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NOVEMBER 2000
E110 FIREYE
FLAME-MONITOR
BURNER MANAGEMENT CONTROL
FOR USE WITH THE
MICROPROCESSOR-BASED
EP AND EPD STYLE
PROGRAMMER MODULES
UL
E110 with ED510 Display Module
LISTED APPROVED
DESCRIPTION
The Fireye E110 FLAME-MONITOR System is a microprocessor based burner management
control system designed to provide the proper burner sequencing, ignition and flame monitoring pro-
tection on automatically ignited oil, gas, and combination fuel burners. In conjunction with limit and
operating controls, it programs the burner/blower motor, ignition and fuel valves to provide for
proper and safe burner operation. The control also provides current operating status and lockout
information in the event of a safety shutdown. The manner in which this information is displayed is
dependent on the type of programmer (EP or EPD) and display module (ED510 or ED500).* Refer
to Flame-Monitor PROGRAMMER SELECTION later in this document for the various combina-
tions of programmer and display modules.
The E110 consists of the EB700 chassis, dust cover, and shortened mounting screw (P/N 48-1836).
The display module (ED510 or ED500), if required, must be ordered separately. Interchangeable
programmer and flame amplifier modules allow for complete versatility in selection of control func-
tion, timing, and flame scanning means. Functions such as pre-purge, recycling interlocks, high fire
proving interlock, and trial for ignition timing of the pilot and main flame are determined by the pro-
grammer module. The E110 Flame-Monitor can be used with ultra-violet, autocheck infrared, photo-
cell, flame rod, or self-check ultraviolet flame scanners by choosing the proper amplifier module.
The eighteen (18) terminal wiring base allows for many functional circuits including motors, valves,
and ignition transformers as well as multiple interlocks such as high purge, low purge, fuel valve and
running interlock circuits. The E110 uses the same wiring base as the Fireye E100 Flame-Monitor
control, D Series and C Series Controls and is directly interchangeable with most models without
rewiring.
Additional functions of the Flame-Monitor system include:
A non-volatile memory which allows the control to remember its history and present position
even when power is interrupted.
A constant flame signal read-out via display module or 0-10 VDC output (EPD programmers
only).
Read-out of main fuel operational hours and complete cycles via display module.
Modbus communications via RS485 multi-drop link.
* The ED500 display was the predecessor of the ED510 display and uses an older design. It does not have the latest features
of the ED510 display module.
CAUTION: While programmers are mechanically interchangeable in that they mate with a
common wiring base, you should select the correct model for your application. Inappropriate
application of a control could result in an unsafe condition hazardous to life and property.
Selection of a control for a particular application should be made by a competent profes-
sional, such as a boiler/burner service technician licensed by a state or other government
agency.
FLAME-MONITOR SPECIFICATIONS
Supply Voltage: 120 VAC (+10%, -15%) 50/60 Hz
Power Consumption: 25 VA
Shipping Weight: (E110 Approx.) 5 lbs. (2.3kg)
Operating Temperature Limits:
With ED500 Display: - 40F Minimum, +125F Maximum
- 40C Minimum, +52 C Maximum
With ED510 Display: 32F minimum, +125F Maximum
0C Minimum, +52 C Maximum
Humidity: 85% R.H. Maximum (Non-condensing)
MAXIMUM MINIMUM
CONTROL 140F 60C - 40F - 40C
Scanner UV1A, UV2, 200F 93C - 40F - 40C
UV8A, 45UV3
45UV5-1007, 45UV5- 200F 93C - 40F - 40C
1009
Photocell 45CM1 165F 74C - 40F - 40C
Flame Rod 1500F 816C - 40F - 40C
(Tip 2460 F)
48PT2 125F 52C - 40F - 40C
LOAD RATINGS
Terminal ratings may be selected from either column A or B: (select the rating from the column for each terminal which best applies to
the connected load on that terminal).
* F.L.A. = full load amps L.R.A. = locked rotor amps
ELECTRICAL RATINGS
VA ratings (not specified as pilot duty) permit the connection of transformers and similar devices
whose inrush current is approximately the same as their running current.
VA Pilot Duty ratings permit the connection of relays, solenoid valves, lamps, etc. whose total oper-
ating load does not exceed the published rating and whose total inrush current does not exceed 10
times the rating.
Running and locked rotor ratings are intended for motors. VA and VA Pilot Duty loads may be
added to a motor load provided the total load does not exceed the published rating.
WARNING: This equipment is a Class B digital apparatus which complies with the Radio
Interference Regulations, CRC c.1374.
CAUTION: Published load ratings assume that no contact be required to handle inrush cur-
rent more often than once in 15 seconds. The use of control switches, solenoid, relays, etc.
which chatter will lead to premature failure. It is important to run through a test operation
(with fuel shut off) following the tripping of a circuit breaker, a blown fuse, or any known
instance of chattering of any external current consuming devices.
APPROVALS
Underwriters Laboratories Inc.: Listed Guide MCCZ File MP1537
Canadian Standards Association: File #LR7989
Acceptable by: Industrial Risk Insurers (I.R.I.)
Factory Mutual Approved
Year 2000 Compliant in accordance with BSI document DISC PD2000-I:1998
WARNING: This equipment generates and can radiate radio frequency energy, and if not
installed and used in accordance with the instruction manual may cause interference to radio
communications. It has been tested and found to comply with the limits for a Class A comput-
ing device pursuant to Subpart J of part 15 of FCC Rules, which are designed to provide rea-
sonable protection against such interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to cause interference in which case
the user, at his own expense, will be required to take whatever measures which may be
required to correct the interference.
SCANNER SELECTION
129-145-1, -2, -3 Remote Display Mounting Kit (for ED510) with 4, 8 or 2 cable respectively E-8002
ED500 Display Module (8 character LED Display) E-8101
ED400 Remote display mounting kit (for ED500) E-8001
ED550 Remote display cables (for ED500) E-8001
E300 Expansion Module E-3001
E350-3, -6 Expansion Module cables in 3 and 6 lengths E-3001
ED150-3, -6, -15, -25 Remote Reset cables in 3, 6, 15 and 25 lengths E-8001
ED600 Multi-port Cable Adapter E-8001
ED610 Multi-port Adapter (for ED510 and RS485 communications) E-8002
E500-3 Communication Interface (up to 6 Flame-Monitor controls) E-5001
E700 Software Program to Monitor E500 Operation. IBM Compatible E-7001
60-2333 Noise Line Filter E-1021
EC485 RS232 to RS485 converter for direct connect EC-4851
ED512-2, -4, -8 Communications interface cables in 2, 4 and 8 lengths E-8002
ED580-2, -4, -8 Remote display cables in 2, 4 and 8 lengths E-8002
E1R1 60-1386-2
E1R2 Surface Mount
E1R3 (shown)
EUV1
EUVS4
ERT1
60-1466-2
Cabinet Mount
FLAME SCANNERS
CAUTION: The UV1, UV2, UV8A and 45UV3 ultra-violet flame scanners and associated
amplifier modules are non-self checking UV systems and should be applied only to burners
that cycle often (e.g.: a minimum of once per 12 hours) in order for the safety checking circuit
to be exercised. If component checking is required during burner operation for constantly
fired burners, utilize the self-checking ultra-violet flame scanners (45UV5) with associated
amplifier module (EUVS4), or the infrared flame scanner (48PT2) with associated Auto
Check amplifier (E1R1, E1R2, E1R3).
FIREYE Pre-purge Proven Proven Intermit- Interrupted Early Spark Pilot Main Running Firing Rate
PART program- High Fire Low Fire tent Igni- Ignition/ Termination Trail-for-Ignition Trail-for-Ignition Interlock Motor
NUMBER ming Purge Start tion/Pilot Pilot (3/P CKT) Circuit
(Seconds) Interlock Interlock Term 5 Term 5
(D/8 Ckt) (M/D Ckt) Term 6 Term 6
2
EPD/EP PROGRAMMERS
EPD160 301 Yes Yes No Yes No 10 10 Non Recycle Yes
EP160 Supervised 10 15
EPD1678
EPD161 30 1 Yes Yes No Yes No 10 10 Non Recycle Yes
EP161 Supervised 10 30
WARNING: Installer must be trained and qualified. Follow the burner manufacturers in-
structions, if supplied. Otherwise, proceed as follows:
INSTALLATION OF CONTROL
Wiring Base
Mount the wiring base on the burner or on a panel. The location should be free from excessive vibra-
tion and within the specifies ambient temperature rating. The base may be mounted in any angular
position.
