Fireye M-series ii User manual

FIREYE

MODULAR

M-SERIES II

FLAME SAFEGUARD CONTROLS

WARNING: Selection of this control for a particular application should be made by a com-

petent professional, licensed by a state or other government agency. Inappropriate application

of this product could result in an unsafe condition hazardous to life and property.

DESCRIPTION

Fireye® Modular M-Series II Flame Safeguard Controls are compact, modular burner management

systems for intermittent operation. They are designed to provide automatic ignition and continuous

flame monitoring for commercial sizes of heating and process burners that use gas and/or light oil

fuels.

Flame monitoring is accomplished by miniature UV scanners or Flame Rod detectors and plug-in

amplifier and programmer modules which connect into a standard chassis and wiring base. Inter-

changeable programmer and amplifier modules allow for complete versatility in selection of control

function, timing, and flame scanning means. Functions such as re-ignition or non-recycle are deter-

mined by the programmer module. Type of flame scanner (UV or Flame Rod) and Flame Failure

Response Time (F.F.R.T.) are determined by the amplifier module.

LED indicator lights on all programmer modules indicate the operating status of the control.

In the event of ignition failure, or following a safety shutdown, the unit locks out, activating an

alarm circuit. Manual reset is required. Remote reset (via remote pushbutton or power interruption)

is available on the MC120RE and MC230R chassis. A detailed description of the various program-

mer modules is found later in this document. Test jacks are provided to permit flame signal measure-

ment during operation.

Modular M-Series II controls incorporate a safety checking circuit that is operative on each start. If

flame (real or simulated) is detected prior to a start or during the purge, the fuel valves will not be

energized, and the unit will lock out.

The Modular M-Series II controls use the same wiring base as the Fireye UVM and TFM Controls

and are designed to be interchangeable with most models without rewiring. See INSTALLATION

OF CONTROL, SCANNERS, AND FLAME DETECTORS for temperature and wiring require-

ments.

C-4000-E

MARCH 22, 2007

SPECIFICATIONS

Supply:

120 V (min. 102, max. 132) 50/60 Hz. (MC120E and MC120RE)

230V (min. 196, max 253) 50/60Hz (MC230 and MC230R)

Table 1: AMBIENT TEMPERATURE LIMITS

Power Consumption:

12 VA (Operating)

Shipping Weight (Approx.):

5 lbs. (2.3 Kg.)

Table 2: LOAD RATINGS (15 Amps circuit breaker*connected in series between terminal 1 and 7).

MAXIMUM MINIMUM

Control 140qF (60qC) - 40qF(- 40qC)

Scanner UV1A,

UV2, UV8A, 45UV3

200qF (93qC) - 40qF(- 40qC)

Flame Rod

(Tip 2460 F)

1500qF (816qC) - 40qF(- 40qC)

Fireye

Terminal

Typical Load Maximum Rating & 120V 50/60 Hz

or 230V 50/60 Hz.

3 or 4

Individual

or combined

Pilot valve(s)

Solenoid valve

Ignition Transformer

125 VA pilot duty (solenoid valve) plus

250 VA (Transformer)

5Main Fuel Valve(s) 125 VA pilot duty (solenoid) or

25 VA pilot duty (solenoid) and

400 VA (opening) motorized

8Motor or contactor Motor normally energized and de-energized by the operating

control whose rating must be suitable. Terminal 8, for the 120V

series products, is rated to de-energize 9.8 FLA, 58.8 LRA, on

safety lockout, for the 230V series products, is rated to de-

energize 5.2 FLA, 31.2 A LRA, on safety lockout.

AAlarm 50 VA, pilot duty

*Circuit breaker, type standard delay suggested Potter & Brumfield.

#W67-X2Q12-15V or equivalent.

Specification: Single pole, series trip, white toggle.

Max. Line voltage 250 VAC 50/60 Hz.

Current rating 15 Amps.

VDE approved breaker 0642/EN60934.

Insulation resistance: 100 Megohms at 500VDC.

Operating Temperature: -40qC to 85qC.

OUTLINE DIMENSIONS

ORDERING INFORMATION

CHASSIS (COMMON FOR ALL CONTROLS, INCLUDES DUST COVER):

MC120E 120 VAC Supply, 50 Hz/60 Hz

MC120RE 120 VAC supply, 50 Hz/60 Hz. Remote reset capability.

MC230 230 VAC Supply, 50 Hz/60 Hz

MC230R 230 VAC Supply, 50 Hz/60Hz. Remote reset capability.

PROGRAMMER MODULES:

MP100, MP100ERe-ignition operation, 10 second ignition safety time.

MP102, MP102ENon-Recycle operation, 5 second ignition safety time.

NOTE: Programmers with the suffix "E" (e.g. MP100E) are for use with the MC230 and MC230R

Chassis only.

(50.8)

1/2-14 STRAIGHT

FEMALE PIPE THREAD

1” DIA

(25.4)

UV1A UV SCANNER

36” FLEXIBLE CABLE (UV1A3)

72” FLEXIBLE CABLE (UV1A6)

(50.8)

36” (1m APPROX.)

FLEXIBLE CABLE

3/8” PIPE THREAD

13/16 DIA.

