

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION QD1 Quick Disconnect Cables This section applies to QD1 quick disconnect cables. If not using the QD1 cables, refer to "Servo Wiring" on page 2-24. QD1 cables are ITC-ER (Exposed Run) and do not need to be run in conduit if the following are true: •...

  • Page 35: Flame Scanner/Relay

    The FlexFit can be configured for multiple styles of scanners, including UV, UVSC, and IR. The FlexFit provides a power supply and the analog inputs for the flame intensity relay display. Preferred Instruments flame scanners are intended for monitoring all gas, oil, and waste gas fired burners.

  • Page 36: Flame Relay

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Flame Relay When a flame of sufficient intensity is detected (>25%), the scanner will activate the output relay and the flame relay LED will illuminate. The flame relay LED is a single-color LED. If the flame signal falls below the minimum threshold for > 3 seconds or an internal circuit or sensing element test fails, the output relay will deactivate, the 4-20mA output will go to 0mA, and the flame relay LED will shut off.

  • Page 37: Flame Scanner Wiring

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION • Choose a sighting location providing an unobstructed view of the flame under all firing conditions. Under no conditions should the scanner see igniter spark. • A scanner monitoring a pilot flame should be positioned so that no flame will be detected if the pilot flame is too small to reliably and safely light the main flame.

  • Page 38: Zp Oxygen Sensor System Overview

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION ZP Oxygen Sensor System Overview FlexFit-CC OXYGEN SENSOR Detector ALARM BACK NEXT RESET SILENCE Home ENTER Menu Fuel Air VSD Probe Aux 1 Aux 2 Prefrerred Utiliteis Manufacturing Corp• Danbury, CT 7-wire Cable Figure 2 –...
  • Page 39 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION cell. Calibration gas can be injected into space behind the ceramic and quartz filters to allow on-line calibration without removal from the stack. Measuring Reference Thermal Electrode Electrode Insulator...

  • Page 40: Probe

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Probe The probe is a stainless-steel assembly that mounts on a 3" 125# flange (flat face) located on the flue gas duct or stack. The probe protrudes into the flue gas stream and directs boiler flue gases from the middle third of the flue gas stream to the detector. The probe design provides for the removal of the detector for service or replacement without the need for probe removal.

  • Page 41: Oxygen Probe Mounting Location

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Oxygen Probe Mounting Location Probe Length 3" – 125# flange (20, 30, 45, 65, or 90") (flat face) 2 1/4" dia. 4 3/4" Terminal Box 1/2" FNPT Calibration gas No Insulation (1/4"...

  • Page 42: Rotating The Probe To Lower Detector Flange Temperature

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION If the duct is insulated, the nipple and flange are not insulated, and the proper nipple length is used (see chart in Installation Note sketch), the detector flange temperature will not exceed 260 °F. If the detector temperature exceeds 260 °F, use one or all the fol-...

  • Page 43: Oxygen Sensor Wiring

    Run all wires in one conduit. 500' maximum wiring length. Avoid splices. • Use only Preferred Instruments P/N 190130 cable between the ZP and FlexFit. The twisted, shielded cell and T/C wire with twisted AC wiring prevents electrical noise. •...

  • Page 44: Operation

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Operation Internally, the cell and heater operate at 800 °C (1470 °F). The system should remain powered up whenever possible. The heater uses less than 70 Watts (typically 40-50 W). Do not subject the detector to excessive heat-up and cool-down cycles. If the burner cycles more than once per day, the ZP oxygen sensor should not be routinely powered-up and down every time the burner cycles on and off.

  • Page 45: Zp Oxygen Sensor Calibration

    Low and high gas oxygen concentrations are entered into parameters "P2.3.13 O2 Low Cal Gas %" and "P2.3.14 tion gas for combustion O2 High Cal Gas %" on page 4-68. Calibration test gas that is tested and certified can be obtained from Preferred Instruments. The applications is 0.4-2%, calibration can be aborted at any step by selecting the EXIT command.
  • Page 46 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION This page intentionally left blank 2-38 Installation...