All wiring should comply with applicable electrical codes, regulations and local ordinances. Use
moisture resistant wire suitable for at least 90 degrees C. Good electrical wiring practice should be
followed to ensure an adequate ground system. Refer to Fireye Service Note 100 separately and
General Grounding Rules, later in this document, for recommended grounding methods
A good ground system should be provided to minimize the effects of AC quality problems. A prop-
erly designed ground system meeting all the safety requirements will ensure that any AC voltage
quality problems, such as spikes, surges and impulses have a low impedance path to ground. A low
impedance path to ground is required to ensure that large currents involved with any surge voltages
will follow the desired path in preferences to alternative paths, where extensive damage may occur to
equipment.
Refer to suggested Wiring Diagram on page 30.
WARNING: Controls require safety limits utilizing isolated mechanical contacts. Electronic
limit switches may cause erratic operation and should be avoided.
CAUTION: Ensure that electric power is turned off. Refer to SN-100 for recommended
grounding techniques.
If either a ground or a short circuit is detected, it must be eliminated before the control is plugged
into the wiring base and power turned on.
Test the electrical field wiring for short circuits and grounds. The recommended method requires the
use of an ohmmeter set on its lowest resistance scale.
Note: When using ultra-violet or infrared scanning, be sure to remove any jumpers on the wiring
base which ground the S2 terminal.
1. Touch the meter probes together and calibrate accurately to ensure a reliable test.
2. Disconnect the neutral wire (L2) from the control system at the power source. Clip one meter
test lead to the grounded green terminal on the lower right side of the wiring base and with the
other probe touch each other terminal. At no time should the meters show continuity or read 0
ohms.
3. Reconnect the neutral wire (L2) at the power source. Remove the test probe from the grounded
terminal and reconnect it to Terminal L2 in the wiring base. With the other probe, touch each
other terminal. It is normal to obtain a resistance reading on the meter at some terminals during
this test as there are resistive loads (coils, transformers, lamps, etc.) connected whose normal
DC resistance may be less than 5 ohms. However, at no time should the test meter read zero
ohms.
4. With Flame-Monitor removed, measure voltage from L2 to all other terminals. Reading should
be zero on all terminals except Ll.
1. Check the electrical tabs on the bottom of the chassisif they are bent out of position, reposi-
tion them with your fingers so that they are in line as shown here.
2. Select the appropriate programmer and amplifier modules for your application. Remove the dust
cover from the chassis. Insert the amplifier module into the slot marked Flame Amplifier Module
and gently push the module into position. Insert the programmer module into the slot marked
Programmer Module and gently push the module into position. Attach the display to the pro-
gram module and plug ED580-1 into RJ45 connections.
3. Slide the slots at the bottom of the assembled control over the tabs on the wiring base. Push the
control into position. Insert a screwdriver through the hole in the top of the control and tighten
the retaining screw.
4. Electric power may now be turned on.
OPERATION
The programmer module determines the functional operation of the E110 control (e.g. purge timing,
trial for ignition timings, recycle or non-recycle operation, etc.). For purposes of illustration, we will
be looking at the EP160/EPD160 Programmer functions and messages associated with the ED510
display module in this bulletin. Because the messages change depending upon which EP style
programmer is being used, it is necessary to check the bulletin covering the specific program-
mer for exact details. Refer to the suggestions shown in this bulletin before proceeding to power the
Fireye E110 Flame-Monitor system. Items such as scanner installation, short circuit tests and safety
information should be reviewed.
10
CAUTION: On initial power-up and on restarts following a power failure, the control will
perform self-test diagnostics for 15 seconds.
6. When the prepurge is completed, the firing rate motor is driven toward the low purge damper
position (10-12 ckt. made). The ED510 will display:
PURGE 0:35
LOW FIRE PURGE
7. Following the minimum 30 second delay (to permit the firing rate motor to get to the low fire
position), the control will wait for the low fire switch (M-D) to close. When it closes, the trial for
ignition sequence will start. If after ten minutes, the M-D circuit is not closed, the control will
lockout. The EPD167 will wait indefinitely for the M-D circuit to close.
11
8. The trial for ignition period begins with Terminal 5 and 6 being energized simultaneously. This
is known as PTFI (Pilot Trial for Ignition). The ED510 will display:
PTFI 0:02
IGNITION TIMING
This period is ten seconds in duration. If no flame is detected after ten seconds, the control will de-
energize Terminals 5 and 6 and lockout. When flame is detected during this 10 second period, the
ED510 will display
PTFI 20
FLAME SIGNAL
FLAME SIGNAL
0-9 NOT ACCEPTABLE
10 MINIMUM ACCEPTABLE
20-80 NORMAL
9. With flame proven at the end of PTFI, the main flame trial for ignition (MTFI) period begins.
Terminal 7 is energized. The ED510 will display:
MTFI 35
FLAME SIGNAL
Terminal 5 is de-energized 10 seconds later and Terminal 6 is de-energized after another 5 seconds.
10. The firing rate motor is now sent to the auto position (10-11 ckt made) and is under the com-
mand of the proportional controller. The ED510 will display:
AUTO 40
FLAME SIGNAL
NOTE: Trial-for-Ignition timings depend on the programmer selected. The timing charts on pages 11
and 4 point out the differences in the EP(D)160, EP161, EP165, and EP(D)170.
Normal Shutdown
1. When the operating control circuit (L1-13) opens, the main fuel valve is de-energized. The firing
rate motor is driven to the low purge position (10-12 ckt mode).
2. Following a 15 second post purge, the burner/blower motor is de-energized.
3. The burner is now off and the ED510 will display
STANDBY
L1-13 OPEN
Burner history can be displayed by using ED510 keypad. See bulletin E-5101.
BACKLIT DISPLAY
The ED510 display has a two (2) line by sixteen (16) character backlit LCD display. The backlit
function is energized when power is applied to the FLAME MONITOR.
Contrast Control: The contrast for the LCD display is factory set. If the contrast must be adjusted
for any reason (e.g.: remote mounting), a potentiometer is provided on the back of the ED510 display
board. Refer to bulletin ED-5101 for detailed information.
LOCKOUTS
When a safety shutdown occurs, the control will display a message indicating LOCKOUT and the
reason for the lockout. The alarm circuit (Terminal A) will be energized. The non-volatile memory
will remember the status of the control even if a power failure occurs. By momentarily depressing
12
the reset button on the display, the control can be reset. The button must be held down for one second
and then released. Very little force is required to do this. Do not press hard.
Safety Shutdown
1. If the running interlock circuit does not close, the control will lockout and the blower motor will
be de-energized. If the interlock circuit opens during a start-up or firing period, all fuel valves
will be de-energized and the control will lockout.
2. If the proven high fire circuit (D-8) has not closed after a ten (10) minute Hold period at the
start of prepurge, the control will lockout.
3. If the low fire start circuit (M-D) has not closed after a ten (10) minute Hold period at the end
of prepurge, the control will lockout.
4. If dipswitch 6 is in the Up position (3-P prove open to start-enabled), and the 3-P circuit is
closed at the start of the operating cycle, the control will hold for one (1) minute waiting for the
3-P circuit to open. If, after one (1) minute, the 3-P circuit does not open, the control will lock-
out.
5. If pilot flame is not detected during the 10 second trial for ignition period, the pilot valve and
ignition transformer will be de-energized and the control will lockout on safety.
6. If main flame is not detected at the end of the main flame trial for ignition period, all fuel valves
will be de-energized and the control will lockout on safety.
7. If the main flame fails during a firing cycle, all fuel valves will be de-energized within 4 seconds
maximum, after loss of flame signal and the control will lockout on safety.
8. The EP165and EP(D)166 programmers will lockout on a power interruption.
9. If flame is detected when the operating control (L1-13) is open, the control will wait sixty (60)
seconds and then lockout if flame is still present. If the operating control closes and flame is
detected during purge, the blower motor (term M) remains energized and the purge sequence is
put on hold. If the flame signal goes away within sixty (60) seconds, the control will proceed
with a normal start-up. If flame signal is still present after sixty (60) seconds, the control will
lockout.
