® E-1101 MARCH 28, 2013 E110 FIREYE FLAME-MONITOR™ BURNER MANAGEMENT CONTROL FOR USE WITH THE MICROPROCESSOR-BASED EP AND EPD STYLE PROGRAMMER MODULES E110 with ED510 Display Module APPROVED DESCRIPTION The Fireye® E110 FLAME-MONITOR™ System is a microprocessor based burner management control system designed to provide the proper burner sequencing, ignition and flame monitoring protection on automatically ignited oil, gas, and combination fuel burners.
® CAUTION: While programmers are mechanically interchangeable in that they mate with a common wiring base, you should select the correct model for your application. Inappropriate application of a control could result in an unsafe condition hazardous to life and property. Selection of a control for a particular application should be made by a competent professional, such as a boiler/burner service technician licensed by a state or other government agency.
® ELECTRICAL RATINGS VA ratings (not specified as pilot duty) permit the connection of transformers and similar devices whose inrush current is approximately the same as their running current. VA Pilot Duty ratings permit the connection of relays, solenoid valves, lamps, etc. whose total operating load does not exceed the published rating and whose total inrush current does not exceed 10 times the rating. Running and locked rotor ratings are intended for motors.
® APPLICABLE BULLETINS E120, Flame-Monitor Chassis, 220 VAC Operation, FM approved E-1201 Programmers, Non-Recycle Operation EP-1601, EPD-1601 Programmers, Recycle Operation EP-2601, EPD-2601 Programmers, Non-Modulating EP-3801, EPD-3801 Amplifiers EAMP1 Display, ED510 ED-5101 Expansion Module E-3001 All bulletins are available in .pdf format at www.fireye.com.
® FIREYE® FLAME-MONITOR™ Selection Guide 1. SELECT CHASSIS E110 FLAME-MONITOR, 120 VAC operation E120 FLAME-MONITOR, 220 VAC operation 2. SELECT PROGRAMMER EP Programmers provide selectable operation (e.g. extended purge time) EPD programmers have integral LED indicator display. NON-RECYCLE OPERATION EP160 EPD160 EP161 EPD161 RECYCLE OPERATION EP260 EPD260 DESCRIPTION NON-MODULATION DESCRIPTION 10 and 15 sec. TFI EP380, EP387, EPD380 30 sec.
® FIREYE P/N 6 DESCRIPTION BULLETIN ED510 Display Module (2 line x 16 characters LCD Display) ED-5101 129-145-1, -2, -3 Remote Display Mounting Kit (for ED510) with 4', 8' or 2' cable respectively E-8002 E350-3, -6 Expansion Module cables in 3' and 6' lengths E-3001 ED150-3, -6, -15, -25 Remote Reset cables in 3', 6', 15' and 25' lengths E-8001 ED600 Multi-port Cable Adapter E-8001 ED610 Multi-port Adapter (for ED510 and RS485 communications) E-8002 E500-3 Communication Interface (up
® FLAME-MONITOR Ordering Information E110 Flame-Monitor (One required) ED510 Display Module E110 consists of: EB700 Chassis Required with EP Programmers Optional with EPD Programmers EC600 Dust Cover Mounting Screw (48-1836) EP programmers must have an Eng. code of 28 or later (e.g. 9414-28). EPD Programmers must have an Eng. code of 02 or later.
® FLAME SCANNERS UV90 UV8A 45UV5 45UV3-1050 69ND1 UV1A 48PT2-9000 CAUTION: The UV1, UV2, UV8A, UV90 and 45UV3 ultra-violet flame scanners and associated amplifier modules are non-self checking UV systems and should be applied only to burners that cycle often (e.g.: a minimum of once per 12 hours) in order for the safety checking circuit to be exercised.
