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Service Manual for Flame Safeguard & Combustion Controls

1. SERVICE MANUAL FOR FLAME SAFEGUARD AND COMBUSTION CONTROLS FLAME DETECTORS M SERIES CONTROL D SERIES CONTROL FLAME MONITOR by Willy Vandermeer WV 01 SEPTEMBER 8 2006 FIREYE INC FLAME SAFEGUARD amp COMBUSTION CONTROLS Preface This manual provides the basic principles of operation and application of Fireye flame safeguard controls It is not intended to improve on or replace any of the technical bulletins that are factory shipped with the controls Field technicians preparing for a wider base of knowledge in this field may benefit significantly from this document Although this manual should prove beneficial at various levels it is directed towards service technicians and operating personnel which service the equipment described in this manual on a regular basis However this manual presupposes the reader possesses an adequate background in the fundamentals of burners heaters and boilers including utilization of the various fuels burned and the control systems associated with this type of equipment The content of this manual outlines the Fireye flame safeguard FSG environments as well as the principles of operation and installation of the various f
2. BLOWER RATING LIMIT CLOSED BLOWER 0 aper ott La START BLOWER O FIREYE O AUTO RLOCK LIMITS CLOSED BLOWER O PURGE TA O FIREYE O AUTO LOW FIRE START LIMIT CLOSED e BLOWER y on Le PILOT TRIAL O FIREVE FOR IGNITION AUTO O LOWER PURGE PILOT ome E PROVEN O AUTO BLOWER o TH O pe O AUTO O BLOWER O PURGE o TH 4 FIREYE AUTO a PURGE o TH O FAREYE o AUTO ERMINALS L1 L2 ERMINALS L1 13 ERMINAL M A ERMINALSD 8 3 30 SECONDS MODULATOR DRIVEN TO LOW FIRE TERMINALS 10 12 e WW TERMINALS M D 4 VOLTAGE ON TERMINALS 5 AND 6 5 1 8 2 18 25VDC ON TEST JACKS VOLTAGE ON TERMINAL 7 VOLTAGE ON TERMINAL 5 6 INTERRUPTED 6 ERMINALS 10 11 1 13 OPE IODULATOR SENT TO LOW FIRE ERMINALS 10 12 5 SECONDS BLOWER ONLY Fig 53 Control Sequence Diagram for 70D10 and 70D20 control Note In order to measure voltages at wiring terminals remove the control s cover and measure at access point as shown above ERMINALS 3 P RUNNING INTERLOCKS ERMINALS 13 3 PROOF OF VALVE CLOSURE A IODULATOR RELEASED TO AUTOMATIC VOLTAGE ON TERMINAL 7 TERMINATED A A IODULATOR HELD AT LOW FIRE TERMINALS 10 12 IODULATOR SENT TO HIGH FIRE TERMINALS 10 X A 1 WER FLAME SAFEGUARD amp COMBUSTION CONTROLS 70D10
3. CONTROL LOGIC FLOW DIAGRAM NORMAL CYCLE FOR EP300 AND EPD3OO SERIES PROGRAMMER MODULES Fig 75 Logic flow diagram for EP 300 series programmers Page 64 FLAME SAFEGUARD amp COMBUSTION CONTROLS amp TROUBLE SHOOTING FLAME MONITOR E110 CONTROL No voltage at term L1 L2 All LED s off on EPD programmer nothing on display on EP programmer e Electrical supply switched off Blown fuse or tripped breaker Bent tab on bottom of control Loose connection Wiring error Improper voltage at term L1 L2 e Min operating voltage 102vac e Max operating voltage 132vac No voltage at term 13 Standby L1 13 Open e Burner on off switch off Operating or limit control open Loose connection Wiring error Check for bad tabs see Fig 48 No voltage at term 3 Lockout Fuel Valve End Switch e Fuel valve s proof of closure switch open e System has no POC switch and no jumper installed at terminals 3 13 e Check for bad tabs see Fig 48 Blower motor does not start e Control is in lockout Motor three phase power off Defective motor or contactor Check for bad tabs see Fig 48 If no voltage at term M replace chassis Control locks out on False Flame e Flame is detected at inappropriate time e Check for actual flame being detected e Check for incorrect scanner wiring causing electrical noise causing false signal See page 57 e Defective UV tube gi
4. Fig 68A Control relay in running interlock circuit Page 55 FLAME SAFEGUARD amp COMBUSTION CONTROLS The following are extensive and very helpful tips for wiring issues with regard to Flame Monitor applications They are contained in Service Note 100 provided and released by Fireye in 1998 For clarity the entire service note is included below Copies of this excellent service note can be obtained at your Fireye distributor or at Fireye s web page www fireye com GROUNDING METHODS FOR FIREYE FLAME MONITOR APPLICATIONS SERVICE NOTE 100 Definition The primary function of electrical grounding required by the National Electrical Code NEC is to provide safety for equipment and personnel from abnormal electrical conditions The grounding also provides a path for dissipation of the high energy electrical discharges caused by lightning as well as prevents build up of static charges on equipment and materials In addition the ground establishes an equipotential or zero voltage reference for the electrical system A good ground system should be provided to minimize the effects of AC quality problems A properly 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 foll
5. CHECK EXPANSION MODULE CHECK PROGRAMMER CHECK SCANNER COMBUSTION AIR END SWITCH OPEN CONTROL PANEL SWITCH OPEN CYCLE COMPLETE D 8 HIGH LIMIT D 8 LIMIT CLOSED D 8 LIMIT OPEN DAMPER POSITION END SWITCH OPEN E300 MSG SELECT E340 OP CNTL OPEN E340 SAFETY INTLK OPEN F D FAN INTLK FALSE FLAME FLAME FAIL FLAME SIGNAL FUEL VALVE STATE CHANGE HIGH FIRE PURGE HIGH GAS PRESSURE O High electrical noise Check phase on L1 L2 is the same as on the control s interlock circuits Defective amplifier Defective IR scanner cell See page 56 Voltage on terminal 7 at improper time Defective Chassis Defective programmer Expansion module part no E300 failed Replace E300 Voltage on terminals 5 6 at improper time Defective Chassis Defective programmer UV scanner Self Check failure Defective UV tube Defective shutter assembly Electrical noise on scanner wiring This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P Operator open L1 13 unit in post purge Run Check switch placed in Check modulator driven to high position Dipswitch 6 is enabled Check for D 8 circuit open on start has not passed Unit will hold for 30 second for
6. Improper voltage at term L1 L2 e Min operating voltage 102vac e Max operating voltage 132vac No voltage at term 7 e Burner on off switch off e Operating or limit control open e Loose connection e Wiring error Voltage at term 7 but not term 8 e Control is in lockout Alarm LED on e False flame signal detected Flame LED is on Check for false flame being detected or possibly incorrect scanner wiring causing electrical noise e Defective UV tube giving false flame signal e Defective control chassis Voltage at term 7 but not term 6 e Interlock s wired between term 8 and 6 open Airflow LED remains off e Wiring error Control locks out before prepurge begins e Prove Airflow Term 8 6 open on start is selected enabled via its dipswitch It seems prepurge is too long e Check dipswitch settings on programmer module PTFI starts PTFI LED on programmer module lights but no power on term 3 amp 4 e Fuse is blown Inside program module for MC120 on chassis for MEC120 type control Pilot fails to establish PTFI LED on for 10 seconds followed by lockout No visual presence of flame e Fuel supply shut off e Air in fuel line needs purging e Defective pilot valve e Incorrect fuel pressure check pilot reg e Defective ignition transf Check for spark e Incorrect spark gap at igniter assembly e Incorrect location of spark electrode tips in relation to pil
7. 45 D Series Specifications 46 Flame Monitor oooooccocinoccconncocccccononccininnnncinno 47 Specifications noaeaeneneeeeeeeena 47 Amplifier Modules 48 Programmer Modules ssnaasennnaneen 49 Dipswitch Gettings 50 Wiring Schematics seeeeeeeeeeeaeeee 52 Supply Voltage Tolerance 55 3 P Circuit Tolerance cee 55 Grounding Methods eeeeeeeeeeee 56 Display Module 58 EPD Style Proorammers 59 Flame Monitor Messages 60 Logic Flow Diagrams sseeeeeeeeea 62 Trouble Shooting Flame Monitor 65 Page 2 FLAME SAFEGUARD amp COMBUSTION CONTROLS The control of fuel fired equipment can be divided into two categories Flame Safeguard Control and Combustion control Flame Safeguard Control provides operation and monitoring for safety in meeting fuel handling and equipment design limitations Combustion Control provides operation and monitoring for a burner s capacity by varying its output based on process demand FLAME SAFEGUARD By definition the term Flame Safeguard FSG covers all aspects of safety in operation of fuel fired equipment This includes the flame detection device used to sense the presence of flame the fuel safety shut off valves fuel safety limits auxiliary safety limits sequencing and timing relays and any other controls used in conjunction with the burner safety contro
8. L1 13 AUX 3 OPEN L1 13 OPEN LINE FREQUENCY NOISE DETECTED LOCKOUT HISTORY LOW ATOMIZING PRESSURE LOW FIRE PURGE LOW FIRE SIGNAL LOW GAS PRESSURE LOW OIL PRESSURE LOW OIL TEMPERATURE LOW WATER LOW WATER M D LIMIT CLOSED M D LIMIT OPEN M D LOW LIMIT OIL GUN END SWITCH OPEN FLAME SAFEGUARD amp COMBUSTION CONTROLS This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P PTFI Started Flame not yet proven This is an E300 message and refers to a limit in circuit L1 13 This is an E300 message and refers to a limit in circuit L1 13 This is an E300 message and refers to a limit in circuit L1 13 Operating cont
9. eet 3 RECYCLE EPD382 EP382 INTERMITTENT 5 RECYCLE 5 Et yee ege EP383 NO TERMITTENT RECYCLE 5 Es io ie EPD390 EP390 90 nO YES 3 YES YES YES 4 RECYCLE 10 oF AS e o 10 INTERMITTENT 5 ALL PROGRAMMERS HAVE A MAXIMUM 4 SECOND FLAME FAILURE RESPONSE TIME WITH THE EXEPTION OF THE EP165 EP166 AND EP265 2 SEC ALL EPD AND EP PROGRAMMERS HAVE SELECTABLE 3 TO P PROVE OPEN ON START FEATURE VIA DIPSWI EP165 LOCKS OUT ON POWER INTERRUPTION DI OD A Ob oh Fig 57 Flame Monitor selection chart Programmer PROGRAMMERS The programming module is the hearth of the system Figure 57 represents a chart of the most common programmers and lists the programming sequence Note that programming functions in the sequence may be selectable via dipswitches located on the module THE EPD167 WAITS INDEFINITELY FOR THE LOW FIRE START SWITCH M D TO CLOSE THE EP163 PURGE AND IGNITION TIMINGS ARE PROGRAMMABLE VIA THE ED510 DISPLAY MODULE THE EP383 PURGE IGNITION FFRT AND POST PURGE TIME IS PROGRAMMABLE VIA THE ED510 DISPLAY MODULE INTERMITTENT OR INTERRUPTED PILOT OPERATION MAY BE SELECTED VIA DIPSWITCH OR VIA EDS CH PROGRAMMER ADDS 30 SECOND AFTER PRE PURGE TO ALLOW DAMPER MOTOR TO DRIVE TO LOW FIRE POSTION PUGE TIMINGS CAN BE EXTENDED VIA THE DIPSWITCHES LOCATED ON THE PROGRAMMER MODULE EP380 EP381 EP382 AND EP390 HAVE
10. 4 ATTERM 3 AND 4 THE FUSE IS BLOWN O rave A PERIOD j f L A O ALARM MAIN ON y VOLTAGE ON TERMINAL 5 IGNITION OFF fo OPR CTRL AIR FLOW VOLTAGE ON TERMINALS 1 3 5 6 7 AND 8 FLAME ALARM CALL FOR HEAT po VOLTAGE ON TERMINAL 1 ONLY TERMINATED af Fig 42 Control sequence diagram for M series TYPE 200 PROGRAMMER control with 200 series programmer Voltage at ape terminals can be measured as shown when PROVEN control s cover is removed ae TERM 7 TERM 8 gt PURGE COMPLETE FIRING PERIOD TERM 3 STABILIZATION PERIOD 8 SEC PTFI H MODEL ONLY 5 10 SEC TERM 4 gt TERM 5 gt Page 33 FLAME SAFEGUARD amp COMBUSTION CONTROLS M SERIES CONTROL SEQUE 500 SERIES PROGRA OPR CTRL O AIR FLOW O PTFI O FLAME lt O ALARM START BLOWER OPR CTRL S cal a O PTFI O FLAME O ALARM H OPR CTRL ern IGNITION one PILOT GAS O ALARM H OPR CRL AIR FLOW em PILOT o aas 4 PROVEN O ALARM OPR CTRL Y 9 Arrow PILOT STABALIZATION Wi Fave PERIOD O ALARM INTERRUPT PILOT opr CRI y o AR FLOW wl sie E e O ALARM CALL FOR HEAT TERMINATED VOLTAGE Ol VOLTAGE O VOLTAGE O VOLTAGE O VOLTAGE Ol VOLTAGE Ol VOLTAGE Ol VOLTAGE O VOLTAGE O VOLTAGE O VOLTAGE Ol VOLTAG
11. 70D20 CONTROL SEQUENCE DIAGRAM O BLOWER PURGE om a o O FIREYE o AUTO IA PAN 5 SEC TERM 5 IF POC IS NOT CLOSED AT START START UP WILL NOT BE INITIATED 70D10 WILL LOCK QUT 3 P RUNNING INTERLOCK CIRCUIT MUST BE CLOSED WITHIN 10 SECONDS OR LOCKOUT WILL OCCUR 70D10 70D10 ONLY 70D20 PURGE NOT SUPERVISED WAITS FOR M D TO CLOSE 71D60 PROGRAMMER 10 SEC TERM 5 15 SEC TERM 6 71D70 PROGRAMMER 71060 PROGRAMMER TERMINAL 5 5 SEC TERMINAL 6 10 SEC 71D70 PROGRAMMER TERMINAL 6 10 SEC 10 SEC TERM 6 Page 43 FLAME SAFEGUARD amp COMBUSTION CONTROLS 70D30 CONTROL SEQUENCE DIAGRAM v O AIRFLOW o m na An ERMINALS L1 L2 O FIREYE RATING LIMIT ERMINALS L1 13 CLOSED START BLOWER J TERMINAL M Sen lt RLOCK LIMITS ERMINALS 3 P RUNNING INTERLOCKS O FREE CLOSED ERMINALS 13 3 PROOF OF VALVE CLOSURE 1 Vv 71D81 PROGRAMMER 15 SECONDS 71D80 PROGRAMMER 30 SECONDS 71D90 PROGRAMMER 90 SECONDS PRE PURGE COMPLETE A LOW FIRE START TERMINALS M D 2N LIMIT CLOSED d y 0 arrow A em le PILOT TRIAL VOLTAGE ON TERMINAL X 5 SECONDS e X o nee FOR IGNITION VOLTAGE ON TERMINAL 5 amp 6 10 SECONDS 3 AIRFLOW e PILOT 1 amp S2 me PROVEN 18 25VDC ON TEST JACKS O arrow Ze La VOLT
12. AIR FLOW TRANSFORMER BURNER CONTROL SWITCH SWITCH H 120vac e SUPPLY Fig 36 Typical wiring arrangement for pilot ignited burner using M series 500 programmer Note For Micro M wire limits between 7 and 6 not 8 and 6 LIMIT OPERATING FUEL SWITCHES CONTROLS INT LOCKS PRIMARY MAIN FUEL VALVE Br SECONDARY MAIN FUEL VALVE IF USED IGNTION BURNER CONTROL SWITCH ELECTRONIC CIRCUIT H 120vac e 4 SUPPLY Fig 37 Typical wiring arrangement for direct spark ignited burner using M series 500 programmer Note For Micro M wire limits between 7 and 6 not 8 and 6 Page 29 FLAME SAFEGUARD amp COMBUSTION CONTROLS amp 1 WwW SCANNER FLAME ROD OR PHOTOCELL LIMIT L SWITCH LL PILOT GAS VALVE EN S MAN 1S 2 TOCKOUT FUEL ALARM VALVE SPARK IGNITION LR COIL BURNER CONTROL SWITCH H 120vac e H SUPPLY N Fig 38 M series control wired for operator to start up each time the burner is fired FOR M SERIES II WIRE L1 TO 7 ONLY e WwW SCANNER FLAME ROD OR PHOTOCELL VOLTAGE SOURCE Y 3 FLAME ON FOR MICRO M INDICATION WIRE L1 TO 6 ONLY FLAME OFF INDICATION H 120vac SUPPLY N NOTE USE 100 SERIES PROGRAMMER ONLY OUTPUT FUSE SHOULD BE REMOVED Fig 39 M series control wired as flame switch only Page 30 FLAME SAFEGUARD amp COMBUSTION CONTROLS amp e IN SCANNER FLAME ROD OR PHOTOCELL BURNER CONTROL
13. Fireye supplied ED512 cables provide the ferrite cores attached to the cables For longer runs beyond the lengths of ED512 proper twisted shielded pair cable must be utilized 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 contactor located in the control panel or across any high voltage ignition wires Refer to Fireye bulletin E 8002 for proper installation O Expansion Module For connection to an E300 expansion module the Fireye E350 cable must be utilized with the green grounding wire being connected to the green screw at the Flame Monitor end Care must be taken not to route the expansion module cable in close proximity to any starter motor contactor located in the control panel or across any high voltage ignition wires It is not good practice to route the E350 cable in the same race way as the high voltage control wires Scanners The armored cable supplied with the Ultra Violet and Infrared scanners should be connected to equipment by means of a good mechanical connection such as a conduit fitting lt may be necessary to utilize heat insulator 35 69 to isolate the sensing end of the scanner from
14. OPERATING LIMITS CLOSE TERM LI 13 MADE en v _ IS FVES MADE TA NO LOCKOUT PURGE ie RM 3 13 cee ee gt 13 lt 3 FUEL VALVE END SWITCH CONTROL WILL HOLD aren bi ae SR TO MING ne IS RUNNING VILK MADE y NO p LOCKOUT PURGE FOR 3 P TO BE MADE pe TINO MIN TE e ee INES PAN E 2 SELECTED PREPURGE PURGE 0 05 TIME BEGINS A y _ _ SELECTED PREPURGE ss TIMECOMPLETED EE AAA Sear tert ase a Ge IS LOW FIRE INTLK Ma NO HOLD PURGE 0 00 aS TOMIN MADESTERMM D oOo gt M LIMIT OPEN AA SE O IGNITION AND PILOT VALVE PTFI 0 00 ENERGIZED TERMX 5 amp 6 gt lexmon TIMING SS AAA IS FLAME PROVEN WITHIN NO LOCKOUT PTFI a 10 SECONDS gt FLAME FAIL Am TERM X OFF 5 SECONDS AFTER BEING ENERGIZED PILOT STABILIZATION PTFI 22 i gt TERM 5 amp 6 ON FOR 10 SECONDS PTFI aa ee o GE Wee GN EE MAIN FUEL VALVE MTFI 22 ENERGIZEDIERM 7 0 gt FLAME SIGNAL AAA ape e RA TERM 5 OFF 10 SCONDS AFTER TERM 7 ON E IS MAIN FLAME PROVEN Ma NO LOCKOUT MI TERM 6 REMAINS ON DURING FIRING PERIOD d ___AFTER PILOT WITHDRAWN P FLAME FAIL YES y A CONTROL IN RUN MODE R AUTO 40 _ TERM7 8 6 REMAIN ENERGIZED P FLAME SIGNAL PS CN DEMAND SATISFIED AS POST PURGE 0 06 _ OPERATING LIMIT OPENS TERM L1 13 _ gt CYCLE COMPLETE es M POST PURGE COMPLETE 15 SEC 7 STANDBY OPERATING LIMIT OPEN TERM L1 13 gt 13 OPEN
15. off cycle MEP102 Same as MEP100 with 10 sec PTFI MEP103 Fixed 10 sec PTFI 10 sec MTFI and Post purge Will retry once on pilot failure MEP104 Non recycle on flame fail 10 sec PTFI MEP105 Non recycle on flame fail lockout on limit failure 10 sec PTFI MEP100P Same as MEP100 with 15 sec Post purge MEP230 Selectable PTFI Pre purge timing Recycle or Non Recycle Prove limits open on start MEP230H Same as MEP230 with 8 sec Pilot stabilization period MEP234 Selectable PTFI Pre purge timing Prove limits open on start 10 sec Pilot proving MIEL Post purge Non Recycle on flame fail MEP235 Same as MEP230 with lockout on limits open 10 sec after start Non Recycle on limits or loss of flame MEP236 Same as MEP230 with 3 sec additional ignition on with main fuel For use with intermittent pilot only MEP290 Same as MEP230H with 90 second post purge MEP560 Same as MEP230H with 10 sec MIEL Run Check switch MEP561 Same as MEP560 without pilot stabilization period MEP562 Same as MEP560 with lockout on loss of flame and limit circuit open Daughter board Fuse Fig 32 Remote reset communications and display output are all features located on the daughter board Picture shows board with display output only Note Micro M has fuse located on chassis Amplifier Modules are selected based on the type of flame detector and the required FFRT The following amplifier modules are available MEUV
16. COMPLETELY COVER SIGHT OPENING NOT THIS NOT THIS BUT THIS Fig 19 Scanner sight tube must provide unobstructed view of flame Optical flame detectors need to be mounted on a sight tube Care should be given that the sight tube permits an unobstructed view of the pilot and or main flame Both pilot and main flame must completely cover the scanner s field of view Preference should be given to an angular about 5 to 25 degrees on axis view perpendicular with the fuel nozzle TARGET ABOVE REFRACTORY I SIGHT TUBE ee TARGET BELOW REFRACTORY Fig 20 Scanner sighting Infrared scanners must not sight hot refractory as this may cause unwanted signal or detector saturation If at all possible aim infrared scanners away from refractory as shown in Fig 20 Alternately extending the length of the sight tube or place scanner orifices inside the sight tube arrangement in order to minimize refractory sighting In any event a hot refractory hold in test should be performed Ultra Violet scanners should be aimed at the first one third of the flame This is the area where the maximum UV signal from a flame is found Page 19 FLAME SAFEGUARD amp COMBUSTION CONTROLS Swivel mounts are used to simplify scanner sighting They are available for Y and 1 NPT scanner mountings and are bolted to the burner front The scanner sight tube is threaded into the swivel mount with the sca
17. D 8 to open followed by lockout Se page 51 Waiting for terminals D 8 to close Maximum wait is 10 minutes followed by lockout This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P From here press MODE key to access the pre programmed lockout messages stored in memory associated with the E300 expansion module This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P Flame has been detected at an in appropriate time Control did not have or lost flame signal Flame proven signal strength shown in upper right hand corner 0 9 Not acceptable 10 Minimum acceptable 20 80 Normal During PTFI the voltage sensed has changed from the previous cycle See page 54 figures 65 and 66 Modulator motor send high 10 X made This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P Page 60 HIGH OIL PRESSURE HIGH OIL TEMPERATURE HIGH PRESSURE HIGH STACK TEMPERATURE HIGH TEMPERATURE HIGH WATER LD FAN INTLK IGNITION TIMING L1 13 AUX 1 OPEN L1 13 AUX 2 OPEN