(206)

UV2 UV SCANNER

2 3/8

(60.3)

1 3/16

(30)

1/2

(12.7)

”L”

1/2-14 NPT

13/16 HEX

(20.6)

15/16 HEX

(23.8)

”L” LENGTH AS SPECIFIED: 12”, 18”, 24” (304.8, 457.2, 609.6)

69ND1 FLAME ROD

5 3/16

MOUNTING BASE

2 1/4”

(57.2mm)

1 1/2”

(38.1mm)

UV8A SCANNER

1/2 X 14 ST.

PIPE

THREAD

1 IN. DIA.

(25.4mm)

SHIELDING OF 6 FT. (1830mm)

LEADS IS REQUIRED

.700 DIA. FITTING (17.8mm)

FOR WATER-TIGHT CONDUIT

5 5/16

41/2

1/2

3/16” DIA. MOUNTING

HOLES (4)

KNOCKOUTS (12)

FOR 1/2”

CONDUIT

HOLE FOR

3/4”

SIGHTING

PIPE

SCREW

1/4-20 THD

2 7/8”

(73)

2”

(50.8)

1 5/8”

(41)

3 1/4”

(82)

2/N

1.48"

(37.6mm)

UV SCANNER

TYPE 45UV3

MODEL 1050

AMPLIFIER MODULES: USE WITH SCANNERS:

MAUV3 UV amplifier, 3 second F.F.R.T. UV1A, UV2, UV8A, 45UV3-1050

MAUV1T UV amplifier, 1 second F.F.R.T. UV1A, UV2, UV8A, 45UV3-1050

MART3 Flame rectification amplifier, 69ND1

3 second F.F.R.T.

MART1T Flame rectification amplifier, 69ND1

1 second F.F.R.T.

UV SCANNERS:

UV1A3 1/2” NPT connector, 3’ (914mm) flex. cable

UV1A6 1/2” NPT connector, 6’ (1829mm) flex. cable

UV2 3/8” NPT connector, 3’ (914mm) flex. cable

UV8A 1/2” NPT 90 degree angle head, 6’ (1829mm) flex. cable

45UV3-10503/4” sleeve/setscrew mount

FLAME DETECTORS:

69ND1-1000K4 12 inch (304.8mm) flame rod, 1/2” NPT connector

69ND1-1000K6 18 inch (457.2mm) flame rod, 1/2” NPT connector

69ND1-1000K8 24 inch (609.6mm) flame rod, 1/2” NPT connector

WIRING BASE (COMMON FOR ALL CONTROLS):

61-3060 Closed wiring base, surface mounting

61-5042 Open wiring base, cabinet mounting

For a complete system, choose one of each of the following:

— Chassis — UV Scanner or Flame Detector

— Programmer Module — Wiring Base

— Amplifier Module

WARNING: Installer must be trained and qualified. Follow the burner manufacturer’s

instructions, if supplied. Otherwise, proceed as follows:

INSTALLATION OF CONTROL, SCANNERS, AND FLAME DETECTORS

Wiring Base

Mount the wiring base on the burner or on a panel. The location should be free from excessive vibra-

tion and within the specified ambient temperature rating. The base may be mounted in any angular

position.

All wiring should comply with applicable electrical codes, regulations, and local ordinances. Use

moisture resistant wire suitable for at least 90 degrees C. Circuit recommendations are found on

Pages 14 through 15. Consult the factory for assistance with non-standard applications.

WARNING: Controls require safety limits utilizing isolated mechanical contacts. Solid state

limit switches are not acceptable and should not be used due to their high leakage currents.

Installing the Programmer and Amplifier Modules

WARNING: Remove power from the control before proceeding.

Select the appropriate programmer and amplifier modules for your application. Remove the dust

cover from the chassis. Insert the amplifier module into the slot in the center of the chassis and gen-

tly push the module into position. Insert the programmer module into the slot at the right side of the

chassis and gently push the module into position.

WARNING: Turn off the power when installing or removing the control.

INSTALLATION - UV SCANNERS

Where possible, obtain the burner manufacturer’s instructions for mounting the scanner. This infor-

mation is available for most standard burners. The scanner mounting should comply with the follow-

ing general instructions:

1. Locate the scanner within 30 inches (76cm) of the flame to be monitored, closer if possible.

2. Select a scanner location that will remain within the ambient temperature limits of the UV-eye

scanner (200qF/93qC). If cooling is required, use (a) an insulating coupling (Fireye part #35-69)

to reduce conducted heat; (b) a window coupling (Fireye part #60-1257) to seal off furnace or

burner pressure; (c) cooling air to reduce the scanner sight pipe temperature.

3. Mount rigidly a short length (10-20cm) of 1/2sor 3/4sblack iron pipe in a position that permits

an unobstructed view of the pilot and/or main flame.

CAUTION: The scanner must not sight the ignition spark directly, or any part of the burner

that can reflect the spark back to the scanner.

4. 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.

5. A correct scanner application will not see a pilot flame that is too small to ignite the main flame

reliably. Note particularly the test for minimum pilot that is described on Page 12.

6. On installations having negative pressure combustion chambers, a small hole (1/8sor 3/16s)(3 or

5mm)drilled in the sight pipe will assist in keeping the pipe clean and free from smoke.

7. Two scanners may be installed on one burner if it is necessary to view two areas to obtain reli-

able detection of the flame. They should be wired in parallel.