NOTE: Manual Reset is required following any safety shutdown.
NOTE: Depressing and releasing the reset button during a cycle will cause the control to shut the
burner down and recycle.
* Refer to programmer selection on page 8 to determine which programmers offer non-recycle operation of the running inter-
lock circuit (ckt. 3-P).
13
4. Purge Interlock: Generally a firing rate motor linkage position switch or a differential air-pres-
sure switch, that proves a maximum purge air flow rate. It is connected between Terminals D and
8. The purge interlock proves that the purge air flow rate is at maximum during the purge.
5. Running Interlocks: These generally are air flow switches, high and low fuel pressure switches,
oil temperature switches, atomizing media pressure switches, and excess smoke density controls.
These interlocks prove proper conditions for normal operation of the burner. They are wired in
series and connected between Terminals 3 and P.
6. Low Fire Start Interlock: Generally a firing rate motor linkage position switch or a damper
position switch, will prove both the linkage and dampers are in their proper positions to begin
burner light off. This switch is connected between Terminals M and D.
14
YES
NO LOCKOUT +
5 IS AIR FLOW SWITCH MADE? 3-P
MODULATOR SENT
YES
FROM LOW TO
HIGH FIRE NO HOLD 10 MIN. THEN LOCKOUT +
MTFI 35
13 TERMINAL 5 CUT OUT 10 SEC. AFTER 7 CUT IN
FLAME SIGNAL
14 TERMINAL 6 CUT OUT 15 SEC AFTER 7 CUT IN
MODULATOR SENT NO LOCKOUT +
FROM LOW FIRE
TO AUTO
15 IS FLAME PROVED?
AUTO 40
YES
FLAME SIGNAL
16 TERMINAL 7 REMAINS POWERED
MODULATOR SENT
FROM AUTO TO 17 DEMAND SATISFIED L1-13 OPENS POST PURGE 0:05
LOW FIRE
CYCLE COMPLETE
18 TERMINAL 7 DE-ENERGIZED
MODULATOR HELD
AT LOW FIRE STANDBY
19 BLOWER STOPS 15 SEC. AFTER L1-13 OPENS
L1-13 OPEN
15
ED510 MESSAGES
RUN MESSAGES
STANDBY The operating control of the FLAME-MONITOR (terminals L1-13) is open.
L1-13 OPEN
PURGE 0:05 Firing rate motor sent to high fire (term. 10-X made), purge timing displayed upper
HIGH FIRE PURGE right hand corner.
PURGE 0:35 Firing rate motor sent to low fire (term. 10-12 made), purge timing displayed in
LOW FIRE PURGE upper right hand corner.
PTFI 0:02 PTFI timing started. Pilot not proven yet. PTFI timing displayed in upper right
IGNITION TIMING hand corner.
Pilot flame proven during PTFI. Flame signal strength displayed in upper right
PTFI 19
hand corner.
FLAME SIGNAL
MTFI 25 Main flame proven during MTFI. Flame signal strength displayed in upper right
FLAME SIGNAL hand corner.
Modulator motor sent to auto position (term 10-11 made). Flame signal strength
AUTO 40
displayed in upper right hand corner.
FLAME SIGNAL
POST PURGE 0:05 Demand satisfied. L1-13 open. Blower motor de-energized 15 seconds after L1-13
CYCLE COMPLETE opens.
HOLD MESSAGES
HOLD STANDBY 0:23 Dipswitch #6 (3-P Proven Open to Start) is set in the Up position (Enabled). At the
3-P INTLK CLOSED start of the cycle, the 3-P circuit was closed. It will hold in this position for 60 sec-
onds and then lockout if the 3-P circuit does not open.
The control has driven the firing rate motor to high purge (term. 10-X made) and is
HOLD PURGE 0:00 waiting for the high fire switch (term. D-8) to close. It will hold this position for
D-8 LIMIT OPEN ten (10) minutes and then lockout if the D-8 circuit does not close. Applies to
EP(D)160, EP(D)161, EP165, EP166, EPD167 and EP(D)170 programmers.
Dipswitch #6 (3-P Proven Open to Start) is set in the up position (enabled). At the
HOLD PURGE 0:00 start of a cycle the D-8 circuit was closed. It will hold in this position for 30 sec-
D-8 LIMIT CLOSED onds and the lockout if the D-8 circuit does not open. Possible solution is to
remove jumper from D-8 circuit or properly set the firing rate motor and switches.
Applies to EP(D)160, EP(D)161, EP165, EP166, EPD167 and EP(D)170 pro-
grammers
Dipswitch #6 (3-P Proven Open to Start) is set in the up position (enabled). At the
HOLD PURGE 0:30 end of high fire purge and beginning of low fire start, the M-D circuit is closed. It
M-D LIMIT CLOSED will hold in this position for 30 seconds and then lockout if the M-D circuit does
not open. The solution is to remove jumper from the M-D circuit or properly set
the firing rate motor and switches. Applies to EP(D)160, EP(D)161, EP165,
EP166, EPD167 and EP(D)170 programmers
16
The control has finished purge and the firing rate motor is driving to the low fire
HOLD PURGE 0:00 position (term. 10-12 made) waiting for the low fire start switch (term. M-D) to
M-D LIMIT OPEN close. It will hold this position for ten (10) minutes and then lockout if the M-D
circuit does not close, excluding the EPD167.
The running interlock circuit (3/P) has not closed within the first ten (10) seconds
HOLD PURGE 0:10
of purge. The control will hold for ten (10) minutes and then lockout. Applies to
3-P INTLK OPEN
recycle programmers only.
Flame has been sensed during the burner off time (term. L1-13 open) or during the
HOLD STANDBY 25 purge period. This message will hold for sixty (60) seconds and then lockout if
FALSE FLAME flame is still present. Flame signal strength is displayed in the upper right hand
corner.
LOCKOUT MESSAGES
Dipswitch #6 (3-P Proven Open to Start) is set in the Up position (Enabled). At the
LOCKOUT STANDBY
start of the cycle, the 3-P circuit was closed, and the control has waited 60 seconds
3-P INTLK CLOSED
for the 3-P circuit to open.
LOCKOUT PURGE The control has held for more than 10 minutes waiting for the high fire switch (D-
D-8 LIMIT OPEN 8) to close. Applies to EP(D)160, EP(D)161, EP165, EP166, EPD167 and
EP(D)170 programmers.
Dipswitch #6 (3-P proven open to start) is set in the up position (enabled). The D-
LOCKOUT PURGE 8 circuit has been closed for 30 seconds at the start of cycle. Applies to EP(D)160,
D-8 LIMIT CLOSED EP(D)161, EP165, EP166, EPD167 and EP(D)170 programmers
LOCKOUT PURGE The running interlock circuit (3-P) has opened during the purge period or failed to
3-P INTLK OPEN close within the first 10 seconds of purge on non-recycle programmers or has not
closed within 10 minutes on recycle programmers.
LOCKOUT STANDBY The fuel valve end switch wired between terminals 13 and 3 opened during purge
13-3 FUEL VALVE END SWITCH or at start up.
LOCKOUT PURGE The control has held for more than 10 minutes waiting for the low fire switch (M-
M-D LIMIT OPEN D) to close. This does not apply to the EPD167.
LOCKOUT PTFI The running interlock circuit (3-P) has opened during the pilot trial for ignition
3-P INTLK OPEN period. Applies to non-recycle programmers only.
LOCKOUT MTFI The running interlock circuit (3-P) has opened during the main trial for ignition
3-P INTLK OPEN period. Applies to non-recycle programmers only.
LOCKOUT AUTO The running interlock circuit (3-P) has opened during the main burner on period.
3-P INTLK OPEN Applies to non-recycle programmers only.
17
Flame has been sensed during the burner off time (term. L1-13 open) or during the
LOCKOUT STANDBY purge period for sixty (60) seconds.
FALSE FLAME
A flame failure occurred during the pilot trial for ignition period.
LOCKOUT PTFI
FLAME FAIL
LOCKOUT MTFI A flame failure occurred during the main trial for ignition period.
FLAME FAIL
LOCKOUT AUTO A flame failure occurred during the main burner on period.