18. FAN OPEN DAMPER CLOSE DAMPER IGNITION AUTO FLAME F rae ZS NU OCA JS af a 0 O Fig 72 EPD programmer module LED indicator lights Shown here with description added above each EPD style programmers are provided with a series of seven LED indicator lights to annunciate the current operating status Figure 72 shows the symbols of each LED with a description above Alarm lights when unit is in lockout Fan Lights when blower motor is energized Open Damper Blinks when damper is driven to high purge position lights constant when high purge limit is made Term D 8 Close Damper Blinks when damper is driven to low fire position lights constant when high purge limit is made Term M D Ignition Blinks during PTFI Lights constant during MTFI Auto Lights when MTFI complete and control releases to automatic Terminals 10 11 made blinks when RUN CHECK switch is in Check mode during Run period Flame Lights whenever flame is detected While the burner is off L1 13 open the LED s blink every 60 seconds to indicate the off condition Pressing the Reset button also causes the LED s to blink in succession The LED s also are used to provide information on the reason for the last lockout The reset button must be pressed twice to reset any lockout During any lockout pressing the reset button once will cause the LED s to light up according to a code in
19. Figure 45 is an example of a control wiring arrangement for a small power burner mounted on a steam boiler Fused control voltage L1 is wired to terminal 1 from where it is run to the boiler on off switch From the switch a wire is run to the boiler operating control and terminated at terminal 7 completing L1 to 7 Running interlocks are shown wired between terminals 8 and 6 some of these such as low water cut off may be found wired in series with the operating control between terminals 1 and 7 To operate close the on off switch On a call for steam and with other limits wired into the 1 to 7 circuit satisfied terminal 8 will become energized starting the combustion air blower All limits wired between terminals 8 and 6 must be satisfied and a control sequence will begin as described in figure 43 Two stage firing control is achieved via separate controller not shown Page 38 FLAME SAFEGUARD amp COMBUSTION CONTROLS FIREYE D SERIES D series flame safeguard controls in addition to the standard functions of M series flame safeguard control provide those functions required for fully modulating burners of unlimited capacity Some of these functions are 1 Firing rate motor positioning for purge light off and run auto position 2 Air damper fully open position supervision during purge Low fire start position supervision Proof of fuel valves closed supervision Early ignition spark termination Post purge ti
20. Installing The Control Wiring error Wiring base not grounded Control panel not grounded Step down transformer primary side neutral not grounded e Ignition transformer not grounded Page 65 FLAME SAFEGUARD amp COMBUSTION CONTROLS GH Pilot fails to establish Display reads PTFI for 10 seconds followed by lockout No visual presence of flame Lockout PTFI Flame Fail e Pilot Fuel supply shut off Air in fuel line needs purging Defective pilot valve Incorrect fuel pressure check pilot reg Defective ignition transf Check for spark Incorrect spark gap at igniter assembly Incorrect location of spark electrode tips in relation to pilot burner Incorrect wiring of pilot components e Check for correct voltage at term 5 or 6 during PTFI If none check for dirty or bent tab at bottom of control chassis See figure 48 Also check wiring base tabs Pilot fails to be detected Display reads PTFI for 10 seconds followed by lockout Yet visual presence of flame Lockout PTFI Flame Fail e Flame detector not detecting flame Inadequate pilot flame Improper amplifier module installed Flame rod not making contact with flame Defective flame rod porcelain Grounding surface of pilot assembly Flame Rod too small corroded Replace pilot burner See page 8 e Incorrect detector wiring See page 57 e Flame rod system No ground path from pilot burner to FSG control Provide ground wire from c
21. MULTIPLE BURNER SYSTEM UTILIZING SEMI AUTOMATIC OPERATION WITH M SERIES CONTROLS IN CASCADING SEQUENCE WHEN PILOT 1 IS PROVEN PTFI FOR PILOT 2 BEGINS WHEN ALL PILOTS ARE PROVEN MANUAL SAFETY VALVE MAY BE OPENED FLAME FAILURE OF ANY BURNER WILL TRIP MAIN FUEL VALVE AND ALARM WILL SOUND FLAME AMPLIFIER Fig 40 M series controls in cascading sequence for multi burner system Page 31 FLAME SAFEGUARD amp COMBUSTION CONTROLS M SERIES CONTROL SEQUENCE DIAGRAM 100 SERIES PROGRAM MODULE O OPR CTRL O AIR FLOW O Pm O FLAME o ALARM WIRNG TERMINAL ACCESS POINTS ON M SERIES CHASSIS VOLTAGE ON TERMINAL 1 OPR CIR AR FLOW Jm lg e VOLTAGE ON TERMINAL 7 o FLAME ALARM START BLOWER po VOLTAGE ON TERMINAL 8 OPR CIR S arrow A S WW lt VOLTAGE ON TERMINAL 6 MN O ALARM OPR CIR O Ar Flow E Sch lt VOLTAGE ON TERMINALS 3 AND 4 IN o ALARM OPR CTRL 4 AIR FLOW PILOT mm d S VOLTAGE ON TEST JACKS VDC FLAME PROVEN O ALARM y MAIN ON VOLTAGE ON TERMINAL 5 IGNITION OFF OPR CTRL Wi arrow 8 2 lt VOLTAGE ON TERMINALS 1 3 5 6 7 AND 8 O ALARM CALL FOR HEAT VOLTAGE ON TERMINAL 1 ONLY TERMINATED MICRO M LED BLINKS UNTIL LIMITS ARE MADE IF PTFI ILUMI
22. PTFI failure or following a safety shutdown the lockout switch trips activating an alarm circuit UVM and TFM controls incorporate a safe start check circuit that is operative on each start If flame real or simulated is detected prior to a start or during prepurge the unit will perform a safety shutdown Below are the M Series models UVM1D UV FFRT 0 8 sec Relight UVM1F UV FFRT 4 0 sec Relight UVM2 UV FFRT 4 0 sec Recycle UVM3 UV FFRT 4 0 sec Non Recycle UVM3H UV FFRT 4 0 sec Non Recycle TFM1D FL Rod FFRT 0 8 sec Relight TFM1F FL Rod FFRT 4 0 sec Relight TFM2 FL Rod FFRT 4 0 sec Recycle TFM3 FL Rod FFRT 4 0 sec Non Recycle TFM3H FL Rod FFRT 4 0 sec Non Recycle Purge timing Cards for M2 M3 or M5 Card Prepurge HIE MT55 5 sec 5 sec MT74 7 sec 4 sec MT304 30sec 4 sec MT710 7 sec 10 sec MT904 90sec 4 sec MT3010 30 sec 10 sec MT6010 60 sec 10 sec MT9010 90 sec 10 sec Page 23 FLAME SAFEGUARD amp COMBUSTION CONTROLS FIREYE M SERIES II Fireye Modular M Series II controls are of solid state design and provide a multitude in basic styles of functions The M Series Il is a compact modular design flame safeguard control designed to provide automatic ignition and flame monitoring for commercial heating and process burners Interchangeable programmer and flame amplifier modules allow for versatility in selection of control functions timing and f
23. amp COMBUSTION CONTROLS TROUBLE SHOOTING AND TESTING OF FLAME DETECTORS Any flame detector system must be thoroughly inspected and tested prior to putting the system into permanent service The following is a suggested listing of tests used to assure a safe system of flame detection 1 Flame signal measurement required for all types of flame detectors 2 Hot refractory saturation test required for infrared flame detectors 3 Hot refractory hold in test required for visible light and infrared flame detectors 4 Ignition spark sensing test required for ultraviolet flame detectors 5 Ignition interference test required for flame rod type detectors 6 Pilot turndown test required for all flame detector types when used to detect pilot flame Fig 17 Infrared scanner P N 48PT2 contains Cell P N 4 263 1 and Lens P N 61 436 FLAME SIGNAL MEASUREMENT A steady flame signal of at least recommended minimum strength must be maintained throughout the operation of the burner The minimum acceptable signal strength is listed in the technical bulletin of the control used The flame signal can be checked via test jacks provided located on flame amplifier module or via its control display readout Unstable readouts may be caused by Unstable flame conditions Incorrect supply voltage Defective detector wiring Electrical noise on detector wiring Dirty viewing lens A a 6 Faulty dete
24. at igniter assembly Incorrect location of spark electrode tips in relation to pilot burner e Incorrect wiring of pilot components Pilot fails to be detected Blower and TFI LED s on for 10 seconds followed by lockout Yet visual presence of flame e Flame detector not detecting flame Inadequate pilot flame Improper amplifier module installed Flame rod not making contact with flame Defective flame rod porcelain Grounding surface of pilot assembly too small corroded Replace pilot burner See page 8 e Incorrect detector wiring e Flame rod system No ground path from pilot burner to FSG control Provide ground wire from control chassis to pilot assembly Provide ground to terminal S2 Flame detector dirty Incorrect line of sight for flame detector Unstable pilot flame Defective flame detector or amplifier module Page 45 FLAME SAFEGUARD amp COMBUSTION CONTROLS It takes seconds before the pilot flame is detected after pilot valve and ignition transformer are energized e Incorrect location of spark electrode tips in relation to pilot burner e Incorrect too high fuel pressure e Incorrect primary air adjustment on pilot burner Main flame fails to establish after PTFI Blower TFI and Fireye LED s on e Run check switch in check located in programmer modules Main manual shut off valve closed Defective main ESD fuel valve Improper fuel pressure Main valve opening causes
25. continued for faster means of flame failure detection lt was found that a gas flame envelope could carry a small electrical current This characteristic led to the development of a new and electronic type of flame detection A rod flame rod was inserted into the flame and the conductivity of the flame if present could be measured Although this system eliminated reaction time issues it proved unreliable Any high resistance short in the sensing circuit could also simulate flame This was later overcome by the introduction of the flame rectification circuit whereby the alternating current AC has to be rectified to direct current DC in order to be accepted as flame signal This system is still widely in use today Both the bimetal or thermocouple and flame rod systems require direct contact with either the flue gases or flame envelope and it was not until the mid 1940 s that optical flame detection became a reality The first optical detector was a photocell to sense visible light in oil burners followed by infra red detectors in the 1950 s and ultra violet detectors in the 1960 s Ongoing developments continue Page 3 FLAME SAFEGUARD amp COMBUSTION CONTROLS to fine tune these sensors to meet the ever increasing demands for safety in the industry TYPES There are many types of flame safeguard controls designed for use in residential commercial and industrial applications Residential FSG controls generally r
26. firing rate motor is driven to terminals 10 X made and proven at terminals D 8 closed the high purge position At the end of the pre purge timing EP100 and 200 series only the firing rate motor is driven to the low fire light off position 10 12 made EP100 and 200 series programmers will add a minimum 30 seconds maximum 10 minutes to the pre purge timing waiting for low fire start switch to be proven closed EP300 series programmers do not have firing rate motor circuit control These programmers do not prove high fire purge position and do not have a minimum wait period for low fire start switch to close PTFI is initiated immediately after selected prepurge period is completed and low fire end switch is made PROVING THE RUNNING INTERLOCK CIRCUIT 3 P OPEN ON START Dipswitch 6 provides the option to prove the running interlock circuit terminals 3 P open at the start of the each operating cycle which also includes that the high purge interlock D 8 and low fire start interlock M D are switching open and closed at the appropriate times 1 All series programmers H this option is enabled Switch 6 is up the running interlock circuit terminals 3 P must be open at the start of each operating cycle terminals L1 13 closing If the 3 P circuit is closed at the start of a new operating cycle the control will hold for 1 minute waiting for this circuit to open If
27. radiation intensity is required as received from the flame envelope to be accepted as flame on Only special applications can operate safely with this amplifier Consult factory before using The E1R3 does not provide oil spray rejection protection which may result in unsafe operation if not properly applied Oil Spray Rejection implies that the system responds to any significant change in level of flame brightness such as a flame out condition where oil continues to be sprayed in front of bright hot refractory Consult factory before using Page 48 PRE PURGE PROGRAM MING SECONDS PROVEN HIGH FIRE PURGE PROVEN LOW FIRE PURGE INTERLOCK INTERLOCK M D Cki FLAME SAFEGUARD amp COMBUSTION CONTROLS INTERMIT TENT IGNI TION PILOT INTERRUPTED IGNITION PILOT EARLY PILOT SPARK TRIAL FOR IGNITION MAIN TRIAL FOR IGNITION TERMI NATION TERMS TERMS lt RUNNING INTERLOCK 3 P CH FIRING RATE MOTOR CIRCUIT FLAME FAILURE RESPONSE TIME FFRT 2 D 8 Ck 30 SUPERVI YES 30 SUPER O RECYCLE 30 SUPERVI O RECYC 30 SUPERVI O RECYC 30 SUPER O RECYO 30 SUPERVI O RECYCLE 30 EPD260 EP260 RECYCLE 30 EPD261 EP261 RECYCLE EPD265 3 EP265 RECYCLE 6 EPD270 EP270 RECYCLE 10 EPD380 EP380 3 RECYCLE INTERMITTENT 2 EPD381 EP381 10
28. should be present The system will perform a Safe Start Check as first part of its sequence A system lockout will occur if a bad tube is detected during safe start check If a tube fails during normal operating flame on conditions the bad tube may not be recognized until a system re start when a safe start check is initiated It is for this reason that scanner self check systems were developed A self check system for an UV tube type flame detector consists of an optical shutter device placed directly in the path of the tube s UV radiation The shutter opens and closes continuously effectively blocking the UV radiation for a brief period 0 25 to 0 75 sec depending on design but less than the FFRT The FSG system drives the scanner self check shutter mechanism and checks for the scanner s pulse count to stop during the shutter closed period Scanner pulse counts detected during the shutter closed time causes the system to react to scanner self check failure by shutting off fuel and going to lockout When using UV tube type flame detectors a scanner with self check feature is mandatory for burners or appliances that are designed for continuous operation Current l AC Cycle T l ount l l Dte am ros MUL a Fig 12 UV tube detector AC current operation principle Continuous operation is defined as 24 hours of continuous use In addition UV self checking scanners are mandatory
29. switching open and closed at the appropriate times dipswitch 6 Note All dipswitch functions become PERMANENT after the control has been powered for more than eight 8 hours After this Burn In period changing the position of any dipswitch will not have any effect on the operation of the programmer module Figures 58 and 59 show dipswitch location and functions Dipswitches 1 and 2 are inactive on EP100 and 200 series programmers The EP300 series programmer utilizes dipswitch 1 to determine if the programmer will recycle or not when the running interlock circuit terminals 3 P opens during the firing cycle The programmers are shipped with the switch in the Recycle switch down position The EP300 series programmer utilizes dipswitch 2 to select Intermittent or Interrupted operation of terminal 6 Pilot or first stage valve When selected for intermittent operation terminal 6 remains energized throughout the firing period When selected for interrupted operation terminal 6 is energized for 10 seconds during PTFI and 15 seconds during MTFI before de energizing These programmers are shipped with dipswitch 2 in the down position Intermittent operation PRE PURGE TIMING Dipswitches 3 4 and 5 are for pre purge timings Purge timings are selectable as per the charts shown in figure 58 O Note that only on the EP100 series programmers the selected purge timing is not initiated until the
30. the wiper moves toward W the resistance between R and B increases and the reverse is true in that if the wiper moves toward B the resistance between R and W increases The modulating motor has a similar feed back potentiometer which works in conjunction with a balancing relay The unequal currents flowing through each side of the balancing relay will cause the relay to pivot engaging the appropriate motor windings Increasing resistance in the B wire of the motor circuit will cause the motor to drive to the low or closed position Increasing the resistance to the W wire of the motor circuit will cause the motor to drive to the high or open position As is clear from figure 62 resistance between R and B or R and W are manipulated by the Flame Monitor s firing rate motor switching circuit causing the desired effect during the control sequence Figure 63 shows the wiring when using a 4 20 mA control system FLAME MONITOR TERMINALS 4 20 Ma CONTROLLER Fig 63 Firing rate motor switching wiring when using 4 20 mA damper motor Page 53 FLAME SAFEGUARD amp COMBUSTION CONTROLS FLAME MONITOR TERMINALS y IGNITION TRANSFORMER af Fig 64 Wiring arrangement for spark cut off feature EP170 programmer only When using an EP100 series programmer and the ignition spark needs to be terminated prior to main trial for ignition use an EP170 module and wire as shown in figure
31. used on standing pilot burners with flame rod detection Page 24 FLAME SAFEGUARD amp COMBUSTION CONTROLS Programmer Modules are the heart of the system and are selected based on functions required The following models are available MP100 Relight operation Control will relight on flame failure during main flame on Locks out if pilot fails to be detected MP102 Non relight 5 sec PTFI MP230 Selectable prepurge and PTFI timing recycle non recycle operation MP230H Same as MP230 with pilot stabilization period MP560 Same as MP230H with 10 sec MTFI Includes run check switch MP561 Same as MP560 with lockout on flame fail and running interlock Amplifier Modules are selected based on type of flame detector and required FFRT The following flame amplifier modules are available MAUV1 UV Detector 2 4 sec FFRT MAUV1T UV Detector 0 8 sec FFRT MART1 Flame Rod Detector 2 4 sec FFRT MART1T Flame Rod Detector 0 8 sec FFRT Page 25 FLAME SAFEGUARD amp COMBUSTION CONTROLS FIREYE MICRO M SERIES Fireye Micro M Series controls are of microprocessor based design and as with the M Series Il are a modular burner management system designed to provide automatic ignition and continuous flame monitoring for commercial sizes of heating and process equipment firing any type of fuel The Micro M design is backward compatible to the wiring base of existing UVM TFM and M Series II controls The Micro M i
32. will remain within the ambient temperature limits of the scanner For UV scanners model 45UV5 this is max 140 F 60 C and for model UV1A maximum temperature is 200 F 94 C Minimum temp is 40 F C 8 If cooling is required you can use an insulating coupling Fireye 35 69 for UV1A scanners and Fireye 35 127 1 for 45UV5 scanners to reduce conducted heat Cooling air can be added to reduce sight pipe temperatures 9 UV1A and 45UV5 scanners are not designed to seal off any sight pipe pressures To seal off positive furnace pressures in access of 12 WC use Fireye 60 1257 Y NPT quartz window O arrangement for UV1A scanners For 45UV5 scanners use Fireye 60 1199 1 NPT quartz window arrangement 10 When possible install the scanner on a standard NPT pipe 1 2 NPT for UV1A and 1 NPT for 45UV5 whose position is rigidly fixed If the sight pipe sights through refractory do not extend it more than halfway through Swivel type mounts are available if desired Fireye 60 302 for UV1A and Fireye 60 1664 3 for 45UV5 scanners 11 The sight pipe must permit an unobstructed view of the pilot and or main flame Both pilot and main flame must completely cover the scanners field of view 12 Smoke or unburned combustion gases absorb UV energy On installations with negative pressure combustion chambers a small hole drilled in the sight pipe may assist in keeping the pipe free from smoke For positive p
