Fireye D40 Series User manual


DESCRIPTION
FIREYE® Series D40-41 Burner Management Controls provide ignition and flame failure protection
for manually started oil or gas burners. Plug-inAmplifier Modules permit the selection of ultraviolet,
repetitive self-check ultra-violet,AUTOCHECK infrared, or rectification methods of flame detection.
Thecontrolsystemincludesasafestartcheck,effectiveoneachstart.Ifflamesignal(realorsimulated)
is detected, the unit cannot be started. For increased safety and reliability, Fireye 72D1R3 AU-
TOCHECK infrared amplifier (using the pulsing flame signal) and 72DUVS ultraviolet amplifier
(usinga scannershutter) checkthe functionof theflame detectingsystem forcomponent failureduring
each burner firing cycle. Meter test jacks on each amplifier module provide flame signal readout with a DC
voltmeter. Flame failure response time is four seconds (max.). When amplifier modules with T suffix are
used, the flame failure response time is reduced to one second (max.).
The control provides three SPDT and one SPNO load switches for external loads and starting circuits.
FireyeD40-41BurnerManagementcontrolsmaybeadaptedtoasimplecontrolsystemorasabuilding
block with auxiliary devices to provide additional functions.
SPECIFICATIONS
SupplyVoltage:
D40-120V (min. 102V: Max. 132V) 50/60 Hz.
D41-230V (Min. 196V: Max. 253V) 50/60 Hz.
Power Consumption (Operating): 20VA.
Maximum Simultaneous Connected Load: 2000VA.
Ambient limits: Max. Min.
Control-Amplifier 120º F (49º C) - 40º F (- 40º C)
UV1-UV2-UV8A Scanner 200º F (94º C) - 40º F (- 40º C)
45UV5 Scanner 135º F (65º C) - 40º F (- 40º C)
48PT2 Scanner 125º F (52º C) - 40º F (- 40º C)
45CM1 Scanner 165º F (74º C) - 40º F (- 40º C)
69ND1 Flame Rod (Tip 2460F) 1500º F (816º C) - 40º F (- 40º C)
D-4041
SEPTEMBER 2001
SOLID STATE
Burner Management
Controls
SERIES D40-41

2

MODEL CHANGE NOTICE
All 70D40/41 models produced before May 1986 have terminal load ratings as shown in boxA below.
Beginning with May 1986 production, 70D40/41 models bear the CODE 2 (or higher) Label and
have the terminal ratings shown in box B below.
ORDERING INFORMATION
Each complete Fireye Series D40-41 system includes:
1. A Control chassis and cover.
2. A plug-in amplifier.
3. A flame Scanner.
4. A Wiring Base
To specify a surface mounted control system for 120 volts 50/60 Hz. with Infrared (AUTOCHECK)
flame detection, with four second flame failure response timing, surface mounted, select the following:
70D40 Control and Cover
72D1R1 Plug-in amplifier
48PT2 Flame Scanner (specify cable length and mount)
60-1386-2 Wiring Base
FireyeD40-41 controlssupersedesimilar FireyeC-Series controls andaredirectly plug-in replaceable.
The following chart illustrates the comparison.
Control 70D40 withAmplifier 72DUV1 will also replace a Fireye Type 25DU4 model 5040 provided
the wiring is changed to the appropriate wiring shown later in this document.
Note: When a C-Series unit is replaced with a D-Series unit, the chassis retaining clip (for a quarter
turn fastener) in the wiring base must be replaced with a threaded clip that is supplied with each D-
Series Control.
A. Code 1 terminal load ratings all models: B. Terminal Load ratings for 70D40/41 Code 2 Models:
Max. Rating of each external load terminal: TERMINAL MAXIMUM RATINGS
TERMINAL 7 ONLY: Alternate
Rating — 300 VA transformer
and 130 VA pilot duty; and max-
imum combined load of not
more than 3 motorized valves
—
Holding — 180 VA
Opening— 635 VA
Locked Rotor — 730 VA
3, 5, 6, 8, X, A 125 VA PILOT DUTY
120 VAC 230 VAC
7
Code 2
or higher models
only
250 VA Pilot Duty or Motor rating as given
below:
5 amps 2.5 amps
Voltage 120 VAC 230 VAC
125 VA
Pilot Duty
125 VA
Pilot Duty
FULL LOAD 9.8 A 5.1 A
LOCKED ROTOR 58.8 30.6 A
D SERIES C SERIES
OBSOLETE PART NUMBER COMPONENTS
D40-5030 Control 70D40
Amplifier 72D1R1 Type 26DF4 Model 5030
D41-5131 Control 70D41
Amplifier 72D1R1T Type 26DF4 Model 5131
D40-5060 Control 70D40
Amplifier 72DUV1 Type 25DU4 Model 5060
D41-5161 Control 70D41
Amplifier 72DUV1T Type 25DU4 Model 5161
D40-5050 Control 70D40
Amplifier 72DRT1 —
D41-5151 Control 70D41
Amplifier 72DRT1T —