FLAME FAIL
LOCKOUT PTFI This message appears because of ignition cable noise. Reroute scanner wires away
SCANNER NOISE from high voltage ignition cables. Check for proper spark gap or cracked porce-
lain. Check for proper grounding of wiring base and power supply. Replace worn
ignition cable and/or faulty connections.
LOCKOUT PURGE Excessive current or short circuit detected on terminals 5, 6, or 7 during PTFI,
SHORT CIRCUIT TERM 5,6,7 MTFI, or Auto. The control will lockout upon sensing this condition on two con-
secutive cycles.
During pilot trial for ignition period, voltage sensed on terminal 7 is different from
LOCKOUT PTFI
the previous cycle. (e.g.: jumper added or removed between term. 7 and 5 or 6).
FUEL VALVE STATE CHANGE
LOCKOUT A power interruption to terminals L1 and L2 has caused the control to lockout.
AC POWER FAIL Applies to EP165 and EP166 programmers only.
CHECK MESSAGES
CHECK PURGE 0:15 The "Run-Check" switch has been placed in the Check position during purge and
D-8 HI LIMIT will hold indefinitely. The firing rate motor is being driven to the high purge posi-
tion.
CHECK PURGE 0:45 The "Run-Check" switch has been placed in the Check position after high fire
M-D LOW LIMIT purge and will hold indefinitely. The firing rate motor is being driven to the low fire
position.
CHECK PTFI 19 The "Run-Check" switch has been placed in the Check position during the pilot
FLAME SIGNAL trial for ignition period. Flame signal strength is displayed in the upper right hand
position. The control will lockout on safety only when no flame signal is sensed for
a continuous 30 seconds while the control is in the Check position.
18
The "Run-Check" switch has been placed in the Check position during the main burner on
CHECK AUTO 25
period. and the firing rate motor is driven to the low fire position. Flame signal strength is
LOW FIRE SIGNAL
displayed in the upper right hand corner.
CHECK STANDBY 00 The Check-Run switch has been placed in the Check position with the operating control
UNIT ADDRESS circuit (L1-13) open. Every time the Reset button is depressed and held for one second will
increment the Unit Address by one. Refer to programmer bulletin for additional informa-
tion on Unit Address.
DIAGNOSTIC MESSAGES
LOCKOUT AUTO
Flame signal detected during shutter Stuck scanner shutter. Replace 45UV5
CHECK SCANNER close time on 45UV5 scanner. scanner.
LOCKOUT AUTO
The E300 Expansion Module has a Replace E300 Expansion Module.
CHECK EXPANSION MODULE defective optocoupler.
LOCKOUT AUTO
AUTO CHECK AMPLIFIER FAIL Amplifier has failed diagnostic checks. Replace amplifier.
FIREYE ED510
Defective programmer. Replace programmer.
SYSTEM ERROR
19
AUTO 40
Number of hours Terminal 7 (main fuel) is energized.*
BNR HOURS 823
AUTO 40
Number of burner operating cycles. (L1-13 closed).*
BNR CYCLES 385
AUTO 40 Sub-menu to display the cause of the last 15 lockouts. The MODE key is required
LOCKOUT HISTORY to display the actual lockouts.
Sub-menu to program the messages associated with the operation of the E300
AUTO 40
expansion module. The MODE key is required to enter the sub-menu.
E300 MSG SELECT
AUTO 40 Sub-menu to display information pertaining to the operation of the control. The
SYSTEM INFO MODE key is required to enter the sub-menu.
20
LOCKOUT HISTORY
The sub-menu LOCKOUT HISTORY will display the last six (6) lockouts, along with the burner
cycle and burner hour when the lockout occurred. When the MODE key is pressed, the screen will dis-
play the most recent lockout condition and the number of that lockout (e.g. LO #127 represents the
127th lockout of that control). The SCRL key will display the Burner Hour, followed by the Burner
Cycle when the lockout occurred. The SCRL key will advance to the next lockout, and repeat the
sequence listed above. The MODE key will exit the sub-menu.
PRESS SCREEN DISPLAYS DESCRIPTION
SCRL AUTO 45 Scrolling through the historical information. Control has released to auto
LOCKOUT HISTORY > modulation, flame signal strength = 45.
MODE LO #158 PURGE The last (most recent) lockout condition. This is the 158th lockout of the
D-8 LIMIT OPEN control.
SCRL LO #158 PURGE The last lockout occurred after 136 hours of burner operation.
@ BNR HOURS 136
SCRL LO #158 PURGE The last lockout occurred on the 744 burner cycle.
@ BNR CYCLE 744
SCRL LO #157 AUTO The next to last lockout condition. This is the 157th lockout of the control.
3-P INTLK OPEN
MODE AUTO 45 Screen has returned to the run message. Control has released to auto
FLAME SIGNAL modulation, flame signal strength = 45.
21
GROUP 4 NON-RECYCLE
E340 SAFETY INTLK OPEN HIGH TEMPERATURE BLOWER MOTOR INTLK
HIGH WATER AIR FLOW OPEN I.D. FAN INTLK
LOW WATER OIL GUN END SWITCH OPEN F.D. FAN INTLK
HIGH PRESSURE HIGH STACK TEMPERATURE
22
PROGRAM SETUP
The sub-menu PROGRAM SETUP allows the user to review the various operational settings of
the programmer module (e.g. programmer type, purge timing, etc.). The MODE key is used to enter
the PROGRAM SETUP sub-menu, and the SCRL key is used to advance through the sub-menu.
Press Screen Displays Description
SCRL AUTO 45 SCRL key advances through the historical information until
PROGRAM SETUP > Program Setup is displayed. Control has released to auto
modulation, flame signal strength = 45.
SCRL AUTO 45 Software Engineering code of the programmer module is code 28.
ENGR CODE NO. 28
SCRL AUTO 45 Unit Address is 00. Refer to programmer bulletin to modify Unit
UNIT ADDRESS #00 Address.
23
SYSTEM INFO
The sub-menu SYSTEM INFO allows the user to review information pertaining to the operation of
the control (e.g. average main flame signal strength, status of the high fire and low fire end switches,
etc.). This information can be very helpful when setting the damper linkages on the firing rate motor.
The MODE key is used to enter the PROGRAM SETUP sub-menu, and the SCRL key is used to
advance through the sub-menu.
Press Screen Displays Description
SCRL AUTO 45 SCRL key advances through the historical information until
SYSTEM INFO > System Info is displayed. Control has released to auto
modulation, flame signal strength = 45.
MODE AUTO 45 The average flame signal strength of the pilot flame = 22
AVG. PILOT FLM 22
SCRL AUTO 45 The average flame signal strength of the main flame = 40.
AVG. MAIN FLM 40
SCRL AUTO 45 The total number of short circuits (excessive current) detected on
SHORT CKTS. 0 terminals 5, 6, and 7. The short circuit condition must be sensed
twice consecutively to be considered a short circuit.
SCRL AUTO 45 The status of the high fire end switch (D-8) is closed.
D-8 LIMIT CLOSED
SCRL AUTO 45 The status of the low fire end switch (M-D) is closed.
M-D LIMIT CLOSED
SCRL PRESS RESET TO While the control is in STANDBY position (L1-13 OPEN)
CLEAR HISTORY pressing and releasing the RESET key will clear current burner
hours, cycles and lockout history.
The EP(D) programmer updates the messages to the ED510 display at least once every 8
seconds. If the ED510 display does not receive information from the EP(D) programmer
within 10 seconds the ED510 will display:
FIREYE ED510
WAITING FOR DATA
This can be the result of a defective connection between the programmer and display,
defective cable, defective drivers in the programmer or display, or an electrical noise tran-
sient causing the EP(D) programmer to cease communication.
Removing and restoring power should be executed to recover proper operation. Refer to
bulletin SN-100 for recommended techniques for display installation.
24
COMMUNICATIONS
The protocol to be used is Modbus RTU. This is implemented by the master (PC, PLC, etc.) issuing
a poll to the slave (Flame-Monitor) and the slave responding with the appropriate message.
A typical format of a poll request is as follows:
DST FNC ADR ADR DAT DAT CRC CRC
HI LO HI LO LO HI
DST refers to the logical address of the slave.
FNC is the function being requested. FNC 03 is a read request.
ADR is the message number or register number of the data being requested. In Modbus, register
addresses begin at 40001 but is interpreted as address 00.