® FIREYE PART NUMBER Pre-purge programming (Seconds) Proven High Fire Purge Interlock (D/8 Ckt) Proven Low Fire Start Interlock (M/D Ckt) Intermittent Ignition/ Pilot Yes Yes No Interrupted Ignition/ Pilot Early Spark Termination Pilot Trial-for-Ignition Term 5 Term 6 Main Trial-for-Ignition Term 5 Running Interlock (3/P CKT) Firing Rate Motor Circuit Term 6 2 EPD/EP PROGRAMMERS EPD160 EP160 EPD1678 301 Supervised No 10 10 10 1 EPD161 EP161 30 Supervised Yes EP165 7 301 Supervise
® For a complete system, choose one of each of the following: - Chassis - Programmer Module - Amplifier Module - Flame Detector - Wiring Base WARNING: Installer must be trained and qualified. Follow the burner manufacturers instructions, if supplied. Otherwise, proceed as follows: INSTALLATION OF CONTROL Wiring Base Mount the wiring base on the burner or on a panel. The location should be free from excessive vibration and within the specified ambient temperature rating.
® 3. Reconnect the neutral wire (L2) at the power source. Remove the test probe from the grounded terminal and reconnect it to Terminal L2 in the wiring base. With the other probe, touch each other terminal. It is normal to obtain a resistance reading on the meter at some terminals during this test as there are resistive loads (coils, transformers, lamps, etc.) connected whose normal DC resistance may be less than 5 ohms. However, at no time should the test meter read zero ohms.
® TYPE EP(D)160 DIPSWITCH SETTINGS NON-RECYCLE RUNNING INTERLOCKS (3/P) PURGE TIME - 30 SEC.* FLAME FAILURE RESPONSE TIME 4 SEC. 1 2 3 4 5 6 INACTIVE Down Down Down Down PROGRAMMING SEQUENCE LFS CLOSED (MD) HFS L1/13 CLOSED ON (D8) FIRING PERIOD L1/13 OFF M T E R M I N A L S PURGE 30 SEC 5 POST PURGE 15 SEC MIN 30 SEC PTFI 10 SEC MTFI 10 SEC Refer to appropriate programmer bulletin for a complete description of the dipswitch functions.
® 8. The trial for ignition period begins with Terminal 5 and 6 being energized simultaneously. This is known as PTFI (Pilot Trial for Ignition). The ED510 will display: PTFI 0:02 IGNITION TIMING This period is ten seconds in duration. If no flame is detected after ten seconds, the control will deenergize Terminals 5 and 6 and lockout. When flame is detected during this 10 second period, the ED510 will display PTFI 20 FLAME SIGNAL FLAME SIGNAL 0-9 10 20-80 9.
® LOCKOUTS When a safety shutdown occurs, the control will display a message indicating LOCKOUT and the reason for the lockout. The alarm circuit (Terminal “A”) will be energized. The non-volatile memory will remember the status of the control even if a power failure occurs. By momentarily depressing the reset button on the display, the control can be reset. The button must be held down for one second and then released. Very little force is required to do this. Do not press hard. Safety Shutdown 1.
® 3. 4. 5. 6. Fuel Valve End Switch Interlock: This is generally an integral switch mounted on the main fuel valve and activated by the valve stem. It is connected between Terminal 3 & 13. The fuel valve end switch interlock prevents a burner start-up if the valve stem is not in the “valve closed” position. Purge Interlock: Generally a firing rate motor linkage position switch or a differential air-pressure switch, that proves a maximum purge air flow rate. It is connected between Terminals D and 8.
® EP(D)160 LOGIC FLOW DIAGRAM NORMAL CYCLE MODULATOR SENT TO LOW FIRE 1 POWER ON TERMINALS L1 & L2 2 OPERATING CONTROL CLOSED L1-13 3 ARE LIMITS L1 TO 13 MADE? STANDBY L1-13 OPEN NO YES 4 IS F.V.E.S. MADE 13-3 NO LOCKOUT + NO LOCKOUT + NO HOLD 10 MIN.