  • Page 47: Section 3 - Operation & Commissioning

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Section 3 – Operation & Commissioning Section Contents Initial Steps ....................3-40 Servo Setup Step 4 – Configure the Servos' Zero and Direction of Travel Operating the FlexFit ................... 3-40 ...................

  • Page 48: Initial Steps

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Initial Steps WARNING The commissioning engineer must read these instructions carefully and be certain they fully understand this product’s requirements and the application as it applies to the specific fired equipment being retrofitted or installed. Failure to follow these instructions could result in damage to the product and/or a haz- ardous condition.

  • Page 49: Lcd Screen Indicators

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION UP and DOWN buttons – In select mode, these buttons move the cursor around the LCD screen to editable items. Select mode is identified Select Mode vs. by a blinking solid cursor (  ).

  • Page 50: Menu Tree

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Menu Tree Password Flame Safety P1.1.1 Enter Password Fuel 1 Enable P1.1.2 Change Password Fuel 2 Enable P1.1.3 Log Out Purge Sec MAF/Run Interlocks Safe Start Test P1.1.4 PAF Switch Installed P1.1.5...

  • Page 51: Figure

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Setup P2.3.1 Oxygen Analyzer Option O2 Analyzer P2.3.2 Setup O2 Trim Option P2.3.3 Low O2 Alarm SP O2 Calibration P2.3.4 Low O2 Lockout Option P2.3.5 Low O2 Lockout SP Setup P2.3.6...

  • Page 52: Figure

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION 24 Hour Recycle P3.3.1 Scanner Check 24hr Recycle Option P3.3.2 Scanner Check Time of Day, xx:00 Local/Remote Mode P3.4.1 CFH Local Mode P3.4.2 CFH Start Deviation P3.4.3 CFH Stop Deviation P3.4.4...

  • Page 53: Entering And Navigating The Main Menu

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Flame Safety Options P1.2.1 M78 PFEP, Pilot Proving Seconds P1.2.2 Post Purge Sec P1.2.3 FD Fan Start Delay P1.2.4 Alarm SP, Flue Temp P1.2.5 Lockout SP, Flue Temp P1.2.6 Assured Low Fire Cutoff P1.2.7...

  • Page 54: Password Levels

    To obtain a temporary password for the FlexFit, navigate to Main Menu > Utilities > Date/Time and S/N, and record the date, Note time, and serial number exactly as it appears. Do not update or change anything yet! Once you have this information, contact Preferred Do not change the date or...

  • Page 55: Configuring Parameters

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Configuring Parameters The robustness and flexibility afforded by the FlexFit is accomplished via a parameter-based setup procedure. The parameters required to commission a FlexFit can be found below and in "Section 4 – Parameters". Not all parameters will necessarily be used for each application, and it is up to the commissioning engineer to determine which parameters are required and their correct setting.

  • Page 56: Servo Setup Step 1 - Configure The Servos' Travel Limit Switches

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Servo Setup Step 1 – Configure the Servos' Travel Limit Switches WARNING Misalignment of the servo shaft relative to the valve (or damper) shaft can result in equipment damage, system malfunction, injury, or death. To avoid damaging the servo, valve, or damper, jog the servo buttons slowly and frequently check for binding.

  • Page 57: Servo Setup Step 5 - Configure The Servos' Span By Seeking Limits

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Servo Setup Step 4 – Configure the Servos' Zero and Direction of Travel WARNING If the burner has been commissioned previously, re-zeroing a servo changes all combustion curves that use this servo. The technician must re-vali- date (and adjust if necessary) the affected curves in commissioning mode before the burner can be operated in run mode.