DAT is the number of words being requested. A word is an integer consisting of 2 bytes.
The normal response from a slave is as follows:
25
Message 00 and message 05 are unique in that a limited number of successive registers can be com-
bined with these requests. For example, a request to message 00 can contain up to 6 data words. The
response to this would contain STATUS, MSGN, GSTAT, TIMER, FLAME and LOGSTAT. If the
requested data word count (DAT) were to be 2 then the response would contain STATUS and MSGN
only.
The MSGN being transmitted is a numerical value and must be interpreted by the communicating
device, which actually is an advantage since this can be made to be whatever message text the end
user wants. In other words, it allows for programming custom messages without actually changing
the message in the programmer. Refer to the message table for a complete description.
The Flame-Monitor stores its burner on time and system on time (L1 powered) in minutes. The pro-
grammer normally converts this to hours for display purposes. The information being supplied by
Modbus will be the actual time in minutes and it is up to the communicating device to do the conver-
sion. Since the maximum value stored in the Flame-Monitor is 9,999,999 minutes, the maximum
value in hex therefore is 98967FH and comprises two data words. The maximum cycle count is
999,999 decimal or F423FH, still two data words.
All values are represented in a HEX or base 16 format.
GSTAT determines the type of value TIMER represents. TIMER can be a running timer such as is
used in purge, a flame signal or meaningless. Only the lower nibble of GSTAT has any value. If this
value is 0 then the TIMER value has no meaning. The value in TIMER is a background minute timer
in the Flame-Monitor and should be ignored. If GSTAT is between 4 and 7, the TIMER represents
the current value flame signal. If GSTAT is a 1, 2, or 3 then TIMER represents a running timer value.
The baud rate of the Flame-Monitor is fixed at 4800 bits per second. The format of the data is 8 data
bits, no parity and 1 stop bit. Due to the RS485 format, the communication format is considered half-
duplex. That is, only one user is permitted on the communication lines at a time.
The information contained in INPUTS and OUTPUTS represents the status of the interlocks and
relays respectively. For the INPUTS, a 1 in the interlock position defines the interlock as being on or
energize where the 1 in any bit position in the OUTPUT register signifies the relay as being ener-
gized.
INPUTS
Term P Term 5/6 Term D Term 8 Term 7 Term 3 Term 13
Air Flow Ignition Low Fire Ref High Fire Main Fuel FVES or Op Ctrl
POC
A 1 in the opto-coupler position indicates the opto-coupler is on or interlock closed.
OUTPUTS
Term 11 Term M Term 6 Term 5 Term 7 Term A Term X
Auto (RA1) Blower (RB) Ignition FVES (RV) Pilot Main Fuel Alarm (RL) High Fire
(RA2) (RP) (RF) (RH)
LOGSTAT is an indication of what logic module the control is currently in during its operating
sequence and is used for diagnostic purposes only. The message displayed corresponds to the current
logic module. The range of values are 4FH for Standby, 47H for PostIdle through 4DH for Shut
down 2. Note that the above values are represented in hexadecimal format.
It is suggested that repeated polling interval not be less than 200 mSec per request. Requesting data
such as burner minutes, system minutes and burner cycles should be kept at a minimum due to the
amount of processing time required to gather that data.
26
EXPLANATION OF LOGSTAT
Table 2
LOGIC DISPATCHER
VALUE (hex) FLAME-MONITOR
45H MPOSTIDLE
46H MPREPURGE1
47H MPURGE
48H MPOSTPURGE
49H MTFI
4AH MTFMF
4BH MAUTO
4CH MSHTDWN1
4DH MSHTDWN2
4EH MIDLE
Logstat represents the current software module the Flame-Monitor is currently executing. They are
named as close to the logic module the actual burner sequence is in. For instance, in the Flame-Mon-
itor, MPURGE represents High Fire Purge where MPOSTPURGE represents the low fire start period
where the mod motor is sent to the low fire position in preparation for pilot light-off. MSHUTDWN1
represents the post purge period after a complete cycle or the cool down period after a lockout.
MIDLE or STANDBY is the period of time where the operating control is open or the control is in
lockout waiting for reset. On instances of false flame during the purge period, the control algorithm
forces the control back to STANDBY until false flame ceases or lockout occurs.
MPREPURGE1 is the period of time prior to PURGE where the control checks the status of the air
flow interlocks or the high fire proving switch (D-8). If either switch is found open, the control will
remain in this state until the respective switch closes or lockout occurs.
MTFI represents the pilot trial for ignition stage of a burner sequence. MTFMF represents the main
trial for main flame period where main fuel is introduced along with pilot and igniter.
MAUTO is the run period of the burner sequence.
MPOSTIDLE and MSHTDWN2 are small periods of time where certain internal tests are conducted
and general cleanup before and after a cycle is performed.
The Flame-Monitor outputs the current displayed message as well as the historical lockout messages
as numbers. The table that follows correlates the message number with the actual displayed test mes-
sage.
27
Table 1
DEC HEX FLAME-MONITOR
1 1 L1-13 OPEN
2 2 FALSE FLAME
3 3 LOW FIRE PURGE
4 4 D-8 LIMIT OPEN
5 5 3-P AIR FLOW OPEN
6 6 LOCKOUT LINE FREQUENCY NOISE DETECTED
7 7 FLAME FAIL
8 8 UNIT ADDRESS
9 9 M-D LIMIT OPEN
10 A IGNITION TIMING
11 B MTFI
12 C FLAME SIGNAL
13 D CYCLE COMPLETE
14 E L1-13 OPEN
15 F LOCKOUT AC POWER FAIL (COEN)
16 10 LOCKOUT SHORT CIRCUIT TERMINAL 5,6 or 7
17 11 D-8 LIMIT OPEN
18 12 M-D LIMIT OPEN
19 13 LOCKOUT FLAME FAIL - MTFI
20 14 FALSE FLAME
21 15 LOCKOUT 3-P INTLK OPEN (PURGE)
22 16 3-P INTLK CLOSED
23 17 3-P INTLK CLOSED
24 18 HIGH FIRE PURGE
25 19 PLEASE WAIT
26 1A LOCKOUT 3-P INTLK OPEN
27 1B LOCKOUT 3-P INTLK OPEN (MTFI)
28 1C LOCKOUT 3-P INTLK OPEN (PTFI)
29 1D LOCKOUT 13-3 FVES OPEN
30 1E FALSE FLAME (PURGE)
31 1F FLAME SIGNAL
32 20 D-8 HI LIMIT (CHECK)
33 21 M-D LOW LIMIT (CHECK)
34 22 FLAME SIGNAL
35 23 LOW FIRE SIGNAL (CHECK)
36 24 FLAME SIGNAL
37 25 LOCKOUT FLAME FAIL (AUTO)
38 26 3-P INTLK OPEN
39 27 FUEL VALVE STATE CHANGE
E300 EXPANSION MODULE LOCKOUT MESSAGES
40 28 3-P AIR FLOW OPEN
41 29 3-P high water
42 2A 3-P low water
43 2B 3-9 high gas pressure
44 2C 3-P low gas pressure
45 2D 3-P low oil pressure
46 2E 3-P low oil temperature
47 2F 3-P low atomizing media
48 30 3-P high steam pressure
49 31 3-P high temperature
50 32 3-P aux #4 open
51 33 3-P aux #5 open
52 34 3-P aux #6 open
28
29
Lockout
Alarm Circuit
Firing Rate
Motor S1 S2
Switching Firing Rate Ignition And Fuel Valve
(See Insert) Burner Motor Motor Switching Control Circuit Plug In Flame
Control Circuit (See Insert) Flame Amplifier Rod
or
FIREYE Photocell
WIRING BASE 10 11 L1 L2 3 M D P X 12 13 5 6 7 8 A S1 S2 Only
TERMINALS
LIMIT OPERATING
SWITCHES S1
FIREYE
TERMINAL
10 X 12 11 BLACK
BURNER/ GAS MAIN L2
BLOWER IGNITION PILOT FUEL LOCKOUT
AUTO TRANSFORMER ALARM
COM HI LO MOTOR VALVE VALVE(S)
L1
R
45UV5 1009
POTENTIOMETER 5 6 5 6 7
CONTROLLER
JUMPER
R W B Trial for
Trial for
OIL Ignition/ Ignition/
T T
IGNITION GAS PILOT IGNITION SOLENOID FIREYE
TRANSFORMER VALVE TRANSFORMER VALVE Pilot Main
FIRING PART
RATE
NUMBER (Seconds) (Seconds)
MOTOR
Term 5 Term 5
POWER WIRING ARRANGEMENT FOR IGNITION TRANSFORMER WIRING ARRANGEMENT FOR Term 6 Term 6
SUPPLY & GAS PILOT VALVE FOR SPARK CUTOFF FEATURE SPARK IGNITED OIL BURNER
EP(D)160 10 10
PROGRAMMER EP(D)170
EPD167 10 15
10 10
Caution: All safety limit switches should be approved as EP(D)161
limit controls and should be wired directly in the circuit of 10 30
the Flame Safeguard control. The use of electronic switch- EP(D)165* 10 0
es to close interlock circuits may cause erratic operation. 10 10
EP(D)166* 10 0
10 15
Refer to Service Note 100 (SN100) or Suggested Grounding
Rules later in this document. 5 0
EP(D)170 10 10
30
EXTENDED PREPURGE
With EPD programmers, it may be necessary to extend the pre-purge timing on the Flame Safeguard
Control to greater than 30 seconds. This can be accomplished by adding a time delay relay in the L2/
M and D/8 circuit and wired in the following manner:
The maximum extended purge time will be 10 minutes. The maximum time delay setting should be
91/2 minutes. If the time delay relay does not close the D-8 circuit within 10 minutes of the start, the
Flame-Monitor control will LOCKOUT and the message will be LOCKOUT D-8 HI PURGE
OPEN.
