Sigma FireFly User manual

Firefly Manual with Four Channel Control_Revision 00_05_16_2017
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FireFly Flame Effect System
For 4 and 8 channel Controllers with Manual and DMX modes

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Firefly Manual with Four Channel Control_Revision 00_05_16_2017
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Table of Contents
FireFly FlameEffectSystem ..............................................................................................................................1
1. Introduction...............................................................................................................5
1.1 Identification...........................................................................................................................................5
2. RelatedDocumentation.............................................................................................6
2.1 Information Documents.........................................................................................................................6
3. GeneralOverview......................................................................................................7
3.1 General operation of Flame Systems ...................................................................................................7
4. FireFlyOverview........................................................................................................9
4.1 Equipment provided...............................................................................................................................9
4.1.1 Basic setup .....................................................................................................9
4.1.2 MANUAL MODE Operation Selected............................................................11
4.1.3 DMX MODE Operation Selected...................................................................12
4.1.4 Safety............................................................................................................14
4.1.5 ADDITIONAL SAFETY INFORMATION........................................................16
4.1.6 FireFly Flame Control Panel..........................................................................18
4.1.7 FireFly Burner Head......................................................................................19
4.1.8 HOSES .........................................................................................................19
4.1.9 CABLES........................................................................................................20
4.1.10 FUEL SOURCE ............................................................................................20
4.1.11 STRIKING THE SYSTEM.............................................................................20
4.1.12 REPAIR and MAINTENANCE.......................................................................20
4.1.13 FireFly SPECIFICATIONS............................................................................21
4.1.14 4-Channel Flame Control Panel SPECIFICATIONS.....................................21
4.1.15 8-Channel Flame Control Panel SPECIFICATIONS.....................................21
5AbbreviationsandAcronyms.................................................................................22
6Flame Effects Plan...................................................................................................23
7Temperature Vs. Pressure Liquid Propane...........................................................27
8Related Documentation..........................................................................................29

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1.Introduction
1.1 Identification
This document contains the general overview of the unit and its operation, safety
features, control and specifications

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2.RelatedDocumentation
2.1Information Documents
The following documents although not referenced herein and/or not directly applicable,
do amplify or clarify the information presented in this document. These documents are
not binding on the content of this document. Please see the enclosed documents for
further detailed information.
• 4-Channel FireFly Controller Drawing
• 8-Channel Firefly Controller Drawing
• 4-Channel FireFly Connection Drawing
• 8-Channel Firefly Connection Drawing
• Burkert Valve Operation Instructions ( 6013)
• Burkert Valve Operation Instructions ( 5281)
• Honeywell™ Pilot Burner / Igniter Literature
• Honeywell™ Intermittent Pilot Module

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3.GeneralOverview
3.1General operation of Flame Systems
NOTE: The following information applies to both the 4 channel and 8 channel
control systems
Read this manual completely and understand all of the topics before attempting to
operate the FireFly effect system. Extreme caution is to be taken at all times when
servicing and operating this device. At no time should any persons orient themselves in
direct line with the output of this device. Special care must be taken to prevent
accidental discharge of this device. Lock out and tag out procedures must be adhered
to at all times when this device is not in show mode.
This manual is intended to provide a basic understanding of the system described. It
should not be considered an exhaustive operational detail of this system. On the job
training is the only way to learn the subtle nuances of this particular special effects
system.
Operators must:
• Understand and be familiar with the operating manual and instructions.
• Acquire hands-on experience in the operation of the system.
• Demonstrate competency by experience and training.
• Demonstrate conceptual and operational knowledge of the system’s
components and their interaction.
• Be responsible for storage, setup, operation and strike of the flame effect
equipment and the supervision of any assistants.
• Be at least 21 years of age.
• Never use or handle flame effects while under the influence of any
substance that can impair judgment, such as intoxicating beverages,
narcotics or controlled substances, prescription or non-prescription drugs.
At no time should any changes be made to the control software, hardware configuration,
or wiring without the expressed, written permission of Sigma Services, Inc.
Servicing is to be performed only by Sigma Services, Inc. personnel. Appropriate safety
equipment is to be worn at all times when handling or servicing this equipment. Safety

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is not a negotiable topic.
Every effort has been made to provide technical specifications of the various
parts and sub-systems used in this device.
The design of this system and its operating software is proprietary information. No
mechanical copying or alteration of the system is allowable.
This manual describes the flame effect system first in an overview, then by breaking
down the operational sequence. Lastly, a control system schematic and the
components’ technical data sheets have been provided.
The responsibility for safe operation of this system is in the hands of the operator. At no
time should it be operated in an unsafe manner.
The system must be rendered safe when not in use. Administrative and physical
measures must be taken to prevent use of the flame system by unqualified personnel.