  • Page 58: Commission Mode

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION • Ensure the Servo position in degrees (Pxx.x) display is within +/- 5 degrees of the actual position. If the displayed position is negative (i.e. "P-45.0"): The wrong "Closed" direction button (CW or CCW) was pressed during the ZERO procedure.

  • Page 59: Flame Scanner Tests

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Note that if a position (purge or ignition) needs to be verified, the FlexFit will continue to hold for "P1.2.7 HOLD Alarm Delay" seconds. At the end of this time, the common alarm horn will sound. If the purge or ignition position has not been verified by the allowed "P1.2.8 HOLD Lockout Delay"...

  • Page 60: Main Flame Test

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION If a flame is not detected, the FlexFit will lockout. Readjust the ignition curve points, pilot flame, igniter, or flame detector, reset the FlexFit, and restart the burner. After a satisfactory pilot flame is established, turn the burner switch to OFF.

  • Page 61: Entering Additional Curve Points

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION until the emissions target for the selected fuel is obtained. Select S to store the curve point. The message displayed will say "Data Saved". The first curve point is now established. If the data is not stored before exiting Set Curve Points, the output will not be saved, and all settings will revert back to the previous values.

  • Page 62: Verifying Curves

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Set Avoid – Common with burners that are set up for low NO operation or are fitted with VSDs, there may be a certain firing rate that produces an audible harmonic or undesirable vibration. The technician can program the FlexFit to skip over this point. The fuel servo degrees from any place on the curve is entered into this option.

  • Page 63: Tuning

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Tuning The PID provides a Proportional, Integral, and Derivative control algorithm. The PID equation used in the FlexFit is called the "Parallel" form by the Instrument Society of America (ISA).

  • Page 64: Documentation

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION decreasing the time between repeats the loop will have the ability to correct the error and return to the setpoint in an acceptable amount of time. • With the loop in automatic, observe how long it takes the process to return to setpoint.

  • Page 65: Section 4 - Parameters

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Section 4 – Parameters Section Contents Introduction ....................4-60 P2.4.3 SP Lag Time O2 Trim ............4-69 Flame Safety ....................4-60 P2.4.4 +/- Max Fire Trim, O2 ............4-69 Flame Safety > Basic .................4-60 P2.4.5...
  • Page 66 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P4.1.5 Low Alarm SP, Draft ............4-78 Draft Control > Options ................4-81 P4.1.6 Alarm Delay Sec, Draft ............4-79 P4.3.1 Adjustable Start Draft Option ..........4-81 P4.1.7 Draft Setpoint ..............4-79 P4.3.2 Adj Start Draft SP ..............4-81 Draft Control >...
  • Page 67 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Alphabetical List of Parameters +/- Avoid Gap, Firing Rate ................4-77 HOLD Alarm Delay ..................4-62 +/- Max Fire Trim, O2 .................. 4-69 HOLD Lockout Delay .................. 4-62 4-20 Off-Curve Lockout Deadband %, Aux 2 ..........4-67 Local Firing Rate Control Source ..............4-70...

  • Page 68: Introduction

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Introduction In the list below, each parameter is identified as follows: • Parameter number – This is a unique identifier for each parameter (e.g. P1.1.4). The preceding letter "P" designates this as a parameter number.

  • Page 69: Flame Safety > Advanced

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P1.1.2 F nable Menu > Setup > Flame Safety Password Level: Engineer Restricted? This disables/enables fuel 2 and selects what type of fuel is being used. When fuel 2 is selected, the FlexFit screen will display the label selected here.

  • Page 70: Flame Safety > Flex Sequences

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P1.2.4 a SP, F larM Menu > Advanced Settings > Flame Safety Options Password Level: Technician Restricted? This determines at what temperature a high flue gas temperature alarm will sound. If the flue gas temperature is greater than the "Alarm SP, Flue Temp"...
  • Page 71 This determines if the flex sequence option is used. This feature gives the engineer more options related to burner ignition. Options: Disabled: The flex sequence option is not used. The FlexFit 110 options are instead used. Gas Leak Test options are not available.