FLAME MONITOR D
WIRING BASE
8
L1 L2
M
H
110V
N
N.O. TIME DELAY CONTACT
HIGH FIRE
INTERLOCK TIME DELAY RELAY.
ADJUSTABLE TIMING UP
TO 91/2 MINUTES
5 6 7
SPST
RELAY
L2
31
INSTALLATION /TESTING
Check-Run Switch
The Check-Run switch is located on the top of the EP Programmer Module (note photograph) and
can be used to stop the control in its firing sequence at any time except during MTFI. If moved dur-
ing the MTFI period, it is non-functional and automatic programming continues. It is designed to aid
in set-up, start-up and check-out of the burner and its associated interlocks.
Following are the modes of operation:
1. When power is applied to the control (Ll-L2) and the operating control circuit is closed (L1-13),
the purge period begins and the firing rate motor is sent to the Hi Purge position. If the Check-
Run Switch is moved to the Check position before the Hi Fire Switch (D-8) is made and the 30
second purge ends, the control will display:
The control will hold in this position indefinitely to allow the operator to make interlock switch
and linkage adjustments. To continue in the cycle, move the Check-Run switch to Run to allow
the control to advance.
2. If the Check-Run switch is moved to the Check position after the purge period reaches 30 sec-
onds, but before 60 seconds, the control will display:
The control will hold in this position indefinitely to allow the operator to make interlock switch
and linkage adjustments.To continue the cycle, moving the Check-Run Switch to Run will allow
the control to advance.
3. After the PTFI period has begun, switching back to the Check position will stop the program in
the PTFI period, allowing for pilot and/or scanner alignment adjustments to be made. The con-
trol will display:
CHECK PTFI 19
FLAME SIGNAL
It will hold in this position indefinitely as long as the flame signal strength is above the threshold
of 10. If it drops below 10 for thirty consecutive seconds, lockout will occur and the message on
the display will read Flame Fail PTF1.
4. Switching from run to check during the burner on period will drive the modulator circuit to low
fire (10-X Closes). This allows for low fire fuel-air adjustments and holding the burner at low
fire. Consult your boiler/burner instructions for low fire hold firing recommendations. The con-
trol will display
CHECK AUTO 25
LOW FIRE SIGNAL
As an aid adjusting the burner linkages, pilot, etc., a check-run selector is provided on each EP-
and EPD Series Programmer Module.
32
OPERATIONAL TEST
WARNING: Before testing the control operation on the boiler, close the manual main shut-off
fuel valve. Failure to do this may cause injury or property damage.
Voltage Test
A Voltage Check is necessary to identify a potential problem with the supply to the control. This
could be caused by an improperly sized or faulty transformer, faulty load coils or low entry voltage.
Follow this procedure:
1. Using the Service Adapter (60-2107), monitor the L1-L2 supply throughout a complete burner
cycle. The acceptable voltage range is 102V-132V. At no time during the cycle should the volt-
age dip below the minimum level.
2. Check other load terminal (M/L2, 5/L2, 6/L2, 7/L2) for voltage at improper times or improper
values.
CAUTION: Before making a pilot flame test, manually shut off the fuel supply to the main
burner.
1. At the start of PTFI, place the Check-run switch in the check position.
2. Observe the pilot flame signal on the display. If the average signal is below the minimum of 10,
readjust the pilot flame or realign the flame detector.
33
3. During the pilot flame test, if flame is not detected for a continuous 30 seconds, the control will
lockout. To re-establish the pilot flame trial for ignition (PTFI), manual reset of the lockout
switch is required, and a complete prepurge accomplished.
4. When UV flame detection is used, a test is required to verify that UV radiation from the ignition
spark is not being detected. To accomplish this, manually shut off both pilot and main fuels. Ini-
tiate a normal start-up, and when the PTFI display comes on, observe the display which should
read no signal more than 4. If more than 4 is observed, realign the UV scanner, and/or shield the
spark from the scanners view.
5. With all methods of flame detection, check pilot flame failure response by manually shutting off
the pilot fuel and then initiate a normal start-up. With no pilot flame present, the control will de-
energize the pilot assembly at the end of the trial for ignition interval, and the control will lock-
out. Also check to verify that the ignition spark does not give a flame signal on infrared or
flame rod applications.
Main Flame Test
NOTE: This test requires an interrupted pilot (a pilot that shuts off after main flame has been estab-
lished.
1. Proceed through a normal startup. After the pilot flame is shut off, observe the reading on the
display. If the signal reading is low, readjust main flame or realign detector.
2. Check main flame failure protection by manually shutting off the main fuel supply. Within 4 sec-
onds after main flame goes out, the fuel valve will be de-energized. The alarm circuit will be
energized following safety lockout.
Minimum Pilot Test
CAUTION: The minimum pilot test must be accomplished by a trained and qualified burner
technician.
This test assures that the flame detector will not detect a pilot flame too small to reliably light off the
main flame. The test should be made on every new installation and following any reapportioning of
the flame detector. This procedure should not be used on a direct spark ignited burner.
CAUTION: If the main flame does not ignite immediately, shut off the main fuel. Realign the
detector to require larger minimum pilot flame.
7. Repeat the test until a reliable and smooth light-off occurs with the minimum pilot.
8. After this test is completed, increase the fuel to the pilot to its normal setting.
34
Scanner Wiring
Care should be taken to see that ignitor cables and scanner cables are routed away from one another on
all installations. These cables, when crossed or run together, may interfere with the proper operation of
the flame safeguard control.
If you are experiencing erratic operation or inappropriate characters on the display during the trial for
ignition period, the cause is likely to be ignitor noise. Check for worn ignitor cable insulation, broken
or cut insulation or loose connectors at the electrode and transformers.
35
INSTALLATION
Do not run high voltage ignition transformer wires in the same conduit with flame detection wiring.
Do not run scanner wires in a conduit with line voltage circuits.
Ensure the frame of the ignition transformer is securely connected to control panel frame or preferably
the burner frame.
The Flame-Monitor chassis (EB700) contains a transient suppressing device connected internally across
hot and neutral and then to the internal bracket. For this to be effective the chassis must be screwed
securely into the wiring subbase.
REMOTE DISPLAY
When the ED510 is to be remotely mounted on the front of the control panel, the ED580 cable must
contain a ferrite core, currently supplied by Fireye with the cable. High frequency currents flow more to
the surface of the conductor. The 60 Hz ground system, properly designed, has sufficient low-imped-
ance at 60 Hz to maintain all metal surfaces at the same ground reference. But, this same system is
unable to provide this at higher frequencies, because of the increased impedance caused by the skin
effect. The purpose of the ferrite core is to provide a low-impedance at these higher frequencies and
absorb this unwanted energy.