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4.FireFlyOverview
4.1Equipment provided
This system is intended to provide a special effect flame. As with all potentially
dangerous special effects, the operator should be in full view of the burner device at all
times during operation.
The system consists of: a burner control panel, a burner head, and the interconnecting
hose and cables. Each of these parts will be discussed in detail on following pages.
4.1.1 Basic setup
• Inspect the entire system to make sure that no damage has occurred
since its last use
• Place the control panel at the operator firing position
• Place the burner head(s) in its desired location
NOTE: 4 channel controllers can have from 1 to 4 burner heads while
8 channel controllers can have from 1 to 8 burner heads.
• Place the propane tank(s) in its desired location
NOTE: Typical installations require one propane tank for each burner
head installed. For 4 channel controllers, this can be up to 4 tanks
while for 8 channel controllers this can be up to 8 tanks.
NOTE: Custom installations can reduce the number of propane tanks
required through the use of an accumulator tank and manifold; If your
installation requires consolidation of the propane fuel tank sources,
please contact Sigma Services for assistance.
• Connect the control cable(s) from the control panel to the burner head (7-pin
Male connects to Controller and 7-pin Female connects to the Burner Head).
NOTE: When connecting the burner head to the controller, make note
of the channel the burner head is connected to; i.e. CH#1, Ch#2, Ch3.
The channel corresponds to the manual and DMX control commands
that are used by the operator to control each burner head.
NOTE: There is one 7-pin control cable for each burner head installed.
For 4 channel controllers, this can be up to 4 control cables while for 8
channel controllers this can be up to 8 control cables.
• Connect the ESTOP valve cable to the control panel (4-pin Male connector)

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NOTE: When connecting the ESTOP control cable to the controller,
make note of the channel of the burner head to which the propane
tank/ESTOP valve is connected to; i.e. CH#1, Ch#2, Ch3. The channel
to which the Burner Head is connected should also be the channel to
which the ESTOP cable is connected.
NOTE: There is one 4-pin ESTOP valve control cable required for
each propane tank installed. For 4 channel controllers, this can be
up to 4 tanks while for 8 channel controllers this can be up to 8 tanks.
• Connect the regulator to the propane tank fitting (NOTE: propane tanks
use left-handed threads)
NOTE: There is one regulator required for each propane tank. The
regulator is included as part of the standard Sigma Services ESTOP
control cable assembly.
• Connect the gas hose from the burner head to the ESTOP valve assembly.
NOTE: A small ball valve located on the quick-connect fitting
prevents the hose from being attached or detached while the valve is
open. Close valve to attach the hose.)
• At each installed propane tank, open the supply valve.
• At each installed ESTOP valve assembly, open the manual isolation valve.
WARNING: Using an approved leak detection method, verify no gas
leaks are detected between each propane tank and connected ESTOP
valve assembly before proceeding!!!!
• At each Installed Burner Head, Open the manual isolation valve.
• At the flame control panel, connect a 120Vac, 60Hz power source.
• At the flame control panel ,use the Sigma Services provided key to place
the MODE switch in desired operational mode (MANUAL, OFF, or DMX are
the available modes).
• At the flame control panel, use the Sigma Services provided key to release
the ESTOP Switch; Verify the ESTOP valve assembly is energized.
WARNING: Using an approved leak detection method, verify no gas
leaks are detected between each ESTOP valve assembly and
connected Burner Head assembly before proceeding!!!!
• At the ESTOP valve assembly, check the pressure regulator is set to the
desired operating pressure (20psi is the nominal factory setting); adjust the

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pressure as needed to meet the requirements of the installation.
4.1.2 MANUAL MODE Operation Selected
4- Channel Flame Control Panel – Manual Controls (Left), Cable
Connections (Center), (DMX Relay Board (Right)
8- Channel Flame Control Panel – Manual Controls (Left), Cable
Connections (Center), (DMX Relay Boards (Right)
• At the flame control panel, determine which Burner Head(s) is to be
operated.
•At the control panel, locate the ARM switch for each connected Burner
Head to be operated and then press an d release the switch; i.e for a
Burner Head connected to CH #2 and CH #3 on the control panel, press
and release the ARM CH #2 and ARM CH #3 switches to attempt to
generate a pilot flame at each Burner Head.
•At each ARM switch, the YELLOW led will be illuminated indicating the
power is being delivered to the burner head connected to that channel.
•At each Burner Head being ARMed, the flame safeguard control will begin a
Trial For Ignition (TFI) sequence. A spark will be generated across the
igniter and pilot gas will be released through the igniter orifice.
•If pilot gas is not ignited or the presence of a flame is not detected by the
flame safeguard within 15s, the TFI fails and the flame safeguard shut off
for several seconds. After a short rest, the flame safeguard will restart the
TFI. The TFI is set to retry 3 times before lockout occurs.
Resetting of a TFI lockout is performed by removing power to the
Burner Head; press and release the ARM switch to remove power
and then press and release the ARM switch again to reapply
power.
•When the flame safeguard detects a valid pilot flame, the main effect valve
power is returned to the control panel causing the GREEN led (ARMED