AMPLIFIER PROGRAMMER

8. The UV-eye scanner is designed to seal off the sight pipe up to pressures of 1 PSI (.07kg/cm2)

when the scanner lock nut is firmly tightened. Pressures in excess of 1 PSI (.07kg/cm2) should

be blocked from the scanner. A quartz lens coupling (Part #60-1290) or quartz window coupling

(Part #60-1257) may be used. Each is rated from -3 to +100 PSI max. (-.2kg/cm2to +7kg/cm2

max.).

9. To increase scanner sensitivity, a quartz lens coupling (Part #60-1290) may be used. The quartz

lens permits location of the UV-eye twice the distance noted in Item 1. Use 1/2sx11/2snipple

between UV1A scanner and union. Use 3/8sclose nipple and 1/2sby 3/8sbushing on UV-2 appli-

cations.

General Requirements

1. As close as possible — 30s(76cm)or closer.

2. As cool as possible — Not over 200qF/93qC.

3. Avoid sighting the spark — Resight scanner, shield between spark and scanner, or orifice to

reduce reflected signal from spark.

4. Must see pilot and/or main flame — Scanner view must be unobstructed,

5. Minimum pilot test — See Page 12.

Typical Scanner Installations

Wiring of UV Scanners

The UV1A scanner is supplied with 3' (90cm) or 6' (180cm) of flexible cable. The UV-2 scanner is

supplied with 3' (90cm) of flexible cable. If it is necessary to extend the scanner leads, the following

instructions apply:

1. Scanners without armored cable must be wired using metal cable or rigid conduit.

2. High voltage wiring must not be installed in the same conduit with flame detector wiring.

3. Selection of Scanner Wire:

a. Use #14, 16, or 18 gauge wire with 90qC, 600 volt insulation for up to 200 feet (60M)of

distance. (approx. 20% signal loss at 100 feet [30M], 40% signal loss at 200 feet [60M]).

b. Asbestos insulated wire should not be used.

c. Multi-conductor cable is not recommended without prior factory approval.

d. High voltage ignition wiring should not be installed in the same conduit with flame detector

wires.

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.

SCANNER

METHODS OF COOLING SCANNER

INSULATING

TUBING

SEALING UNION

FORCED

AIR

EXTEND SIGHTING TUBE

6”(152mm) OR 8”(203mm)

DO NOT EXTEND MORE THAN

HALF-WAY INTO REFRACTORY

4. Installation of Extended Scanner Wiring:

— For extended scanner wiring up to 500 feet (150M), and for shorter lengths to reduce signal

loss, use a shielded wire (Belden 8254-RG62 coaxial cable, or equal) for each scanner wire

of UV1, UV2. The ends of the shielding must be taped and not grounded.

5. Multiple Scanner Installations:

— The wiring from multiple UV scanners may be installed in a common metallic conduit.

— Multi-conductor cable is not recommended without prior factory approval.

INSTALLATION - 69ND1 FLAME ROD

The 69ND1 flame rod proves a gas pilot flame and/or main gas flame. It is a spark plug type unit

consisting of 1/2sNPT mount, a KANTHAL flame rod, a glazed porcelain insulating rod holder and

a spark plug connector for making electrical connections. The 69ND1 is available in 12s(304.8mm),

18s(457.2mm) or 24s(609.2mm) lengths.

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 1/2sNPT coupling.

The following instructions should be observed:

1. Keep flame rod as short as possible.

2. Keep flame rod at least 1/2s(12.7mm)from 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. If the flame is nonluminous (air and gas mixed before burning), the electrode tip should extend

at least 1/2s(12.7mm)into the flame, but not more than halfway through

5. If the flame is partly luminous, the electrode tip should extend only to the edge of the flame. It is

not necessary to maintain absolutely uninterrupted contact with the flame.

6. It is preferable to angle the rod downward to minimize the effect of sagging and to prevent it

from coming in contact with any object.

7. An adequate grounding surface for the flame must be provided. The grounding surface in actual

contact with the flame must be at least four times greater than the area of the portion of the

flame rod in contact with the flame. It is essential to adjust the flame rod and ground area ratio

to provide a minimum signal reading of 6VDC.

Note: Interference from the ignition spark can alter the true signal reading by adding to, or sub-

tracting from it. This trend sometimes may be reversed by interchanging the primary wires (line volt-

age) to the ignition transformer. This interference can also be reduced by the addition of grounded

shielding between the flame rod and ignition spark.

WRONG POSITION

OF ROD

INADEQUATE FLAME

PILOT BURNER

CORRECT POSITION

OF PILOT FLAME

CORRECT

POSITION

OF ROD

8. Proven types of flame grounding adapters, as shown below, may be used to provide adequate

grounding surface. High temperature stainless steel should be used to minimize the effect of

metal oxidation. This assembly may be welded directly over the pilot or main burner nozzle

WIRING OF FLAME RODS

For proper operation of flame rectification systems (flame rods), it is necessary to maintain at least

20 megohms insulating resistance in the flame rectification circuit.

1. The scanner should be wired using metal cable or rigid conduit.

2. High voltage wiring must not be installed in the same conduit with scanner wiring.

Selection of Scanner Wire

1. Use #14, 16, or 18 gauge wire with 90qC, 600 volt insulation for up to 100 feet (30M) distance.

2. The type of insulation used with flame rectification wiring is important, since it must protect

against current leakage resistance to ground. Use Belden 8254-RG62 Coaxial Cable (or equal)

for runs greater than 100 feet (30M). Maximum wiring run not to exceed 400 feet (120M).

