Fireye EP160 User manual

1
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The Fireye EP160, EP161 (extended MTFI), EP163 (programmable), EP170 and EP174 (early spark
termination), EP165, EP166 (pilot stabilization) or EP177 (early spark termination and programma-
ble operating parameters) programmer modules are used with the FLAME-MONITOR Burner Man-
agement Control System (P/N’s E100 and E110). Several operational characteristics of the
programmer are determined by six (6) dipswitches located on the side of the programmer. These
characteristics include forced blower motor start delay (dipswitch 1), extended purge timing
(dipswitches 3, 4, 5) and the option requiring the 3-P running interlock circuit to be proven open at
the start of the operating cycle (dipswitch 6). Dipswitch 2 is inactive. Models EP163 and EP177
characteristics are programmed via the ED510 Display Module, rather than by dipswitch.
The EP160, EP161, EP163, EP165, EP166, EP170, EP174 and EP177 programmers provide start-up
programming, safe-start check, and flame monitoring supervision. They insure open damper (high
purge) prepurge, proof of low fire position, and fuel valve end switch safety checks. A running inter-
lock circuit on the FLAME-MONITOR system constantly monitors the limit switches, air flow
switches, and fuel pressure switches through the programmer. The programmer control is designed
to initiate a safety lockout if any of these circuits are open at the improper point in the control cycle.
The programmer module will de-energize all fuel valve circuits within four (4) seconds (max.) fol-
lowing a flame failure [two (2) seconds for the EP165 and EP166], or at the end of the pilot trial for
ignition period if no flame is detected. An alarm circuit will be energized following a safety lockout.
The programmer module includes an RJ45 style connector to interface with an integral or remote
alpha-numeric display (P/N ED510). It is also backward compatible with the ED500 display. It
includes two (2) additional RJ style connectors to connect to an E500 communication interface in a
multi-drop configuration or allow communication via a Modbus protocol. The programmer will also
communicate with the E500 via the ED550 cables to provide backward compatibility.
The programmer is the heart of the FLAME-MONITOR System and features a plug-in design for
ease of installation. It is micro-processor based and stores the burner cycles, burner hours, system
hours, and lockout history (with burner cycle and burner hour time stamp) which are accessible via
the ED510 alpha-numeric display, E500 Communication Interface, InTouch Wireless Monitoring
System or Modbus communications. If replaced, the new programmer card will begin accumulating
a new history.
Refer to Bulletin E-1101 for detailed information on the FLAME-MONITOR System.
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CAUTION: To prevent shock hazard, remove power from the system wiring base before
proceeding. Remove control from the wiring base before proceeding.
The EP programmer modules are used with the Fireye EB700 and E110 chassis. They are installed in
the chassis by inserting the EP programmer module into the second slot on the control. This slot is
marked “Programmer Module” on the side of the chassis. Refer to bulletin E-1101 for complete sys-
tem information.
The programmer module is designed to fit only in the proper slot. It cannot be snapped into place if
inserted in the wrong location. DO NOT FORCE THEM.
An amplifier module, display module ED510 (ED500 is obsolete), flame scanner, and wiring base
are also required for the FLAME-MONITOR control.
All programmers with an Engineering code of 28 or later (e.g. 9414-28) are compatible with both the
ED500 and ED510 display modules. See “Programmer and Display Module Compatibility” later in
this document. The Engineering code is located on the back side of the board in the lower right hand
corner. The EP163 programmer requires the ED510 display for initial configuration programming.
%4463:%07
Underwriters Laboratories Inc.:
MCCZ File MP 1537
Controls, Primary Safety - Listed
MCCZ2 File MP1537
Controls, Primary Safety - Component
MCCZ7 File MP1537
Controls, Primary Safety Certified for Canada
MCCZ8 file MP1537
Controls, Primary Safety Certified for Canada - Component
ACCEPTABLE BY: INDUSTRIAL RISK INSURERS (I.R.I.)
FACTORY MUTUAL (FM) APPROVED
WARNING: This equipment generates, uses and can radiate radio frequency energy, and if not
installed and used in accordance with the instruction manual, may cause interference to radio
communications. It has been tested and found to comply with the limits for a Class A computing
device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable
protection against such interference when operated in a commercial environment. Operation of
this equipment in a residential area is likely to cause interference, in which case the user, at his
own expense, will be required to take whatever measures may be required to correct the interfer-
ence.

3
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Note: EP160, EP161, EP163, EP165, EP166, EP170, EP174 and EP177 have non-recycle running
interlock circuits (3/P).
WARNING: While all controls are mechanically interchangeable because they mate with a com-
mon wiring base, you must select the correct model for your application. Inappropriate application
of a control could result in an unsafe condition hazardous to life and property.
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Several operational characteristics of the EP160, EP161, EP165, EP166, EP170 and EP174 program-
mer modules are determined by six (6) dipswitches located on the side of the programmer. These
characteristics include purge timing (dipswitches 3, 4, 5) and the option requiring the 3-P running
interlock circuit to be proven open at the start of the operating cycle, and that the D-8 (Purge Inter-
lock) and M-D (low fire start interlock) switches open and close at the appropriate times (dipswitch
6). Dipswitch 2 is inactive. (Refer to later sections in this bulletin describing the EP163 program-
mer).