® ED510 MESSAGES RUN MESSAGES The operating control of the FLAME-MONITOR (terminals L1-13) is open. STANDBY L1-13 OPEN PURGE HIGH FIRE PURGE 0:05 Firing rate motor sent to high fire (term. 10-X made), purge timing displayed upper right hand corner. PURGE LOW FIRE PURGE 0:35 Firing rate motor sent to low fire (term. 10-12 made), purge timing displayed in upper right hand corner. PTFI IGNITION TIMING 0:02 PTFI timing started. Pilot not proven yet. PTFI timing displayed in upper right hand corner.
® HOLD PURGE M-D LIMIT OPEN 0:00 HOLD PURGE 3-P INTLK OPEN 0:10 HOLD STANDBY FALSE FLAME 25 The control has finished purge and the firing rate motor is driving to the low fire position (term. 10-12 made) waiting for the low fire start switch (term. M-D) to close. It will hold this position for ten (10) minutes and then lockout if the M-D circuit does not close, excluding the EPD167. The running interlock circuit (3/P) has not closed within the first ten (10) seconds of purge.
® Flame has been sensed during the burner off time (term. L1-13 open) or during the purge period for sixty (60) seconds. LOCKOUT STANDBY FALSE FLAME A flame failure occurred during the pilot trial for ignition period. LOCKOUT PTFI FLAME FAIL LOCKOUT MTFI FLAME FAIL A flame failure occurred during the main trial for ignition period. LOCKOUT AUTO FLAME FAIL A flame failure occurred during the main burner on period. LOCKOUT PTFI SCANNER NOISE This message appears because of ignition cable noise.
® CHECK STANDBY UNIT ADDRESS 00 The “Check-Run” switch has been placed in the Check position with the operating control circuit (L1-13) open. Every time the Reset button is depressed and held for one second will increment the Unit Address by one. Refer to programmer bulletin for additional information on Unit Address. DIAGNOSTIC MESSAGES LOCKOUT AUTO CHECK AMPLIFIER POSSIBLE CAUSE — High electrical noise — Defective field wiring. — Defective amplifier. — Defective IR scanner.
® HISTORICAL INFORMATION /SYSTEM SUB-MENUS At any time the control is powered, the SCRL key will scroll through and display the total number of burner cycles, burner lockouts, and system hours on the bottom line of the ED510 display. The top line will continue to show the current run mode of the control (e.g. PURGE, AUTO, etc.).
® LOCKOUT HISTORY The sub-menu “LOCKOUT HISTORY” will display the last six (6) lockouts, along with the burner cycle and burner hour when the lockout occurred. When the MODE key is pressed, the screen will display the most recent lockout condition and the number of that lockout (e.g. LO #127 represents the 127th lockout of that control). The SCRL key will display the Burner Hour, followed by the Burner Cycle when the lockout occurred.
® TO MODIFY THE E300 MESSAGES All three keys: Mode, Reset and Scroll, are used to modify the E300 messages. The Mode key is used to enter or exit the sub-menu associated with the E300 messages. The Scroll key is used to advance through the various terminals or selectable messages. The Reset key is used to modify a terminal message and select a new message. To modify the E300 messages: Press the Scroll key until the ED510 displays E300 MSG SELECT.
® USER PROGRAMMED E300 MESSAGES In addition to selecting the lockout alarm messages for the E300 Expansion Module from a menu selection via the ED510 display, the user can also program any message (up to 40 characters in length) for the individual terminals of the E300 using a dumb terminal (or PC with communication software) and the appropriate interface cables. Refer to bulletin E-3001 for complete details.
® SYSTEM INFO Press SCRL The sub-menu “SYSTEM INFO” allows the user to review information pertaining to the operation of the control (e.g. average main flame signal strength, status of the high fire and low fire end switches, etc.). This information can be very helpful when setting the damper linkages on the firing rate motor. The MODE key is used to enter the “PROGRAM SETUP” sub-menu, and the SCRL key is used to advance through the sub-menu.