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light) on the FIRE button to illuminate.
WARNING: Check for leaks again before proceeding!!!
•At the control panel, locate the FIRE switch for each connected Burner
Head to be operated and then press and hold the switch; i.e for a Burner
Head connected to CH #2 and CH #3 on the control panel, press and
release the FIRE CH #2 and FIRE CH #3 switches to attempt to generate a
main effect flame at each Burner Head. Release the switch to stop FIRE.
•At the ESTOP valve assembly, check the pressure regulator setting is still
close to the desired operating pressure; adjust the pressure as needed.
4.1.3 DMX MODE Operation Selected
4- Channel Flame Control Panel – Manual Controls (Left), Cable
Connections (Center), (DMX Relay Board (Right)
8- Channel Flame Control Panel – Manual Controls (Left), Cable
Connections (Center), (DMX Relay Boards (Right)
• Verify a master DMX Controller and DMX cable are connected to the DMX
IN port of the flame control panel.
• If the flame control panel is the last piece of equipment in the DMX daisy
chain, verify a proper End Of Line (EOL) termination resistor is installed on
the DMX OUT port of the flame control panel.
NOTE: The flame control panel uses a 3-pin XLR style connector for
DMX IN and DMX OUT. When using 5-pin DMX cables, a XLR turn-
around adaptor is required.
•The flame controller includes one or more Logic Systems DMX Relay
boards. These boards use a base – 1 configuration for the DMX address
dipswitch setting; i.e. the dipswitch setting value is ALWAYS 1 LESS than
the actual DMX address value.
•Dipswitch binary to decimal values are as follows:
SW1 = 1; SW2 = 2; SW3 = 4; SW4 = 8; SW5 = 16

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SW6 = 32; SW7 = 64; SW8 = 128; SW9 = 256
SW10 = ALWAYS KEEP OFF!!! (NOT USED for binary
address)
Example: Decimal value 185 becomes binary ‘010111001’
NOTE: The DMX address is ALWAYS +1 higher than the
binary address setting (the DMX address would be 186 using
the binary 185 setting from the previous example above).
•For the 4-Channel controller, the default DMX start address is set to 1
(dipswitch set to binary 0 ‘0000000000’).
DMX Channel #1 = FIRE CH #1
•DMX Channel #2 = FIRE CH #2
•DMX Channel #3 = FIRE CH #3
•DMX Channel #4 = FIRE CH #4
•DMX Channel #5 = ARM CH #1
•DMX Channel #6 = ARM CH #2
•DMX Channel #7 = ARM CH #3
•DMX Channel #8 = ARM CH #4
•For the 8-Channel controller, the default DMX start address for board #1 is
set to 1 (dipswitch set to binary 0 ‘0000000000’) and the DMX start address
for board #2 is set to 9 (dipswitch set to binary 8 ‘0000001000’).
•DMX Channel #1 = FIRE CH #1
•DMX Channel #2 = FIRE CH #2
•DMX Channel #3 = FIRE CH #3
•DMX Channel #4 = FIRE CH #4
•DMX Channel #5 = FIRE CH #5
•DMX Channel #6 = FIRE CH #6
•DMX Channel #7 = FIRE CH #7
•DMX Channel #8 = FIRE CH #8
•DMX Channel #9 = ARM CH #1
•DMX Channel #10 = ARM CH #2
•DMX Channel #11 = ARM CH #3
•DMX Channel #12 = ARM CH #4
•DMX Channel #13 = ARM CH #5