33. wiring base when using Micro M control e Flame detector wiring in common conduit Should be in separate conduit e Interference by x rays or extreme sources of electrical noise e Defective main safety shutoff valve e Defective main gas regulator Page 36 FLAME SAFEGUARD amp COMBUSTION CONTROLS A SQ BURNER FILTERS b Ca DAMPERS i KS SCREEN NN CODARIN AM A 4 A ae J N if ei A E DAMPER SS DAMPER NN L E MOTOR A K4 o gt TEMP TEMPERED AIR CONTROL BLOWER HIGH amp LOW AIRFLOW LIMITS N gt NAC ON IGN N MOTOR SRT LS STRANSE PSP SF OC TEMP LIMIT PLOT SX O VALVE p Dr i D REMOTE CONTROL PANEL Zz VALVE com MAIN PANEL LIGHTS CY t VALVE Yy a CAS SUPPLY I D Se yee MA LA HEAT SWITCH 1 y Sat e EXHAUST INTERLOCKS 1 oe FUSE DISCONNECT 10000 MOTOR OVERLOADS STARTER e COL eF SI es Le e ENS TO POWER Le TAS BLOWER SUPPLY Te DS Fig 44 Typical application for M series control in a direct fired make up air unit Figure 44 is an example of a control wiring arr
34. within 1 minute the circuit 3 P does not open the control will lockout If circuit 3 P is proven open the control will start its cycle The blower motor will energize terminal M and the control will wait 10 seconds for circuit 3 P to be proven closed If not proven closed within 10 seconds a lockout will occur 2 EP100 series programmers only lf this option is enabled Switch 6 is up terminals D 8 high fire purge and terminals M D low fire start interlocks are also monitored for open and closed during the programming sequence If these circuits are proven closed at inappropriate periods during the prepurge and light off sequence the control will hold for 10 seconds then lockout Page 51 FLAME SAFEGUARD amp COMBUSTION CONTROLS o gt FIRING RATE GD ei nea E FIRING RATE M Y ZU NO MOTOR SWITCHING 8 SL A BURNER MOTOR A IGNITION amp FUEL VALVE LOCKOUT COMMON SC CONTROL CIRCUIT HIGH LOW CONTROL CIRCUIT ALARM T FLAME ROD q PURGE e Al A INTERLOCK 120 VAC A oe 50 60 Hz m v v y y SCANNER e RUNNING CIR UV N INTERLOCK SS en He F V INTERLOCK BURNER SWITCH a LIMIT OPERATING SWITCHES BURNER BLOWER MOTOR MOTOR A AN e TERMINAL 8 NOT USED ON EP200 SERIES PROGRAMMERS LA A GOOD EARTH GROUND IS ESSENTIAL A GROUND SCREW IS PROVIDED IN
35. 1 UV non self check 0 8 sec FFRT MEUV4 UV non self check 3 sec FFRT MEUVS1 UV self check 0 8 sec FFRT MEUVS4 UV self check 3 sec FFRT MERT1 Flame Rod 0 8 sec FFRT MERT4 Flame Rod 3 sec FFRT MEIR1 Infrared 0 8 sec FFRT MEIR4 Infrared 3 sec FFRT MECD1 Cadmium Sulfide 0 8 sec FFRT MECD4 Cadmium Sulfide 3 sec FFRT Fig 33 Measuring flame signal Page 27 FLAME SAFEGUARD amp COMBUSTION CONTROLS amp UMT OPERATING FUEL SWITCHES CONTROLS INT LOCKS all S G a SCANNER FLAME ROD y d SS OR PHOTOCELL PILOT GAS VALVE MAIN FUEL VALVE SPARK IGNITION BURNER CONTROL SWITCH H 120vac H SUPPLY N Fig 34 Typical wiring arrangement for pilot ignited burner using M series 100 and 200 programmer Note For Micro M wire limits between 7 and 6 not 8 and 6 LIMIT OPERATING FUEL SWITCHES CONTROLS INT LOCKS SS SEN SONR FLAME ROD K K 62 OR PHOTOCELL BURNER MOTOR l g OR CONTACTOR A I a SECONDARY TOCKOUT MAIN FUEL VALVE IF USED ALARM SPARK IGNITION BURNER AIR FLOW CONTROL SWITCH H 120vac e SUPPLY Fig 35 Typical wiring arrangement for direct spark ignited burner using M series 100 and 200 programmer Note For Micro M wire limits between 7 and 6 not 8 and 6 Page 28 FLAME SAFEGUARD amp COMBUSTION CONTROLS amp LIMIT OPERATING FUEL SWITCHES CONTROLS INT LOCKS INTERMITTENT PILOT GAS VALVE INTERRUPTED GAS PILOT VALVE AND IGNITION
36. 64 FLAME MONITOR TERMINALS IGNITION TRANSFORMER Fig 65 Wiring arrangement for spark ignited oil burner Direct light off oil burners may be wired as per figure 65 This arrangement may cause the control to lockout on the first light off attempt and show the message Fuel valve state change This is because the control does not expect voltage at terminal 7 during PTFI Resetting the control will cause it to accept it When the jumper between 6 and 7 is removed it will again lockout displaying this message requiring a reset to accept and continue FLAME MONITOR TERMINALS al cas x FUEL FUEL SELECT SELECT RELAY RELAY N C NC MO PILOT ON EN S CONTROL SELECT SEA A REAY IGNITION G TRANSFORMER vave N e e e Fig 66 Combination fuel burner wiring with relay for jumpering terminals 6 7 When changing fuels on combination burners where Direct Spark is used on oil it is normal to jumper terminals 6 7 To assure that burner operation is not interrupted immediately following the change over as described above see figure 65 one of two things must be done 1 Interrupt power to L1 L2 momentarily when changing fuels just before the initial cycle on the new fuel 2 Install a relay contact between terminals 6 and 7 with the relay energized by terminal 7 This will jumper 6 to 7 only after PTFI is complete and will be accepted by progr
37. 886 11 986 11 049 gas ane 18 993 17 855 10 553 9 920 137 080 128 869 9 130 8 583 oig 18 126 17 277 10 071 9 599 153 120 145 947 10 198 9 720 Coal 14 030 12 900 3 500 3 100 Table 1 Comparative heating values for typical fuels In order to burn a liquid fuel most burners atomize the liquid Atomization is the formation of the smallest possible droplets This is required in order to expose as much surface area of the fuel as possible within the flame envelope Steam atomization can be accomplished by projecting steam tangentially across jets of oil at the oil nozzle resulting in a conical spray of finely divided oil after the mixture leaves the nozzle Air atomization is accomplished by using air as an atomizing agent in an arrangement such as a proportioning inside mixing type oil burner using low pressure air as an atomizing agent Large capacity oil burners use two steps to get the oil combustible atomization and vaporization Vaporization converts oil from the liquid to the Vapor State by application of heat at the flame front By first atomizing the oil into millions of tiny droplets the exposed surface area is increased many times and the oil can vaporize at its highest rate For good atomization and vaporization a large volume of air must be initially mixed with the oil particles Mechanical atomization atomization without the use of either air or steam is synonymous with pressure at
38. AGE ON TERMINAL 7 e FIREYE arrow Ze VOLTAGE ON TERMINAL 5 INTERRUPTED e FIREYE O dE CAL FOR HEAT L1 13 OPEN gt FREE TERMINATED VOLTAGE ON TERMINALS 8 7 TERMINATED C eene gt 15 SECONDS BLOWER ONLY Fig 54 Control Sequence Diagram for 70D30 control Note In order to measure voltages at wiring terminals remove the control s cover measure at access point as shown above and IF POC IS NOT CLOSED AT START START UP WILL NOT BE INITIATED WAITS FOR M D TO CLOSE TERM X SPARK IGNITION 5 SEC TERM 5 INTERRUPTED PILOT TERM 6 INTERMITTENT PILOT Page 44 FLAME SAFEGUARD amp COMBUSTION CONTROLS GH TROUBLE SHOOTING D SERIES CONTROL No voltage at term L1 L2 All LED s off e Electrical supply switched off Blown fuse or tripped breaker Bent tab on bottom of control Loose connection Wiring error Improper voltage at term L1 L2 e Min operating voltage 102vac e Max operating voltage 132vac No voltage at term 13 e Burner on off switch off e Operating or limit control open e Loose connection e Wiring error No voltage at term 3 All LED s off e Fuel valve s proof of closure switch open e System has no POC switch and no jumper installed at terminals 3 13 e Bent tab on bottom of control Blower motor does not start Blower and Purge LED s on e Control is in lockout Motor three phase pow
39. D 5 FLAME SIGNAL c v ee A DEMAND SATISFIED K POST PURGE 0 06 POSITION TERM 10 12 e OPERATING LIMIT OPENS TERM L1 18 ___ CYCLE COMPLETE A v Een POST PURGE COMPLETE 15 SEC p STANBY POSITION TERM 10 12 et OPERATING UMOREN TERM Diesel Soc o ELS Orel CONTROL LOGIC FLOW DIAGRAM NORMAL CYCLE FOR EP100 AND EPD1 OO SERIES PROGRAMMER MODULES Fig 73 Logic flow diagram for EP 100 series programmers Page 62 FLAME SAFEGUARD amp COMBUSTION CONTROLS GH e i BOWER ON TERMINALS LI amp L2 p STANDBY TERM 10 12 es MIR ON TERM CIT SIOFEN 2 E no v _ OPERATING LIMITS CLOSE TERML1 13MADE c v SCH IS FVES MADE AS NO LOCKOUT PURGE o TERM 3 13 ave gt 133 FUEL VALVE END SWITCH YE y E CONTROL WILL HOLD A rr an COR MAX TO MIN IS RUNNING INTLK MADE NO p LOCKOUT PURGE FOR 3 P TO BE MADE MANO MN TERM SSE a a A Sa RINIEK OPEN E gt ON peat oT SELECTED PREPURGE J p PURGE 0 05 TERM 10 X e e IME BEING e an ove oe Z HIGH FIRE PURGE _ v _ tee A SELECTED PREPURGE a 3 p PURGE 0 05 TERM 10 12 Oe A LOW FIRE PURGE e M II SANNUM S i e y IS LOW FIRE INTLK O NO y HOLD Pe 0 00 MAX 10 MIN MADE TERMM DO gt
40. E Ol VOLTAGE O CE DIAGRAM MODULE ERMINAL 1 7 ERMINAL 7 E 2 A ERMINAL 8 6 ERMINAL JI ERMNA 2 ERMINALS 3AND 4 4 ESTJACKS VDC ALS 3AND 4 3 ALS 3 4 AND 5 A ALS 3 4ANDS Zei IAL 4 INTERRUPTED ALS 1 3 5 6 7 AND 8 IAL 3 AND 5 TERMINATED Fig 43 Control sequence diagram for M series control with 500 series programmer Voltage at terminals can be measured as shown when control s cover is removed WEG TERMINAL ACCESS POINTS ON M SERIES CHASSIS MICRO M ARE MADE CAN BE SELECTED PROVE OPEN ON START WITH MICRO M LED BLINKS UNTIL LIMITS PURGE TIME AS PER DIPSWITCH SELECTIO ONLY MODELS 560 AND 562 HAVE STABILIZATION PERIOD 1F PTFI ILUMINATES BUT NO VOLTAGE A AT TERM 3 AND 4 THE FUSE IS BLOWN A LOA 10 SEC MTFI PERIOD A IN a MC120P CHASSIS ONLY ERE STABILIZATION PERIOD 8 SEC 560 amp 562 ONLY FIRING PERIOD TYPE 500 PROGRAMMER LIMITS PROVEN START TERM 7 TERM 8 gt 4 TERM Ar PURGE COMPLETE TERM 4 r PTFI 5 10 SEC TERM Ar Page 34 FLAME SAFEGUARD amp COMBUSTION CONTROLS GH TROUBLE SHOOTING M SERIES CONTROL No voltage at term L1 L2 e Electrical supply switched off Blown fuse or tripped breaker Bent Tab on bottom of control Loose connection Wiring error
41. E SAFEGUARD amp COMBUSTION CONTROLS TIPS FOR FLAME DETECTOR MOUNTING AND ENCLOSURES Flame rod applications allow for pin point accuracy in location of a pilot flame Particular attention should be given to the ability of the pilot flame to light off the main flame reliably and under all conditions INCORRECT ROD POSITION a INADEQUATE PILOT FLAME D i PILOT BURNER CORRECT ROD POSITION Fig 18 Importance of flame rod placement As is shown in Fig 18 it is important that the flame rod enters the pilot flame from the side so as to safely prove an adequate pilot flame under all draft conditions Note the rectangular plates attached to the pilot burner assembly to provide a large grounding surface Proven types of flame grounding adapters as shown may be used to provide adequate grounding High temperature stainless steel should be used to minimize the effect of metal oxidation and these assemblies may be welded directly to the pilot burner nozzle When the pilot burner assembly includes a spark igniter care should be given to place it opposite the flame rod Also interference form the ignition spark can alter the true signal by adding to or subtracting from it Interchanging the primary wires line voltage to the ignition transformer sometimes may reverse this trend The addition of grounded shielding between flame rod and ignition spark may also reduce this interference O FLAME MUST
42. FUNCTION 4 RECYCLE ON 3 P LIMITS OPEN NON RECYCLE ON 3 P LIMITS OPEN INTERMITTENT PILOT ON TERMINAL 6 INTERRUPTED PILOT ON TERMINAL 6 DIPSWITCH POSITION MINIMUM gt SELECTABLE PREPURGE TIMINGS EP381 EP380 EP390 Me PROVE 3 P OPEN DISABLED PROVE 3 P OPEN ENABLED DIPSWITCHES ARE NOT ACTIVE ON PROGRAMMERS EP383 EP390WR AND EP390WN Fig 58 Description programmer dipswitch functions Upper aw is for EP100 and EP200 series lower chart is for EP300 series DN DOWN Figure 59 shows the location of the dipswitches on the programmer Note that indications DN and UP in figure 58 relates to DOWN and UP for the switches as shown in figure 59 A further detailed description of the usage of the dipswitches can be found on the next page UP Fig 59 Dipswitch location DOWN Figure 58 shows dipswitch functions for all programmer modules Page 50 FLAME SAFEGUARD amp COMBUSTION CONTROLS DIPSWITCHES Several operational characteristics of the EP160 Ep161 EP165 EP166 and EP170 programmer modules are determined by six dipswitches located on the side of the programmer These characteristics include purge timing dipswitches 3 4 5 The dipswitches are also used to select the option of proving the 3 P running interlock open at the start of the each operating cycle which includes that the high purge interlock D 8 and low fire start interlock M D are
43. Flame Monitor Display Module part no ED510 with connector cable part no ED580 1 A key feature of the Flame Monitor system is its diagnostics capabilities Current operating status and safety lockout information are displayed on the alphanumeric display module part no ED510 shown in figure 69 The display module is designed to operate with the EP and EPD style programmer modules as well as the Micro M control series Operation with EPD style modules requires remote mount The display module provides the following features and capabilities e Two line each 16 character LCD backlit display e Continuous display of current burner operating status including burner safety lockout information e Three key tactile dome keypad allowing access to display functions such as last six lockout conditions complete with burner cycle and burner hour time stamp e Mounts directly onto the front face of EP style programmer modules e Module connects to EP EPD style modules or Micro M control via standard RJ style connector see figure 69 e Designed for use with EP style programmer modules but can be used with EPD style programmer or Micro M control when using remote mount kit utilizing standard DIN sized panel door opening 92 mm X 92mm e The display module can mounted 8 feet away from the control when using ED580 length cable or hundreds of feet away when using belden cable plus the ED610 adapter board When mou
44. IS Y a Se s a BURNER LIMIT OPERATING RED BLIK gt SWITCH SWITCHES 0 BURNER d rv GAS MAINS y N L BLOWER IGNITION PILOT FUEL LOCKOUT l MOTOR ae VALVE WALVE S ALARM J eit 45UV5 J e e e A PURGE INTERLOCK CIRCUIT ONLY FOR MODEL 70D10 A FIRING RATE MOTOR SWITCHING CIRCUIT ONLY FOR MODELS 70D10 70D20 Fig 51 Wiring schematic for 70D10 and 70D20 gt o gt y e amp NOT USED BURNER MOTOR A Not sep GNITION amp FUEL VALVE LOCKOUT e o CONTROL CIRCUIT S CONTROL CIRCUIT ALARM FLAME ROD Wi 7 3 NOT USED a FLAME gt 50 60 Hz CT v AVY y y SCANNER eme Y RUNNING BIN N INTERLOCK Ree HTN LG WS E ek E a 2 FM INTERLOCK Q 82 13 2 P 3 IN Le _e e y BURNER LIMIT OPERATING RED SWITCH SWITCHES 3 A A oN INTER INTER H BURNER Y EN RUPTED MITTENT MAIN i N Zen BLOWER C IGNITION y PILOT PILOT FUEL LOCKOUT MOTOR TRANSFORMER VALVE VALVE VALVE S _ ALARM bi N E NX J SES 45UV5 e Ki kd FOR SPARK IGNITED OIL BURNER WIRE PRIMARY MAIN OIL VALVE TO TERMINAL 6 WIRE SECONDARY MAIN OIL VALVE TO TERMINAL 7 A FOR USE OF TERMINAL X EIN EN TERMINALS 10 AND 5 Fig 52 Wiring schematic for 70D30 A JUMPER WIRE MUST BE INSTALLED BETWEEN Page 42
45. M D LIMIT OPEN oy E IGNITION AND PILOT VALVE PTFI 0 00 ENERGIZED TERM5 86 gt IGNITION TIMING jai A ISFLAME PROVEN WITHIN NO LOCKOUT PTFI _ SELECTED PTFITIME PERIOD P FLAME FAIL YES en y _ PILOT STABILIZATION PTFI 22 PERIOD ss gt FLAME SIGNAL D A TERM 7 ON AT END OF PTFI pa haa ES S ee A LV TERM 5 OFF 10 SEC AFTER TERM 7 ON 4 GEN ee hh Si TERM 6 OFF 15 SEC AFTER TERM 7 ON ENE RM o A A SMAINFLAMEPROVEN NO LOCKOUT MIFI ___AFTER PILOT WITHDRAWN gt FLAME FAIL YES oe CAN eee ron lt SEN CONTROL IN RUN MODE f p AUTO 40 LOW FIRE TO AUTO TERM 10 11 ca a TERM T REMANS ENERGIZED FLAME SIGNAL O ae ees D ES DEMAND SATISFIED aa p POST PURGE 0 06 POSITION TERM 10 12 OPERATING LIMIT OPENS TERM L1 19 CYCLE COMPLETE a v FS i e POST PURGE COMPLETE 15 SEC p STANDBY POSITION TERM 10 12 Ps OPERATING UMT OPEN TERM 18 ENSIS OPEN CONTROL LOGIC FLOW DIAGRAM NORMAL CYCLE FOR EP200 AND EPD200 SERIES PROGRAMMER MODULES Fig 74 Logic flow diagram for EP 200 series programmers Page 63 FLAME SAFEGUARD amp COMBUSTION CONTROLS GH POWER ON TERMINALS L1 amp L2 gt STANDBY LIMITSONTERM L1 130PEN Ei 13 OPEN een Aen
46. NATES BUT NO VOLTAGE AT TERM 3 AND 4 THE FUSE IS BLOWN Fig 41 Control sequence diagram for M series control with 100 series programmer Voltage at terminals can be measured as shown when control s cover is removed Page 32 TYPE 100 PROGRAMMER START TERM 7 TERM 8 gt LIMITS PROVEN FIRING PERIOD SAFE START CHECK PERIOD TERM 3 r TERM 4 gt TERM 5 gt FLAME SAFEGUARD amp COMBUSTION CONTROLS M SERIES CONTROL SEQUENCE DIAGRAM 200 SERIES PROGRAM MODULE VOLTAGE ON TERMINAL 1 7 fo OPR CTRL O AIR FLOW 8 3 om a VOLTAGE ON TERMINAL 7 O FLAME ol AARM 2 5 A 4 C suen 2 VOLTAGE ON TERMINAL 8 6 1 WIRNG TERMINAL ACCESS POINTS ON M SERIES CHASSIS 0 orr cm N Kl E Su mmm VOLTAGE ON TERMINAL 6 1 O ALARM MN MICRO M LED BLINKS UNTIL LIMITS VOLTAGE ON TERMINAL 6 2 ARE MADE CAN BE SELECTED PROVE OPEN ON START WITH MICRO M Boron N A AIR FLOW Ol pr IGNITION VOLTAGE ON TERMINALS 3 AND 4 PURGE TIME AS PER DIPSWITCH o nave PILOT GAS LA 2 SELECTION H SR N ONLY 200 MODELS WITH H IN gn lg PILOT VOLTAGE ON TEST JACKS VDC 3 PART NUMBER HAVE STABILIZATION Rave PROVEN PERIOD H OPR CTRL yY A IF PTFI ILUMINATES BUT NO VOLTAGE ole PILOT STABALIZATION EN A S Sec VOLTAGE ON TERMINALS 3AND 4 3
47. OWER ON TERMINALS LI AL p STANDBY TERM 10 12 MTS ON TERM EEN a Ll 13 OPEN c w OPERATING LIMITS CLOSE TERM LT 13MADE en H _ IS FVES MADE e NO LOCKOUT PURGE EM ERM 3 13 o a gt 133 FUEL VALVE END SWITCH YES A v IS RUNNING INTLK MADE y NO LOCKOUT PURGE WITHIN 10SEC TERM 3 P 133 INTLK OPEN YES v q MS ee TS HIGH FIRE INTLKMADE NO y LOCKOUTPURGE EA Ars a D TERM 10 X _ WITHIN 10 MIN TERM D 8 D 8 LIMIT OPEN YES e v SELECTED PREPURGE gt PURGE 0 05 B TIME BEGINS o gt HIGH FIRE PURGE v Ti EE rocha E po SELECTED PREPURGE e PURGE 0 05 H P TERM G21 ______TIMECOMPLETED gt LOW FIRE PURGE A y A See Se GR IS LOW FIRE INTLK NO HOLD PURGE 0 00 IO IN gt MADE TERMM D gt M D LIMIT OPEN SEEN Wel 2 IGNITION AND PILOT VALVE s PTF 0 00 ENERGIZED ERM5 amp 6 gt IGNITION TIMING c v ISFLAME PROVEN WITHIN NO LOCKOUT PTFI _ SELECTED PIFI TIME PERIOD gt FLAME FAIL YES BG Se RES Sp PILOT STABILIZATION PTFI 22 o PERIOD J gt ELAME SIGNAL v TERM 7 ON AT END OF PTFI Ee A Szeen d TERM 5 OFF 10 SEC AFTER TERM 7 ON 4 Bue gt e NL 22 TERM 6 OFF 15 SEC AFTER TERM 7 ON Saree aire n v S IS MAIN FLAME PROVEN i LOCKOUT MTFI AFTER PILOT WITHDRAWN FLAME FAIL YES A tL teri tied AN CONTROL IN RUN MODE f p auo 40 LOW FIRE TO AUTO TERM 10 11 Se EAM T REMAINS ENERGIZE
48. SELECTABLE INTERMITTENT OR INTERRUPTED 15 SEC PTFI OPERATION OF TERM 6 VIA DIPSWITCH THESE PROGRAMMERS CAN USE TERM X FOR SPARK TERMINATION REQUIRES TERM S 10 AND 5 TO BE JUMPERED EP380 EP381 EP382 AND EP390 HAVE SELECTABLE RECYCLE OR NON RECYCLE OPERATION VIA DIPSWITCH DURING MIEL TERMINAL 6 IS ENERGIZED FOR 5 SECONDS BEFORE MII 10 SEC FOR EP165 AND EP265 15 SEC FOR EP166 ONLY D DISPLY MODULE WITH EP383 Programmers for the Flame Monitor system are designated with prefix EP or EPD EP programmers are designed to receive the ED510 display module snapped into the face of the module EPD programmers are designed with an integral LED display and are compatible to be used with an additional remotely mounted ED510 display module Page 49 FLAME SAFEGUARD amp COMBUSTION CONTROLS DIPSWITCH NUMBER 4 NOT ACTIVE DIPSWITCH POSITION PROGRAMMER TYPE EP160 EP170 EP161 EP165 EP166 SELECTABLE PREPURGE TIMING PROVE 3 P OPEN PROVE 3 P OPEN TERMINAL TIMINGS PTFI MTFI TERM 5 TERM TERM 5 TERM 6 NOTE A 30 SECOND LOW FIRE PURGE IS ADDED TO THE SELECTED PURGE TIME DISABLED ENABLED 1 EP165 EP265 DURING MIEL TERM 6 REMAINS ENERGIZED FOR 5 SEC PILOT STABILIZATION BEFORE ENERGIZING TERM 7 FOR 10 SEC 2 EP166 DURING MIFI TERM 6 REMAINS ENERGIZED FOR 5 SEC PILOT STABILIZATION BEFORE ENERGIZING TERM 7 FOR 15 SEC DIPSWITCH NUMBER