  • Page 72: Gas Valve Leak Test Option

    VPPS is made throughout the test period. If a leak is detected in either valve, the FlexFit will lockout. Otherwise, upon completion, the FlexFit will place the burner in the appropriate next state (standby or purge). See "Figure 1 – 4 FlexFit 110 Flex Sequence Timing Diagram"...

  • Page 73: Table 4 - 2 Gas Leak Test Timing Calculation Example Data

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION ×   +   TOTAL DOWN 1728   Pipe Train Volume ft Upstream Valve Outlet Cavity Volume ft TOTAL Downstream Valve Inlet Cavity Volume ft Total Pipe Area in...

  • Page 74: Fuel-Air

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P1.3.11 F PtIon Menu > Advanced Settings > Flex Sequences > Flex Gas Leak Test Password Level: Engineer Restricted? This is enabled when fuel 2 valve leak testing is required.

  • Page 75: Fuel-Air > O2 Analyzer

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P2.2.3 4-20 r /100%, a Menu > Tuning > Aux 2 4-20 Password Level: Technician Restricted? This determines the time (seconds) the 4-20 mA device requires to make a 100% change in response to a FlexFit 4-20 mA output change.

  • Page 76: Fuel-Air > O2 Trim

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P2.3.6 o2 c urVe eVIatIon ockout Menu > Setup > O2 Analyzer > Setup Password Level: Engineer Restricted? This sets the maximum difference between the Flue Gas Oxygen and the O Curve.

  • Page 77: Fuel-Air > Fgr

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P2.4.2 M , o2 t InuteS ePeat Menu > Tuning > O2 Trim Parameters Password Level: Technician Restricted? This determines the PID Integral ramp rate, expressed in Minutes-per-Repeat. A smaller value makes the integral ramp in less time, faster.

  • Page 78: Firing Rate > Basic

    Menu > Setup > Firing Rate Password Level: Technician Restricted? If using a Preferred Utili- This is set to match the sensor or transmitter used as the control source for local firing rate control. ties supplied boiler outlet Options: 135 Ohm Demand sensor, select one of the following for "Local Firing...

  • Page 79: Firing Rate > Tuning

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION If "P3.6.1 Cold Start Warmup Option" is enabled, then "Local Firing Rate Control Source" cannot be 135 Ohm Demand or 4-20 P7810 Demand. P3.1.2 t herMIStor djuStMent Menu > Setup > Firing Rate...

  • Page 80: Firing Rate > 24 Hour Recycle

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P3.2.4 r Menu > Tuning > Firing Rate Password Level: Technician Restricted? This determines the upper limit setpoint for all local and remote modes of operation. This parameter cannot be overridden by the display, Modbus, DHW demands, etc.
  • Page 81 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Finally, parameter "P3.5.1 T27 Options" can cause a CFH based of a 120 V contact closure to terminal 27. See "Figure 4 – 5 Call for Heat Logic" for a flowchart of the call for heat logic, and see below for a description of the parameters mentioned above.
  • Page 82 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Setting a negative number here sets the start point above the setpoint. (I.e., set this parameter to a negative number, if you want the boiler cycle to start before the pressure or temperature drops below the setpoint).

  • Page 83: Firing Rate > Lfh-Dhw-Warm Standby

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION rate is overridden and proportionally cutback. The cutback proportional band will equal (0.5 * P3.2.1). See "P3.2.1 Proportional Band, Rate PID" on page 4-71. Options: 0.5 to 2000.0 [Default 2000.0] Note 2000.0 disables the remote rate cutback logic.

  • Page 84: Firing Rate > Advanced

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION • Override timer is reset to 0 minutes The cold start cycle ends when boiler outlet > "P3.6.3 Deactivate SP, Cold Start" or PID firing rate < cold start firing rate or the operator places the firing rate to manual.