In programmer models with engineering code 39 and above, for a PPC5000 to recognize a new
cycle, dipswitch 1 now invokes a 3 second delay after the operating switch closes to when the blower
motor, terminal M, becomes powered. On a quick recycle, this will all force terminal M to become
de-energized for 3 seconds.
WARNING: THE INAPPROPRIATE SELECTION OR APPLICATION OF A PROGRAMMER
MODULE COULD RESULT IN AN UNSAFE CONDITION HAZARDOUS TO LIFE AND
PROPERTY. The various programmer modules (EP160, EP260, and EP380) are interchangeable
because they plug into a common chassis. Changing the dipswitches modifies the operation of each
programmer module. Care should be taken to insure the proper dipswitch settings. Selection of the
programmer module and setting the dipswitches for a particular application should be made by a
competent professional, such as a Boiler/Burner technician licensed by a state or other govern-
ment agency, engineering personnel of the burner, boiler, or furnace manufacturer (OEM) or in
performance of duties based on information from the OEM.
(-47;-8',)7-2%'8-:)
(-47;-8',*36')(&03;)61383678%68()0%=
When using a PPC5000 for boiler control operation, for the PPC5000 to recognize the beginning of a
new burner operating cycle, it is necessary to force the blower motor (terminal M) off or non-pow-
ered for a short period of time. Placing dipswitch 1 in the UP position will delay the blower from
starting 3 seconds after the operating control (terminal 13) closes or force the blower motor to de-
energize for 3 seconds in the event of a quick recycle. The function of dipswitch 1 is not made per-
manent after 8 hours of operation.
(-47;-8',)7496+)8-1-2+
Dipswitches 3, 4, & 5 determine the purge timing for the programmer module. Purge timings are
selectable from 30 seconds to 30 minutes. On the EP160, EP161, EP165, EP166, EP170 program-
mer, the purge timing is not initiated until the firing rate motor is driven to the high fire position (10-
X made) and the high fire switch is proven closed (term D-8). At the end of the purge timing, the fir-
ing rate motor is driven to the low fire position (10-12), and the control waits an additional 30 sec-
ond (minimum) until the low fire start interlock is proven closed (M-D). Refer to the table on
dipswitch functions to select the various purge timing.
UP
DOWNPRINTED CIRCUIT BOARD
FRONT COVER

7
(-47;-8',4(1(-28)603'/',)'/
Dipswitch 6 provides the option to require that the 3-P, D-8, and M-D interlock circuits be proven
closed and open at the appropriate times.
1. If this option is enabled (switch 6 is up) the 3-P Running Interlock circuit must be proven open
at the start of the operating cycle (when the L1-13 circuit first closes). If the 3-P circuit is closed
at the start of the operating cycle, the blower motor will not energize (terminal M), and the con-
trol will “Hold” for one (1) minute waiting for the 3-P circuit to open. If, after one minute, the 3-
P circuit does not open, the control will lockout. If, within one minute the 3-P circuit does open,
the blower motor will energize (terminal M), and the control will wait up to ten (10) seconds for
the 3-P circuit to be proven closed.
2. If this option is enabled (switch 6 is up), the D-8 High-Fire Purge interlock circuit must be
proven open at the start of purge before the Flame-Monitor™ will drive the firing rate motor to
the high-fire position, (at which time the switch must then be proven closed). If the D-8 inter-
lock circuit is closed at the start of the purge period, the control will “Hold” for ten (10) seconds,
then lockout.
3. If this option is enabled (switch 6 is up), the M-D Low-Fire-Start interlock circuit must be
proven open at the end of high-fire purge before the Flame-Monitor will drive the firing rate
motor to the low-fire position, (at which time the switch must then be proven closed). If the M-
D interlock circuit is closed at the end of the high-fire purge period, the control will “Hold” for
ten (10) seconds, then lockout.
Note: If a particular installation does not have operational switches in all three circuits listed
above, (such as an installation where there is no High-Fire -Purge switch installed, and a perma-
nent jumper is wired between terminals D-8), dipswitch 6 should not be enabled.
*The EP160, EP161, EP165, EP166, EP170 programmers are shipped with this option disabled (switch 6 is down).

8
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463+6%11)6%2((-740%=13(90)'314%8-&-0-8=
Two display modules are available for the FLAME-MONITOR control system (P/N's ED500 and
ED510). The ED500 is an 8 character LED display that physically mounts in the card rack of the
EB700 chassis. The ED510 is a 2 line by 16 character LCD with keypad to provide both current and
historical information pertaining to the operation of the control. The ED510 display physically
mounts onto the front cover of the programmer module. Refer to Bulletin ED5101 for a complete
description of the features and capabilities of the ED510 display module. Programmers with an Engi-
neering code of 28 or later (e.g.: 9414-28) are compatible with both the ED510 and ED500 display
module. Programmers with an Engineering code before 28 are only compatible with the ED500 dis-
play.