3

DESCRIPTION OF FIREYE SERIES D40-41 COMPONENTS
Control Chassis and Cover Amplifier Flame Scanner
Use with
70D40 (120VAC) 50-60 Hz
or
70D41 (230VAC) 50/60 Hz
Rectification
72DRT1 2-4 sec. FFRT
72DRT1T 1 sec. FFRT
45CM1-1000 Photocell w/filter.
45CM1-1000Y Photocell w/o filter.
69ND1-1000K4
1
/
2
" mount 12" (300mm) Flamerod.
69ND1-1000K6
1
/
2
" mount 18" (300mm) Flamerod.
69ND1-1000K8
1
/
2
" mount 24" (300mm) Flamerod.
Infrared (IR) “Autocheck”
72D1R1 2-4 sec. FFRT
72D1R1T 1 sec. FFRT
*72D1R3 2-4 Sec. FFRT
*72D1R3T 1 Sec. FFRT
* For specific applications see note below.
48PT2-1003
1
/
2
" straight mount 96" (24000mm) cable.
48PT2-9003
1
/
2
" angle mount 96" (24000mm) cable.
48PT2-1007
1
/
2
" straight mount 48" (12000mm) cable.
48PT2-1007
1
/
2
" angle mount 48" (12000mm) cable.
Ultraviolet (UV)
72DUV1 2-4 sec. FFRT
72DUV1T 1 sec. FFRT
UV8A
1
/
2
" angle mount 72, (1800mm) wire (no cable).
UV1A3
1
/
2
" straight mount 48, (900mm) cable.
UV1A6
1
/
2
" straight mount 48, (1800mm) cable.
UV2
3
/
8
" straight mount 48, (900mm. cable.
45UV3 1050
3
/
4
" straight mount cast aluminum housing, 72"
(1800mm) wire (no cable).
70D40 Only 72DUVS4 Repetitive Self-Check
2-4 sec. FFRT
72DUVS1T Repetitive Self-Check
1 sec. FFRT
45UV5-1009 1" mount 72" (1800mm) wire (no cable).
120VAC shutter.
or
45UV5-1008 1" BSP mount 72" (1800mm) wire (no cable).
120VAC shutter.
70D40M Only Infrared (IR) AUTOCHECK
72D1R3TM 1 sec. FFRT
For special applications see Note below.
48PT2-1003
1
/
2
" straight mount 96" (24000mm) cable.
48PT2-9003
1
/
2
" angle mount 96" (24000mm) cable.
48PT2-1007
1
/
2
" straight mount 48" (12000mm) cable.
48PT2-1007
1
/
2
" angle mount 48" (12000mm) cable.
70D41 Only 72DUVS1T or 72DUVS4 45UV5-1007 1" BSP mount 72" (1800mm) wire, no cable.
230VAC shutter
Wiring Base 60-1386-2 Standard base for surface mounting
60-1466-2 Open base for cabinet mounting
NOTE: Infrared “AUTOCHECK” amplifier modules 72D1R3, 72D1R3T, and 72D1R3T may be used for burner applications firing special fuel such as saw-
dust, sander dust, low BTU gas. The 72D1R3 type amplifiers are not to be used on any liquid fuel fired burner as it may result in malfunction causing
damage to property and/or injury to personnel.
ACCESSORIES / SPARE PARTS
Part No. Description Used with Part NO. Description Used with
4-263-1 Firetron Cell 48PT2 60-302 Swivel Mounting Flange 48PT2, UV1
4-230 922 Photocell 45CM1 60-801
1
/
2
" Coupling w/Pyrex Window 48PT2
4-314-1 UV Tube 45UV5, 45UV3 60-1199 1
" NPT Coupling w/Quartz Window 45UV5-1009
10-88 Set of 3 orifice plugs 48PT2 60-1257
1
/
2
"
Coupling w/Quartz Window UV1
35-69
1
/
2
" NPT Heat Insulator 48PT2-UV1 60-1290
1
/
2
" Coupling w/Quartz Lens UV1
35-127-1
1
" NPT Heat Insulator 45UV5-1009 60-1664-3
1
" NPT Swivel Mounting Flange 45UV5-1009
35-127-3
1 " BSP Heat Insulator 45UV5-1007/8 60-1664-4 1 " BSP Swivel Mounting Flange 45UV5-1007/8
46-38 Quartz Lens 45UV5 61-436 Lens Cap 48PT2