  • Page 85: Draft Control

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P3.7.2 h , 0-100% IMIter Note Menu > Advanced Settings > Firing Rate Settings Password Level: Operator Restricted? This does not affect Determines the high fire setpoint to which the FlexFit will limit the firing rate.

  • Page 86: Draft Control > Basic

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION • Adjustable Start Draft Option – On installations with excessively negative draft levels (very tall stack, oversized ID fan, badly leaking stack damper) that are preventing the burner from lighting off, parameter "P4.3.1 Adjustable Start Draft Option"...

  • Page 87: Draft Control > Tuning

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P4.1.6 a larM elay raFt Menu > Setup > Draft Password Level: Operator Restricted? This determines the draft alarm delay (seconds). If the measured draft is greater than "P4.1.5 Low Alarm SP, Draft" for longer than "Alarm Delay Sec, Draft"...
  • Page 88 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P4.2.7 d raFt orward PtIon Menu > Tuning > Draft > Tuning Password Level: Technician Restricted? This determines if a feed forward signal is used with the draft control. Feed forward causes the draft damper to start to move as soon as the firing rate changes for rapid response to burner load changes.

  • Page 89: Draft Control > Options

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P4.2.14 d raFt orward urVe alueS Menu > Tuning > Draft > FeedForward Curves Password Level: Technician Restricted? The Y values for fuel 2. See "P4.2.11 Draft FeedForward Fuel 1 Curve X Values".

  • Page 90: Modbus

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION P5.1.3 b utton See "Button Set 3" description. Modbus P6.1.1 M odbuS Menu > Advanced Settings > Modbus Setup Password Level: Technician Restricted? Selects either Modbus RTU or Modbus ASCII protocol.

  • Page 91: Section 5 - Troubleshooting

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Section 5 – Troubleshooting Section Contents General Troubleshooting Tips ..............5-84 Reading is Higher than Expected ............5-89 Lockout Data ....................5-86 Cell Can't Reach Operating Temperature .......... 5-89 I/O Data Display ..................

  • Page 92: General Troubleshooting Tips

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION General Troubleshooting Tips As Murphy's Law would predict, burner control system issues usually happen at the worst possible time. Therefore, it's wise to be prepared with a troubleshooting plan. Often, we are quick to jump directly into fixing a problem when, in fact, it would benefit us to be methodical with our process.
  • Page 93 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION • Always ask: "Would a failure of this type cause these symptoms?" • Ensure you have identified the faulty component and not just another symptom of a different fault.

  • Page 94: Lockout Data

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Lockout Data If the condition results in a lockout, a snapshot of the value of virtually every input, output, servo and sensor at the time of the lockout is stored in the FlexFit memory. Time/date stamped lockout data for each of the last 10 lockouts can be viewed via the LCD by going to Main Menu >...

  • Page 95: Not At Position" Lockouts

    120 VAC line voltage conditioners from Control Concepts, Sola, or Preferred p/n 70438 (or 70439) can help reduce this noise. More exotic line conditioning power transformers and some UPS systems are also possible solutions.

  • Page 96: Zp Oxygen Analyzer Troubleshooting

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Re-seek limits on servo; valve may need to be loosened or re-greased (if re-greasing the valve, re-seek servo limits afterward, as there will be a change in the torque exerted by the servo). See section "Servo Setup" on page 3-47 for more information.

  • Page 97: Slow Response Time

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION % Oxygen Cell mV 16.0 5.569 17.0 4.233 18.0 2.973 19.0 1.782 20.0 0.651 20.6 21.0 -0.4238 22.0 -1.449 23.0 -2.428 24.0 -3.366 25.0 -4.266 Table 5 – 3 Cell mV Vs. % Oxygen Slow Response Time •...

  • Page 98: Low Calibration Gas Flow Rate

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Low Calibration Gas Flow Rate Disconnect the tubing at the calibration port on the detector. Verify that the gas is flowing up to the detector. If the detector flange is overheated, the elastomer calibration gas check valve may become stuck shut. Use a toothpick or paper clip to gently push open the check valve.