49. SIDE THE WIRING BASE Fig 60 Wiring schematic for EP100 and 200 series programmer gt R GEN MAIN IGNITION PILOT FUEL LOCKOUT T VALVE VALVE S 1 ALARM PURGE INTERLOCK CIRCUIT USED ONLY ON EP100 SERIES PROGRAMMERS o gt EN NOT USED BURNER MOTOR A Nor USED IGNITION amp FUEL VALVE LOCKOUT ES e o CONTROL CIRCUIT CONTROL CIRCUIT ALARM FLAME ROD K A NOT USED 120 VAC a FLAME 50 60 Hz mm XZ AT v h SCANNER 7 A X_7RUNNING Se IRIUN N INTERLOCK m F V INTERLOCK fe s gt y e o Le BURNER S LIMIT OPERATING SWITCH SWITCHES a zt NX oN i INTER INTER f S BURNER So RUPTED MITTENT MAN S BLOWER s IGNITION PILOT PILOT FUEL LOCKOUT MOTOR RC VALVE VALVE VALVES L ALARM A SN at A Ki Ki e If FOR SPARK IGNITED OIL BURNER 1 WIRE PRIMARY MAIN OIL VALVE TO TERMINAL 6 IN WIRE SECONDARY MAIN OIL VALVE TO TERMINAL 7 Fig 61 Wiring schematic for EP300 series programmer FOR USE OF TERMINAL X A JUMPER WIRE MUST BE INSTALLED BETWEEN TERMINALS 10 AND 5 Page 52 FLAME SAFEGUARD amp COMBUSTION CONTROLS WIRING Figures 60 and 61 show generic wiring schematics for flame monitor Needless to say each application has its peculiarity and style But these diagrams in conjunction wit
50. UP SCANNER NOISE SHORT CIRCUIT TERM 5 6 7 SYS HOURS SYSTEM ERROR SYSTEM INFO UNIT ADDRESS WAITING FOR DATA O From here press MODE key to display details on operating parameters of programmer and amplifier module Electrical noise on scanner wiring See page 57 Scanners Short circuit or excessive current detected on terminals 5 6 or 7 See page 40 Before installing the control Number of hours the control has been powered L1 L2 Programmer module failure Replace programmer module From here press MODE key to display details on operating parameters of the control Run Check switch placed in Check L1 13 operating control is open press reset button here for one second intervals to increase unit address Communication between control and display module is disrupted and needs time to correct Plugging in the ED510 display while control is powered may cause this Running ED580 cable with other power wiring also causes this See page 57 Remote display Removing and restoring power while ED510 is connected will recover proper operation Page 61 FLAME SAFEGUARD amp COMBUSTION CONTROLS scraps rat tea l P
51. _ REMOVED HEAT INSULATOR _ PART NO 35 69 N 1 2 NPT STEEL NIPPLE 3 4 NPT ELECTRICAL CONNECTION Fig 26 Enclosure rated for Class 1 amp 2 DIV 1 Groups B C D E F amp G and NEMA 4 for UV1A or 48PT2 scanner For NEMA 4X this housing must be epoxy coated For the larger self check type 45UV5 scanners when used in areas requiring hazardous area classification these can be ordered with special enclosures Figure 27 shows the European style CENELEC approved housing rated at IP 66 This enclosure is also available for scanners using fiber optics HAZARDOUS AREA ENCLOSURE FOR FLAME DETECTOR EXTRA HEAVY LENS e nf Ee AIR PURGE THREADED FOR ACCESS TO DETECTOR Fig 27 Cut away view of flame detector mounted in Cenelec approved hazardous area enclosure rated IP 66 NEMA 4X Page 21 FLAME SAFEGUARD amp COMBUSTION CONTROLS COMMON TERMS IN FLAME SAFEGUARD Flame failure response time FFRT is the time from loss of flame to the closure of fuel valve s This may vary from 4 seconds maximum to less than 1 second The control may respond by recycling or re lighting the burner or by going into a safety lockout requiring manual reset Prepurge is required to provide a complete air change to the combustion chamber A prepurge time is a period of time after the combustion air fan has been started and proven sometimes the combustion a
52. a BEN AT 80 Coal gt Gas gt I I 4 60 I Refractory l l at 3000 F l l 40 I Refractory l at 1000 F l I 0 I 100 200 1300 Lon 500 600 700 800 900 1000 1100 1200 1 2g 38 Wavelength in nanometers 3 2 Fig9 Radiation characteristics for common fuels VISIBLE LIGHT FLAME DETECTORS Detection of flame by seeing its visible light is the way man detected flame since it was first observed There are two standard detectors used for sensing flame in the visible region a photo emissive cell photocell and a cadmium sulfide cell cadcell A photocell device is a glass enclosed structure tube which has been completely evacuated There are two elements within the tube a thin metal plate that acts as the cathode and a collector wire assembly which acts as the anode When light strikes the cathode electrons are emitted which are drawn to the anode The current in this type of tube is very small and requires considerable amplification before it can operate a relay Photocells are of the rectification detector type where AC voltage is applied but the operation of the electronic system depends on DC voltage It is the job of the photocell to allow current flow and to convert alternating current to direct current when sensing flame A cadcell device is a small device that is constructed from an insulating plate covered with a deposit of cadmium sulfide that is mounted in a protectiv
53. adiation gt 400 NM visible infra red region on the cell The cell responds in a O modulating fashion harmonized with the variations in radiation amplitudes given off by the combustion process Not only do flames flicker in this way the flicker frequency is actually different within the zones of the flame If we look back at figure 8 for a moment it would be the ultra violet region of the flame nearest the nozzle the ignition zone which has the least amplitude but the highest flame flicker frequency The opposite end farthest from the burner nozzle produces the most amplitude of radiation but of the lowest flicker frequency Thus a flame scanner mounted on the burner front looking parallel with fuel flow would have the best possible view to pick up as much as possible of the ignition zone of its targeted flame Should its targeted flame disappear it would likely pick up radiation of lower frequency from hot surfaces such as refractory If the detector s circuitry is designed in a way that it can be selective in the frequency it accepts as flame signal then discrimination between targeted flame and background can be achieved Flame flicker frequency is noted in Hertz Flicker frequencies in flames can be found from 5 upward to well over 200 Hz Variations in higher or lower frequencies found in flames are related to a variety of functions in burner design and fuel burned Burner designs such as gun type or ring type produce
54. ammer FLAME MONITOR TERMINALS HIGH FIRE INTRLK MOTOR TIME STARTER DELAY SEOL A Fig 67 Extending the prepurge for EPD programmer modules With EPD programmers there are no dipswitch selectable pre purge timings Prepurge is limited to 30 seconds Figure 67 shows how prepurge may be extended using a timer Maximum time delay setting should not exceed 10 minutes see page 51 Page 54 FLAME SAFEGUARD amp COMBUSTION CONTROLS FLAME MONITOR TERMINALS TIME DELAY RELAY DAE 2 SEC LIMITS BURNER SWITCH Fig 68 Suggested wiring for power switch over systems SUPPLY VOLTAGE TOLERANCE The Fireye Flame Monitor is designed for an input voltage of 120vac 50 60Hz with tolerance of 10 and 15 At a voltage drop to approximately 85vac the control will shut down and perform an internal reset Restoration of input voltage to within the specified parameters will render the Flame Monitor operational again Sometimes a power brownout or a switchover to a UPS systems may cause problems to the input voltage Brown outs cause voltage drops and switchovers may cause very short Microsecond power interruptions to the control s input voltage Both of these may at times actually go unnoticed by the Flame Safeguard control but their effect may be just enough to cause the fuel valves to close When this happens the FSG control will interpret it as a flame failure
55. angement for an air make up unit Air make up units are generally mounted on the roof of the building and are provided with a remote control panel which is located inside the building for ease of operating the equipment All other equipment shown is located on the unit Fused 3 phase power is run to a disconnect which generally is attached to the outside of the unit From the disconnect the 3 phase power wires are run to the motor starter overloads and on to the blower motor A step down transformer provides 120vac control voltage L1 hot and L2 neutral From the transformer L1 is run through a fuse and connected to the fan switch located in the remote control panel To operate close the fan switch The inlet damper motor opens and exhaust interlocks are checked MOTOR FLAME SAFEGUARD CONTROL When the dampers are fully open the damper end switch closes and will provide voltage to the motor starter coil starting the blower motor Outside air is now forced into the building To heat the make up air close the heat switch This will energize the flame safeguard control by powering its terminal 7 and 1 and a control sequence will begin as described in figure 41 Temperature control is achieved via a direct acting control valve having a capillary tube in the discharge duct Prepurge is not required in air make up equipme
56. as The tube is said to be Firing By design this arc wanders back and forth along the electrodes never staying in one place thus preventing damage to the electrodes by over heating A quartz lens is needed to focus the UV radiation directly on the detector tube electrodes Generally the voltage supplied to the tube is AC DC voltage may also be used along with a square pulse generator Voltage across the electrodes will go to zero for each half cycle of AC allowing the tube to restore itself to a non ionized or quenched state On the next voltage half cycle the current is re established across the electrodes in order to fire if UV radiation is present Fig 10 UV radiation detection tube Fireye part no 4 320 The amount of firings during each cycle is known as the count The maximum counts of firings during one second is the number of counts during one half cycle times twice the frequency of the supply voltage See figure 12 When flame is present and UV radiation enters the tube the system begins to count When the flame disappears UV radiation stops and the system stops counting A flame relay is part of the system An electronic circuitry receiving the count signal from the detector pulls in the flame relay which remains in as long as its pre set threshold is satisfied The count is directly related to the intensity of the UV radiation a very intense source of UV radiation may produce several thousand count
57. asflame Fig 8 Flame rod system operational diagram Advantages of flame rod applications a Location sensitive Flame rod detectors prove the flame with extreme location sensitivity The flame must be where the relative small rod can be in contact with it This is most useful in controlling for example that a pilot flame is detected only when it is at the optimum location to reliably ignite the main burner Flexibility in placing the rod can assure this Also this location sensitivity will detect flame lift off and as such can be used to prevent unstable flame conditions for both pilot and main flames b Fast response time The relative low cost flame rod system has been put to use replacing many and sometimes working as an auxiliary to slow responding bi metal and thermocouple based systems c Fail safe system Using electronics this system responds safely to abnormal conditions such as open or short circuits leakage to ground all causing the system to fail safe Ideally the flame rod is mounted vertically alongside its vertical burner nozzle with only the tip bent in to make contact with the flame envelope When installing a flame rod on a horizontally orientated burner assembly care must be given to favor installing the rod on either one of the sides of the burner or directly below with the tip bent up to make contact Installing the rod directly above the burner assembly is least favored as this may allow
58. 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 for 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 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 solenoid and ignition transformer at PTFI and the 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 Page 57 FLAME SAFEGUARD COMBUSTION CONTROLS DISPLAY MODULE REFERA TO BULLETIN ED Fig 69
59. capacity of terminals 5 6 and 7 See page 55 e Insufficient grounding to control wiring base e Flame detector wiring in common conduit Should be in separate conduit e Interference by x rays or extreme sources of electrical noise e Defective main safety shutoff valve e Defective main gas regulator WV 01 SEPTEMBER 8 2006 Page 67
60. ctor rod flame rod cell infrared or tube UV 7 Excessive detector temperatures 8 Detector location HOT REFRACTORY SATURATION TEST Performed to insure that hot refractory does not blind or saturate the detector preventing it from sighting radiation from the targeted flame a Start burner b Monitor flame while heating refractory c Note if any decline in flame signal as refractory heats d If signal declines detector likely sights refractory Try re sighting scanner to see little or no refractory If not possible try placing an orifice in front of scanner lens to reduce field of vision Alternately changing to a UV scanner may resolve this problem HOT REFRACTORY HOLD IN TEST This test is done for infrared detectors to determine whether there is enough hot refractory sighted combined with shimmer inside the combustion chamber which could duplicate false flame signal a Start burner b Monitor flame while heating refractory c With refractory at maximum temperature close manual fuel valve s d With flame now out take note of the time it takes for the FSG control to drop out its flame relay close electric fuel valves e If d is not within the flame failure response time FFRT of the FSG control the system is experiencing hot refractory hold in Corrective measures must be taken Try re sighting scanner to see little or no refractory If not possible try placing an orifice in front o
61. d to an earth ground With the other test lead make contact with each terminal in the wiring base At no time should the meter read other than infinity O Now reconnect the neutral to terminal L2 and remove the test lead from the ground terminal and reconnect this lead to neutral terminal L2 Again make contact with the other probe on each terminal in the wiring base Some terminals may provide resistance readings coils transformers lamps etc these readings should not exceed 5 ohms A reading of zero ohms on any terminal would indicate a short circuit and must be rectified before installing the control into the wiring base Before installing the control into the wiring base check the electrical tabs on the bottom of the chassis If they are bent out of position reposition them with your fingers The control is shipped with a red tag which has the proper angle marked on it If the red tag is not available use your own judgment in order to line up each tab uniformly with respect to its neighbor See figure 48 Fig 48 Tabs on bottom of wiring base of D series and Flame Monitor series control With the unit complete module retainer in place and screwed down insert the chassis into the wiring base and tighten retaining screw Having assured yourself that all interlocks and valves are properly wired and that the sequence of operation is correct close the manual fuel valves and proceed with checking all safety interlocks
62. d with single burner appliances such as furnaces and boilers in mind These appliances require that the flame safeguard control properly sequences the operation of the burner system energizing the combustion air blower motor purging the combustion chamber of any combustibles opening pilot fuel valve and energizing ignition establishing main flame and monitoring flame for failure All components must be energized in the proper sequence to prevent unburned fuel from accumulating in the equipment where it could cause a hazardous condition It continuously senses presence or absence of flame while controlling the operation and sequence of all components on the burner in the proper order Industrial FSG controls generally operate in a multi burner environment This environment places different demands on flame safeguard controls the most important of which is the ability of the flame detection system to discriminate between its targeted flame and other flames sharing the combustion chamber Programming and sequencing logic in a multi burner appliance generally resides in a burner management system BMS which may be in the form of a programmable logic controller PLC or a relay logic panel or a combination of both A separate Fireye bulletin Flame Safeguard Controls in Multi Burner Environments publication WV 96 deals with this subject in detail COMBUSTION Combustion or burning is a rapid combination of oxygen with fuel res
63. dicating the reason for the lockout condition These codes are available in the technical bulletin provided with each programmer The ED510 display module can be used on any EPD style programmer either mounted remote for permanent use or hand held for service use only Page 59 FLAME SAFEGUARD amp COMBUSTION CONTROLS FLAME MONITOR MESSAGES As previously mentioned a key feature of the Flame Monitor is its diagnostic capabilities Below is a listing of all Known and available messages at the time of writing These have been arranged in alphabetic order for ease of locating each MESSAGE DESCRIPTION 3 PLOW GAS This is an E300 message and refers to PRESSURE a limitin circuit 3 P 3 PLOW OIL This is an E300 message and refers to PRESSURE alimit in circuit 3 P 3 PLOW OIL This is an E300 message and refers to TEMPERATURE a limit in circuit 3 P 3 PLOW WATER 13 3 FUEL VALVE This is an E300 message and refers to a limit in circuit 3 P The POC switch wired between END SWITCH terminals 3 13 opened before MTFI 3 P AIR FLOW This is an E300 message and refers to OPEN alimitin circuit 3 P 3 PATOMIZING This is an E300 message and refers to MEDIA alimitin circuit 3 P 3 P AUX 4 OPEN 3 PAUX 5 OPEN 3 P AUX 6 OPEN This is an E300 message and refers to a limit in circuit 3 P This is an E300 message and refers to a limit in circuit 3 P This is an E300 messa
64. ding a ground must be avoided 7 Installing ground rods at the burner control panel defeats the purpose of a single point ground as described above and could also present a safety hazard Upgrade or Retrofit It is recommended to change the existing P Series chassis to a new Flame Monitor subbase 60 1386 2 or 60 1466 2 If the installation is an upgrade particularly using a P FM adapter this means the wiring has been in place for a number of years and probably over time has had other wires added to the system All wiring and terminal connections should be inspected for tightness Long wires should be shortened and routed directly point to point instead of lengthened using wire nuts If the existing frame is used the frame of the P Series chassis should be well bonded to the panel and the adapter securely screwed into the chassis Often C Series and or D Series subbases are not properly grounded so the same rules for the P Series should apply The subbases for the C and D Series were factory painted and not plated Good bonding screws with star washers should be utilized Refer to General Rules above Installation Does not run high voltage ignition transformer wires in the same conduit that contain flame detection wiring Do not run scanner wires in a conduit with line voltage circuits Page 56 FLAME SAFEGUARD amp COMBUSTION CONTROLS Ensure the frame of the ignition transformer is securely connected to control panel