Care must be taken not to route the ED580 cable in close proximity to any starter motor contactors
located in the control panel or across any high voltage ignition wires. Refer to Fireye bulletin E8002 for
proper installation.
COMMUNICATIONS
When interfacing Fireye controls to a communication system, be it an E500, PLC or other microproces-
sor based device, ferrite cores should also be utilized. Proper twisted shielded pair cable must be uti-
lized. In a multi-drop system, the shields should be tied together within a cabinet and not to any ground
point. The shield at the source end of the cable of the multi-drop connection can then be terminated to
ground. Source end is defined as the originating end of the communication system
Care must be taken not to route communication cables in close proximity to any starter motor contactors
located in the control panel or across any high voltage ignition wires. Refer to Fireye bulletin E8002 for
proper installation.
SCANNERS
The armored cable supplied with the Ultra-Violet and Infrared scanners should be connected to equip-
ment by means of a good mechanical connection such as a conduit fitting. It may be necessary to utilize
heat insulator (P/N 35-69) to isolate the sensing end of the scanner from boiler ground. Care must be
taken not to route the scanner cable across the high voltage ignition cable. The high energy ignition
cable should be checked periodically for cracking, connections and aging.
In applications using flame rod units and the ERT1 amplifier, it may be beneficial to route a separate
return wire from the S2 terminal to the flame rod assembly. This will minimize the effects of transient
currents flowing into the Flame-Monitor.
In all cases, scanner wires should be routed in separate conduit and not joined with any high voltage AC
or ignition cables.
36
MAINTENANCE
Periodically, the spark electrode should be inspected for proper gapping and cracked ceramics. At
ignition time, the high energy from the ignition transformer will attempt to conduct to the point of
least resistance and with an improper spark gap, where the conduction takes place will no longer be
controlled.
The VA rating of the control transformer must be sized to handle the inrush currents of the pilot sole-
noid and ignition transformer at PTFI and then the inrush currents of the main fuel valve assembly at
MTFI time.
Inspect neatness of wiring in junction boxes and cabinets. It is best to have connections short and
direct and also not having wires bunched up and tied off. Also, connections should be periodically
inspected for tightness and corrosion.
INSTALLATION - UV SCANNERS
Where possible, obtain the burner manufacturers instructions for mounting the scanner. This infor-
mation is available for most standard burners. The scanner mounting should comply with the follow-
ing general instructions:
1. Position the UV1, UV2 scanner within 30 inches of the flame to be monitored; the 45UV5
within 72 inches, closer if possible.
2. Select a scanner location that will remain within the ambient temperature limits of the UV Scan-
ner. If cooling is required, use an insulating coupling (Fireye #35-69 for UV1, UV2 Scanners,
#35-127-1 for 45UV5) to reduce conducted heat.
3. The UVl, UV2, 45UV5 Scanners are designed to seal off the sight pipe up to 1 PSI pressure.
Higher furnace pressures should be sealed off. To seal off positive furnace pressure up to 100
PSI for UV1, UV2 Scanners, install a quartz window coupling (#60-1257) For 45UV5 Scanners,
use #60-1100 coupling. Add cooling air to reduce the scanner sight pipe temperature.
4. Install the scanner on a standard NPT pipe (UV1: 1/2", UV2: 3/8, 45UV5: 1") whose position
is rigidly fixed. If the scanner mounting pipe sights through the refractory, do not extend it more
than halfway through. Swivel flanges are available if desired (#60-302 for UV1, UV2 Scanners,
#60-1664-3 for 45UV5). The sight pipe must permit an unobstructed view of the pilot and/or
main flame, and both pilot and main flames must completely cover the scanner field of view.
NOT THIS NOT THIS BUT THIS NOT THIS NOT THIS BUT THIS
5. Smoke or unburned combustion gases absorb ultraviolet energy. On installations with negative
pressure combustion chambers, a small hole drilled in the UV1, UV2 sight pipe will assist in
keeping the pipe clean and free from smoke. For positive pressure furnaces, provide clean air to
pressurize the sight pipe, if necessary.
6. Two UV1 or UV2 Scanners may be installed on the burner if it is necessary to view two areas to
obtain reliable detection of the flame. They should be wired in parallel. Only one repetitive self-
checking 45UV5 Scanner may be installed on a burner.
7. To increase scanner sensitivity with UV1, UV2 Scanners, a quartz lens permits location of the
scanner at twice the normal distance. Use l/2 x 1 l/2 pipe nipple between UV1 Scanner and the
coupling. Use 3/8 pipe nipple and a l/2 x 3/8 bushing on UV2 installations.
8. Request the assistance of any Fireye field office for recommendations of a proper scanner instal-
lation on a non-standard application.
37
SCANNER
INSULATING
The maximum UV sig- TUBING
nal from a flame is
found in the first one- SEALING
UNION FORCED
third of the visible AIR
flame taken from the
point where the flame EXTEND SIGHTING TUBE
begins. The scanner 6(1524) OR 8(2032)
sight pipe should be
aimed at this area. METHODS OF COOLING SCANNER
SHUTTER OPEN
3.7 SEC.
38
WIRING - UV SCANNERS
To connect the scanner to the control, the UV1 Scanner is supplied with 36 or 72 of flexible cable.
The 45UV5 is supplied with four 72 lead wires. Install them in a suitable length of flexible armor
cable and connect it to the control. A conduit connector is supplied with the scanner. Connect black
wires (shutter) to terminals L1, L2; red wires (UV tube) to terminals S1, S2.
If it is necessary to extend the scanner wiring, the following instructions apply:
Scanner wires should be installed in a separate conduit. The wires from several scanners may be
installed in a common conduit.
1. Selection of Wire
a. Wiring: For extended scanner wiring up to 500 feet, and for shorter lengths to reduce signal
loss, use a shielded wire (Belden 8254-RG62 coaxial cable, or equal) for each scanner wire
of UV1, UV2 and each red wire of the 45UV5. The ends of the shielding must be taped and
not grounded.
b. Asbestos insulated wire should be avoided.
c. Multiconductor cable is not recommended without prior factory approval.
2. High voltage ignition wiring should not be installed in the same conduit with flame detector
wires.
3. INSTALLATIONINFRARED SCANNER TYPE 48PT2
Where possible, obtain the burner manufacturers instructions for mounting the scanner, otherwise
proceed as follows:
A single scanner is used to detect both pilot and main flames. The sight pipe on which the scanner
mounts must be aimed so that the scanner sights a point at the intersection of main and pilot flames.
Proper scanner positioning must assure the following:
1. Reliable pilot flame signal.
2. Reliable main flame signal.
3. A pilot flame too short or in the wrong position to ignite the main flame reliably, must not be
detected.
4. Scanner must have an unobstructed view of flame being monitored.
5. Flame being monitored must completely cover the scanner field of view.
6. To avoid nuisance shutdowns, it is important to avoid sighting hot refractory and to keep scanner
temperature low (below 125 F) (52C).
7. When the proper position has been established, drill a hole through the furnace wall and install a
4" to 8 length of threaded l/2 black iron pipe on which to mount the 48PT2 scanner.
8. When satisfactory sighting position has been confirmed by operating tests, the sight tube should
be firmly welded in place.
SCANNER TARGET
SCANNER MUST NOT ABOVE REFRACTORY
SIGHT REFRACTORY SCANNER
LINE-OF-SIGHT
COMBUSTION
CHAMBER
SCANNER
SIGHTING TUBE
SCANNER
39
Wiring
Attach the cable supplied with the scanner to a junction box. Splice the cable wires to a pair of wires
not smaller than #l8. Install the complete run in a separate conduit to the control. Continuous con-
duit bonding between scanner and the control is mandatory! Scanner may be located up to 100
feet from control. Do not pass scanner wiring through any junction box containing other wires. Do
not run other wires through scanner conduit. Asbestos insulated wire should be avoided.
Keeping the Scanner Cool
The Infrared Scanner (Temperature Limit 125 F) should never get too hot to grasp comfortably in
the hand. Keep the scanner cool by one or more of the following methods.