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•DMX Channel #14 = ARM CH #6
•DMX Channel #15 = ARM CH #7
•DMX Channel #16 = ARM CH #8
• At the flame control panel, determine which Burner Head(s) is to be
operated.
• Determine what DMX address that corresponds to the ARM ON/OFF
control for each connected Burner Head to be operated (NOTE: The
address dipswitch of the DMX Relay board inside the control panel
MUST be set to match the master DMX controller settings); i.e. for a
Burner Head connected to CH #2 and CH #3 on the control panel, from the
Master DMX controller, command ARM ON #2 (DMX Channel #10) and
ARM ON #3 (DMX Channel #11) to attempt to generate a pilot flame at
each Burner Head.
•At each control panel ARM switch, the YELLOW led will be illuminated
indicating the power is being delivered to the burner head connected to that
channel.
•At each Burner Head being ARMed, the flame safeguard control will begin a
Trial For Ignition (TFI) sequence. A spark will be generated across the
igniter and pilot gas will be released through the igniter orifice.
•If pilot gas is not ignited or the presence of a flame is not detected by the
flame safeguard within 15s, the TFI fails and the flame safeguard shut off
for several seconds. After a short rest, the flame safeguard will restart the
TFI. The TFI is set to retry 3 times before lockout occurs.
Resetting of a TFI lockout is performed by removing power to the
Burner Head; command a ARM OFF to remove power and then
command a ARM ON to reapply power.
•When the flame safeguard detects a valid pilot flame, the main effect valve
power is returned to the control panel causing the GREEN led (ARMED
light) on the control panel FIRE button to illuminate.
WARNING: Check for leaks again before proceeding!!!
•Determine the DMX address that corresponds to the FIRE ON/OFF control
for each connected Burner Head to be operated; i.e for a Burner Head
connected to CH #2 and CH #3 on the control panel, from the master DMX
controller command FIRE ON #2 (DMX Channel #2) and FIRE ON #3 (DMX
Channel #3) to attempt to generate a main effect flame at each Burner
Head. Command a FIRE OFF #2 and FIRE OFF #3 to stop the generation
of the main effect.
• At the ESTOP valve assembly, check the pressure regulator setting is still
close to the desired operating pressure; adjust the pressure as needed
4.1.4 Safety

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Every effort must be made to prevent propane gas leakage. Leaks can be detected by
several means. A rich soap-and-water solution can be sprayed directly on the gas
connections; any bubbles or foam creation indicates a leak. Also, commercially
available electronic leak detectors can be used. Any leaks must be repaired
immediately. For assistance, please contact Sigma Services, Inc.
WARNING Fire or explosion hazard can cause property damage, severe injury,
or death. If you smell gas or suspect a leak, turn off the gas at the manual supply
valve. Do not introduce a source of ignition or touch any electrical switch or
telephone until you are sure that no spilled gas remains present.
In all applications, you should insure that any materials in close proximity to the burner
head do not reach high temperature from the radiant heat. This is most easily achieved
through the use of a non-contact infrared temperature probe. These are available from
many commercial supply stores.
An approved fire extinguisher must be present at all times when fuel gas is present.
This system is designed to provide short duration flame effects. The most frequently
used effects are “bursts” of 1-second duration. While longer burn times are possible,
the FireFly should never be fired for more than 10 minutes without a cool-down period.
The FireFly System can be used indoors or outdoors. Special care must be taken to
prevent the control panel and burner head from getting wet. If these components get
wet, disconnect them from electrical power and the propane tank. The control panel
should then be opened and allowed to dry before use. If the Intermittent Pilot Module
(in the burner head) gets wet, it MUST be replaced.

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CAUTION: Burner head will be very HOT!!! Allow it to cool before handling, packaging
or placing in close proximity to flammable materials.
WARNING Electrocution hazard can cause serious injury or death. Do NOT
touch the spark terminal. The ignition circuit generates over 10,000 volts
and electrical shock can result.
4.1.5 ADDITIONAL SAFETY INFORMATION
• Only use an outdoor extension cord having a 3-prong and receptacle that
accepts the Flame Control Panel plug. The Flame Control Panel has a 3-
conductor cord and a 3-prong grounding type plug to fit a properly grounded
outlet. Replace damaged cords.
• The electrical rating of the extension cord must be greater than or equal to
the electrical rating of the Flame Control Panel. Use an extension cord with 14
gauge or thicker wire and that has a label stating it is suitable for outdoor
use when used in a outdoors application.
• Do not abuse any electrical cord. Never yank it to disconnect from the
receptacle. Keep all cords away from heat, flammable substances and sharp
objects.
• Devices for retaining the extension cord connection to the power supply cord are
available where ever fine extension cords are sold.
• The connection between the Flame Control Panel and the extension cord must
always remain dry and kept off of the ground.
• Disconnect the Flame Control Panel from the power supply when not in use,
changing propane tanks, before servicing, cleaning, etc.
• Do not insert foreign objects in this product.
• To avoid electric shock, DO NOT clean the Flame Control Panel or the FireFly
Burner Head by spraying water or immersing in water.