65. e enclosure covered by a glass window This device acts like a resistor which is sensitive to light When the cell is in the dark the resistance of the element will be high gt 50K ohms When exposed to light from a flame the resistance will drop to a few thousand ohms and enough current will flow to pull in a relay without further amplification Flame detectors that operate in the visible region will also operate from other light sources such as daylight or light from lamps It is therefore necessary to make sure that they are used only in locations where they cannot be exposed to other sources of light Visible light from hot refractory may also activate these sensors APPLICATION INSTALLATION Visible light flame detectors are used primarily in commercial and or industrial oil fired burners Generally they are not applied to gas burning equipment as a well adjusted gas flame gives off Page 11 FLAME SAFEGUARD amp COMBUSTION CONTROLS insufficient visible light for detection In applying these detectors special attention must be given to 1 As with all optical detectors the cell must have full view of the flame monitored 2 Care should be given to protect it from possible visible light emitted by hot refractory or other sources 3 The detector must be protected from ambient temperatures in excess of 165 F 74 C 4 Proper wire must be used to connect the detector Temperatures above 125 F 52 C may require
66. e 20 Sealing Union 20 Purging Cooling Air 20 Enclosures ssssosenieeeeeeesrrnnreeserrrne 21 Common Terms In Flame Safeguard 22 Prepurge tacita 22 PRE gtcee tid o a tl em 22 MTF gebei eg eeh Ee eeEEA 22 Post lire i ico dead 22 Types Of Pilot Burners 000aaae 22 Interrupted Pilot 22 Intermittent Pilot 22 Standing Plot 22 Flame Safeguard Controls 22 Operating Interlock Circuit 22 Running Interlock Circuit 22 M Series Flame Safeguard Controls 23 UVM amp TFM Controls eee 23 M Series Il Controls nnnenaeneeeeaene 24 Micro M Series Controls 26 M Series Wiring Schematics 28 M Series 100 Control Sequence 32 M Series 200 Control Sequence 33 M Series 500 Control Sequence 34 Trouble Shooting M Series 35 M Series Typical Application 37 M Series Typical Application 38 D Series Flame Safeguard Controls 39 Assembly cocoooooocccccccncconananoncncnoncninnnnnos 40 Before Installing the Control 40 LED Indicator Lights 41 Flame Signal Strength 41 Run Check Switch 41 D Series Wiring Schematics 42 D10 20 Series Control Sequence 43 D30 Series Control Sequence 44 Trouble Shooting D Series
67. e see that the furnace background radiation focused on our detector drastically reduces its electrical resistance leaving almost no room for the cell to respond to flame flicker modulation To minimize this saturation effect it is desirable to sight the detector such that radiation from the ignition zone is maximized while radiation from furnace background is minimized A task not always made possible within burner design A later chapter dedicated to scanner sighting and positioning deals with this issue in more detail Lets look at frequencies of flame flicker as related to fuel being fired Back in figure 9 we observed that oil and coal flames have strong radiation in the visible wavelength and gas flames do not Anyone having seen oil and coal flames through a burner s sight glass will confirm the relative brightness of these fuels while burning whereas gas flames tend to be more transparent or dim All fuels however radiate profusely in the infra red region of the flame spectrum Where the detector is sighted at the ignition zone of the targeted flame it is not uncommon to find that the lowest frequencies increase dramatically in a flame off condition This is due to the ignition zone of the targeted flame masking the bright background low frequency radiation while the targeted flame is on Upon disappearance of the targeted flame this background radiation comes into full view INSTALLATION OF INFRARED SCANNER Where p
68. ely on a thermocouple inserted into the pilot flame The heat in the thermocouple generates just enough voltage to hold in a magnetic coil which holds in a spring loaded plunger inside the automatic gas valve allowing gas flow to the burner The plunger is manually pushed in and the pilot lit followed by a short period of time for the thermocouple to start generating enough current to hold in the plunger This system requires that the pilot flame is on at all times whether the burner is on or off As this wastes fuel more modern residential equipment utilize an automatic pilot light on demand via spark ignition combined with flame rod flame detection Fig 2 Burner control panel with Fireye Flame Monitor and First out expansion module Commercial FSG controls are divided into Primary and Programming controls The distinction between primary and programming is that primary controls have a minimum in operating parameter logic such as safe start check trial for ignition flame failure response time and lock out functions This makes them ideally suitable for appliances such as small direct light off no pilot burner burners and burners for make up air heaters direct or indirect fired Programming controls operate with many additional functions such as pre purge proof of O purge low fire start check fuel valve closed post purge and other functions Both residential and commercial FSG products are designe
69. er off Defective motor or contactor Bent tab on bottom of control Defective control chassis If no voltage at term M replace chassis Blower runs but control locks out before end of purge Blower Airflow and Fireye LED s on e False flame is detected e Check for actual flame being detected e Check for incorrect scanner wiring causing electrical noise causing false signal e Defective UV tube giving false flame signal e Defective amplifier module Oo Blower runs purge is not initiated 70D10 locks out 70D20 does not Airflow LED remains off e Interlock s wired between term 3 and P open e Wiring error e Bent tab on bottom of control 70D10 only Modulator driven to high but no further progress in program sequence Blower and Purge LED s on e High fire purge interlock end switch not made Terminals D 8 Modulator driven to low but no further progress in program sequence Blower LED on e Low fire end switch not made Terminals M D PTFI starts TFI LED on programmer module lights but no power on term 5 amp 6 Control locks out e Replace 70D control chassis Pilot fails to establish Blower and TFI LED s on for 10 seconds followed by lockout No visual presence of flame Fuel supply shut off Air in fuel line needs purging Defective pilot valve Incorrect fuel pressure check pilot reg Defective ignition transf Check for spark Incorrect spark gap
70. f scanner lens to reduce field of vision Alternately changing to an adjustable frequency range type infrared scanner or to a UV scanner may resolve this problem IGNITION SPARK SENSING TEST This test is required on UV type detectors proving that the detector is not picking up UV radiation from the ignition spark creating a false flame sensing condition a Shut off pilot and main manual fuel valves b Start burner Page 17 FLAME SAFEGUARD amp COMBUSTION CONTROLS c Monitor for any flame signal during ignition spark period d There should be no signal what so ever e If any signal take corrective action Either re sight the detector or shield the detector from the spark via a metal shield at ignition electrode IGNITION INTERFERENCE TEST The ignition interference test is done on any flame rod system It serves to determine whether or not ignition interference is creating a false flame signal from electrical noise created by the ignition and superimposed on the flame rod system Note that this can be either additive or subtractive to the flame signal a Start normal burner cycle b Monitor flame signal during and after spark ignition c If a noticeable difference is observed ignition interference is experienced and the following may help to alleviate a Check for proper grounding area b O Maintain maximum distance between ignition electrode and flame rod c O Check ignition electrode s spacin
71. flame current is rectified Fig 6 Electron flow through ionization within the flame envelop Generally referred to as a Flame Rectification System it is achieved by placing a grounding electrode in the flame that is several times generally 4 times larger than the flame rod or electrode An AC supply voltage is applied across the electrodes During half of the AC cycle the flame rod is positive and the ground rod is negative The positively charged ions will flow to the negatively charged grounding area As the grounding area is larger its capacity to hold electrons is increased resulting in a relative high flame current flowing through the flame during this first half cycle During the second half cycle the reverse process will take place However the capacity of the flame rod to hold electrons is less than the grounding area and the resulting flame current is smaller The greater the ratio of grounding area to flame rod area the greater the rectified current The only accepted type of current by the system is this rectified flame current Any high resistance type short circuit will result in an AC type flame current which is rejected by its FSG control The large grounding electrode generally forms part of the burners fuel nozzle helping to stabilize and hold the flame firmly in place Flame rods are simply small diameter metal rods supported by an insulator in order to be able to mount it such t
72. flames with a wide range of frequencies where as spud type gas and low NOx burners do not Relative resistance 100 20 ul Time 2 gt V7 El Steady Vs 7 Flame light source H Flicker Fig 15 R cell response to IR DC radiation and flame flicker Fuel oils and coal produce wide ranges of frequencies where as fuel gas particularly low NOXx or sub Stoichiometric combustion does not Page 15 FLAME SAFEGUARD amp COMBUSTION CONTROLS This ability of the flame scanner to pick up flame flicker frequency can be adversely affected by over powering low frequency radiation from furnace background Flame on Relative resistance 100 N 80 oh off 60 Background Backdround 20 0 gt XN E Y time sas VY 7 Muy Y y TI D Y i Fig 16 R cell saturation effect from abundant low frequency infrared radiation Strong sources of this low frequency radiation wil have a saturation effect Also called Washout saturation inhibits the cell s ability to maintain a high enough electrical resistance value rendering it unable to monitor flame flicker Imagine that in figure 16 the symbolic flashlight represents the low frequency IR visible light radiation from furnace background and that the symbolic flame represents the ignition zone of the targeted flame W
73. for proper shut down of the burner Cautiously proceed through a burner light off process Page 40 FLAME SAFEGUARD amp COMBUSTION CONTROLS est Jacks Reset Button LED Indicators Fig 49 LED INDICATOR LIGHTS A 70D30 control chassis is equipped with three LED indicator lights each of which are labeled 1 Airflow Lights when running interlock limits are made Terminals 3 P 2 TFI Lights during trail for ignition 3 Fireye Lights when flame is detected A 70D10 and 70D20 control chassis is equipped with five LED indicator lights each of which are labeled 1 Blower Lights when blower circuit is energized Terminal M 2 Purge Lights when firing rate motor is driven to high fire prepurge position Terminals 10 X TFI Lights during trail for ignition Fireye Lights when flame is detected Auto Lights when firing rate motor is released to modulate Terminals 10 11 NAO FLAME SIGNAL STRENGTH Test Jacks are provided on the front of the amplifier module to accommodate measuring the flame signal strength using a 1 000 ohm volt or greater DC voltmeter or a digital meter with an input impedance of 500K ohms or greater Normal flame signal strength reads 18 25vdc Flame Relay drop out is approximately 5vdc O RUN CHECK SWITCH A run check switch is located on the side of the programmer module A small tool such as a screwdriver is required to operate it Puttin
74. frame or the burner frame The Flame Monitor chassis E100 E110 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 so that the spot face on the bracket located in the E100 E110 chassis comes in contact with the locking nut located in the 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 ED580 cable High frequency currents flow more to the surface of the conductor The 60 Hz ground system properly designed has sufficient low impedance 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 contactor located in the control panel or across any high voltage ignition wires Refer to Fireye bulletin E 8002 for proper installation Communications When interfacing Fireye controls to a communication system be it an E500 PLC or other microprocessor based device ferrite cores should also be utilized
75. fuel pressure limits high or low to trip e Wiring error to main fuel valve Main flame lights but goes out when pilot flame is shut off Blower LED on e Main burns off ratio Main fuel pressure too high e Main burner improperly adjusted e Scanner does not detect main flame Oo Flame Signal diminishes with time after main burner lights e Main burns off ratio Main fuel pressure too high Main burner improperly adjusted Infrared detector saturates see page 16 Bad UV tube in ultraviolet flame detector Steam atomization blocks flame signal UV detector on steam atomized oil burner Reposition detector for more angular view if possible e Pilot burner pulled away from flame rod by main burner firing Flame rod systems on natural draft burners e Excessive scanner temperatures Burner locks out on Flame Failure during main flame firing e Main burns off ratio Main fuel pressure too high Main burner improperly adjusted Infrared detector saturates see page 16 Bad UV tube in ultraviolet flame detector Steam atomization blocks flame signal UV detector on steam atomized oil burner O Reposition detector for more angular view if possible Pilot burner pulled away from flame rod by main burner firing Flame rod systems on natural draft burners Power spike unnoticed by FSG but closing fuel solenoid valves Operating or running interlock limit weak causing short d
76. g 1 16 to 3 32 d O Replace deteriorated ignition flame rod leads PILOT TURN DOWN TEST Required on any type of flame detection system this test should be performed on a Any new installation b Following any changes to the detector s location or viewing angle c Following replacement of the flame detector This test serves to assure that the detector is positioned such that it will not detect a pilot which is insufficient to reliably light off its main burner The minimum pilot is the smallest possible pilot flame that a flame detector will sight to hold in the flame relay on its FSG control a Shut manual fuel valve to main burner test firing valve b Start burner c Monitor flame signal during pilot trial for ignition PTFI Some systems Fireye Flame Monitor and Fireye MP560 have a run check switch to stop and hold program during PTFI for this purpose d O Reduce fuel supply to the pilot burner until flame signal is at its minimum see technical bulletin of FSG control for this information This is the minimum pilot detectable Light off main fuel and insure that the main flame lights off promptly and smoothly within 1 second If light off appears to be delayed re sight detector so that a larger minimum pilot flame is required Repeat test until main lights smoothly with minimum pilot After completion of test restore pilot flame to its normal capacity Page 18 FLAM
77. g the switch into the Check position prevents the control from proceeding beyond pilot trial for ignition PTFI in fact maintaining pilot until the switch is again placed in the Run position This allows for adjustment of the pilot flame such as a Pilot Turn Down Test as described on page 18 Terminal Test Points Run Check Switch Fig 50 For trouble shooting the control there are voltage test point for each terminal These are identified and located on the edge of the chassis board see figure 50 When trouble shooting be sure that 1 Wiring is accordance with instructions Contact tabs on bottom of chassis are not bent out of position 3 Chassis is firmly secured in wiring base 4 The Run Check switch is in the desired position 5 The correct amplifier module is installed for the flame detector used 6 The flame detector is clean 7 The lock out switch is reset Page 41 FLAME SAFEGUARD amp COMBUSTION CONTROLS o gt FIRING RATE GD ei SWITCHING FIRING RATE M Y Z 23 MOTOR SWITCHING SL ZA A BURNER MOTOR A A IGNITION 8 FUEL VALVE LOCKOUT COMMON SC CONTROL CIRCUIT HISH ZA LOW CONTROL CIRCUIT ALARM FLAME ROD PURGE N INTERLOCK 120 VAC AN a FLAME 50 60 Hz Va A y y SCANNER e RUNNING IRIUN N INTERLOCK Xx _2 FM INTERLOCK ED 62 13 2 e Ze S
78. ge and refers to a limit in circuit 3 P 3 P HIGH GAS This is an E300 message and refers to PRESSURE alimit in circuit 3 P 3 P HIGH This is an E300 message and refers to PRESSURE alimit in circuit 3 P 3 P HIGH This is an E300 message and refers to TEMPERATURE a limit in circuit 3 P 3 P HIGH WATER 3 PINTLK OPEN 3 P NO FUEL SELECTED 3 P INTLK CLOSED AC POWER FAIL AIR FLOW OPEN AUTO CHECK AMPLIFIER FAIL BLOWER MOTOR This is an E300 message and refers to a limit in circuit 3 P Circuit 3 P has failed to close within first 10 seconds of purge Or has opened during operating cycle This is an E300 message and refers to a limit in circuit 3 P Dipswitch 6 is enabled Check for 3 P circuit open on start has not passed Unit will hold for 60 second for 3 P to open followed by lockout Se page 51 Power interruption caused the control to lockout EP165 and 166 only This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P Amplifier module failure Replace amplifier module This is a message selected from the INTLK E300 message menu and refers to a limit in either circuit L1 13 or 3 P BNR CYCLES Number of hours operating control L1 13 has been closed BNR HOURS Number of hours terminal 7 has been energized BNR LOCKOUTS Number of control safety lockouts CHECK AMPLIFIER CHECK CHASSIS
79. h the flame monitor control sequence diagram give a clear indication of the function of each terminal at specific periods in the control sequence Use these schematics in conjunction with the equipment s wiring diagram FIRING RATE MOTOR CIRCUIT FIRING RATE MOTOR Fig 62 Firing rate motor switching wiring when using Slide wire Potentiometer EP100 and 200 series programmers utilize terminals 10 11 12 and X to control the firing rate motor during the pre purge and light off period e The control needs to drive the motor to the high fire position and maintain it there during the pre purge period Relay RH Terminals 10 X e The control drives the firing rate motor to the low fire position and maintains it there for both PTFI and MIEL Relay RH Terminals 10 12 e The control releases the motor to the modulating controller upon completion of successfully establishing main flame and the withdrawal of the plot flame Relay RA1 Terminals 10 11 SO Figure 62 shows the wiring for a proportioning controller with slide wire 135 ohm potentiometer system A potentiometer or variable resistor consists of a fine wire wound around a core term W B A wiper rests on this assembly and moves along the windings The wiper is connected to terminal R As the wiper moves back and forth as determined mechanically by the process demand the resistance between R and W and between R and B changes If
80. h the information is displayed depends on the type of programmer selected The Flame Monitor System is of modular design allowing flexibility in adaptation to various applications The system consists of a wiring base control chassis amplifier module programmer module display module and dust cover The interchangeable aspect of these components provides for complete versatility in selection of control function timing and flame scanner means Functions such as pre purge recycle or not on interlocks proving of high damper position during pre purge and trial for ignition timings are determined by the choice of programmer module Amplifier modules are selected based on flame detector used Main features and benefits of the Flame Monitor include e A non volatile memory allowing the control to remember its history and present position even when power has been interrupted e A constant flame signal readout via display module or 0 10 VDC output on the EPD programmer modules e Read out of main fuel operational hours and complete cycles via display module e Modbus communications via RS485 multi drop link e Selectable pre purge timings via dipswitch settings e A service Run Check switch allowing the operator to stop the program sequence in any of the three events Pre purge PTFI or Auto e Ability to mount its display module remotely SPECIFICATIONS Supply voltage 120 VAC 10 15 50 60Hz Consumpt