-14368%28-2*361%8-32h40)%7)6)%('%6)*900=
()8)'8-2+%-6*03;7;-8',4'037)(%*8)678%68
In code 39 programmers and above, the method used to detect the air flow switch closed at the begin-
ning of a cycle has been changed to avoid any nuisance lockouts. Currently, after the operating con-
trol closes, the programmer waits 10 seconds for the air flow switch to close and if not closed will go
into lockout. The EP programmers utilize the open damper switch interlock, D-8, to determine the
wait time for the air flow switch to close. If, at the start of a cycle after a blower turns on, the D-8
interlock is detected as closed, most likely indicating a jumped high fire switch, the programmer
allows 20 seconds for the air flow switch to close. Alternatively, at startup, if the D-8 interlock is
open, indicating the firing rate motor is at the low fire position and the damper is closed, the pro-
grammer will not check for the air flow switch closed until 10 seconds after the open damper switch
has closed and the purge period has begun. This means the programmer will send the mod motor to
the high fire position, forcing the high fire damper switch to close, and will then begin its 10 second
timer to check for the air flow switch to close.
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9
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The EP Programmer modules have a set of six (6) dipswitches on the side of the programmer to
modify various functions associated with the operation of the programmer (e.g. purge timing, prove
3-P circuit open to start, etc.). THESE FUNCTIONS BECOME PERMANENT AFTER THE
CONTROL HAS BEEN POWERED FOR EIGHT (8) HOURS.*After this burn-in period,
changing position of the dipswitches will not change the operation of the programmer.
Note: The function of dipswitch 1 is not stored.
The user can bypass the burn-in period via the ED510 display module. Use the SCROLL and MODE
key to select the “Programmer Set-Up” Sub-Menu (Refer to bulletin ED-5101) and then the
SCROLL key to display the prompt:
PRESS RESET TO
ACCEPT SETTINGS
Press the Reset key at this prompt and the screen will display:
YOU AGREED TO
ACCEPT SETTINGS
After the above key sequence is completed, changing the position of the dipswitches will not change
the operation of the programmer.
463+6%11-2+8,))4463+6%11)613(90)
The EP163 Programmer Module provides a number of operational characteristics that are selected
via the ED510 Keypad/Display rather than by dipswitch selection. The following is a list of the pro-
grammable functions associated with the EP163 Programmer Module:
— Selectable purge (selectable from 6 seconds to 40 seconds in 2 second increments - default
setting is 40 seconds).
— Prove the operation of the 3-P Running Interlock Circuit.
— Prove the operation of the High Fire Purge Interlock (D-8).
— Prove the operation of the Low Fire Start Interlock (M-D).
— Selectable timings on terminals 5 and 6 during Pilot Trial For Ignition (PTFI).
— Selectable timings on terminals 5 and 6 during Main Trial For Ignition (MTFI).
— Selectable Post Purge Timing of 1 or 15 seconds.
13(-*=-2+8,)463+6%11)6
1. Insert the EP163 programmer module into the EB700 chassis and connect the ED510 Keypad/
Display.
2. Open the operating control (L1-13) circuit. The EP163 cannot be modified unless the operating
control is open.
3. The PROGRAM SETUP sub-menu will be used to display the programmable functions. Press
the SCRL key until the PROGRAM SETUP sub-menu is displayed.
4. Press the MODE key to enter the PROGRAM SETUP sub-menu. The SCRL key will advance
through the selections in the sub-menu. The first four items displayed in the sub-menu are PRO-
GRAMMER TYPE EP163, ENGR CODE, AMPLIFIER TYPE, and FFRT TIME 4 S. These
items are not programmable.
5. Press the SCRL key and the next item displayed (and first programmable item) is PURGE
TIME followed by the current setting (default setting = 40 seconds). The available purge tim-
ings are from 6 to 40 seconds, in 2 second increments.
6. Press and hold the RESET button for 1 second to enter the “Modify” mode (providing the con-
trol was not in a lockout condition). After a 2-3 second delay, the control will display SCRL TO
MODIFY on the top line of the display (replacing STANDBY).
*Programmer module EP163 has a fifty (50) hour burn-in period.

10
7. Press the SCRL key to advance through the allowable selections. The selections will roll over
from the last selection to the first one.
8. Press and hold the RESET button for one second to choose and store in memory the appropriate
selection.
Note: Following the purge period, the EP163 will initiate PTFI as soon as the M/D circuit closes
(eliminating the 30 seconds minimum wait period).
9. The SCRL key will advance through the following selections. Follow steps 1 through 8 to mod-
ify the selections.
10. PROVE 3-P OPEN Y
Available selections are Yes (Y) and No (N). Yes is the default selection. If selected Y, at the
start of the operating cycle, the control will check to see if the 3-P circuit is open before energiz-
ing the blower motor. If closed, the control will hold for 60 seconds and then lockout.
11. PROVE D-8 OPEN N
Available selections are Yes (Y) and No (N). No is the default selection. If selected Y, the con-
trol will check to see if the D-8 circuit is open before driving the firing rate motor to the high fire
position (10-X). If closed, the control will hold for 60 seconds and then lockout.
12. PROVE M-D OPEN Y
Available selections are Yes (Y) and No (N). Yes is the default selection. If selected Y, the con-
trol will check to see if the M-D circuit is open at the end of the purge period before driving the
firing rate motor to the low fire position (10-12). If closed, the control will hold for 60 seconds
and then lockout.
13. PTFI TIMING 5 SEC
This selects the timings for terminals 5 and 6 during Pilot Trial For Ignition (PTFI). Available
selections are 5 and 10 seconds. The default value is 5 seconds. Timing selection applies to both
terminal 5 and 6. The control will begin MTFI as soon as flame is detected (following 2 second
check at the start of PTFI). For example, 3 seconds into PTFI, flame signal detected, terminal 7
is energized.