  • Page 99: Lcd Messages

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Pressure Gauge Inches of Water Aspirator Bulb Figure 5 – 2 Detector Leak Test LCD Messages The FlexFit LCD messages that are listed on the following pages describe alarm and shutdown conditions. This alphabetical list of messages provides explanations and possible corrective actions that the technician can use as a starting pointing for troubleshooting.
  • Page 100 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION FlexFit Powered Up The FlexFit has been turned on. Leak Test Delayed Until Pre-Purge A post purge SSOV leak test has been delayed until prior to the next purge.

  • Page 101: Curve Commissioning Error Messages

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Pilot Trial The pilot flame trial is in progress Post Purge In Progress The boiler is in the post purge state Purge Complete The purge has been completed Purging...

  • Page 102: Oxygen Cell Status And Messages

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Error, A Single Fuel Must Be Selected To store a point in commission mode or to activate verify mode, the desired fuel must be selected. Error, Fuel Feedback Must Be Within Curve Min and Max Can't exit commission mode or activate verify mode, unless the fuel valve position is within the range of the fuel curve points.
  • Page 103 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION O2 Analyzer Calibration in Progress Informs the user that an O calibration is in progress. WARNING: Low O2 Lockout and O2 Trim are Bypassed during Calibration. YES=Continue, EXIT=Abort A warning appears to remind the technician O...

  • Page 104: Trip Messages

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION ERROR: O2 Cell T/C Short, Heater Open, or VAC Open, Press EXIT Check O cell thermocouple field wiring. ERROR: O2 Cell T/C or wiring: Open Circuit, Press EXIT Check O cell thermocouple field wiring and detector for an open circuit.
  • Page 105 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Curve Device Setup Or Data Changed, Please Reverify Lockout A change was made to a servo or analog output device that affects curve values. Reverify/adjust curve points. Curve Fuel Values Not In Ascending Order Lockout The fuel servo degrees (X-axis of the curves) must be entered in order from lowest to highest.
  • Page 106 The span between the user entered "Min Fuel" and "Max Fuel" is too small. Nonvolatile Storage Corruption Lockout There is a corruption of the nonvolatile storage (likely due to power surge/brownout). Contact Preferred Instruments. O2 A/D Error Hold then Lockout Both parameters "P2.3.4 Low O2 Lockout Option"...
  • Page 107 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION O2 Cell Not at Temperature Hold then Lockout Both parameters "P2.3.4 Low O2 Lockout Option" and "P2.3.8 Oxygen Malfunction Lockout Option" are enabled and an O analyzer cell temperature error was detected that could cause a false O reading.
  • Page 108 Servo data does not match the CC; a more specific reason is not available. Servos may have been swapped. Zero servo, seek limits, and reverify all curve points. If the problem persists, please contact Preferred Instruments. Servo # Deadband Data Bad Hold then Lockout Data was corrupted (possibly by electrical noise) Set the proper servo deadband.
  • Page 109 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Servo # Pot Reference Voltage Out of Range Hold then Lockout Servo # (0-6) detected a potentiometer voltage error that can cause an incorrect servo position feedback. Can be caused by electrical noise or a malfunction.

  • Page 110: General Alarm, Error & Warning Messages

    Upon this startup, the second set of curves will be fixed. Copy the FlexFit curves to the LCD curves by selecting "Copy FF -> LCD" Problem fixed! If this continued to be an error, please contact Preferred Instruments. Curve Mismatch! LCD has INVALID combustion curves The backup curve data has been corrupted.
  • Page 111 Press the RESET button on the LCD (or cycle power to the FlexFit). If this Internal Error does not occur again, it was probably a nuisance trip. If the same or similar code occurs again, please contact Preferred Instruments. Low Draft Draft pressure lower than "P4.1.5 Low Alarm SP, Draft"...