81. hat the tip end of the rod can project into the flame Flame rods typically are made of a material called Kanthal a high temperature alloy capable of operating in temperatures of up to 2400 degree F or 1300 degree C Other materials for even higher temperature ratings such as Globar a ceramic material are also available Requirements for successful flame rod applications are a Stable flame no movement from flame rod b Gas burners only premixed were possible c Adequate flame rod to grounding area proportioning 4 to 1 minimum d Proper placement of flame rod in flames short as possible yet adequate contact e Proper rectifying flame current and associated circuitry FLAME ELECTRODE FLAME GROUND IGNITION ELECTRODE A H FLAME RETENTION NOZZLE Fig 7 Typical pilot burner assembly with flame rod flame detection Page 8 FLAME SAFEGUARD amp COMBUSTION CONTROLS Emax FLAME ROD AC VOLTAGE Emax Lon ee e ee elen e e gt T 1 50s 20 ms f 50 Hz 1 i l l l FLAME ROD l RECTIFIED 1 CURRENT l l tIlmax Imax gt 4 ISOLATED COMMON RETURN WIRE FLAME ROD CURRENT AMPLIFIER CIRCUIT FLAME ROD Q LOW CAPACITANCE NON SHIELDED WIRE EARTH ZERO POTENTIAL AS BURNER FRONT PLATE Applied AC voltage between flame rod and burner plate causes rectified current to flow through ionised gas g
82. heir enclosures provide protection against wind blown dust and weather hazards such as rain sleet or snow 3 4 FLEX CONNECTOR SEALING UNION X 1 2 NPT MALE WITH PYREX WINDOW PART NO 60 801 3 4 FLEX WEATHER PROOF d Y HEAT INSULATOR INFRARED SCANNER PARTNO 35 69 PARTO 48P12 1007 LOCKNUT AND RING REMOVED Fig 25 Weather proofing a 48PT2 scanner For applications with a 48PT2 infrared scanner where that extra bit of protection is required you may consider the assembly described in figure 25 Here the heat insulator P N 35 69 supplied with all 48PT2 scanners is used backwards The scanner has its lock nut and ring removed and is inserted into the female threaded end of the 35 69 It will seat on the ridge where the female threads end and threading in a weatherproof flexible conduit connector completes the assembly Finally insert the male threaded portion of the 35 69 into the sealing union P N 60 801 and mount it on the sight tube To meet specified NEMA ratings the detector needs to housed in an enclosure which is certified to the desired rating For the relative small UV1A and 48PT2 scanners various types of enclosures are available ranging from junction boxes to instrument enclosures Industrial type thermocouple heads are readily available in NEMA ratings varying from the lowest to the highest See figure 26 O FIREYE 48PT2 1007 SCANNER FLEX CABLE
83. imes also wired into the operating interlock circuit preventing the burner from operating unless the device allows it and recycling the burner when the condition is met RUNNING INTERLOCK CIRCUIT The running interlock circuit when closed insures the operating limits of all safety devices wired into it are met The term running interlock circuit refers to the fact that some of the safety devices being checked are not into play until the flame safeguard control has started its cycle For example the combustion air fan is first turned on by the control and then its proper operation is verified via an air proving device Page 22 FLAME SAFEGUARD amp COMBUSTION CONTROLS Some examples of running interlocks e High temperature or pressure limits High and low fuel pressure limits High and low water cutoff Proof of closure switch on fuel valve s Combustion airflow limit The above mentioned operating and running interlock circuits along with the flame detector circuitry are inputs to the system A flame safeguard system also needs to control and operate various equipment found on a burner via its outputs For example e Combustion Air fan Ignition transformer Pilot fuel valve Main fuel valve Modulation motor Flame safeguard controls can be classified in three main groups 1 Non programming controls 2 Programming controls 3 Flame switches FIREYE M SERIES FLAME SAFEGUARD CONTROLS A F
84. in some locations regardless of continuous operation Ultra violet accounts only for about one percent of available radiation in the flame spectrum UV also is relatively weak and is easily blocked by unburned fuel products of combustion smoke water vapor and other common substances found in and around flames Accordingly a detector close to the root of the flame picks up UV most easily and UV radiation from background or adjacent flames tends to be a much weaker signal With proper scanner sighting and set up of associated controls UV flame scanners remain a simple well trusted and acceptable option in today s FSG systems Page 13 FLAME SAFEGUARD amp COMBUSTION CONTROLS y Fig 13 UV self check scanner Fireye part no 45UV5 INSTALLATION UV SCANNERS Where possible obtain the burner manufacturer s instructions for mounting the scanner This information is available for most standard burners The scanner mounting should comply with the following general instructions 1 Reliable pilot signal 2 Reliable main flame signal 3 A pilot too small or in the wrong position to ignite the main flame reliably must not be detected 4 The scanner must have an unobstructed view of flame being monitored 5 Monitored flame must completely cover the scanner s field of view 6 Position the scanner within the closest distance from the flame to be monitored within 72 inches is recommended 7 Select a location that
85. ion 25 VA Temp Limits 40 to 125 F Display 32 to 125 F Humidity 85 R H max non condensing Terminal load ratings e Term 5 amp 6 550 VA pilot duty e Term 7 250 VA pilot duty e Term M 9 8 F L A 58 8 L R A e Term 10 11 12 X 125 VA pilot duty e Term A 50 VA pilot duty Page 47 FLAME SAFEGUARD amp COMBUSTION CONTROLS GH AMPLIFIER MODULES Fig 56 Amplifier Module Amplifier modules used in conjunction with the Flame Monitor System are selected based on the type of flame detector The amplifier module is installed in the third set of guide channels found in the Flame Monitor Chassis where it is clearly marked Amplifier Module There is a total selection of six amplifier modules The following table assists in clarifying the specifics of each Fireye Part Description Use with Number Scanner UV non self UV1A EUV1 check UV8A amplifier 45UV3 UV self 45UV5 1007 EUVS4 check 45UV5 1008 amplifier 45UV5 1009 Autocheck E1R1 infrared 48PT2 amplifier Autocheck E1R2 infrared 48PT2 See note 1 amplifier For special applications Consult factory Autocheck E1R3 infrared 48PT2 See note 2 amplifier Without oil fog rejection ERT1 amplifier 69ND1 Rectification 45CM1 Note 1 Note 2 The E1R2 has increased sensitivity which may result in unsafe operation if not properly applied Increased sensitivity implies that far less infrared
86. ir damper is driven and proven to the high purge position during which the combustion chamber and flue gas passages are provided with minimum of four complete air changes Pilot Trial For Ignition time PTFI is the maximum time allotted for the system to establish and detect the pilot flame during start up Failure to establish the pilot flame within the selected PTFI will cause the flame safeguard system to lockout on safety requiring a manual reset Main Trial For Ignition time MTFI is the maximum time during which both the pilot and main fuel safety valve s are permitted to be open before the pilot valve is de energized and the flame safeguard system is to supervise the main flame alone Post Purge time is a short period of time 10 15 sec after the a burner cycle during which the combustion air fan continues to operate evacuating products of combustion from the furnace area TYPES OF PILOT BURNERS Interrupted Pilot is a pilot that is ignited during each burner cycle and withdrawn after establishing main flame at the end of MTFI Intermittent Pilot is a pilot that is ignited with each cycle and remains on throughout the entire running cycle and is terminated the same time as the main flame at the completion of each cycle In order to have an MTFI period the burner must utilize an interrupted pilot unless two separate flame detectors are used one for pilot and one for main O Standing Pilot or continuou
87. ireye M series type flame safeguard control provides the minimum basic functions to safely operate a burner It monitors the inputs from the operating control interlocks limits and flame detector and translates these into control outputs to the combustion air fan motor ignition transformer pilot fuel valve and main fuel valve Fireye M series controls are used for supervision of small and moderate size burners firing gas and light fuel oil Fig 28 M Series model TFM1 control O UVM TFM CONTROLS Fireye UVM and TFM controls discontinued in 1999 and replaced by the Fireye M Series Il control provide five basic styles of function 1 M1 Relight 2 M2 Recycle with prepurge 3 M3 Non recycle with prepurge 4 M3H Non recycle with prepurge and pilot stabilization period M5 Non recycle with prepurge pilot stabilization period and interrupted pilot pi The UVM and TFM controls monitor both pilot and main flames and with pilot ignited burners prevent the main fuel valve from being energized until the pliot flame is proved With spark ignited burners the trial for ignition is safely limited to 10 seconds with 4 seconds available in models M2 M3 M3H and M5 Plug in purge timer cards for use with M2 M3 M3H and M5 provide selectable 7 or 30 or 60 or 90 second prepurge A running interlock circuit is provided for an airflow switch and other limits and is monitored throughout the operating cycle In the event of
88. it to prove a lazy upward bending inadequate flame Some atmospheric burner assemblies use a runner type pilot a pilot that is used to light off more than one burner It may consist out of a tube with holes drilled along its side through which fuel gas is burned An assembly such as this requires it to be proven at its ignition source and also at the extreme end of the runner pilot A thermocouple may be used to prove the pilot at the ignition source and a flame rod may be used to prove it at its extreme with the flame rod system in charge of main fuel On some direct fired air handling units burners are installed which are of significant length requiring the main flame to be detected at the end farthest away from the ignition source This also has proven to be an ideal job for flame rod systems INSTALLATION AND APPLICATION The Fireye part number 69ND1 flame rod is a spark plug type unit consisting of Y NPT mount a Kanthal flame rod a glazed porcelain insulating rod holder and a spark plug connector for making the electrical connection The 69ND1 is available in 12 18 or 24 lengths Page 9 FLAME SAFEGUARD amp COMBUSTION CONTROLS The flame rod may be located to monitor only the gas pilot flame or both the gas pilot and main gas flames It is mounted on a NPT coupling The following installation instructions should be observed 1 Keep flame rod as short as possible 2 Keep flame rod at least Y fr
89. l system The main functions performed by a flame safeguard system are 1 Safely starting and stopping of the burner either manually semi automatically or automatically 2 Enforcing proper event sequencing during starting and stopping 3 Performing flame supervision via sensing and reacting to presence or absence of flame 4 Guarding the system against conditions outside of the equipment s design limitations HISTORY Around the turn of the 20th century FSG was limited to mechanically shutting off the fuel in the event of a flame failure There was no way of detecting flame so the weight of the unburned fuel such as fuel oil was used as a means of detection The fuel oil when the flame went out ended up being collected in the furnace area or overflowed into an exterior container where its weight was used to cause a lever to close the fuel supply valve As electricity began to play a role in the industry around the 1930 s giving rise to electrically controlled valves electromechanical ways of detection were also developed Bimetal and thermocouple type instruments were developed which reacted to the temperature in flue gases or to direct radiation from the flame and many of these are still in use today The bimetal and thermocouple method although suitable for low capacity applications proved too slow for high fuel input type applications and the Fig 1 Fireye P Series control Model 26RJ8 search
90. lame detector devices and their associated control systems Page 1 FLAME SAFEGUARD amp COMBUSTION CONTROLS amp Flame Safeguard aaaneeeee 3 HISTORY A ete eee 3 un wie eee ee Sects eck Ra ee 4 Commerce A Industrial iii 4 Combustion sena a aiae a cnn 4 BEES ha a e e eden 5 Fue Sarai aa 6 Eladio eater hed eet eerie 7 Flame Detection ceceeeeesteeeeteeees 7 aw E WEE 7 Installation A application 9 Radiation Properties of Flames 10 Visible Light Flame Detectors 11 Application amp Installation 11 Ultra Violet flame Detection 12 UV TUDE lt table 12 Non Get Check 13 Sel Check seach a 14 Wiring UV Gcanners 14 Infrared Flame Detectors 15 Flame Elcker 15 IR Cell Saturation nnanaaeeeeeenaeeen 16 Installation Tips 16 Wiring IR Scanners seseseeeeeeeen 16 Trouble Shooting amp Testing of Scanners 17 Flame Signal Measurement 17 Hot Refractory Saturation Test 17 Hot Refractory Hold In Test 17 Ignition Spark Sensing Test 17 Ignition Interference Test 18 Pilot Turn Down Test 18 Tips For Flame Detector Mounting And Enclosures ao ae e raaa aeni 19 Flame Rod 19 Optical Deiechors 19 Infrared Gcanners 19 Ultra Violet Gcanners 19 Swivel Mounts sssseneeeeeeeeeeeeeeeeeee
91. lame detector types The programmer module determines control functions Detector type and flame failure response time FFRT are determined by the amplifier module Fig 29 M Series Il Control with cover chassis with modules amplifier and programmer module SO Programmer modules may be equipped with dipswitches to select Purge timing Pilot Trial for Ignition PTFI timing and Recycle or Non Recycle operation The M Series Il has a clear plastic window covering all dipswitches which must be in the closed and permanently locked position in order for the programmer to be operational Programmer modules are also provided with LED indicator lights characterizing the operating status of the control The following components are required for a complete system Control Chassis Amplifier Module Programmer Module Wiring Base Flame detector oe ON gt The Control Chassis for the Modular M Series Il control are designed to receive the flame amplifier and programmer module which insert into their respective slot The following models are available when selecting the chassis MC120 120vac 50 60 Hz MC120R 120vac 50 60 Hz Remote reset MC120P 120vac 50 60 Hz Post purge MC230 230vac 50 60 Hz MC230R 230vac 50 60 Hz Remote reset Fuse Jumper Fig 30 Programmer module Showing location of jumper and replaceable fuse Fuse protects contro outputs Jumper is on 100 series programmers only and is clipped when
92. lame envelope are the two most commonly used flame characteristics used in FSG flame detection hardware In industrial FSG systems emission of radiation is used for main flame detection by means of optical flame detectors lonization by means of a flame rod is generally used for detection of a gas igniter flame Commercial and light industrial FSG systems may at times apply a single detector to detect both main and igniter flames FLAME ROD Flame lonization is the process of heat in the flame causing the molecules in and around the flame envelope to collide with one another with sufficient force to free some of the outer electrons of the atoms that make up the molecules In this way free electrons and positive ions have been created This ionization process allows a very small current to be conducted through the flame Flame conductivity is low Resistance can vary from 100 000 to 100 000 000 ohms Current conducted through the flame flame current is generally in the range of 2 4 micro amps If two Page 7 FLAME SAFEGUARD amp COMBUSTION CONTROLS electrodes were placed in a flame and a voltage was applied a current would be conducted between the two rods flame rods Naturally the positively charged ions would flow to the negatively charged rod In order to use this process to determine presence of flame and to prevent the potential hazard of a high resistance short to ground effectively simulating flame signal the
93. le light is towards the infra red portion of the spectrum Flame detectors are designed sensitive within either ultra violet visible or infra red radiation Various aspects determine the proper selection of flame detector type Ultra violet at about one percent is the least available of the three types of radiation from a flame Generally the first 1 3 of a burner flame is the main source of ultra violet radiation High temperature flames give of high amounts of UV radiation Both oil and gas flames radiate sufficient UV for detection Visible radiation amounts to ten percent of total radiation and is detectable by the human eye in the various colors blue with orange yellow for gas flames and bright yellow for oil and powdered coal flames Infrared is emitted at about ninety percent of total radiation emitted by burner flames and is found mostly in the last 2 3 of the flame Hot furnace parts such as refractories emit IR radiation when above 1000 F Page 10 FLAME SAFEGUARD amp COMBUSTION CONTROLS SO Light energy gt 3 Heat energy 10 of useful waveband 8 3 of useful waveband X Rays lt g gt Micro waves rays Radio 25 Ultra violet Visible Infra red Zone Zone Zone Relative y O A ie A i Intensity Middle UV Violet Blue Green Yellow Orange Red Xy g 42 46 52 59 65 7 2 100 T Hi H
94. lso compatible with 45UV5 1009 self check UV scanners 48PT2 Infra Red scanners and Cadmium Sulfide detectors Amplifier modules are selected based on type of flame detector and required flame failure response time FFRT Programmer modules are equipped with smart LED s and may be equipped with dipswitches to select Purge timing Pilot Trial for Ignition PTFI timing and Recycle or Non Recycle operation A Burn in Time at which the dipswitch setting become permanently stored occurs after 8 hours of continuous operation of the control The following components are required for a complete system Control Chassis Amplifier Module Programmer Module Wiring Base Flame Detector oe ON gt Page 26 FLAME SAFEGUARD amp COMBUSTION CONTROLS The control Chassis for the Micro M series control is designed to receive the flame amplifier and programmer module which insert into its respective slot When selecting a control chassis the following modules are available MEC120 120vac 50 60 Hz MEC120R 120vac 50 60 Hz Remote Reset MEC120D 120vac 50 60 Hz Display Output MEC120C 120vac 50 60 Hz Communications MEC120RC 120vac 50 60 Hz With R and C MEC230 230vac 50 60 Hz With R D and C Programmer Modules are the heart of the system and are selected based on functions required The following models are available MEP100 Relight operation 10 sec PTFI MEP101 Same as MEP100 but allows flame signal during