MAINTENANCE

Type UV1, UV2, UV8A, and 45UV3 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 rou-

tinely using a soft cloth dampened with concentrated detergent.

Type 69ND1 Flame Rod

The flame rod and its insulator should be kept clean by washing routinely with soap and water. Rods

should be routinely replaced as they oxidize.

Flame Signal Strength

Routine observation of the flame signal strength will forewarn any deterioration in the capability of

the flame detector or its application.

Periodic Safety Check

It is recommended that a procedure be established to test the complete flame safeguard system at

least once a month. This test should verify the proper operation of all limit switches and safety inter-

locks as well as flame failure protection and fuel safety shutoff valve tightness.

Rotation

It is recommended that control and scanner units purchased as spares be installed periodically.

BOMB FIN

GROUNDING

ASSEMBLY

THREADED ROD

ASSEMBLY

MC120E REMOTE RESET CHASSIS

The MC120RE and MC230R Chassis provides remote reset capabilities in the event of a lockout

condition. The remote reset chassis can be reset in any of the following ways:

1. Depress and release the reset button built into the chassis. This reset button will always reset the

control.

2. To reset the control via a remote pushbutton. Wire a momentary dry contact pushbutton into the

two (2) terminals located on the chassis (on the same PC board as the built-in reset switch) and

depress the button for one (1) second. The maximum distance the remote reset switch can be

wired from the control is 1,000 feet (300M).

CAUTION: Remote reset is recommended only on a control solely for proved ignition pro-

gramming (pilot ignited burner) or a control for use only with appliances in which unburned

fuel cannot accumulate and that is intended for installation in inaccessible locations such as

open-flame, ceiling-suspended gas heaters.

LED INDICATOR LIGHTS

The Programmer Modules have 5 LED lights to indicate the operating status of the control. The

function of these lights are:

Operating Control: This LED is energized whenever the burner control switch (Terminal #7) along

with the various limit switches, operating controls and fuel interlocks are closed.

Air Flow: This LED is energized whenever the air flow switch is closed between Terminals #8 and

#6, and power is on Terminal #8.

PTFI: This LED is energized only during the Ignition Safety Time.

Flame On: This LED is energized whenever a flame signal is detected by the UV scanner or Flame

detector.

Alarm: this LED is energized whenever a safety lockout occurs. (See APPLICATION AND FUNC-

TION section).

APPLICATION AND FUNCTION - MP100, MP100E

The MP100 and MP100E Programmer Modules are designed as a replacement for the Fireye M1

Series “re-ignition” controls. It provides ignition and Flame Safeguard for heating or process light

oil or gas fired burners. The Amplifier Module should be selected based on the type of flame scanner

(UV scanner, or flame rod), and the required Flame Failure Response Time (F.F.R.T.). See ORDER-

ING INFORMATION on Page 4 for the appropriate part numbers.

Pilot Ignited Burners

The typical wiring arrangement illustrated on Page 16 for pilot ignited burners provides the follow-

ing function:

1. With power applied, and the limit-operating control circuit closed (Operating Control LED

lit), the burner motor circuit is energized. The air flow switch circuit closes (Air Flow LED lit).

2. Following a short-time delay (4 to 6 sec.), KL-1 closes, energizing Terminal 3 which powers the

pilot gas valve, and Terminal 4 which powers the spark ignition. A 10 sec. trial for ignition is

initiated (PTFI LED lit).

3. When pilot flame is detected (Flame LED lit), KF-1 closes, energizing Terminal 5 which pow-

ers the main fuel valve, and KF-2 opens, de-energizing Terminal 4 which shuts off the spark

ignition.

4. When the operating control opens its circuit, or if a power failure occurs, the control is de-ener-

gized. When power is restored, the control will restart.

NOTE: Controls with UV amplifiers (MAUV3 and MAUV1T) are always powered via Terminal #1.

5. In the event the pilot flame is not detected by the end of the trial for ignition period, the pilot gas

valve and spark ignition are de-energized. A safety lockout occurs which de-energizes the

burner motor and energizes the lockout alarm circuit (Alarm LED lit) approximately 10 to 30

seconds after the safety shutdown occurs.

6. In the event of a flame failure during a firing period, the main fuel valve is de-energized and the

spark ignition re-energized. A 10 sec. trial for ignition is initiated (PTFI LED lit). If flame is

detected (Flame LED lit) during the trial for ignition period, the main fuel valve is re-energized

and the spark ignition de-energized. If flame is not detected during the trial for ignition period,

the pilot gas valve and spark ignition are de-energized. A safety lockout occurs which de-ener-

gizes the burner motor and energizes the lockout alarm circuit (Alarm LED lit) approximately

10 seconds after the safety shutdown occurs.

7. Manual reset is required following any safety lockout.

NOTE: Wait 10 seconds after lockout before resetting the control.

Direct Spark Ignited Burners

The typical wiring arrangement illustrated on Page 16 for direct spark ignited burners provides the

following function:

1. With power applied, and the limit-operating control circuit closed (Operating Control LED lit),

the burner motor circuit is energized. The air flow switch circuit closes (Air Flow LED lit).