4

INSTALLATION
CAUTION:Installer mustbe a trained safetycontroltechnician.VerifythatElectrical Power
is disconnected before starting installation.
Follow the burner manufacturer’s instructions, if supplied. Otherwise proceed as follows.
Wiring Base
Mount the control wiring base on the burner or on a panel.The location should be free from excessive
vibrationandwithinthe specified ambienttemperaturerating.Thebasemay be mountedinanyangular
position.
All wiring should comply with applicable electrical codes and be suitable for 75 ° C min. The terminals
in the wiring base are designed to permit a variety of connection methods - wire loop, eyelet, lug or quick
connect.A green grounding terminal is provided for equipment bonding. Circuit recommendations are pro-
vided further on in this document. Consult with factory for assistance with non-standard applications.
APPROVALS
70D41 only: TUV (Germany)
70D40 only:
Underwriters Laboratories Inc. Recognized: Guide MCCZ2, File MP 1537
Canadian Standards Association Approved: File LR 7989
Factory Mutual SystemApproved
NewYork Board of Standards and Appeals 743-68-SA
ELECTRICAL RATINGS
VA ratings(notspecifiedaspilotduty)permittheconnectionoftransformersandsimilardeviceswhose
inrush current is approximately the same as their running current.
VApilotduty ratingspermittheconnectionofrelays,solenoidvalves,lamps,etc.whosetotaloperating
load does not exceed the published rating and whose total inrush current does not exceed 10 times the
rating.
Running and locked rotor ratings are intended for motors. VA and VA (pilot duty) loads may be
added to a motor load provided the total load does not exceed the published rating.

5

INSTALLING THE AMPLIFIER MODULE
To assemble or disassemble a control and its plug-in amplifier module, place the unit on a work bench,
remove thetwo module retainer hold downscrewsand lift offthe module retainer.Themodule retainer
cannot be removed if the control is secured onto a wiring base. Insert the appropriate amplifier module
in the slots at the left side of the unit and gently push the module into position.
INSTALLING THE CONTROL
CAUTION: Be sure that the electrical power is shut off. When the wiring is completed and
the plug-in module is installed, install the type D40, D41 unit on the wiring base.
Insert the slots at the bottom of the chassis in the tabs on the base. Push the chassis into position. Insert
the screwdriver through the hole at the top of the chassis and tighten the chassis retainer screw.
INSTALLATION - UV SCANNERS
CAUTION: The UV1, UV2, UV8, 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. (see Operation). If component checking is required during burner operation
for constantly fired burners, utilize the self-checking ultra-violet flame scanners (45UV5) and
associated amplifier module (72DUVS4).
Where possible, obtain the burner manufacturer’s instructions for mounting the scanner. This infor-
mationisavailable for moststandardburners.The scanner mountingshould comply withthe following
general instructions:
1. Position the UV1, UV2 scanner within 18 inches (450mm) of the flame to be monitored; the
45UV5 within 30 inches (750mm), closer if possible.
2. Select a scanner location that will remain within the ambient temperature limits of the UV Scan-
ner (UV1, UV2; 200 ° F, 94 ° C: 45UV5; 135 ° F, 65 ° C). If cooling is required, use an insulating
coupling (Fireye #35-69 for UV1, UV2 Scanners, #35-127-1 for 45UV5) to reduce conducted
heat.
3. The UV1, UV2, 45UV5 Scanners are designed to seal off the sight pipe up to 1 PSI pressure.
Higher furnace pressures should be sealed off. (To seal off positive furnace pressure up to 100
PSI for UV1, UV2 Scanners, install a quartz window coupling (#60-1257) For 45UV5 Scanners,
use #60-1199 coupling. Add cooling air to reduce the scanner sight pipe temperature.
4. Install the scanner on a standard NPT pipe (UV1:
1
/
2
″
,
UV2:
3
/
8
″ , 45UV5: 1") whose position is
rigidly fixed. If the scanner mounting pipe sights through the refractory, do not extend it more than
Replace the module retainer and tighten the two hold down screws. The unit cannot be installed on
a wiring base if the module retainer is not in place.