CAUTION: Main fuel valve (terminal 7) will be powered as soon as PILOT FLAME IS
DETECTED.
14. MTFI TIMING 5/5
This selects the timings of terminals 5 and 6 during Main Trial For Ignition (MTFI). The first
number represents terminal 5, the second number represents timing associated with terminal 6.
Available selections are: 0/5, 5/5, 0/10, 5/10, 10/10, 0/15, and 10/15. Default value is 5/5.
15. POST PURGE 15
Available selections are 15 seconds and 1 second. Default value is 15 seconds.
CAUTION: PER UL 296, A MECHANICAL DRAFT BURNER HAVING AN INPUT IN EXCESS
OF 20 GPH (76 L/H) SHALL PROVIDE A POST-PURGE PERIOD OF NOT LESS THAN 15
SECONDS.
16. UNIT ADDRESS 00
Available selections are 00 through 15. Default selection is 00.
17. ACCEPT SETTINGS N
Available selections are Yes (Y) and No (N). No is the default selection. If selected Y, the system
will accept the current settings (overriding the 50 hour normal burn-in time). If selected No, the
settings will be permanently burned in after a 50 hour burn-in period. After the 50 burn-in time,
the settings will not be able to be changed.
18. Press the MODE key to return to the run message.
WARNING: THE INAPPROPRIATE SELECTION OR APPLICATION OF A PROGRAMMER
MODULE COULD RESULT IN AN UNSAFE CONDITION HAZARDOUS TO LIFE AND
PROPERTY. Care should be taken to ensure the proper selection for each setting. Selection of the
settings for a particular application should be made by a competent professional, such as a Boiler/
Burner technician licensed by a state or government agency, engineering personnel of the burner,
boiler, or furnace manufacturer (OEM), or in performance of duties based on information from
the OEM.

11
463+6%11-2+8,))4463+6%11)613(90)
The EP177 Programmer Module provides early spark termination for the spark ignition that is con-
nected to terminal 5. The EP177 also waits indefinitely for the M-D low fire start switch to close.
This programmer model also provides a number of operational characteristics that are selected via
the ED510 Keypad/Display rather than by dipswitch selection.
When in a modifiable selection, the RESET key is used to enter the modify mode, the SCRL key is
used to modify the value and the RESET key is used to save the value.
The following is a list of the programmable functions associated with the EP177 Programmer
Module:
— Selectable purge (selectable from 30 seconds to 37 minutes – default setting is 30 seconds).
— Prove the operation of the 3-P Running Interlock Circuit at start.
— Terminal 6 operation - Interrupted / Intermittent operation of pilot valve – default is inter-
rupted.
— Prove the operation of the High Fire Purge Interlock (D-8).
— Prove the operation of the Low Fire Start Interlock (M-D).
— Purge Count method, UP or DOWN – default is down.
— Selectable Post Purge Timing of 1, 15, 30, 45 or 60 seconds – default is 15 seconds.
13(-*=-2+8,)463+6%11)6
1. Insert the EP177 programmer module into the EB700 chassis and connect the ED510 Keypad/
Display.
2. Open the operating control (L1-13) circuit. The EP177 cannot be modified unless the operating
control is open.
3. The PROGRAM SETUP sub-menu will be used to display the programmable functions. Press
the SCRL key until the PROGRAM SETUP sub-menu is displayed.
4. Press the MODE key to enter the PROGRAM SETUP sub-menu. The SCRL key will advance
through the selections in the sub-menu. The first four items displayed in the sub-menu are PRO-
GRAMMER TYPE EP177, ENGR CODE, AMPLIFIER TYPE, and FFRT TIME 4 S. These
items are not programmable.
5. Press the SCRL key and the next item displayed (and first programmable item) is PURGE
TIME followed by the current setting (default setting = 30 seconds).
6. Press and hold the RESET button for 1 second to enter the “Modify” mode (providing the con-
trol was not in a lockout condition). After a 2-3 second delay, the control will display SCRL TO
MODIFY on the top line of the display (replacing STANDBY).
7. Press the SCRL key to advance through the allowable selections. The selections will roll over
from the last selection to the first one.
8. Press and hold the RESET button for one second to choose and store in memory the appropriate
selection.
9. The SCRL key will advance through the following selections. Follow steps 1 through 8 to mod-
ify the selections.
The program sequence timings of the EP177 are the same as the EP170 programmer.
The EP177 provides the following adjustments made via the ED510 keypad.
PURGE TIME 30s, 1m, 3m, 5m, 7m, 9m, 10m, 12m, 15m, 16m, 18m, 20m, 22m, 25m,
27m, 30m, 32m, 35m, 37m.
default is 30s
Pre-purge time begins after the open damper proving switch (8) is detected closed.
PROVE 3-P OPEN Y/N default is N
The non-recycling interlocks wired between terminals 3 and P must be open at the start of a cycle.
TERMINAL 6 = INTRP/INTMT default is INTRP (interrupted)

12
The pilot valve terminal can be set for interrupted or intermittent operation. If intermittent (INTMT),
terminal 6 will remain energized during the firing cycle.
PROVE D-8 OPEN Y/N default is N
The open damper proving switch must not be closed at the start of a burner cycle.