2. Following a short-time delay (4-6 sec.) KL-1 closes, energizing Terminal 3 which powers the

primary main fuel valve and Terminal 4 which powers the spark ignition. A 10 sec. Trial for

ignition is initiated (PTFI LED lit).

3. When main flame is detected (Flame LED lit), KF-1 closes, energizing Terminal 5 which pow-

ers the secondary main fuel valve (if used), KF-2 opens de-energizing Terminal 4 which shuts

off the spark ignition.

4. When the operating control opens or if a power failure occurs, the control is de-energized. When

power is restored, the control will restart.

NOTE: Controls with UV amplifiers (MAUV3 and MAUV1T) are always powered via Terminal #1.

5. In the event that main flame is not detected by the end of the trial for ignition period, the primary

main fuel valve and the spark ignition are de-energized. A safety lockout occurs which de-ener-

gizes the burner motor and energizes the lockout alarm circuit (Alarm LED lit) approximately

10 to 30 seconds after the safety shutdown occurs.

6. In the event of a flame failure during a firing period, the secondary main fuel valve (if used) is

de-energized and the spark ignition is re-energized. A 10 sec. trial for ignition is initiated (PTFI

LED lit). If flame is detected (Flame LED lit), the secondary main fuel valve (if used) is re-

energized and the spark ignition de-energized. If flame is not detected during the trial for igni-

tion period, the primary main fuel valve and the spark ignition are de-energized. A safety lock-

out occurs, which de-energizes the burner motor and energizes the lockout alarm circuit (Alarm

LED lit) approximately 10 to 30 seconds after the safety shutdown occurs.

7. Manual reset is required following and safety lockout.

NOTE: Wait 10 seconds after lockout before resetting the control.

APPLICATION AND FUNCTION - MP102 and MP102E

The MP102 and MP102E operates in the same manner as the MP100 and MP100E with the follow-

ing exceptions. The standing pilot and re-ignition features have been eliminated. The ignition safety

time has been changed to 5 seconds and the control will lockout on flame failure.

INSTALLATION TESTING

Use of Test Meter (All Controls)

Testing the Fireye Modular M-Series II Controls requires the use of a test AC-DC multimeter, with a

1,000 ohm/volt DC rating or greater, or a digital meter with 500K input impedance or greater.

With the test meter on the DC scale, and the test meter leads inserted into the test jacks on the ampli-

fier module, a steady DC voltage reading of 4.0 to 6.0 volts (for UV amplifiers) and 6 to 18 volts

(for flame rectification amplifiers) should be obtained when the controls are detecting flame, and

zero volts when no flame is present.

With the test meter on the AC scale, line and load voltages may be measured at the identified test

points on the chassis.

On the Modular M-Series II controls utilizing a flame rectification amplifier, a micro-ammeter may

be connected in series with the wire to Terminal S2. Normal flame will produce a meter reading

between 4 and 10 micro-amps.

Flame Signal Testing (All Controls)

1. Manually shut off the main fuel valve for a pilot ignited burner, or the secondary fuel valve for a

direct spark ignited burner.

2. Set the test meter on the DC scale and insert the test leads into the test jacks on the amplifier

module. (If the meter reads backwards, reverse the meter leads). Red - Plus, Black - Negative.

3. Initiate a normal startup.

4. When flame is established, the test reading should be normal: a steady DC voltage reading of

4.0 to 6.0 volts (for UV amplifiers) and 6 to 18 volts (for flame rectification amplifiers).

5. Inadequate flame signal may be improved by:

a. Assuring that the flame detector and wiring installations have followed the instructions on

Pages 5 through 9.

b Assuring that the flame detector is clean and within the ambient temperature limits.

c Assuring that the flame is sufficiently large to detect.

d Assuring that the flame quality (fuel to air ratio, combustion air velocity) is satisfactory.

e Trying a shorter sight pipe, or increasing the sight pipe diameter.

WARNING: Before making a pilot flame test, manually shut off the fuel supply to the main

burner.

Normal Pilot Flame Test

1. Turn power on and initiate a normal startup.

2. Observe the pilot flame signal on the test meter. If the average flame is below normal, a steady

DC voltage reading of 4.0 to 6.0 volts (for UV amplifiers) and 6 to 18 volts (for flame rectifica-

tion amplifiers), re-adjust the pilot flame or realign the flame detector.

WARNING: DO NOT TOUCH a flame rectification rod with power applied

3. During the pilot flame test and adjustment period, if flame is not detected within 10 seconds, the

control will lock out. To reestablish the pilot flame trial for ignition (P.T.F.I.), manual reset of

the lockout switch is required, and a complete repurge is accomplished.

4. When UV detection is used, a test is required to verify that UV radiation from the ignition spark

is not being detected. To accomplish this, manually shut off both pilot and main fuels. Initiate a

normal startup, observe the test meter which should read no more than 1/2 volt DC. If more than

1/2 volt DC is observed, realign the UV scanner, and/or shield the spark from the scanner’s

view.

WARNING: The minimum pilot test must be accomplished by a trained and qualified burner

technician.

Minimum Pilot Test

This test insures that the flame detector will not sense a pilot flame too small to light the main flame

reliably. It must be made on every new installation as well as following the repositioning of the flame

detector. This procedure should not be used on a direct spark ignited burner.