95. ly e Main burns off ratio Main fuel pressure too high e Main burner improperly adjusted e Scanner does not detect main flame Page 35 FLAME SAFEGUARD amp COMBUSTION CONTROLS Flame Signal diminishes with time after main burner lights e Main burns off ratio Main fuel pressure too high Main burner improperly adjusted Infrared detector saturates see page 16 Bad UV tube in ultraviolet flame detector Steam atomization blocks flame signal UV detector on steam atomized oil burner Reposition detector for more angular view if possible e Pilot burner pulled away from flame rod by main burner firing Flame rod systems on natural draft burners e Excessive scanner temperatures Burner locks out on Flame Failure during main flame firing e Main burns off ratio Main fuel pressure too high Main burner improperly adjusted Infrared detector saturates see page 16 Bad UV tube in ultraviolet flame detector Steam atomization blocks flame signal UV detector on steam atomized oil burner Reposition detector for more angular view if possible e Pilot burner pulled away from flame rod by main burner firing Flame rod systems on natural draft burners e Power spike unnoticed by FSG but closing fuel solenoid valves e Operating or running interlock limit weak causing short drop in voltage unnoticed by FSG but closing fuel solenoid valves e Insufficient grounding to control
96. mings OO Oo Fireye D series solid state programming FSG controls replaced by E Series Flame Monitor microprocessor based controls are comprised of a Chassis a Programmer an Amplifier and a Wiring Base The following is a listing of D Series part numbers and descriptions Fig 46 D Series control chassis with program module and amplifier installed O D Series Chassis e 70D10 Non recycling With modulation terminals e 70D20 Recycling With modulation terminals No high purge position super vision e 70D30 Recycling No modulation terminals No high purge position super vision D Series Programmers e 71D60 30 sec purge 10 15 sec MTFI Use with 70D10 and 70D20 e 71D61 30 sec purge 10 30 sec MTFI Use with 70D10 and 70D20 e 71D70 30 sec purge 10 sec MTFI Use with 70D10 and 70D20 Early spark cut off e 71D80 30 sec purge 5 10 sec MTFI Recycles Use with 70D30 e 71D81 15 sec purge 5 10 sec MTFI Recycles Use with 70D30 e 71D90 90 sec purge 5 10 sec MTFI Recycles Use with 70D30 D Series Amplifiers e 72D1R1 Infrared 2 4 sec FFRT e 72D1R1T Infrared 1 sec FFRT e 72D1R3 Infrared 2 4 sec FFRT for solid fuel only e 72D1R3T Infrared 1 sec FFRT for solid fuel only 72DRT1 Flame Rod 2 4 sec FFRT 72DRT1T Flame Rod 1 sec FFRT 72DUV1 UV 2 4 sec FFRT 72DUVS4_ UV Self Check 2 4 sec FFRT 72DUVS1T UV Self Check 1 sec FFRT D Series Wiring Base e 60 1386 2 Closed wiring base f
97. ncorporates smart diagnostic LED s causing the programmer s LED s to illuminate in a coded sequence identifying the reason for the lockout Fig 31 Micro M series Control with cover chassis with modules programmer and amplifier module O This remains true even if power was removed and later restored during a lockout condition Lockout codes are described in detail in the Micro M technical bulletin MC 5000 There is also provision for Smart Reset in where the control s remote reset terminals of multiple units can be wired parallel to a common push button Useful in a multi burner system where the controls are mounted in a common panel The Smart Reset function allows when the remote reset push button is energized for between 3 and 5 seconds to reset only those controls which are in lockout condition without affecting those which are in normal operation The Micro M control is also compatible with the Fireye alpha numeric display module part no ED510 which can be remote mounted for permanent use via a remote mount kit part no 129 145 or can be used hand held as a service tool to retrieve important service related information Serial communications are available via either a Modbus driver or a Fireye E500 communications interface The Micro M series control provides for greater flexibility in flame detector selection In addition to the standard UV1A non self check UV and Flame Rod applications this control is a
98. nner mounted at the other end When satisfactory aiming is achieved the swivel mount s locking bolts are tightened LOCKING HEAT SCREW INSULATOR PIN 35 69 SCANNER K y EN saree Se ve x 1 2 NPT NIPPLE L SWIVEL MOUNT P N 60 302 Fig 21 48PT2 or UV1A scanner mounting using swivel mount and heat insulating nipple Sealing unions are provided with either a Pyrex for infrared or quartz for UV window and are used to protect the scanner against excessive furnace pressures It is good practice to install these along with a ball valve for servicing HEAT INSULATING NIPPLE P N 35 127 a Ere P e if o BALL VALVE SEALING UNION P N 60 1199 Fig 22 UV self check scanner installed in high furnace pressure application Purging air is used to prevent the sight tube from becoming obstructed by dust or dirt and also serves to keep the scanner cool For large multi burner furnace installations scanner cooling air fan assemblies may be used These fans provide ambient air at a few inches of water column above furnace pressure and this air is distributed to all scanners via cooling air piping On smaller installations instrument air is often used Scanners need very O little of this purge cooling air 4 SCFM or 113L min is recommended Fireye self check scanners are provided with a 3 8 NPT purge air opening Infrared 48PT2 and UV UV1A
99. not a power problem In applications where this occurrence may be suspected figure 68 shows a way to help alleviate this problem The assumption is and the time delay relay should be selected as such that the relay coil would trip along with the fuel valves Setting the DAE Delay After Energize at about two seconds will assure the control will recycle after any brownout or switch over event not lockout O RUNNING INTERLOCK CIRCUIT 3 P On this note it is important to remember that circuit 3 to P the running interlock circuit carries the complete electrical load of whatever is connected to terminals 5 6 and 7 It is therefore important to take into account that each device the sum of all devices and the length of wiring runs in the running interlock circuit 3 P needs to be taken into account when designing and trouble shooting the system The same phenomenon as described above in supply voltage tolerance applies to this circuit as well A weak device or excessive wire runs in 3 P may be the cause of voltage drops or micro power interruptions not noticed by the Flame Monitor but causing the fuel valve s to close simulating a flame failure In extreme cases it may be required to look into isolating the running interlock circuit via the use of a control relay such as shown in figure 68A below FLAME MONITOR TERMINALS CONTROL RELAY NO 3 P LIMITS om CONTROL RELAY Se
100. nt as large amounts of air are moved across the burner area at all times Page 37 FLAME SAFEGUARD amp COMBUSTION CONTROLS PRESS OPERATING oe GAUGE d CONTROL LOW HIGH LIMIT FLUE GAS STEAM OUTLET OUTLET WATER BAFFLE CUT OFF IGNITION TRANSFORMER COMB AIR SWITCH SIGHT BLOWER aan MOTOR COMB AIR CONTROL DAMPER PANEL _ GAS SUPPLY PILOT PILOT i SCANNER de 2 SIGHT JH GLASS VALVE REG gt l CT T MAIN REG F vw PRESS A MAIN WO STAGE VALVE VALVE A NEUTRAL WIRING NOT SHOWN ABOVE MOTOR STARTER DISCONNECT scole OVERLOADS 3PH j ms E e e 5 TO AUX ATA POWER oe EA BLOWER a SUPPLY aa MOTOR ON OFF SW oe AARM E FLAME SAFEGUARD CONTROL 12 i POWER H e FUSE Fig 45 Typical application for M series control on a 3 pass low pressure steam boiler with interrupted pilot and 2 stage firing valve
101. nting the display module not within sight and sound of the burner it may be desirable and required to disable the Reset function A jumper located on the ED610 adapter board disables the reset function when moved from position 1 2 to position 2 3 see bulletin E 8002 Fig 70 ED510 display module mounted on programmer complete with ED580 1 cable Page 58 FLAME SAFEGUARD amp COMBUSTION CONTROLS GH KEYPAD There are three tactile pads to choose from located on the front of the display module SCRL Scroll RESET and MODE SCRL e Used to advance through and display operational information associated with the control including various sub menus Treat it like a NEXT key Where ever you are in a menu pressing this key will scroll you to the next item RESET e Press to reset the control after a lockout condition has occurred The control will reset and if conditions allow the next operating cycle will start Sub menus also make use of this key for things like unit Communication address and customized messages MODE e Use this key to change mode from standard menu to a sub menu Any time a small right pointing arrow appears at the end of a menu item i e LOCKOUT HISTORY you can press the MODE key to enter this sub menu or to exit back to the standard menu EPD STYLE PROGRAMMER MODULES i By ee e eri Le Vd eung r ae a S E Fig 71 EPD style programmer module ALARM
102. om any refractory 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 Ifthe flame is nonluminous as with premixed burners the flame rod tip should extend at least into the flame but not more than half way through 5 If the flame is partly luminous the flame rod tip should extend only to the edge of the flame lt is not necessary to maintain absolutely uninterrupted contact with the flame 6 Itis preferable to angle the rod downward to minimize the effect of sagging and to prevent it from coming into 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 provide maximum flame signal reading 8 Interference from the ignition spark can alter the true flame signal reading by adding to or subtracting from it Interchanging the primary wiring line voltage to the ignition transformer sometimes may reverse this trend This interference can also be reduced by the addition of grounded shielding between the flame rod and ignition spark 9 Proven types of flame grounding adapters may be used to provide adequate grounding surface High temperature stainless steel should be used to minimize
103. omizing The nozzle used in mechanical atomizing consists of Page 6 FLAME SAFEGUARD amp COMBUSTION CONTROLS a system of slots tangential to a small inner whirl chamber followed by a small orifice In passing through the slots the liquid volume is increased The high velocity prevailing in the whirl chamber in a tangential direction imparts a centrifugal effect that forces the oil against the walls of the nozzle It then passes through the orifices in the nozzle tip and into the combustion chamber fanning out into a cone shaped spray of very small particles FLAME A flame is merely a zone within which the combustion reaction takes place at a rate that produces visible radiation A flame front is the contour along which the combustion starts the dividing line between the fuel air mixture and the combustion process In stable flames the flame front appears to be stationary The flame is actually moving towards the burner nozzle s at the same speed that the fuel air mixture is leaving the burner Wide ranges of feed ranges exist in a wide range of burner designs In order to select the most suitable flame detection hardware it is necessary to know the basic characteristics of flames The combustion process actually is surprisingly complicated yet it is only required to understand a few of the general characteristics of flames to assist you in selecting the best detector for the job Common flame characteristics are Produc
104. ontrol chassis terminal S2 to pilot assembly Flame detector dirty Incorrect line of sight for flame detector Unstable pilot flame Incompatible flame detector for fuel used Defective flame detector or amplifier module It takes seconds before the pilot flame is detected after terminal 5 and 6 are energized e Unstable pilot flame e Incorrect location of spark electrode tips in relation to pilot burner e Defective weak ignition transformer e No ground path ignition transformer to burner front e Incorrect too high fuel pressure e Incorrect primary air adjustment on pilot burner e Bad pilot burner assembly Pilot should remain stable when spark ignition is turned off Main flame fails to establish after PTFI Lockout MTFI Flame Fail e Main manual shut off valve closed Defective main ESD fuel valve Wiring error to main fuel valve Improper fuel pressure s Oil not atomized properly Oil nozzle plugged troubles Main valve opening causes fuel pressure limits high or low to trip Main valve opening causing pilot to bow out e Main burner needs pilot burner Goes out when pilot interrupted Needs air fuel or air fuel ratio adjustment at light off position e Furnace pressure incorrect e Scanner detects pilot flame but does not detect main flame Flame Signal diminishes with time after main burner lights e Main burner burns off ratio e Main burner improperly adjusted e Inf
105. or surface mounting e 60 1466 2 Open wiring base for cabinet mounting Page 39 FLAME SAFEGUARD amp COMBUSTION CONTROLS ASSEMBLY To assemble a control and its plug in modules remove the two module retainer hold down screws and remove the module retainer Note this retainer cannot be removed while the control is mounted in its wiring base Insert the amplifier module in the slot at the left side of the control and gently push into position Insert the programmer module into the right side of the control and gently push into position To mount the unit into its wiring base the module retainer must be installed Fig 47 D Series chassis module retainer removed showing insertion of amplifier module BEFORE INSTALLING THE CONTROL Before installing the chassis into its wiring base it is good practice to first do a voltage and short circuit check First verify that the supply voltage terminals L1 and L2 is within the specified rating 120vac 50 60 Hz 132vac max 102vac min Follow this by a short circuit check Use a volt meter set on ohms reading lowest scale Make sure line voltage power supply to control is off Remove the neutral wire from the terminal L2 If a step down transformer supplies the control voltage remove its ground wire from the secondary side neutral also Clip one meter test lead to the ground terminal located in the wiring base The wiring base ground terminal must have a ground wire connecte
106. ossible obtain the burner manufacturer s instructions for mounting the scanner If a single scanner is used to detect both pilot and main flames the sight pipe must be aimed so that the scanner sights a point at the intersection of pilot and main flame Proper scanner positioning must assure the following 1 Reliable pilot signal 2 Reliable main flame signal 3 A pilot too small or in the wrong position to ignite the main flame reliably must not be detected 4 The scanner must have an unobstructed view of flame being monitored 5 Monitored flame must completely cover the scanner s field of view 6 Avoid sighting hot refractory 7 Maintain scanner temperature as cool as possible below 125 F 50 C 8 Use 6 to 8 length of pipe between scanner and hot furnace plate 9 Use Fireye P N 35 69 heat insulator on the end of sight pipe 10 Sight pipe should not extend more than half way through refractory wall WIRING FIREYE IR SCANNER P N 48PT2 Attach the cable supplied with scanner to a junction box Splice the cable wires to a pair of wires not smaller than 18 gauge wire Install the complete run in separate conduit to the control Do not pass scanner wiring through any junction box containing other wires Do not run other wires through scanner conduit Continuous conduit bonding between scanner and control is important The scanner may be located up to 100 feet 30 M from control Page 16 FLAME SAFEGUARD
107. ot burner e Incorrect wiring of pilot components Pilot fails to be detected PTFI LED on for 10 seconds followed by lockout Yet visual presence of flame Flame detector not detecting flame Inadequate pilot flame Improper amplifier module installed Flame rod not making contact with flame Defective flame rod porcelain Grounding surface of pilot assembly too small corroded Replace pilot burner See page 8 e Incorrect detector wiring e Flame rod system No ground path from pilot burner to FSG control Provide ground wire from control chassis to pilot assembly Provide ground to terminal S1 Flame detector dirty Incorrect line of sight for flame detector Unstable pilot flame Defective flame detector or amplifier module It takes seconds before the pilot flame is detected after pilot valve and ignition transformer are energized e Incorrect location of spark electrode tips in relation to pilot burner e Incorrect too high fuel pressure e Incorrect primary air adjustment on pilot burner Main flame fails to establish after PTFI e Run check switch in check 500 series programmer modules only Main manual shut off valve closed Defective main safety shutoff fuel valve Improper fuel pressure Main valve opening causes fuel pressure limits high or low to trip e Wiring error to main fuel valve Main flame lights but goes out when pilot flame is shut off 500 series program modules on
108. ow the desired path in preference to alternative paths where extensive damage may occur to equipment General Rules The Flame Monitor system being microprocessor based requires a ground system that provides a zero voltage reference Fireye bulletin E1101 specifies with the Flame Monitor removed the voltage measured from L2 to all other terminals except L1 should be 0 volts 1 The most effective ground is to run the ground wire in the same raceway as the hot and neutral from the main distribution service panel not intermediate subpanels to the burner control panel and insure that this ground wire is well bonded to the control panel O 2 The wiring base of the Flame Monitor must have earth ground providing a connection between the sub base and the control panel or the burner 3 The earth ground wire must be capable of conducting the current to blow the 20A fuse in event of an internal short circuit A number 14 copper conductor is adequate wide straps or brackets are preferred rather than lead wires 4 The ground path needs to be low impedance less than 1 ohm to the equipment frame which in turn needs a low impedance to earth ground For a ground path to be low impedance at RF frequencies the connection must be made with minimum length conductors having maximum surface areas 5 All connections should be free of non conducting coatings and protected against rust 6 Utilizing conduit as a means of provi
109. r Because air contains primarily 78 nitrogen the required volume of air is generally much larger then the required volume of fuel Primary air is air that is mixed with the fuel before or within the burner s fuel delivery system Secondary air is usually brought in around the burner s fuel delivery system and spun through a diffuser or turning vane system in order to optimize air fuel mixing Tertiary air is air brought in downstream of the secondary air and is sometimes used to control the shape of the flame envelope and or to control flame temperature on low NOx burners BURNERS Burners are a simple device to convert fossil fuels into useable heat energy The primary functions of burners are a Controlled fuel delivery b Controlled combustion air delivery c Controlled fuel and air mixing d Controlled and reliable ignition e Evacuation of products of combustion f Controlled emissions Regardless of fuels fired burners must reliably perform all functions Choices of fuels burned and type of burner affect the difficulties in achieving optimum results in any of these functions The following lists some variations of burner types found a Gaseous fuel fired a Natural draft burner b Inspirating burner c Balanced draft burner d Induced draft burner e Forced draft burner Liquid fuel fired forced or balanced draft a Mechanically atomized b Air atomized c Steam atomized Final fuel deli