6

halfway through. Swivel flanges are available (#60-302 for UV1, UV2 Scanners, #60-1664-3, -4 for
45UV5). The sight pipe must permit an unobstructed view of the pilot and/or main flame, and both
pilot and main flames must completely cover the scanner field of view.
Note: Since oil and gas flames radiate more ultraviolet energy from the base of the flame than from
further out in the flame this fact should be evaluated when installing the scanner sight pipe.
5. 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. The scanner must not see a pilot
flame that is too small to reliably ignite the main flame.
6. Smoke or unburned combustion gases absorb ultraviolet energy. On installations with negative
pressure combustion chambers, a small hole drilled in the UV1, UV2 sight pipe will help to keep
the pipe clean and free from smoke. The 45UV5 has a
3
/
8 ″
plug in the mounting flange that can be
removed. For positive pressure furnaces, provide clean air to pressurize the sight pipe, if necessary.
7. Two UV1, UV2, or 45UV3 scanners may be installed on the burner if it is necessary to view two
areas to obtain reliable detection of the flame. They should be wired in parallel. Only one repeti-
tive self-checking 45UV5 Scanner may be installed on a burner.
8. To increase scanner sensitivity with UV1, UV2 Scanners, a quartz lens permits location of the
scanner at twice the normal distance. Use
1
/
2
″ x 1
1
/
2
″ pipe nipple between UV1 Scanner and the
coupling. Use
3
/
8
″ x close pipe nipple and a
1
/
2
″ x
3
/
8
″ bushing on UV2 installations.
9. Request the assistance of any Fireye field office for recommendations of a proper scanner instal-
lation on a non-standard application.
Wiring — UV Scanners
To connect the scanner to the control, the UV1 Scanner is supplied with 36 ″ (900mm) or 72 ″(1800 mm)
of flexible cable. The UV2 is supplied with 36" (900mm) of flexible cable.
45UV5 120 VAC and 230 VAC Models
CAUTION: Be sure to check that proper line voltage is matched to L1 and L2. Applying 230
VAC to models 45UV5-1008 and 45UV5-1009 will damage scanner. 120 VAC applied to model
45UV5-1007 will not operate scanner.
The 45UV5 is supplied with four 72" (1800mm) lead wires. Install them in a suitable length of flexible
armor cable and connect it to the control. A conduit connector is supplied with the scanner. Connect
black wires (shutter) to terminals L1, L2; red wires (UV tube) to terminals S1, S2.
If it is necessary to extend the scanner wiring, the following instructions apply:
Scanner wires should be installed in a separate conduit. The wires from several scanners may be
installed in a common conduit.
1. Selection of Wire
a. Use #14, 16 or 18 wire with 75 ° C, 600 volt insulation for up to 100 (30.5M) foot distances
(signal loss approximately 20% at 100 feet [30.5M]).
b. ExtendedScannerWiring: Forextendedscannerwiringupto500(152M)feet,andforshorter
lengths to reduce signal loss, use a shielded wire (Belden 8254-RG-62/U coaxial cable, or
equal) foreach scanner wire of UV1, UV2 and eachred wire of the 45UV5. The ends of the
shielding must be taped and not grounded.
c. Asbestos insulated wire should be avoided.
SCANNER MUST HAVE UNOBSTRUCTED
VIEW OF FLAME
NOT THIS NOT THIS BUT THIS
FLAME MUST COMPLETELY COVER
SIGHT OPENING
NOT THIS NOT THIS BUT THIS

7

d. Multiconductor cable is not recommended without prior factory approval.
2. High voltage ignition wiring should not be installed in the same conduit with flame detector wires.
Typical Scanner Installations
INSTALLATION - INFRARED SCANNER TYPE 48PT2
Where possible, obtain the burner manufacturer’s instructions for mounting the scanner, otherwise
proceed as follows:
A single scanner is used to detect both pilot and main flames. The sight pipe on which the scanner
mounts must be aimed so that the scanner sights a point at the intersection of main and pilot flames.
Proper scanner positioning must assure the following:
1. Reliable pilot flame signal.
2. Reliable main flame signal.
3. A pilot flame too short or in the wrong position to ignite the main flame reliably, must not be
detected.
4. Scanner must have an unobstructed view of flame being monitored.
5. Flame being monitored must completely cover the scanner field of view.
6. To avoid nuisance shutdowns, it is important to avoid sighting hot refractory and to keep scanner
temperature low (below 125 ° F, 50 ° C).
7. When the proper position has been established, drill a hole through the furnace wall and install a
4 ″ to 8 ″ length of threaded
1
/
2
″ black iron pipe on which to mount the 48PT2 scanner.
8. When satisfactory sighting position has been confirmed by operating tests, the sight tube should
be firmly welded in place.
SCANNER
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
scannersightpipeshouldbe
aimed at this area.
DO NOT EXTEND
MORE THAN
HALF-WAY INTO
REFRACTORY
FORCED
CLEAN AIR
(FROM DISCHARGE
OF FAN OR COMPRESSOR)
INSULATING
TUBING SEALING
UNION FORCED
AIR
EXTEND SIGHTING TUBE
6”(1524) OR 8”(2032)
DO NOT EXTEND MORE THAN
HALF-WAY INTO REFRACTORY
METHODS
OF
COOLING
SCANNER
CENTER LINE
OF MAIN FLAME
SCANNER
LINE-OF-SIGHT SCANNER TARGET
ABOVE REFRACTORY
COMBUSTION
CHAMBER
PILOT
BURNER
SCANNER
SCANNER
SIGHTING TUBE
MAIN
BURNER
SCANNER MUST NOT
SIGHT REFRACTORY
SCANNER
LINE-OF-SIGHT