1. Manually shut off the fuel to the main burner.

2. Connect a test meter to the test jacks on the Amplifier Module.

3. Initiate a normal startup.

4. Reduce the fuel to the pilot until the DC voltmeter reads 3.5 volts for UV scanners. See WARN-

ING below. This is the minimum pilot. For flame rectification the flame signal for minimum

pilot varies depending on the application. See WARNING below.

5. Slowly turn on the main fuel and insure that the main flame lights off promptly and normally.

WARNING: If light off is delayed, shut off the power to the installation. Realign the flame

detector so that pilot flame detection requires a larger pilot flame. Repeat this test until the

main flame lights reliably with minimum pilot.

6. After the minimum pilot test is completed satisfactorily, increase the pilot flame to normal size,

and observe that the main flame is properly established during a normal cycle.

Flame Failure Test

1. Temporarily connect spark ignition and pilot valve to Terminal #3.

2. Initiate a normal startup.

3. Manually shut off all fuel and observe the loss of flame signal on the test meter.

4. If flame signal does not reduce to zero within the flame failure response time of the control

(F.F.R.T. determined by selection of amplifier), verify that the UV flame detector is not actuated

by the spark. If spark is detected, a metallic shield or relocation of the UV detector sight pipe is

required.

5. IMPORTANT: When the test is completed, reconnect the spark ignition to Terminal #4.

Recommendation

Periodic Safety Check: Test the complete flame safeguard system at least once a month. This test

should verify flame failure safety shutdown and positive fuel cutoff when the fuel valve is de-ener-

gized.

Replaceable Fuse

The programmer modules are designed with a field replaceable fuse. The fuse is located on the

printed circuit board near the connectors. In the event the fuse becomes shorted, the Operating Con-

trol, Air Flow, and PTFI LED’s will light. However, KL or KF (see WIRING ARRANGEMENTS -

later in this document) will not be energized and the control will lock out. The fuse will blow as a

result of an overload condition on Terminals 3, 4, or 5. To replace the fuse, remove the fuse (using a

small screwdriver) and install a Fireye replacement fuse (P/N 23-176) or equivalent 2AG, 8 amp fuse

Type Fast-Acting (e.g. Little Fuse #225008).

Order Fireye replacement fuse P/N 23-183 or equivalent (3.5 amp fuse 2AG Type SLO-BLO) for

programmer modules used with the MC230 and MC230R chassis (e.g. Little Fuse #22903.5).

MAINTENANCE

UV-eye scanner: The UV tube must be kept clean. Use a clean cloth with detergent as often as oper-

ating conditions require. Remove any residual detergent.

ROTATION

It is recommended that units purchased as spares be rotated periodically, so that each unit will be

placed in operation every 90 days.

MAKE

PROPER

BURNER

ADJUSTMENT

DID

OPERATE

CONTROL LED

COME

ON?

DID

PTFI LED

COME ON AFTER

SUITABLE

DELAY?

DID

AIR FLOW

LED

COME

O.C.

ALARM ON

NO HEAT

INSTALL DC VOLTMETER

IN TEST JACKS

SHUT FUEL

SUPPLY COCK

WAIT

MIN

RESET CONTROL

PROGRAMMER OR

MC120 DEFECTIVE

MAKE IT

CALL FOR HEAT

SEE SITUATION

CLOSE WINDOW

AND REPEAT

SITUATION #1

HEAT

BEING

CALLED

FOR?

ON?

PROGRAM.

WINDOW

CLOSED?

YES

SITUATION #1

YES

DID PTFI

SYSTEM

RUNNING?

ALIGN

SCANNER

REPAIR

WIRING

SUCCESSFUL

RESET

REPLACE

PROGRAMMER

DID

FLAME

LED COME

ON?

YES

MP100 4-7 SECONDS

MP230 PREPURGE DELAY TIME

NO YES

NORMAL LOCKOUT

YES

AMPLIFIER

DEFECTIVE

OR MC120 REPLACE SCANNER

REPEAT

SITUATION #1

LED GO OFF

AFTER SUITABLE

DELAY?

M-SERIES II

SERVICE GUIDE

TO RESET THE CONTROL

POWER MUST BE ON. (L1-L2)

THERE A

GOOD

FIRE?

PROPER

ACROSS

S1 & S2

VOLTAGE

WIRING &

TERM. CONTACT

PRESSURE

OK?

S1 S2

SCANNER

POSITION

OK?

PROPER

PILOT VOLTAGE

(120V) ACROSS

3, 2

YES

PROPER

IGNITION

VOLTAGE (120V)

ACROSS

4, 2

YES

PROPER

MAIN VALVE

VOLTAGE (120V)

ACROSS

5, 2

YES

CHECK FUSE IN

PROGRAMMER.

CHECK OUTPUT

YES

WIRING

CHECK FUSE IN

PROGRAMMER.

CHECK FUSE IN

PROGRAMMER.

CHECK OUTPUT

YES

WIRING

CHECK OUTPUT

YES

WIRING

O.C. ON

YES

PRESENT

8-2?

O.C. ON

ALARM ON

YES

REPLACE

MC120

PROGRAMMER

MC120 DEFECTIVE

CHECK BLOWER

SYSTEM

CHECK AIR FLOW

SWITCH AND

CHECK WIRING

BLOWER

ON?