110. rared detector saturates see page 16 e Flame reduces flame flicker as flame temperatures increase Applies to infrared detection only e Bad cell in infrared detector e Bad UV tube in ultraviolet flame detector e Steam atomization blocks flame signal UV detector on steam atomized oil burner Reposition detector for more angular view if possible e Pilot burner pulled away from flame rod by main burner firing Flame rod systems on natural draft burners e Excessive scanner temperatures Provide cooling air to scanner e Electrical noise on scanner wiring Burner locks out on Flame Failure during main flame firing Lockout Auto Flame Fail e Main burns off ratio Main fuel pressure too high Main burner improperly adjusted Infrared detector saturates see page 16 Bad UV tube in ultraviolet flame detector Steam atomization blocks flame signal UV detector on steam atomized oil burner Page 66 FLAME SAFEGUARD amp COMBUSTION CONTROLS GH Reposition detector for more angular view if possible e Pilot burner pulled away from flame rod by main burner firing Flame rod systems on natural draft burners e Power spike unnoticed by FSG but closing fuel solenoid valves See page 55 e Operating or running interlock limit weak causing short drop in voltage unnoticed by FSG but closing fuel solenoid valves Note that each device and the sum of all devices need to carry the electrical load
111. rcuit Fig 14 Infrared scanner with heat insulating mounting nipple Fireye part no s 48PT2 and 35 69 In itself IR and visible light 400 nanometers wavelength and upwards is not overly useful in detecting presence or absence of flame A furnace area of a boiler with hot glowing refractory contains both visible and IR radiation in great abundance and simply detecting the presence or absence of it would not give any certainty of the on or off condition of the targeted flame In order to identify the targeted flame an IR scanner monitors the modulating frequency flicker of the radiation it receives IR is radiated from a flame in a multitude of frequencies called Flame Flicker The burning process consists of a large number of small explosions as molecules of fuel unites and ignites with oxygen Each of these explosions emits light and other radiation giving the flame an appearance of relative steady shape and glow When a high speed film of a flame is played back it reveals that the flame is constantly on the move changing shape and changing in brightness It is the photo detector s ability to monitor flame flicker through the ability to alter its resistance in harmony which makes the flame detector useable to distinguish between flame and other sources of radiation The photo detector most commonly used is the PbS lead sulfide photo resistor The PbS cell lowers its electrical resistance in relation to amplitude of r
112. re has made it important that only qualified technicians are employed in the application of instrumentation hardware used in today s burner operating and safety systems Components making up the system for monitoring and control of burners are subject to standards set by local authorities FUELS Most fuels are mixtures of chemical compounds called hydrocarbons When burning these fuels the final products contain carbon dioxide and water vapor unless a shortage of oxygen exists in which case the products of combustion may contain carbon monoxide hydrogen unburned hydrocarbons and free carbon Heat available from fuels is measured in Btu lb or Kcal kg Btu gal or Kcal l for fuel oil Natural gas fuel is the most straightforward fuel to use It requires no special handling in filtering drying heating etc On the other hand the efficiency in utilization of fuel oils depends to a large extent upon the ability of the burner system to atomize the oil and mix it with combustion air in the correct proportions Heavy fuel oils are usually pre heated with steam Tank heaters may raise heavy fuel oil temperatures sufficiently to reduce O its viscosity in order to facilitate pumping and straining Btu Lb Kcal Kg Er Btu Gal Kcal L Burned Gross Net Gross Net Blast furnace 1 179 1 079 665 599 gas Coke oven 8595 16 634 10 331 9 242 gas Natural 21 830 19 695 12 129 10 943 gas Propane 21 573 19
113. ressure furnaces provide clean purge air to pressurize the sight pipe if necessary 13 A quartz lens can be used to increase scanner sensitivity or to allow location of the scanner at twice the normal recommended distance WIRING UV SCANNERS Fireye UV1A scanners are supplied with 36 or 72 long flexible armored cable The two leads connect to S1 and S2 terminals located in the control s wiring base Fireye 45UV5 scanners are supplied with four lead wires each 72 long These are to be installed in a suitable length of flexible armored cable A conduit connector is supplied with this scanner Connect the two red leads signal to terminals S1 and S2 and the two black leads shutter to terminals L1 and L2 located in the control s wiring base If necessary to extend the scanner wiring the following instructions apply 1 For extended wiring up to 500 feet for each individual scanner wire of an UV1A and each red wire of an 45UV5 scanner use shielded wire Belden 8254 RG62 coaxial cable or equal The ends of the shielding must be taped and not grounded 2 Avoid the use of asbestos wire 3 Multiconductor cable is not recommended 4 Keep any high voltage or ignition wiring away from all scanner wiring Page 14 FLAME SAFEGUARD amp COMBUSTION CONTROLS INFRARED FLAME DETECTION Flame scanners operating in the visible and infra red spectrum utilize a lens photo detector and a solid state frequency tuning ci
114. rol open L1 13 Electrical noise detected on L1 and L2 Refer to page 56 From here press MODE key to access information on the last 6 lockouts stored in memory This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P Modulator motor send low 10 12 made Run Check switch placed in Check modulator driven to low position Flame signal strength is displayed This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P Dipswitch 6 is enabled Check for M D circuit open on start has not passed Unit will hold for 30 second for M D to open followed by lockout Se page 51 Waiting for terminals M D to close Maximum wait is 10 minutes followed by lockout Run Check switch placed in Check modulator driven to low position This is a message selected from the E300 message menu and refers to a limit in either circuit L1 13 or 3 P PROGRAM SET
115. rop in voltage unnoticed by FSG but closing fuel solenoid valves Insufficient grounding to control wiring base Flame detector wiring in common conduit Should be in separate conduit Interference by x rays or extreme sources of electrical noise Defective main safety shutoff valve Defective main gas regulator SPECIFICATIONS Supply Voltage 120vac max 132 Min 102vac Pwr Consumption 20VA operating Max connected load 2000VA Temp Rating Max 125 F Min 40 F Max load ratings for Term 5 amp 6 ind or combined 550Va Term 7 250Va Pilot duty Term M 9 8 F L A 58 8 L R A Term 10 11 12 X 125Va Pilot duty Term A 50Va pilot duty Page 46 FLAME SAFEGUARD amp COMBUSTION CONTROLS FLAME MONITOR Fig 55 Flame Monitor The E110 Flame Monitor is a microprocessor based burner management system It is designed to provide the proper burner sequencing ignition and flame monitoring protection on automatically ignited oil gas and combination fuel burners Field inputs are wired into the control s operating and running interlock circuits and in conjunction with these the control programs the burner s combustion air blower motor ignition and fuel valves to provide for proper and safe operation of the burner One of the strengths of the Flame Monitor system is its ability to display the current operating status plus lockout information in the event of a safety shutdown The manner in whic
116. s per second As such the count is a measure of flame intensity Upon disappearance of flame Page 12 FLAME SAFEGUARD amp COMBUSTION CONTROLS the detectors count goes to zero except for very infrequent firings inherent in this type of design to which the system does not respond UV flame detectors are designed to respond to UV sources in a flame however it is possible for the detector to respond to other sources of UV radiation such as Hot refractory well above 3000 degree F also spark ignition welding arcs halogen light etc Care should be taken to avoid picking up unwanted signal from any of these sources at or near the burner front Ultra violet detection tubes can deteriorate due to degeneration of the special gas inside the tube The cause of this could be over heating the tube subjecting the tube to excessive voltages or subjecting the tube to excessive UV radiation for long periods of time Tubes deteriorated in this way can operate in a random failure mode sometimes firing continuously after having started and failing to quench or sometimes firing inconsistently causing nuisance shutdowns Fig 11 UV Flame scanner non self check Fireye part no UV1A Tubes can also fail in a way that it causes the tube to fire as soon as the normal operating current is applied regardless of presence of UV radiation Any flame safeguard system will pick up a faulty UV detection tube during start up and no flame or signal
117. s pilot is a pilot that burns regardless of whether the burner is firing or not Generally these pilots are used in atmospheric burner systems and most often need to be manually lit In any event a standing pilot must be monitored by a flame detection system FLAME SAFEGUARD CONTROLS A flame Safeguard system consists of a flame safeguard control also called flame relay and a flame detector The primary functions of a flame safeguard control is to 1 Properly sequence the burner s operation through its start up running cycle and its shutdown 2 Provide flame supervision de energizing the fuel supply valves within the flame failure response time if flame is no longer detected 3 Monitor the safety interlocks before and during the operation of the burner 4 Provide safe start check during which the control prevents a burner start up if flame signal is present prior to its next cycle OPERATING INTERLOCK CIRCUIT The operating interlock circuit when closed cycles the burner on and off Burner cycling or operation i e call for heat or call for steam is provided by the Controller The controller is the device which cycles the burner for example An aquastat for hot water systems an area thermostat for commercial heating systems or a pressure sensor for steam boilers The controller is wired into the operating interlock circuit Other devices such as a low water cut off or remote setpoint control are somet
118. scanners need to have fittings installed on the sight tube arrangement to suit HEAT INSULATING NIPPLE P N 35 127 j o PURGE COOLING AIR INLET 3 8 PURGE COOLING AIR INLET HEAT INSULATOR P N 35 69 Fig 23 Purge cooling air details In extremely high temperature applications it may be required to cool the sight tube with cooling water Figure 24 shows how by using an assortment of standard copper fittings a water cooled sight tube may be made COOLING WATER IN 1 2 COPPER TO FIP ADAPTER 3 REQUIRED 1 2 COPPER TO MIP ADAPTER 1 REQUIRED SIGHT TUBE T SCANNER Sag S HEAT INSULATOR PIN 35 69 1X1 2X1 2 COPPER T l 2 REQUIRED COOLING WATER OUT Fig 24 Water cooled sight tube for inch mount scanners The copper tees need the end stops located inside the female inch connections removed in order to allow a inch copper tube to run uninterrupted from the sight tube end to scanner end This arrangement can easily be adjusted to be used with 1 inch mount scanners also Page 20 FLAME SAFEGUARD amp COMBUSTION CONTROLS Enclosures for Fireye standard scanner types 45UV5 UV1A and 48PT2 do not have listed NEMA ratings By design these scanners are suitable for use both indoor and outdoor application and t
119. specially protected wiring ULTRA VIOLET FLAME DETECTION Flame scamners operating in the UV wavelength may utilize an ultra violet detection tube In this type of system when UV radiation is detected the flame is considered present Differentiation or discrimination between the targeted flame and neighboring flames or background is achieved by means of discriminatory scanner sighting This means seeing as little as possible of the background combined with signal sensitivity adjustment or threshold settings to tune out unwanted signal at the detector s controller UV detection tubes should be sensitive only in the far UV wavelength range 200 to 300 nanometers to be considered solar blind Solar blindness is important in prevention of the detector picking up stray light from sources other than the flame spectrum UV detection tubes are made of quartz the tube is sealed and filled with gas It contains two electrodes connected to a source of AC voltage When ultra violet radiation of sufficient strength falls upon the electrodes electrons are released and the gas within the tube becomes conductive through ionization resulting in an electric current flow from one electrode to the other cathode to anode A relative high AC voltage 400 to 1200 VAC is applied to the electrodes resulting in the tube producing an arc between the electrodes when sufficient UV radiation is present to produce the required ionization of the inter electrode g
120. the effect of metal oxidation This assembly may weld directly over the pilot or main burner nozzle 10 Use the proper wire and wiring techniques No 14 wire rated at 9 C or higher is recommended for control to flame rod Actual wire size is not critical Increased resistance that occurs with smaller wire size will not be of significance Type of insulation is important Use wire with the highest leakage resistance to ground In practice SO wire runs can be up to 200 feet long Do not share the flame rod wire with ignition wires in same conduit RADIATION PROPERTIES OF FLAMES Emission of radiation from within a flame is the most widely used media for flame detection The radiation properties of the flame are utilized to operate electronic optical flame sensing devices Electronic sensing is required to achieve the quick flame failure response time FFRT demanded by larger input appliances Depending on type of fuel burned and rated input capacities FFRT is generally from one 1 second to four 4 seconds Flames emit radiation along a wide band of the flame s electromagnetic spectrum which is called the flame spectrum The flame spectrum is made up of ultra violet visible and infra red radiation Ultra violet and infra red radiation are at the opposite extremes of the flame spectrum with only wavelengths of 400 to 800 nanometers visible to the human eye The blue visible light is towards the ultra violet and the red visib
121. tion of heat energy Expansion of gases By product production Radiation emission lonization within the flame envelope a b OD CO OO FUEL AND PRIMARY AIR FLAME ENVELOPE SECONDARY AIR Fig5 Flame envelop O FLAME DETECTION Heat energy from a flame has not been found to be suitable for flame detection Sensors used to detect the presence or absence of heat given off by the flame do not respond fast enough Additionally the need to directly insert a sensing device into the flame to detect the targeted flames heat energy would make such a system subject to high maintenance Expansion of gases as a fuel air mixture burns can be detected and used as flame detection It is not a useful system for main burner flame detection In a multi burner environment it is sometimes seen in igniter flame detection As this system requires the detection of relatively minute changes in pressures at the burner nozzle it deals with tubing which run from the burner nozzle back to delicate pressure measuring devices these systems also are subject to high maintenance to keep them operative Production of by products chemically is a reliable source to detect whether or not combustion is taking place But as with heat energy response time would be too slow and the detection of an individual flame in a multi burner furnace extremely unlikely Emission of radiation by the flame and ionization within the f
122. ulting in release of heat The oxygen comes from air Air is about 21 oxygen and 78 nitrogen by volume Most fuels contain carbon hydrogen and sometimes sulfur A simplification of combustion could be listed in the following three processes carbon oxygen carbon dioxide heat hydrogen oxygen water vapor heat sulfur oxygen sulfur dioxide heat Page 4 FLAME SAFEGUARD amp COMBUSTION CONTROLS The above three products of combustion are chemical compounds They are made up of molecules in which elements are combined in certain fixed proportions As per the law of science matter is neither created nor destroyed in the process of combustion and the heat given off in any combustion process is merely excess energy which the molecules are forced to liberate because of their internal make up Stoichiometric combustion is obtained when no fuel or air goes unused during the combustion process Mixing and burning exactly the right proportions of fuel and oxygen so nothing is left over does this Combustion with too much excess air is said to be lean or oxidizing The excess air or oxygen plays no part in the combustion process In fact it reduces the efficiency The visual effect is a short and clear flame Combustion with too much fuel is said to be rich or reducing producing incomplete combustion The visual effect is a long and sometimes smoky flame The oxygen supply for combustion generally comes from the ambient ai
123. very and combustion air amp fuel mixing varies dependent on the burner types as per the following examples a Gun type gas or oil b Cane spud type gas c Ring type gas d Rotary cup type oil COMBUSTION Alr damper Fuel flow valve SC _ linkage ba S Jackshaft Modulator Motor Fig 3 Principle parts of a forced draft burner Fig 4 Forced draft burner Page 5 FLAME SAFEGUARD amp COMBUSTION CONTROLS A burner must be equipped with a monitoring and control system to assure safe and reliable operation throughout its intended use Complexity of this system is in relation to complexity of the process at hand and can vary from a single burner firing a single fuel to a multi burner environment where many burners are operating into a common combustion chamber and a multiple choice of fuels are burned The larger the burner input or heat release of a burner does not necessarily mean the more complex the monitoring and control system needs to be Conditions effecting complexity of control systems for burners are generally stipulated by Type of process Type of burner Multi or single burner environment Multi or single fuel operation Safety hazard of fuel burned Local codes and standards Redundancy and reliability factors h Continuous or intermittent burner operation a b 2000 Q Technological advances in recent years in particular microprocessor based hardwa
124. ving false flame signal See page 13 e Defective amplifier module Blower runs purge is not initiated EP200 and 300 series Hold Purge 3 P INTLK Open e One of the interlocks wired between term 3 and P is open e Wiring error e Check for bad tabs see Fig 48 Modulator is driven to high but no further progress in program sequence EP100 series Hold Purge D 8 Limit Open e High fire purge interlock end switch not made Terminals D 8 e Ifthe application does not use a high fire end switch to prove high purge position D 8 should be jumpered when using an EP100 series programmer Modulator driven to low but no further progress in program sequence Hold Purge M D Limit Open e Low fire end switch not made Terminals M D e If the application does not use a low fire start switch to prove a safe light off position M D should be jumpered regardless of which series programmer PTFI starts Control locks out Fuel Valve State Change e Control sees that voltage at terminal 7 when terminal 6 is energized is not the same as with last cycle See page 54 for more detail e Control is reading feed back on terminals 5 6 or 7 from PLC or DCS input wiring Install isolation relays PTFI starts Control locks out Short Circuit Term 5 6 7 Check Chassis e Short circuit or excessive current detected at terminal 5 6 or 7 Do test described on page 40 heading Before

Service Manual for Flame Safeguard & Combustion Controls

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Service Manual for Flame Safeguard &amp; Combustion Controls

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Service Manual for Flame Safeguard & Combustion Controls