8

Wiring
Attach the cable supplied with the scanner to a junction box. Splice the cable wires to a pair of wires
not smaller than #18. Install the complete run in a separate conduit to the control.
CAUTION: Continuous conduit bonding between scanner and the control is mandatory!
Scanner may be located up to 100 feet (30.5M) from control. Do not pass scanner wiring
through any junction box containing other wires. Do not run other wires through scanner
conduit. Asbestos insulated wire should be avoided.
Keeping the Scanner Cool
The Infrared Scanner (Temperature Limit 125 ° F, 52 ° C) should never get too hot to grasp comfortably
in the hand. Keep the scanner cool by one or more of the following methods.
1. Use 6 ″ to 8 ″ (152mm - 203mm) length of pipe between scanner and hot furnace front plate.
2. Use insulating tube (Part No. 35-69) on the end of the iron pipe.
3. Force air into sighting tube. Use Fireye Sealing Union (Part No. 60-801).
4. Make sure sighting tube does not extend more than halfway into refractory wall.
INSTALLATION - 45CM1 PHOTOCELL MOUNT
The 45CM1 photocell mount with #922 photocell and Rajah stud terminal, is designed for use in the
blast tube on conventional atomizing oil burners. Two typical applications are shown below.
Test for Incandescent Refractory Hold-In with Photocell Detector
Type 45CM1 Photocell Scanners are actuated by light energy. To assure that the flame failure response
time is not extended by radiation from incandescent refractory, the following test is recommended
1. Operate the burner, following the burner manufacturer’s instructions, until the refractory is at
maximum operating temperature.
2. Turn off the main fuel supply manually.
3. Observe the flame relay which must deenergize within 4 seconds.
4. If the flame failure response time exceeds 4 seconds, reduce the amount of light at the Photocell
with a screen, an orifice, or a filter lens, until the normal flame failure response time is obtained.
INSTALLATION - 69ND1 FLAME ROD
The69ND1flamerodprovesagaspilotflameand/ormaingasflame.Itisa sparkplug typeunitconsisting
of
1
/
2
″ NPT 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 12 ″ (300 mm ), 18 ″ (450 mm ), or
24 ″ (600 mm ) 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
/
2
″ NPT coupling.
The following instructions should be observed:
1. Keep flame rod as short as possible.
2. Keep flame rod at least
1
/
2
″ 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.
SCANNER TYPE 45CM1
(COVER ON) SCANNER TYPE 45CM1
(COVER REMOVED)
BLAST TUBE BLAST TUBE
SHELL
COMBUSTION HEAD

9

4. If the flame is nonluminous (air and gas mixed before burning), the electrode tip should extend
at least
1
/
2
″ (12 .7mm) into the flame, but not more than half-way 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 pro-
vide a maximum signal reading.
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 and may be made ineffective by the addition of grounded shielding between the flame rod and
ignitionspark.This interferencecan also bereducedbytheaddition of groundedshieldingbetweentheflame
rod and ignition spark.
8. Proven types of flame grounding adapters, as shown below, may be used to provide adequate
grounding surface. High temperature stainless steel should be used to minimize the effect of
metal oxidation. This assembly may be welded directly over the pilot or main burner nozzle.
TYPICAL WIRING ARRANGEMENTS
Fireye D40-41 controls may be used on a variety of types of fuel burners and provide a variety of
functions. The typical schematic diagrams shown on the following pages illustrate a simple, and a
more complex method of applying the controls to conventional burner installations. (They are for
information only, and not intended to represent a complete system. Applicable safety codes may
require additional circuits and interlocks.)Additionally, they may be used as flame switches, cascaded
on multiple burner installations, in redundant arrangements, etc. Contact any Fireye Sales Office for
assistance in designing burner control circuits with additional functions.
WRONG POSITION
OF ROD
INADEQUATE FLAME
PILOT BURNER
CORRECT POSITION
OF PILOT FLAME
CORRECT
POSITION
OF ROD
BOMB FIN
GROUNDING
ASSEMBLY THREADED ROD
ASSEMBLY

10

FIGURE 1. SCHEMATIC DIAGRAM OF TYPE D40, D41 CONTROLS
FIGURE 2. TYPICAL SCHEMATIC DIAGRAM FOR SEMI-AUTOMATIC PILOT IGNITED GAS BURNER WITH PROVED
INTERMITTENT PILOT
10 11 L1 L2 3 M D P X
RL RELAY
PLUG-IN
FLAME
SIGNAL
AMPLIFIER
RF RELAY
H
POWER
INPUT
N
12 13 5 6 7 8 A S1 S2
FLAME
SCANNER
BONDING
CONNECTION
(GROUND)
S2S1L1 L2 RED
BLACK
*SCANNER
TYPE 45UV5-1007 (D41) (230VAC) 50/60 HZ
TYPE 45UV5-1008 (D40) (120VAC) 50/60 HZ
TYPE 45UV5-1009 (D40) (120VAC) 50/60 HZ
TEST
JACKS
RL-2
RF-2 RL-3
RF-3 RF-4
RF-1
TO FLAME
SIGNAL
AMPLIFIER
RL-1
INTERNAL WIRING DIAGRAM
*
INTERNAL
EXTERNAL
10 11 L1 D P X
RL RELAY
PLUG-IN
FLAME
SIGNAL
AMPLIFIER
RF RELAY
H
N
12 13 5 8 A
FLAME
SCANNER
BONDING
CONNECTION
(GROUND)
TEST JACKS
*SCANNER
TYPE 45UV5-1007 (D41) (230VAC) 50/60 HZ
TYPE 45UV5-1008 (D40) (120VAC) 50/60 HZ
TYPE 45UV5-1009 (D40) (120VAC) 50/60 HZ
BURNER SWITCH
DISCONNECT
MEANS AND
OVERLOAD
PROTECTION
REQUIRED
TO FLAME
SIGNAL
AMPLIFIER
76
FLAME
ON PILOT VALVE ALARM
MAIN
FUEL
VALVE
RL-2
RF-1
RL-1
RF-4
RF-3
RL-3
RF-2
IGNITION
TRANSFORMER
ALL
LIMITS RUNNING INTERLOCKS
SUPPLY
L2
MOMENTARY
CONTACT
START SWITCH
S2S1L1 L2 RED
BLACK
S1 S2
*
INTERNAL
EXTERNAL
M3