120 VAC

PRESENT

6-2?

FLAME ON

YES

SITUATION #2 SITUATION #3 SITUATION #4

NO HEAT NO HEAT

NO YES

REPLACE FUSE

RESET BREAKER

CHECK

SYSTEM

WIRING

NO YES

REPLACE

MC120

CORRECT

AMPLIFIER

PIN PROBLEM

IS FUSE

OK AND CKT

BREAKER

MADE?

LED’s

YES

NO HEAT

120VAC

PRESENT 120VAC

AMP.

OR PRO.

PINS

ENGAGED

1-2 OR

PROGRAMMER

PINS

7-2?

REMOVE

SCANNER

REPLACE

AMPLIFIER

YES

SEE

SITUATION #1

REPLACE

AMPLIFIER

PROGRAMMER OR

DEFECTIVEMC120

SEE

SITUATION #1

PROGRAMMER OR

DEFECTIVEMC120 REPLACE

SCANNER

SEE

SITUATION #1

YES

CHECK BURNER

WIRING AND FUEL

VALVES. FLAME SHOULD

NOT BE THERE.

FLAME LED

ON?

THIS A UV

SYSTEM?

FLAME LED

ON?

YES

FLAME LED

ON?

FLAME PRESENT

IN BURNER?

TROUBLESHOOTING TIPS

1. Verify that there is a solid earth ground wire brought to the panel that the Fireye base is mounted to.

2. In a rectification system, verify that terminal S1 is solidly earth grounded, and confirm that the flame rod is aligned so it

doesn’t droop near the ignition spark.

3. Confirm that there is no measurable voltage present between the ground screw and terminal 2 (neutral).

4. Confirm that the 120 volt AC supply has its neutral leg earth grounded at the supply, (floating isolation transformers can

cause problems).

5. Confirm that the ignition transformer’s secondary winding is solidly earth grounded. The grounding method is usually

through the transformer case. Dirt, paint, loose mounting hardware, etc., can all be factors.

6. There may be a problem with transients in the main power supply. If you think this may be the problem, you may want to

run a ground wire directly from the pilot assembly back to the electrical panel where the Fireye control is mounted.

M-Series Fuse 2AG 8 amps.

Fireye Part Number: 23-176

Little Fuse Number: 225008

FIGURE 1. TYPICAL MP100, MP100E, MP102, and MP102E WIRING ARRANGEMENT FOR PILOT IGNITED BURNER

Use moisture resistant wire suitable for at least 90qC.

CAUTION: When powered, 560 VAC across S1, S2 with MAUV3 and MAUV1T; 260 VAC

across S1, S2 with MART3 and MART1T.

FIGURE 2. TYPICAL MP100, MP100E, MP102, and MP102E WIRING ARRANGEMENT FOR DIRECT SPARK IGNITED BURNER

Use moisture resistant wire suitable for at least 90qC.

CAUTION: When powered, 560 VAC across S1, S2 with MAUV3 and MAUV1T; 260 VAC

across S1, S2 with MART3 and MART1T.

TERMINAL #1 MUST BE DIRECTLY POW-

ERED AS SHOWN WHEN USING MAUV3 OR

MAUV1T AMPLIFIER MODULES IN ORDER

TO INITIATE SAFETY CHECKING CIRCUIT

OF UV SCANNERS.

LIMIT

SWITCHES

OPERATING

CONTROL

FUEL

INTERLOCKS

BURNER MOTOR

CONTACTOR 8

LOCKOUT

ALARM

AIR FLOW

SWITCH

ELECTRONIC

CIRCUIT

KL KF

FLAME

AMPLIFIER

KL-1

KF-1

KF-2

PILOT

MAIN

SPARK

BURNER

CONTROL

SWITCH

120V/230V

50/60 Hz

SUPPLY

DISCONNECT MEANS

AND OVERLOAD

PROTECTION REQUIRED

** WITH MAUV3 AND MAUV1T AMPLIFIER MODULES,

PRIMARY WINDINGS OF TRANSFORMER ARE TO

TERMINALS #2 & #1.

* WITH MAUV3 AND MAUV1T AMPLIFIER MOD-

ULES,

CONNECTION TO KA IS FROM TERMINAL #1.

** WITH MART3 AND MART1T AMPLIFIER MODULES,

PRIMARY WINDINGS OF TRANSFORMER ARE TO

TERMINALS #2 & #7.

CHASSIS WITH MAUV3

OR MAUV1T

AMPLIFIER MODULES

SCANNER

FLAME ROD

FUEL VALVE

CHASSIS WITH MART3

OR MART1T

AMPLIFIER MODULES

IGNITION

GAS VALVE

CONNECTION TO TERMINAL #1 IS NOT

REQUIRED WITH MART3 OR MART1T

AMPLIFIER MODULE

***

*** WITH MAUV3 AND

MAUV1T,

KB ENERGIZED WHEN

TERM. 1 IS POWERED.

WITH MART3 AND MART1T,

KB ENERGIZED WHEN

TERM. 7 IS POWERED.

(a)

(a) USE 15 AMPS CIRCUIT BREAKER — SEE TABLE 2.