PROVE M-D OPEN Y/N default is N
The closed or low fire start position of the damper must not be closed at the end of open damper pre-
purge time.
PURGE COUNT UP/DWN default is DWN
If selected as DWN, the pre-purge time will start at the selected time and count down to 0.
POST PURGE 1s, 15s, 30s, 60s default is 15s
CAUTION: PER UL 296, A MECHANICAL DRAFT BURNER HAVING AN INPUT IN EXCESS
OF 20 GPH (76 L/H) SHALL PROVIDE A POST-PURGE PERIOD OF NOT LESS THAN 15
SECONDS.
UNIT ADDRESS 00
Available selections are 00 through 15. Default selection is 00.
ACCEPT SETTINGS N
Available selections are Yes (Y) and No (N). No is the default selection. If selected Y, the system will
accept the current settings (overriding the 50 hour normal burn-in time). If selected No, the settings
will be permanently burned in after a 50 hour burn-in period. After the 50 burn-in time, the settings
will not be able to be changed.
Press the MODE key to return to the run message.
WARNING: THE INAPPROPRIATE SELECTION OR APPLICATION OF A PROGRAMMER
MODULE COULD RESULT IN AN UNSAFE CONDITION HAZARDOUS TO LIFE AND
PROPERTY. Care should be taken to ensure the proper selection for each setting. Selection of the
settings for a particular application should be made by a competent professional, such as a Boiler/
Burner technician licensed by a state or government agency, engineering personnel of the burner,
boiler, or furnace manufacturer (OEM), or in performance of duties based on information from
the OEM.

13
6.78=0)'322)'8367
)((MWTPE]7II&YPPIXMR)(
Programmer modules (with Engineering code 28 or later) include an RJ45 style connector to connect
to an alpha-numeric display (P/N ED510). The ED510 can snap onto the front cover of the program-
mer module or be mounted remotely (See Bulletin E-8101— Remote mounting kit). The ED580
cable (provided with ED510 Display) then plugs into the RJ45 style connectors on both the ED510
display and programmer module.
'LIGO6YR7[MXGL
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 MTFI. If moved during the MTFI period, it is not
functional and automatic programming continues. It aids in the set-up and adjustment of the burner
linkages, pilot assembly, etc. Refer to Bulletin E-1101 for a complete description of the Check-Run
Switch.
)'SQQYRMGEXMSR-RXIVJEGIERH-R8SYGL;MVIPIWW1SRMXSVMRK7]WXIQ
Programmer modules include two (2) RJ12 style connectors to connect to the RS485 Interface on the
E500 Communication Interface or InTouch Wireless Monitoring System in a multi-drop wiring con-
figuration with other devices or connect to a Modbus network. Refer to Bulletin E-5001 and
INT-1000 respectively. Up to six (6) each of EP programmers and E340 Boiler Controls (12 total)
can be wired in an E500 multi-drop configuration or up to ten (10) to the InTouch. (Unit address 00
to 31). When connected in this manner, a unit address must be set on each programmer module con-
nected to the RS485 interface. (See Unit Address). Programmers can also be connected to the E500
via the standard flat ribbon cables (ED550).
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14
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There are two methods to program the unit address when the programmer module is connected to the
E500 via the RS485 interface:
1IXLSH3RI)(HMWTPE]SRP]
1. Press the SCRL key until the screen displays PROGRAM SETUP
2. Press the MODE key and the screen displays PROGRAMMER EP160 (or appropriate model).
3. Press the SCRL key until the screen displays UNIT ADDRESS #00 (or appropriate address).
4. Every time the RESET key is held down for 1 second and then released will increase the address
by one.
5. Maximum address is 31. Then the address will roll over to 00.
1IXLSH8[S)(SV)(
1. Make sure the control is not in a lockout condition. If so, press the reset button.
2. Open the operating control (term L1-13).
3. Move the “Check-Run” switch to the Check position.
4. The display will indicate Unit Address 00 (or the current address).
5. Every time the reset button is held down for 1 second and then released will increase the address
by one.
6. Maximum address is 31. Then the address will roll over to 00.
*0%1)132-83613(&97'31192-'%8-327
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 refers to the logical address of the slave.
FNC is the function being requested. FNC 03 is a read request.
ADR is the message number or register number of the data being requested. In Modbus, register
addresses begin at 40001 but is interpreted as address 00.
DAT is the number of words being requested. A word is an integer consisting of 2 bytes.
The normal response from a slave is as follows:
DBC is the data byte count being returned. It must be two times the DAT number from the poll
request.
DATA is the data returned and is always a series of 2 byte integers. If 4 words were requested then
DBC would be 8 and there would be 8 data bytes or 4 data words containing the requested data.
The format of the data is 4800,N,8,1 meaning 4800 baud, no parity, and 1 stop bit.
Below is a table of currently available messages provided by the Flame-Monitor programmers, fol-
lowed by a description where necessary.
(78 *2' %(6
,-
%(6
03
(%8
,-
(%8
03
'6'
03
'6'
,-
(78 *2' (&' (%8%g
,-03
'6'
03
'6'
,-

15
Table 1:
It is suggested that polling intervals not be less than 200 mSec per request. Requesting data
such as burner minutes, system minutes and burner cycles should be kept at a minimum due to
the amount of processing time required to gather that data.