11

FIGURE 3. TYPICAL SCHEMATIC DIAGRAM FOR SEMI-AUTOMATIC PILOT IGNITED GAS OR OIL BURNER WITH
PREPURGE, PILOT TFI, MAIN FLAME TFI AND INTERRUPTED PILOT
NOTE: When a flame rod is used, jumper S2 to the terminal board screw directly above S2 terminal
on mounting base.
The self-checking circuitry in the 72DUVSIT and 72DUVS4 amplifiers is designed to be used with
only one 45UV5 type scanner connected. When two 45UV5 scanners are used, wire the two black L1
and L2 leads in parallel and switch the two red S1 and S2 leads with a relay or selector switch.
CAUTION: Only one scanner can be in the S1 and S2 circuit at one time.
DESCRIPTION OF OPERATION OF TYPICAL SINGLE BURNER SYSTEM (refer to Figure 3)
NOTE: With 72D1R1 Amplifier, Terminals L1 and L2 must be powered for 15 seconds before the
flame signal amplifier will operate.
1. With power applied, burner switch closed, limit switches closed, air flow and fuel interlock
closed, the “Flame Off” light, the purge timer TA and “Purging” light are energized. The “Alarm
Silencing” switch should be switched to the “Silent” position.
2. When the prepurge period expires, contacts TA2 open and de-energize the “Purging” light. Con-
tacts TA1 close. The operator depresses and holds the momentary contact “Start” switch.
3. The circuit to Terminals P-3-11 is completed through the starting interlocks and contacts TA,
and the RL relay is energized. Terminal 7 is energized. The “Alarm Silencing” switch should be
switched to the “Alarm” position.
4. The ignition transformer, timers TB and TC, and the pilot gas valve are energized. Pilot flame is
established and detected. Relay RF is energized.
5. The operator releases the “Start” switch. The ignition transformer and timers TB and TC are de-
energized. The main fuel valve is energized.
6. When the main flame trial for ignition expires, contacts TB1 open and de-energize the pilot
valve, TB2 open and reset the purge timer.
10 11 L1 M P X
RL RELAY
PLUG-IN
FLAME
SIGNAL
AMPLIFIER
RF RELAY
H
N
12 13 8 A S1 S2
FLAME
SCANNER
BONDING
CONNECTION
(GROUND)
TEST
JACKS
*SCANNER
TYPE 45UV5-1007 (D41) (230VAC) 50/60 HZ
TYPE 45UV5-1008 (D40) (120VAC) 50/60 HZ
TYPE 45UV5-1009 (D40) (120VAC) 50/60 HZ
BURNER SWITCH
DISCONNECT
MEANS AND
OVERLOAD
PROTECTION
REQUIRED
TO FLAME
SIGNAL
AMPLIFIER
7
ALARM
MAIN
FUEL
VALVE
RL-2
RF-1
RL-1
RF-4
RF-3
RL-3
RF-2
IGNITION
TRANS-
ALL
LIMITS RUNNING INTERLOCKS
SUPPLY
L2
MOMENTARY
CONTACT
START SWITCH
STARTING
INTERLOCKS
FORMER
TB TC
TB-1
I.C.
T.O. TA
TC-1
(TO)
TA-2
(TO)
PURG-
ING
FLAME
OFF ON
ALARM
SELECTING
SWITCH
S2S1L1 L2 RED
BLACK
TA - Purge Timer, D.P.S.T. contact, delay after energize (D.A.E.) adjustable for required air changes.
TC - Pilot trial-for-ignition timer S.P.S.T. contacts, delay after energize (D.A.E.) set for 10 seconds maximum.
TB - Main flame trial-for-ignition timer. Two sets N.O. contacts. I.C. time open. delay after de-energize (D.A.D.E.).
IC - Instant closed.
TO - Timed open.
TC - Timed closed
TA-1
(TC)
INTERNAL
EXTERNAL
*
TB-2
I.C -T.O.
PILOT
VALVE
56
3D