® COMMUNICATIONS The protocol to be used is Modbus RTU. This is implemented by the master (PC, PLC, etc.) issuing a poll to the slave (Flame-Monitor) and the slave responding with the appropriate message. A typical format of a poll request is as follows: DST FNC ADR HI ADR DAT DAT CRC CRC LO HI LO LO HI DST refers to the logical address of the slave. FNC is the function being requested. FNC 03 is a read request. ADR is the message number or register number of the data being requested.
® 41 6 47 6 53 6 59 6 65 6 71 1-3 72 1-2 73 1 2nd Most Recent Lockout Data 3rd Most Recent Lockout Data 4th Most Recent Lockout Data 5th Most Recent Lockout Data 6th Most Recent Lockout Data Input limits and Expansion Module registers Expansion Module (E300) registers Returns input limits state and lower and upper expansion module (E300) registers.
® The baud rate of the Flame-Monitor is fixed at 4800 bits per second. The format of the data is 8 data bits, no parity and 1 stop bit. Due to the RS485 format, the communication format is considered halfduplex. That is, only one user is permitted on the communication lines at a time. The information contained in INPUTS and OUTPUTS represents the status of the interlocks and relays respectively.
® Table 2: EXPLANATION OF LOGSTAT LOGIC DISPATCHER VALUE DEC 69 70 71 72 73 74 75 76 77 78 HEX 45H 46H 47H 48H 49H 4AH 4BH 4CH 4DH 4EH MODULE FUNCTION MPOSTIDLE MPREPURGE1 MPURGE MPOST PURGE MTFI MTFMF MAUTO MSHTDWN1 MSHTDWN2 MIDLE Wait for air flow and/or high fire switch to close Open Damper Purge Low Fire Purge Pilot Trial Main Trial AUTO Post Purge Post Purge Standby Logstat represents the current software module the Flame-Monitor is currently executing.
® Table 1- Message Table DEC HEX 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 1 2 3 4 5 6 7 8 9 A B C D E F 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 1D 1E 1F 20 21 22 23 24 25 26 27 R H R H H L L C H R E110 FLAME-MONITOR MESSAGES L1-13 OPEN HOLD FALSE FLAME- STANDBY LOW FIRE PURGE HOLD D-8 LIMIT OPEN- PURGE HOLD 3-P AIR FLOW OPEN LOCKOUT LINE FREQUENCY NOISE DETECTED LOCKOUT FLAME FAIL - PTFI CHECK UNIT ADDRESS HOLD M-D LIMIT OPEN IGNITION
® SYSTEM DIAGNOSTIC MESSAGES 54 55 56 57 58 59 76 36 37 38 39 3A 3B 4C L L L L L L L 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 3C 3D 3E 3F 40 41 42 43 44 45 46 47 48 49 4A 4B H H H H H H H H H H H H H H H H 76 77 78 79 80 81 82 4C 4D 4E 4F 50 51 52 L H L H L L R LOCKOUT CHECK CHASSIS LOCKOUT CHECK PROGRAMMER LOCKOUT CHECK AMPLIFIER LOCKOUT CHECK EXPANSION MODULE LOCKOUT AMPLIFIER AUTO CHECK FAIL LOCKOUT SCANNER NOISE LOCKOUT CHECK SCANNER E300 EXPANSION MODULE HOLD MESSAGES L1-13 AUX #1 OP
® SUGGESTED WIRING DIAGRAM FOR EP(D)160, EP161, AND EP(D)170 PROGRAMMERS Lockout Alarm Circuit Firing Rate Motor Switching (See Insert) FIREYE WIRING BASE TERMINALS 10 11 L1 L2 3 M D P X 12 S1 Ignition And Fuel Valve Control Circuit 13 5 6 7 8 A S1 RUNNING INTERLOCK N L1 X 12 LO COM HI 11 S1 S2 RED LIMIT OPERATING SWITCHES FIREYE TERMINAL BURNER/ BLOWER MOTOR AUTO L2 FUEL VALVE INTERLOCK Burner Switch 10 Note: When A Flame Rod Is Used, Jumper S2 To The Green Grounding
® EXTENDED PREPURGE With EPD programmers, it may be necessary to extend the pre-purge timing on the Flame Safeguard Control to greater than 30 seconds. This can be accomplished by adding a time delay relay in the L2/ M and D/8 circuit and wired in the following manner: The maximum extended purge time will be 10 minutes. The maximum time delay setting should be 91/2 minutes.