Messages 00, 05, 08, 10, 15, 21 and 26 are unique in that a limited number of successive registers
can be combined with these requests. For example, a request to message 00 can contain up to 6 data
words. The response to this would contain STATUS, MSGN, GSTAT, TIMER, FLAME and
LOGSTAT. If the requested data word count (DAT) were to be 2 then the response would contain
STATUS and MSGN only. Message 15, last 6 lockouts, can return data ranging from 1 to 6, with 1
referring to the most recent lockout.
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  03+78%8 'YVVIRXPSKMGQSHYPI496+)48*-%983WII8EFPI
  -24987 -RTYXPMQMXWWXEXI
  3984987 3YXTYXVIPE]WWXEXI
  7=71-27 7]WXIQSRQMRYXIW
  &261-27 &YVRIVSRQMRYXIW
  '='0)7 'SQTPIXIH&YVRIV']GPIW
  03'/398'3928 7XSVIH0SGOSYX'SYRX
  03'/398,-7836= 0EWX0SGOSYXWJMVWX[SVHMWQSWXGYVVIRXPSGOSYX
  ():8=4 4VSKVEQQIVHIZMGIX]TI!)4!)4(!1MGVS1
  %148=4 %QTPMJMIV8]TI)9:7!',
)-6!%,
)68)9:!,
1)77%+)
%((6)77
;36(
6)59)78)(
6)74327) :%09)
 2SX9WIH
  *0%1)7-+2%0
%:)6%+)7
48*-ERH%YXS*PEQI7MKREP%ZIVEKIW
  'SQFMRIHWXEXYW 7II(IWGVMTXMSR&IPS[
  1SWX6IGIRX
0SGOSYX(EXE
6IXYVRWGSQTPIXIPSGOSYXHIWGVMTXMSRSJWXSVIHPSGOSYXLMWXSV]
-RGPYHIWPSGOSYXQIWWEKIPSGOSYXQSHYPI$FYVRIVLSYVWERH
$FYVRIVG]GPIW
  RH1SWX6IGIRX0SGO
SYX(EXE
  VH1SWX6IGIRX
0SGOSYX(EXE
  XL1SWX6IGIRX
0SGOSYX(EXE
  XL1SWX6IGIRX
0SGOSYX(EXE
  XL1SWX6IGIRX
0SGOSYX(EXE
  -RTYXPMQMXWERH)\TER
WMSR1SHYPIVIKMWXIVW
6IXYVRWMRTYXPMQMXWWXEXIERHPS[IVERHYTTIVI\TERWMSRQSHYPI
)VIKMWXIVW7II8EFPI
  )\TERWMSR1SHYPI
)VIKMWXIVW
6IXYVRWPS[IVERHYTTIV)\TERWMSRQSHYPIVIKMWXIVW
  6IXYVRSRP]YTTIV)\TERWMSRQSHYPIVIKMWXIV

16
The MSGN being transmitted is a numerical value and must be interpreted by the communicating
device, which actually is an advantage since this can be made to be whatever message text the end
user wants. In other words, it allows for programming custom messages without actually changing
the message in the programmer. Refer to Table 3 for message information.
Message 26 returns the current operating status as well as stored burner hours and burner cycles as a
snapshot of the entire Flame-Monitor system. When all 9 words are requested, the data returned con-
sists of STATUS, MSGN, FLAME, INPUTS, OUTPUTS, BNRMINS, and BNRCYCS
The Flame-Monitor stores its burner on time and system on time (L1 powered) in minutes. For dis-
play purposes, the programmer converts this to hours. The information being supplied by Modbus
will be the actual time in minutes and it is up to the communicating device to do the conversion.
Since the maximum value stored in the Flame-Monitor is 9,999,999 minutes, the maximum value in
hex therefore is 98967FH and comprises two data words. The maximum cycle count is 999,999 dec-
imal or F423FH, still two data words. As an example, the System on Minutes data is transmitted
from the Flame-Monitor to the interface as high word / low word as shown below:
Note: Data from address 9 cannot be accessed directly.
All values are represented in a HEX or base 16 format.
GSTAT determines the type of value TIMER represents. TIMER can be a running timer such as is
used in purge, a flame signal or meaningless. Only the lower nibble of GSTAT has any value. If this
value is 0 then the TIMER value has no meaning. The value in TIMER is a background minute timer
in the Flame-Monitor and should be ignored. If GSTAT is between 4 and 7, the TIMER represents
the current value flame signal. If GSTAT is a 1, 2, or 3 then TIMER represents a running timer value.
The baud rate of the Flame-Monitor is fixed at 4800 bits per second. The format of the data is 8 data
bits, no parity and 1 stop bit. Due to the RS485 format, the communication format is considered half-
duplex. That is, only one user is permitted on the communication lines at a time.
The information contained in INPUTS and OUTPUTS represents the status of the interlocks and
relays respectively. For the INPUTS, a 1 in the interlock position defines the interlock as being on or
active where a 1 in any bit position in the OUTPUT register signifies the relay as being energized.
-24987
A ‘1’ in the opto-coupler position indicates the opto-coupler is on or interlock closed.
)\TERWMSR1SHYPI)0S[IV
)\TERWMSR1SHYPI)9TTIV
3984987
Refer to Fireye bulletin E-1101 for terminal designations.