12

7. The burner will continue to fire until power is shut off, or the limit and operating control circuit
opens, or a flame failure occurs.
INSTALLATION TESTING
Testing Fireye D40-41 controls is accomplished with the use of anAC-DC test meter with 1,000 ohm/
volt input impedance, or a digital meter with 500K input impedance or greater. Test points are located
on the chassis board to assist with measuring line and load voltages. For this test the meter should be
set on the 150 volt AC scale (D40), 300 volt AC scale (D41). Test jacks are located on the amplifier
for measuring flame signal strength. For this test the meter should be set on a scale to read a normal
20-25 volts DC. The DC test voltage may vary plus or minus 5 volts, but should not fluctuate with an
acceptable flame signal.
Note: The Fireye 45UV5 is a repetitive self-check scanner that contains a highly reliable shutter that
closes every 4 seconds to initiate a system check.When the shutter closes, the test jack voltage should
go down to approximately zero, and then back to the normal reading.
Normal Pilot Test
1. Manually shut off the main fuel supply.
2. Initiate a normal start.
3. When the pilot flame is present, observe the test meter. If the meter reading is low, or fluctuates,
increase the size of the pilot flame, improve the alignment of the sight pipe, move the flame
scanner closer to the pilot flame, or verify that the flame scanner is clean.
Minimum Pilot Test
This test insures that the flame scanner will not detect a pilot flame too small to reliably light the main
flame.Itshouldbemadebyaqualifiedpersononeverynewinstallationandfollowinganyrepositioning
of the flame scanner.
1. Manually shut off the main fuel supply.
2. Initiate a normal start up.
3. When the pilot flame is detected, observe the test meter and reduce the size of the pilot flame
until the flame relay just remains energized.
4. Manually, slowly turn on the main fuel which must light immediately from the reduced pilot
flame.
CAUTION: If main flame light off is delayed, shut off the fuel immediately. Realign the flame
scanner so that pilot flame detection requires a larger pilot flame. Repeat this test until the
main flame lights reliably with a minimum pilot flame.
5. After the minimum pilot test is completed satisfactorily, increase the pilot flame to normal size.
This test should be made on every new installation and following change-out of the control
and/or flame detector, any repositioning of the flame detector, air/fuel ratio adjustment or any
other changes that may interfere with reliable light-off of the main fuel.
Test for Spark Pickup (Only required on UV Controls)
1. Shut off all fuel.
2. Initiate a start-up with only the spark ignition energized.
3. Observe the test meter. It should read no more than one volt. If a test meter reading reveals that
UV from the spark is being detected, realign the sight pipe to eliminate it. Relocate the spark or
install a shield to obscure the spark signal from the flame scanner.
4. If a flame scanner sighting change has been made, recheck for normal pilot flame detection.

13

EXTERNAL METER CONNECTIONS
The test jacks are located on the amplifier card, if external access is desired for a panel meter the
shown below will assist you in locating the position to drill through on the front cover. The hole sizes
should be large enough to accommodate the body of the meta probes. The test jacks accept meter
probes up to .080” or 2mm diameter.
MAINTENANCE Humidity Effects
It is good practice to minimize any possible adverse effects of high humidity by keeping control
equipment continuously powered, even during periods when it is not in use.
Scanner
The viewing window must be kept clean. Even a small amount of contamination will reduce the flame
signal reaching the flame scanner. A routine schedule should be set up. Wipe the scanner with a clean
soft cloth. If necessary, dampen the cloth with concentrated detergent.
Type 48PT2 scanners include a replaceable #4-263-1 Firetron cell.
Type 45CM1 scanners include a replaceable #4-230 Phototube #922.
Type 45UV5 and 45UV3 scanners include a replaceable #4-314-1 UV tube.
MAIN
FLAME
REFRACTORY
MAIN
BURNER
PILOT
FLAME
SCANNER
PILOT
BURNER
INSUFFICIENT PILOT
MAIN
FLAME
REFRACTORY
MAIN
BURNER
PILOT
FLAME
SCANNER
PILOT
BURNER
MINIMUM PILOT
MAIN
FLAME
REFRACTORY
MAIN
BURNER
PILOT
FLAME
SCANNER
PILOT
BURNER
NORMAL PILOT
RECOMMED
5/16” TO 3/8” HOLES
TO ACCOMODATE
METER PROBES
1.625
4.73125
.625
ADDING HOLES IN COVER TO ACCESS TEST JACKS
+
+

14

RECOMMENDATION — Periodic Safety Checks
It is recommended that a procedure be established to test at least once a month, the complete flame
safeguard system. The test should verify flame failure safety shutdown, limit switch and interlock
function and positive fuel cutoff when the valves are de-energized.
Rotation
It is recommended that control and scanner units purchased as spares be installed periodically.
FIGURE 4. Mounting UV1A/48PT2 Scanners
FIGURE 5. WIRING BASE TERMINAL LAYOUT
AIR/ENTRY
(PURGE AND COOLING)
UNION COUPLING
#60-1257 WITH QUARTZ WINDOW
#60-1290 WITH QUARTZ LENS
1/2” NIPPLE
HEAT INSULATOR #35-69
(SUPPLIED WITH 48PT2)
1/2” SWIVEL MOUNT
#60-302
MOUNTING WITH HEAT INSULATING NIPPLE
1/2” NIPPLE
1/2” SWIVEL MOUNT
#60-302
STANDARD MOUNTING
BURNER FRONT PLATE FLAME SCANNER
1/2” MOUNT
1/2” NIPPLE
1/2” SWIVEL MOUNT
#60-302
STANDARD MOUNTING WITH PURGING/COOLING AIR
1/2” NIPPLE 1/2” NIPPLE
TEE-PIECE
1/2” NIPPLE
1/2” SWIVEL MOUNT
#60-302
MOUNTING FOR EXCESSIVE FURNACE OR WINDBOX
PRESSURE WITH PURGING/COOLING AIR
1/2” NIPPLE
TEE-PIECE
1/2” NIPPLE,
1 1/2" LONG
AIR/ENTRY
(PURGE AND COOLING)
1/2” SIGHT PIPE
ALTERNATE STANDARD MOUNTING
(NOT ADJUSTABLE)
5/8"
(16)
2"
(51)
2"
(51)
2"
(51)
2"
(51)
RIGHT SIDE
LEFT SIDE
BONDING
CONNECTION
S
2
S
1
A
8
7
6
5
1
3
1
2
X
P
D
M
3
L
2
L
1
1
1
1
0