® CENTER OFF SWITCH 3PDT SHOWN IN OIL POSITION INTERRUPT POWER TO F.M. 5 6 R1NO 7 L1 R1NC OIL GAS OIL OFF OFF GAS GAS OIL OFF R1 CONTROL INPUT VOLTAGE IGNITION TRANSFORMER PV MV MV PILOT VALVE MAIN OIL VALVE MAIN GAS VALVE INSTALLATION /TESTING Check-Run Switch The Check-Run switch is located on the top of the EP Programmer Module and can be used to stop the control in its firing sequence at any time except during MTFI.
® 3. After the PTFI period has begun, switching back to the Check position will stop the program in the PTFI period, allowing for pilot and/or scanner alignment adjustments to be made. The control will display: CHECK PTFI FLAME SIGNAL 19 It will hold in this position indefinitely as long as the flame signal strength is above the threshold of 10. If it drops below 10 for thirty consecutive seconds, lockout will occur and the message on the display will read Flame Fail PTFI. 4.
® TEST CHECKOUT PROCEDURES Normal Pilot Flame Test CAUTION: Before making a pilot flame test, manually shut off the fuel supply to the main burner. 1. At the start of PTFI, place the Check-run switch in the check position. 2. Observe the pilot flame signal on the display. If the average signal is below the minimum of 10, readjust the pilot flame or realign the flame detector. 3. During the pilot flame test, if flame is not detected for a continuous 30 seconds, the control will lockout.
® REFRACTORY REFRACTORY MAIN FLAME PILOT FLAME PILOT FLAME MAIN BURNER PILOT BURNER REFRACTORY MAIN FLAME MAIN BURNER PILOT BURNER SCANNER MAIN BURNER PILOT BURNER SCANNER INSUFFICIENT PILOT MAIN FLAME PILOT FLAME MINIMUM PILOT SCANNER NORMAL PILOT Scanner Wiring Care should be taken to see that ignitor cables and scanner cables are routed away from one another on all installations.
® INSTALLATION Do not run high voltage ignition transformer wires in the same conduit with flame detection wiring. Do not run scanner wires in a conduit with line voltage circuits. Ensure the frame of the ignition transformer is securely connected to control panel frame or preferably the burner frame. The Flame-Monitor chassis (EB700) contains a transient suppressing device connected internally across hot and neutral and then to the internal bracket.
® 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.
® TYPICAL SCANNER INSTALLATIONS SCANNER DO NOT EXTEND MORE THAN HALF-WAY INTO REFRACTORY FORCED CLEAN AIR (FROM DISCHARGE OF FAN) DO NOT EXTEND MORE THAN HALF-WAY INTO REFRACTORY THE MAXIMUM UV SIGNAL FROM A FLAME IS FOUND IN THE FIRST ONE-THIRD OF THE VISIBLE FLAME TAKEN FROM THE POINT WHERE THE FLAME BEGINS. THE SCANNER SIGHT PIPE SHOULD BE AIMED AT THIS AREA.
® WIRING - UV SCANNERS To connect the scanner to the control, the UV1 Scanner is supplied with 36” or 72” of flexible cable. The 45UV5 is supplied with four 72 lead wires. Install them in a suitable length of flexible armor cable and connect it to the control. A conduit connector is supplied with the scanner. Connect black wires (shutter) to terminals L1, L2; red wires (UV tube) to terminals S1, S2.