1. Use 6 to 8 length of pipe between scanner and hot furnace front plate.
2. Use insulating tube (Part No. 35-69) on the end of the iron pipe.
3. Force air into sighting tube. Use Fireye Sealing Union (Part No. 60-801).
4. Make sure sighting tube does not extend more than halfway into refractory wall.
BLAST TUBE
BLAST TUBE
SHELL
COMBUSTION HEAD
40
3. Flame rod should enter the pilot flame from the side so as to safely prove an adequate pilot flame
under all draft conditions.
4. If the flame is nonluminous (air and gas mixed before burning), the electrode tip should extend
at least 1/2 into the flame, but not more than halfway through.
WRONG POSITION
OF ROD
INADEQUATE FLAME
CORRECT
POSITION
OF ROD
PILOT BURNER
CORRECT POSITION
OF PILOT FLAME
5. If the flame is partly luminous, the electrode tip should extend only to the edge of the flame. It is
not necessary to maintain absolutely uninterrupted contact with the flame.
6. It is preferable to angle the rod downward to minimize the effect of sagging and to prevent it
from coming in contact with any object.
7. An adequate grounding surface for the flame must be provided. The grounding surface in actual
contact with the flame must be at least four times greater than the area of the portion of the flame
rod in contact with the flame. It is essential to adjust the flame rod and ground area ratio to pro-
vide a maximum signal reading.
NOTE: Interference from the ignition spark can alter the true signal reading by adding to, or sub-
tracting from it. This trend sometimes may be reversed by interchanging the primary wires (line
voltage) to the ignition transformer. This interference can also be reduced by the addition of
grounded shielding between the flame rod and ignition spark.
8. Proven types of flame grounding adapters, as shown below, may be used to provide adequate
grounding surface. High temperature stainless steel should be used to minimized the effect of
metal oxidation. This assembly may be welded directly over the pilot or main burner nozzle.
MAINTENANCE
Type 48PT2 Infrared and Type UV1, UV2, 45UV5 Ultraviolet an~ 45CM1 Photoelectric Scanners
The viewing area of the scanner must be kept clean. Even a small amount of contamination will
reduce the flame signal reaching the detector by a measurable amount. Wipe the viewing area rou-
tinely using a soft cloth dampened with concentrated detergent.
Type 48PT2 Scanners include a replaceable #4-263-1 Firetron cell.
Type 45CM1 Scanners include a replaceable #4-230 Phototube #922.
Type 45UV5 Scanners include a replaceable #4-314-1 UV tube.
41
Contacts
There are no accessible contacts in the Flame-Monitor. Where contacts are used, their design assures
long trouble-free life when the load circuits are maintained within the published load ratings.
Electrical Noise
In areas of excessive electrical noise, the installation of an electrical noise suppressor (P/N 60-2333)
to the power supply at the control circuit may be helpful.
Humidity
In areas of high humidity, the control chassis should be removed and placed in a dry atmosphere
when the system is expected to be out of service for an extended period.
Rotation
It is recommended that control and scanner units purchased as spares be installed periodically to
ensure proper operation.
42
#60-1664 #60-1664
1 SWIVEL MOUNT AIR ENTRY APERTURE 1 SWIVEL MOUNT
#35-127 (PURGE AND #53-121
HEAT INSULATING NIPPLE COOLING)
2.75
(70)
#60-1664 AIR/ENTRY
1 SWIVEL MOUNT (PURGE ABD COOLING) PURGE AIR ENTRY
#35-127 #35-127
HEAT INSULATING NIPPLE HEAT INSULATING NIPPLE
2.75
(70)
AIR ENTRY
(PURGE AND
1 SIGHT PIPE COOLING)
(BY OTHERS)
#60-1664 AIR/ENTRY
1 SWIVEL MOUNT (PURGE AND COOLING) #60-1199 3/8 PLUG
#35-127 #35-127 #35-127 (BY OTHERS)
HEAT INSULATING NIPPLE HEAT INSULATING NIPPLE HEAT INSULATING NIPPLE
2.75
(70)
43
UV8A Scanner
2 1/4 1/2 X 14 ST. 2
(57.2 PIPE (50.8mm
)
1 1/2
(38.1M
UV8A UV1A3 3 FT. FLEXIBLE CABLE
1 IN. DIA.
(25.4mm) UV1A6 6 FT. FLEXIBLE CABLE
.700 DIA. FITTING (17.8mm)
SHIELDING OF 6 FT. (1830mm)
FOR WATER-TIGHT CONDUIT
LEADS IS REQUIRED
i.e.: Thomas & Betts 5121-TB
WARNING: The leads from the UV8A Scanner to the control must be shielded to prevent electrical
noise from generating a false flame signal to the control.
2 2
(51) (51)
2
(51)
TEE-PIECE
2
(51)
TEE-PIECE
44
5 11/16
CONTROL WITH COVER WIRING BASE (144.5)
AND WIRING BASE MOUNTING HOLES 2 7/16
(61.9)
3 5/8 (92)
1 7/8
(48) KNOCKOUTS FOR 5 1/4
7 9/32 1/2 CONDUIT (7) (133)
5 3/4
(185) 7
(146)
(177.8)
3 7/32
(82) 3/4
(44.4) 25/32
(19.8)
1/4
11/16
1/2 KNOCKOUT 1 3/16 TYP
6 (17.4)
(30.2) (6.35)
(152) 390
1 1/16 4 7/8
TYP
(27) (123.8)
(9.9)
2 7/8 SCREW,
1 TAPPED (73) 1/4-20 THD
(25.4) #6-32,
2 HOLES
7/16 1 7/16
(11.1) HOLE FOR
3/4
TYPE 45CM1 PHOTOCELL SCANNER SIGHTING 3 1/4
WHEN ASSEMBLED PIPE (82)
3 3/16 (81)
2 1/4 1 DIA. 2 1/2
(57) (25.4) (63.5)
1 1/4 DIA.
(31.8) UV SCANNER
TYPE 45UV3 2 1 5/8
9/16 DIA. MODEL 1050 (50.8) (41)
7/16 FLEXIBLE HEAT INSULATOR
(143) 1/2-14
(11) CONDUIT 2 (51) CLEARANCE REQUIRED TO REMOVE
1/2-14 TAPERED
STRAIGHT PIPE THD PIPE THD UV SELF-CHECK
48PT2-1000 SERIES INFRARED SCANNER SCANNER
TYPE 45UV5
WHEN ASSEMBLED MODEL 1009
4 (102)
3 1/8 1 DIA. 2 1/2
1 1/2 (79.4) (25.4) (63.5) 2 4 (102)
13/32 (10)
(38) (51) 1 11/16
8 1/4
(210) HEX
1 1/4 DIA. (43)
(31.8) 72 LEAD
2 5/16
(58.7)
9/16 DIA. HEAT INSULATOR
(143) 1/2-14
1/2-14 TAPERED
STRAIGHT PIPE THD PIPE THD
7/16 DIA. (11) FLEXIBLE CONDUIT 1-11 NPT
3/8-18 NPT FOR
FOR SIGHT
48PT2-9000 SERIES INFRARED SCANNER PURGE AIR CONNECTION
TUBE
45
46
NOTICE
When Fireye products are combined with equipment manufactured by others and/or integrated into
systems designed or manufactured by others, the Fireye warranty, as stated in its General Terms and
Conditions of Sale, pertains only to the Fireye products and not to any other equipment or to the
combined system or its overall performance.
WARRANTIES
FIREYE guarantees for one year from the date of installation or 18 months from date of manufacture
of its products to replace, or, at its option, to repair any product or part thereof (except lamps, elec-
tronic tubes and photocells) which is found defective in material or workmanship or which otherwise
fails to conform to the description of the product on the face of its sales order. THE FOREGOING
IS IN LIEU OF ALL OTHER WARRANTIES AND FIREYE MAKES NO WARRANTY OF
MERCHANTABILITY OR ANY OTHER WARRANTY, EXPRESS OR IMPLIED. Except as
specifically stated in these general terms and conditions of sale, remedies with respect to any product
or part number manufactured or sold by Fireye shall be limited exclusively to the right to replace-
ment or repair as above provided. In no event shall Fireye be liable for consequential or special dam-
ages of any nature that may arise in connection with such product or part.
FIREYE E-1101
3 Manchester Road Nov. 2000
Derry, New Hampshire 03038 USA Supersedes Dec. 1999
48