15

Component Dimensions
2” (51) CLEARANCE REQUIRED TO REMOVE
2
(51)
1/2-14
STRAIGHT PIPE THD
HOLE FOR
3/4”
SIGHTING
PIPE
7 1/4
(184)
6
(152)
5
(127)
KNOCKOUT FOR 1/2"
CONDUIT FITTING
CONTROL WITH COVER
AND WIRING BASE
4 7/8
(123.8)
5 11/16
(144.5) 2 7/16
(61.9)
5 1/4
(133) 7
(177.8)
11/16
(17.4)
1 3/4
(44.4) 25/32
(19.8) 1/4
TYP
(6.35)
25/64
TYP
(9.9)
KNOCKOUTS FOR
1/2” CONDUIT (7)
1 1/16
(27)
1 3/16
(30.2)
WIRING BASE
MOUNTING HOLES
8 1/4
(210)
45O
3/8-18 NPT FOR
PURGE AIR CONNECTION
4 (102)
1 11/16
HEX
(43)
1-11 1/2 NPT
FOR SIGHT
TUBE
2
(50.8)
36” (1m APPROX.)
FLEXIBLE CABLE
3/8” PIPE THREAD
13/16 DIA.
(206)
UV2 UV SCANNER
UV SELF-CHECK
SCANNER
TYPE 45UV5
MODEL 1007, 8, 9
2
(50.8)
1/2-14 STRAIGHT
FEMALEPIPETHREAD
1” DIA
(25.4)
UV1A UV SCANNER
36” FLEXIBLE CABLE (UV1A3)
72” FLEXIBLE CABLE (UV1A6)
72” LEAD
2 7/8
(73)
2
(50.8)
1 5/8
(41)
3 1/4
(82)
SCREW,
1/4-20 THD
45UV3 UV
SCANNER
2 3/8
(60.3) 1 3/16
(30.2)
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
2 1/4
(57) 2 1/2 (63.5)
3 3/16 (81) WHEN ASSEMBLED
1 1/4 DIA.
(31.8)
9/16 DIA.
(143)
1” DIA.
(25.4)
HEAT INSULATOR
(SUPPLIED)
7/16 FLEXIBLE
(11) CONDUIT 1/2-14
TAPERED
PIPE THD
1/2-14
STRAIGHT PIPE THD
48PT2-1000 SERIES INFRARED SCANNER
3 1/8
(79.4) 2 1/2
(63.5)
4 (102)
WHEN ASSEMBLED
1 1/4 DIA.
(31.8)
9/16 DIA.
(143)
1” DIA.
(25.4)
HEAT INSULATOR
(SUPPLIED)
7/16 DIA. (11) FLEXIBLE CONDUIT
1/2-14
TAPERED
PIPE THD
2 5/16
(58.7)
1 1/2
(38) 13/32 (10)
48PT2-9000 SERIES INFRARED SCANNER
TYPE 45CM1 PHOTOCELL SCANNER
1 3/16
(30.2) 17/8(47.6)
1 1/4
(31.8)
1 7/16
(36.5)
7/16
(11.1)
2
(50.8)
1”
(25.4) TAPPED #6-32,
2 HOLES
13/64
(5.1)

16

NOTICE When Fireye products are combined with equipment manufactured by others and/or integrated into
systems designed or manufactured by others, the Fireye warranty, as stated in its General Terms and
Conditions of Sale, pertains only to the Fireye products and not to any other equipment or to the
combined system or its overall performance.
WARRANTIES FIREYE guarantees for one year from the date of installation or 18 months from date of manufacture
of its products to replace, or, at its option, to repair any product or part thereof (except lamps, elec-
tronic tubes and photocells) which is found defective in material or workmanship or which otherwise
fails to conform to the description of the product on the face of its sales order. THE FOREGOING
IS IN LIEU OF ALL OTHER WARRANTIES AND FIREYE MAKES NO WARRANTY OF
MERCHANTABILITY OR ANY OTHER WARRANTY, EXPRESS OR IMPLIED. Except as
specifically stated in these general terms and conditions of sale, remedies with respect to any product
or part number manufactured or sold by Fireye shall be limited exclusively to the right to replace-
ment or repair as above provided. In no event shall Fireye be liable for consequential or special dam-
ages of any nature that may arise in connection with such product or part.
FIREYED-4041
3 Manchester Road SEPTEMBER 2001
Derry, New Hampshire 03038 USA Supersedes April 1999
www.fireye.com