® Wiring Attach the cable supplied with the scanner to a junction box. Splice the cable wires to a pair of wires not smaller than #l8. Install the complete run in a separate conduit to the control. Continuous conduit bonding between scanner and the control is mandatory! Scanner may be located up to 100 feet from control. Do not pass scanner wiring through any junction box containing other wires. Do not run other wires through scanner conduit. Asbestos insulated wire should be avoided.
® NOTE: Interference from the ignition spark can alter the true signal reading by adding to, or subtracting from it. This trend sometimes may be reversed by interchanging the primary wires (line voltage) to the ignition transformer. This interference can also be reduced by the addition of grounded shielding between the flame rod and ignition spark. 8. Proven types of flame grounding adapters, as shown below, may be used to provide adequate grounding surface.
® MAINTENANCE Infrared and Ultraviolet Scanners The viewing area of the scanner must be kept clean. Even a small amount of contamination will reduce the flame signal reaching the detector by a measurable amount. Wipe the viewing area routinely using a soft cloth dampened with concentrated detergent. — Type 48PT2 Scanners include a replaceable #4-263-1 Firetron cell. — Type 45UV5 Scanners include a replaceable #4-314-1 UV tube.
® Mounting 45UV5 Scanner #60-1664 1” SWIVEL MOUNT AIR ENTRY (PURGE AND COOLING) #35-127 HEAT INSULATING NIPPLE APERTURE #53-121 #60-1664 1” SWIVEL MOUNT 2.75” (70) RETAINER #34-181 STANDARD MOUNTING FOR TYPES OF SCANNERS #60-1664 1” SWIVEL MOUNT AIR/ENTRY (PURGE ABD COOLING) #35-127 HEAT INSULATING NIPPLE #35-127 HEAT INSULATING NIPPLE PURGE AIR ENTRY 2.75” (70) MOUNTING FOR HIGH TEMP.
® UV8A Scanner 2 1/4” (57.2MM) 1 1/2” (38.1MM) 1/2 X 14 ST. PIPE UV8A 1 IN. DIA. (25.4MM) 2.53” (64.3MM) 1.06 IN DIA (27.0mm) UV1A3 3 FT. TC-ER CABLE UV1A6 6 FT. TC-ER CABLE .700 DIA. FITTING (17.8MM) FOR WATER-TIGHT CONDUIT I.E.: THOMAS & BETTS 5121-TB SHIELDING OF 6 FT. (1830MM) LEADS IS REQUIRED WARNING: The leads from the UV8A Scanner to the control must be shielded to prevent electrical noise from generating a false flame signal to the control.
® CONTROL WITH COVER AND WIRING BASE 5 11/16 (144.5) WIRING BASE MOUNTING HOLES 2 7/16 (61.9) 3 5/8 (92) 1 7/8 (48) 7 9/32 (185) KNOCKOUTS FOR 1/2” CONDUIT (7) 5 3/4 (146) 3 7/32 (82) 5 1/4 (133) 7 (177.8) 3/4 (19.05) 25/32 (19.8) 1 3/16 (30.2) 4 7/8 (123.8) 1/2” KNOCKOUT 6 (152) 1 1/16 (27) 13/16 HEX (20.6) 2.25 (57.1) 0.390 TYP (9.9) 1/4 TYP (6.35) 1.06” DIA. (27.0) 2.58” (65.6) ”L” 11/16 (17.4) 1.15 (29.2) 15/16 HEX (23.8) 0.5 (12.7) 3/8” PIPE THREAD 36” (1m APPROX.
® NOTICE When Fireye products are combined with equipment manufactured by others and/or integrated into systems designed or manufactured by others, the Fireye warranty, as stated in its General Terms and Conditions of Sale, pertains only to the Fireye products and not to any other equipment or to the combined system or its overall performance.