%HHVIWW %HHVIWW
,MKL;SVH 0S[;SVH
,MKL&]XI0S[&]XI,MKL&]XI0S[&]XI
 , , *,
&MX &MX
8IVQ4 8IVQ 8IVQ( 8IVQ 8IVQ 8IVQ 8IVQ
%MV*PS[ -KRMXMSR 0S[*MVI 6IJ ,MKL*MVI 1EMR*YIP *:)7SV43' 3T'XVP
8IVQ 8IVQ 8IVQ 8IVQ 8IVQ 8IVQ 8IVQ 8IVQ
%Y\ %Y\ %Y\ ,MKL8IQT ,MKL;EXIV 1EMR*YIP *:)7SV43' 3T'XVP
8IVQ 8IVQ 8IVQ 8IVQ 8IVQ 8IVQ 8IVQ 8IVQ
,MKL
4VIWWYVI
0S[+EW4VIWWYVI
SV0S[%XSQM^MRK
1IHME
0S[3MP8IQT 0S[3MP
4VIWWYVI
,MKL+EW
4VIWWYVI
3MP7IPIGXIH +EW7IPIGXIH 0S[;EXIV
8IVQ 8IVQ1 8IVQ 8IVQ 8IVQ 8IVQ% 8IVQ<
%YXS
6%
&PS[IV
6&
-KRMXMSR6% *:)7
6:
4MPSX
64
1EMR*YIP
6*
%PEVQ
60
,MKL*MVI
6,

17
LOGSTAT is an indication of what logic module the control is currently operating in during its cycle
and is used for diagnostic purposes only. If a lockout occurs the current value of LOGSTAT is stored
as part of the lockout information. The message displayed corresponds to the current logic module.
Table 2: )<40%2%8-323*03+78%8
Logstat represents the current software module the Flame-Monitor is currently executing. They are
named as close to the logic module the actual burner sequence is in. For instance, in the Flame-Mon-
itor, MPURGE represents High Fire Purge where MPOSTPURGE represents the low fire start
period where the mod motor is sent to the low fire position in preparation for pilot light-off.
MSHTDWN1 represents the post purge period after a complete cycle or the cool down period after a
lockout.
MIDLE or STANDBY is the period of time where the operating control is open or the control is in
lockout waiting for reset. On instances of false flame during the purge period, the control algorithm
forces the control back to STANDBY until false flame ceases or lockout occurs.
MPREPURGE1 is the period of time prior to PURGE where the control checks the status of the air
flow interlocks or the high fire proving switch (D-8). If either switch is found open, the control will
remain in this state until the respective switch closes or lockout occurs.
P-MTFI represents the pilot trial for ignition stage of a burner sequence. MTFMF represents the
main trial for main flame period where main fuel is introduced along with pilot and igniter.
MAUTO is the run period of the burner sequence.
MPOSTIDLE and MSHTDWN2 are small periods of time where certain internal tests are conducted
and general cleanup before and after a cycle is performed.
The Flame-Monitor outputs the current displayed message as well as the historical lockout messages
as numbers. The table below correlates the message number with the actual displayed test message.
Table 3:
03+-'(-74%8',)6
:%09) 13(90) *92'8-32
()' ,)<
 , 14378-(0) )2)6+->-2+&03;)613836
 , 146)496+) ;%-8*36%-6*03;%2(36,-+,*-6)7;-8',83'037)
 , 1496+) 34)2(%14)6496+)
 , 14378496+) 03;*-6)78%68
 , 18*- 4-03886-%0
 %, 18*1* 1%-286-%0
 &, 1%983 %983
 ', 17,8(;2 4378496+)
 (, 17,8(;2 4378496+)
 ), 1-(0) 78%2(&=
()' ,)< )*0%1)132-8361)77%+)7
  034)2
  *%07)*0%1)78%2(&=
  03;*-6)496+)
  (0-1-834)2,30(
  4%-6*03;34)2,30(
  0-2)*6)59)2'=23-7)()8)'8)(
 *0%1)*%-048*-
  92-8%((6)77
  1(0-1-834)2,30(
 % -+2-8-328-1-2+
 & 18*-
 ' *0%1)7-+2%0%983

18
 ( '='0)'3140)8)
 ) 034)2
 * %'43;)6*%-0'3)2
  7,368'-6'9-88)61-2%0SV
  (0-1-834)203'/398
  1(0-1-834)203'/398
  *0%1)*%-018*-
  *%07)*0%1)03'/398
  03'/3984-280/34)2496+)
  4-280/'037)(03'/398
  4-280/'037)(,30(
  ,-+,*-6)496+)
  40)%7);%-8
 % 03'/3984-280/34)2%93
 & 03'/3984-280/34)218*-
 ' 03'/3984-280/34)248*-
 ( 03'/398*:)734)2
 ) *%07)*0%1)03'/398
 * *0%1)7-+2%0',)'/48*-
  (,-0-1-8',)'/
  1(PS[0-1-8',)'/%983
  *0%1)7-+2%048*-
  03;*-6)7-+2%0',)'/%983
  *0%1)7-+2%018*-
  *0%1)*%-0%983
  4-280/34)2,30(496+)
  *9)0:%0:)78%8)',%2+)
))<4%27-3213(90)1)77%+)7
  4%-6*03;34)2
  4,-+,;%8)6
 % 403;;%8)6
 & 4,-+,+%746)7796)
 ' 403;+%746)7796)
 ( 403;3-046)7796)
 ) 403;3-08)14)6%896)
 * 403;%831->-2+1)(-%
  4,-+,78)%146)7796)
  4,-+,8)14)6%896)
  4%9<34)2
  4%9<34)2
  4%9<34)2
  4*9)07)0)'8
  03'/398',)'/',%77-7
  03'/398',)'/463+6%11)6
  03'/398',)'/%140-*-)6
  03'/398',)'/)<4%27-3213(90)
 % 03'/398%140-*-)6%983',)'/*%-0
 & 03'/3987'%22)623-7)
()' ,)< )*0%1)132-8361)77%+)7

19
34)6%8-32
The EP160, EP161, EP163, EP165, EP166, EP170, EP174 and EP177 programmers provide the
operator with a constant status indication as well as diagnostic information. Programmers with an
Engineering code of 28 or later (e.g.: 9414-28) are compatible with either the ED510 (2 line x 16
character LCD display with keypad for local access to historical information) or ED500 (8 character
LED display).*For purposes of illustration for this bulletin, we will be looking at the EP160 Pro-
grammer functions and messages associated with the ED510 display module. The ED500 display
messages will be abbreviated versions of those of the ED510. Refer to the suggestions shown in bul-
letin E-1101 before proceeding to power the Fireye FLAME-MONITOR system. Items such as scan-
ner installation, short circuit tests and safety information should be reviewed.