  • Page 112: Common Problems & Solutions

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Common Problems & Solutions Problem Solution A trip or error message is displayed on the LCD screen. • Find the message from the list of messages above and follow the steps provided.

  • Page 113: Section A - Appendix

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Section A – Appendix Section Contents Abbreviations Used in This Manual ............A-106 Parts List ....................A-109 Terms and Definitions ................A-107 Appendix A-105...

  • Page 114: Abbreviations Used In This Manual

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Abbreviations Used in This Manual Abbreviation Description 2OIL #2 Oil 6OIL #6 Oil ALFCO Assured Low Fire Cutoff BGAS Bio-gas Burner Management System (also called Flame Safeguard) British Thermal Unit...

  • Page 115: Terms And Definitions

    PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Abbreviation Description PFEP Pilot Flame Establishing Period Proportional–Integral–Derivative (See the definition of PID Controller). POCS or POC Proof of Closure Switch PROP Propane Pounds per Square Inch PTFI Pilot Trial for Ignition Px.x.x...
  • Page 116 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Term Definition Feed Forward When a process value lags a change in effect that causes it, that change in effect is directed to a control element prior to the process value changing (e.g. the fuel valve posi- tion could be fed forward to a draft controller to cause a draft damper to pre-position prior to the firing rate causing a draft change).
  • Page 117 UTILITIES MFG CORPORATION Parts List For a list of available Servo Mounting Brackets/Couplings, Gas/Oil Control Valves, Pressure/Differential Pressure Switches, Temperature Switches, Flow Meters, Transmitters, custom cables, etc., contact Preferred Instruments at (203) 743-6741 or visit www.preferred-mfg.com Part Number Lead Time...
  • Page 118 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Part Number Lead Time Description 190680 1 week ZP Probe Mounting Kit, includes: • (1) 3” 125# cast iron threaded flange • (1) 3” pipe, half-coupling, threaded • (1) 3” x 8” long pipe nipple, threaded both ends •...
  • Page 119 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Preferred Instruments FlexFit Parameter Documentation Sheet Facility: Date: Boiler #: Fuel: Boiler Mfg: Burner Mfg: Parameter Value Range Default Parameter # Flame Safety > Basic P1.1.1 Fuel 1 Enable DISABLED P1.1.2...
  • Page 120 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Parameter Value Range Default Parameter # P2.1.4 Min Hz, FD VSD 5.00 to 50.00 5.00 P2.1.5 FD VSD Off-Curve Lockout Deadband, Hz 0.2 to 0.8 Fuel-Air > Aux 2 P2.2.1...
  • Page 121 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Parameter Value Range Default Parameter # P3.1.4 Span, Custom Blr Outlet Xmtr 5.0 to 2000.0 25.0 P3.1.5 Dec Pt, Custom Blr Outlet Xmtr xxxxx P3.1.6 Thermistor Deg C Option Disabled Firing Rate >...
  • Page 122 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Parameter Value Range Default Parameter # P4.1.4 Draft @ 20 mA, Xmtr Cal -25.000 to 25.000 -1.000 P4.1.5 Low Alarm SP, Draft -25.000 to 25.000 25.000 P4.1.6 Alarm Delay Sec, Draft 0 to 60 Draft Control >...
  • Page 123 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Preferred Instruments FlexFit Boiler Operating Data Sheet Facility: Date: Boiler #: Fuel(s): Boiler Mfg: Burner Mfg: Fuel 1 Variable Speed FlexFit Servo & 4-20mA Output Curve Points Servo Closed...
  • Page 124 PREFERRED FlexFit – Linkageless Control – Revision 1.0 UTILITIES MFG CORPORATION Fuel 1 Fixed Speed FlexFit Servo & 4-20mA Output Curve Points Servo Closed Open Address Outputs Limit Limit Purge Ignition /Output Standby Fuel 1 Servo deg. FD Damper deg.

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