LIMIT

SWITCHES

OPERATING

CONTROL

FUEL

INTERLOCKS

BURNER MOTOR

CONTACTOR 8

LOCKOUT

ALARM

AIR FLOW

SWITCH

ELECTRONIC

CIRCUIT

KL KF

FLAME

AMPLIFIER

KL-1

KF-1

KF-2

PRIMARY MAIN

BURNER

CONTROL

SWITCH

120/230V

50/60 Hz

SUPPLY

DISCONNECT MEANS

AND OVERLOAD

PROTECTION REQUIRED

CHASSIS WITH MAUV3

OR MAUV1T

AMPLIFIER MODULES

SCANNER FLAME ROD

CHASSIS WITH MART3

OR MART1T

AMPLIFIER MODULES

FUEL VALVE

SECONDARY

SPARK

MAIN FUEL

VALVE (IF USED)

IGNITION

FOR INTERMITTENT IGNITION, CONNECT

TO TERMINAL 3

**WITH MAUV3 AND MAUV1T AMPLIFIER MODULES,

PRIMARY WINDINGS OF TRANSFORMER ARE TO

TERMINALS #2 & #1.

* WITH MAUV3 AND MAUV1T AMPLIFIER MODULES,

CONNECTION TO KA IS FROM TERMINAL #1.

** WITH MART3 AND MART1T AMPLIFIER MODULES,

PRIMARY WINDINGS OF TRANSFORMER ARE TO

TERMINALS #2 & #7.

CONNECTION TO TERMINAL #1 IS NOT

REQUIRED WITH MART1 OR MART1T

AMPLIFIER MODULE

***

*** WITH MAUV3 AND

MAUV1T,

KB ENERGIZED WHEN

TERM. 1 IS POWERED.

WITH MART3 AND MART1T,

KB ENERGIZED WHEN

TERM. 7 IS POWERED.

TERMINAL #1 MUST BE DIRECTLY POW-

ERED AS SHOWN WHEN USING MAUV3 OR

MAUV1T AMPLIFIER MODULES IN ORDER

TO INITIATE SAFETY CHECKING CIRCUIT

OF UV SCANNERS.

(a)

(a) USE 15 AMPS CIRCUIT BREAKER — SEE TABLE 2.

CAUTION: Control wiring procedures which deviate from those shown in the diagrams may

bypass safety functions designed in the control. Check with the Fireye Representative before

deviating from the recommended wiring diagrams.

FIGURE 3. ALTERNATE WIRING ARRANGMENT FOR MP100 CONTROLS

Use moisture resistant wire suitable for at least 90qC.

MAIN

IGNITION

STOP

PILOT

START

LIMIT SW

FUEL VALVE

ALARM

ON-OFF

HOT

NEUTRAL

LR-1

LR-2

LATCH

AIR FLOW

SWITCH

MOTOR

A. FOR MANUAL START

CONNECTION TO TERM. #1

IS NOT REQUIRED WITH

MART3 OR MART1T

AMPLIFIER MODULE

A START-STOP STATION MAY BE ADDED TO REQUIRE

OPERATOR START-UP EACH TIME THE BURNER FIRES.

IGNITION

PILOT

B. MULTIPLE BURNER SYSTEMS

IGNITION

PILOT

LIMIT

MANUAL RESET

MAIN GAS VALVE

ALARM

S.P.D.T.

ALARM SILENCE

SWITCH

STOP

START

LR-1

AIR FLOW

COIL OF MOTOR

CONTACTOR LATCH

HOTNEUTRAL

MULTIPLE BURNER SYSTEMS UTILIZING SEMI-AUTOMATIC OPERATION INCORPORATE THE FIREYE

MODULAR M-SERIES II CONTROLS IN A CASCADING SEQUENCE WHEN PILOT #1 IS PROVEN. TRIAL

FOR IGNITION FOR PILOT #2 BEGINS. WHEN ALL PILOTS ARE PROVEN THE SAFETY SHUTOFF VALVE

MAY BE MANUALLY OPENED. FLAME FAILURE OF ANY BURNER WILL TRIP THE MAIN FUEL VALVE AND

SOUND ALARM.

THE TOTAL CONNECTED LOAD MUST NOT EXCEED THE RATING OF THE FIRST CONTROL.

VALVE

RELAY COIL

MAIN GAS VALVE

GAS VALVE

RELAY

GAS VALVE

SWITCH

NOTICE

When Fireye products are combined with equipment manufactured by others and/or integrated into

systems designed or manufactured by others, the Fireye warranty, as stated in its General Terms and

Conditions of Sale, pertains only to the Fireye products and not to any other equipment or to the

combined system or its overall performance.

WARRANTIES

FIREYE guarantees for one year from the date of installation or 18 months from date of manufacture

of its products to replace, or, at its option, to repair any product or part thereof (except lamps, elec-

tronic tubes and photocells) which is found defective in material or workmanship or which otherwise

fails to conform to the description of the product on the face of its sales order. THE FOREGOING

IS IN LIEU OF ALL OTHER WARRANTIES AND FIREYE MAKES NO WARRANTY OF

MERCHANTABILITY OR ANY OTHER WARRANTY, EXPRESS OR IMPLIED. Except as

specifically stated in these general terms and conditions of sale, remedies with respect to any product

or part number manufactured or sold by Fireye shall be limited exclusively to the right to replace-

ment or repair as above provided. In no event shall Fireye be liable for consequential or special dam-

ages of any nature that may arise in connection with such product or part.

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