CAUTION: On initial power-up and on restarts following a power failure, the control will perform
self-test diagnostics for 15 seconds.
7XEVX9T2SVQEP']GPI)44VSKVEQQIV
Note: For direct spark ignited oil burners, substitute the words Main-Oil Valve for Pilot Valve.
1. Constant 120 VAC should be wired to the Ll-L2 terminals on the wiring base.
2. The operating control circuits (Ll-13) will close, signaling the burner to start its firing sequence.
3. Assuming the fuel valve end switch (13-3) is closed, the burner/blower motor (terminal M) cir-
cuit is energized. The running interlock (limit) circuit (3-P) will close (e.g.: all limits, interlocks,
etc. are proven).
4. The firing rate motor (Modulator Motor) is driven toward the high purge open damper position
(10-X circuit made).
))<4%27-3213(90),30(1)77%+)7
 ' 0%9<34)28)61-2%0
 ( 0%9<34)28)61-2%0
 ) 0%9<34)28)61-2%0
 * 4,-+,;%8)68)61-2%0
  403;;%8)68)61-2%0
  4,-+,+%746)7796)
  403;+%746)7796)
  403;3-046)7796)
  403;3-08)14)6%896)
  403;%831->-2+1)(-%
  4,-+,46)7796)8)61-2%0
  4,-+,8)14)6%896)8)61-2%0
  4%9<34)28)61-2%0
  4%9<34)28)61-2%0
 % 4%9<34)28)61-2%0
 & 4*9)07)0)'8
 ' 03'/398',)'/7'%22)6
 ( ,30((0-1-8'037)(
 ) 03'/398(0-1-8'037)(
 * ,30(1(0-1-8'037)(
  03'/3981(0-1-8'037)(
  03'/39843''037)('&320=
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*The EP163 programmer must be programmed via the ED510 display.
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20
5. When the firing rate motor reaches its open damper position, the Hi Purge switch closes (D-8)
and the prepurge interval of 30*seconds is initiated. The ED510 will display:
PURGE 00:05
HIGH FIRE PURGE
If the D-8 circuit does not close, the program will hold in this position for ten minutes waiting
for it to close. If it does not, the control will lockout
6. When the prepurge is completed, the firing rate motor is driven toward the low purge damper
position (10-12 circuit made). The ED510 will display:
PURGE 00:35
LOW FIRE PURGE
7. Following the minimum 30 second delay (to permit the firing rate motor to get to the low fire
position), the control will wait for the low fire switch (M-D) to close. When it closes, the trial for
ignition sequence will start. If after ten minutes, the M-D circuit is not closed, the control will
lockout.
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 00:02
IGNITION TIMING
This period is ten seconds in duration. If no flame is detected after ten seconds, the control will de-
energize Terminals 5 and 6 and lockout. When flame is detected during this 10 second period, the
ED510 will display
PTFI 20
FLAME SIGNAL
9. With flame proven at the end of PTFI, the main flame trial for ignition (MTFI) period begins.
Terminal 7 is energized. The ED510 will display:
MTFI 35
FLAME SIGNAL
Terminal 5 is de-energized 10 seconds later and Terminal 6 is de-energized after another 5 seconds.
10. The firing rate motor is now sent to the auto position (10-11 circuit made) and is under the com-
mand of the proportional controller. The ED510 will display:
AUTO 40
FLAME SIGNAL
NOTE: Trial-for-Ignition timings depend on the programmer selected. The timing charts in the
beginning of this bulletin point out the differences in the various programmers.
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1. When the operating control circuit (L1-13) opens, the main fuel valve is de-energized. The firing
rate motor is driven to the low purge position (10-12 circuit made).
2. Following a 15 second post purge, the burner/blower motor is de-energized.
3. The burner is now off and the ED510 will display
STANDBY
L1-13 OPEN
Burner history can be displayed by using ED510 keypad. See bulletin ED-5101.
*Prepurge timing is selectable via dipswitches.
FLAME SIGNAL
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