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• All repairs to the Flame Control Panel and the FireFly Burner Head must be
performed only by qualified service personnel.
• Read and follow all instructions affixed to the propane tank
• All personnel should be carefully supervised when they are in the area of the
FireFly Burner Head.
• Clothing or other flammable materials should not be hung from the FireFly
Burner Head or placed on or near the FireFly System.
• Any guard or other protective device removed from servicing the Flame Control
Panel or the FireFly Burner Head must be replaced prior to operating.
• It is imperative that the FireFly Burner Head be kept clean at all times.
• The LP-Gas cylinder must be provided with a shutoff valve terminating in an LP
Gas supply cylinder valve outlet specified for in the Standard for Compressed
Gas Cylinder Valve outlet and inlet connections.
• The LP Gas cylinder supply system must be arranged for vapor withdrawal and
cylinder must include a collar to protect the cylinder valve.
• The LP Gas cylinder used shall be constructed and marked in accordance with
the specifications for LP Gas cylinders of the U.S. Department of Transportation
(DOT).
• The FireFly Burner Head shall be used only in a well ventilated space and shall
not be used in any enclosed area.
• The Flame Control Panel and FireFly Burner Head should be stored indoors
when not in use and kept away from children.
• The LP-Gas Cylinder must be disconnected and removed from the FireFly
System, if the appliance is stored indoors.

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• LP Gas cylinder must be stored outdoors in a well ventilated area out of the
reach of children. Disconnected cylinders must have a plastic cap installed and
must not be stored in a building, garage or any other enclosed area.
• The pressure regulator and hose assembly supplied with the FireFly Burner
Head must be used for connection to the LP-Gas cylinder. Replacement
pressure regulators and hose assemblies must be purchased from Sigma
Services Inc.
• Keep the area around the FireFly Burner Head clear and free from
combustible materials, gasoline, and any other flammable vapors and liquid.
4.1.6 FireFly Flame Control Panel
NOTE: A clean, stable source of sine wave AC is needed. Some Ground Fault
Interrupter (GFI) outlets will trip when this system is in the ignition sequence. Some
small generators supply abnormal waveforms that will not work with this system.
The flame control panel MODE Switch allows an operator to select the method used to
control the FireFly Burner Heads. MANUAL MODE allows operation from the 22mm
pushbuttons located on the panels door. DMX MODE allows operation from a operator
provided remote DMX Master Controller.
The flame control panel ARM light (AMBER indicator lamp on each ARM switch)
indicates 24Vac is being provided to the Burner Head Honeywell™ Intermittent Pilot
Module and its related parts located inside the Burner Head. The Honeywell™ module
monitors system status and proves a solid pilot before arming the main flame firing
circuit. It receives feedback from the igniter via a rectification sensor to determine
whether or not it is safe to proceed with the effect.
The flame control panel ARMED light (GREEN indicator lamp on each FIRE switch)
indicates the Honeywell™ has detected a flame at the burner head and has armed the
main flame firing circuit.
The flame control panel EMERGENCY STOP (E-STOP) button provides the
operator with a means to stop the entire flame effect system in the event of an
emergency. Pushing this button will disconnect the electrical power from the
tank mounted E-STOP valve and the flame circuits including the ignition, pilot
and main flame gas valves. A key is required to disengage the Emergency
Stop switch. This provides a means to “lock” the system when not in use. To
disengage the Emergency Stop switch, insert the key and turn it, then pull the
button out; this will return the system to a ready state.
WARNING!!!: Hazardous live voltage is still accessible inside the control
panel when the Emergency Stop button is pressed.

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NOTE: All indicators should be checked periodically to insure proper
working order. The system will still fire the effect with a defective
indicator. A defective indicator should be replaced immediately.
4.1.7 FireFly Burner Head
The burner head houses the Honeywell™ Intermittent Pilot Module, the pilot
valve, the main flame valve, the pilot assembly, and the rectification flame
detector.
During the arming sequence, the Honeywell™ creates a high voltage spark on
the pilot assembly. The pilot valve is energized and a solid pilot flame should be
established. The rectification sensor will detect the pilot flame and report back to
the Honeywell™ that a solid pilot has been established. Upon detection of a
solid pilot flame, the main flame firing circuit is armed. Only then can main flame
fuel be issued.
The burner head is supplied with a basic flame effect nozzle. Other types of
flame burners are available, depending on your application. Contact Sigma
Services, Inc. to discuss your requirements.
4.1.8 HOSES
These are specialized gas hoses and must not be used for anything else.
Periodic inspection of the hoses and replacement of defective units is mandatory.
Care must be taken to protect the hoses from physical, thermal or chemical
damage. Integral to the hose system, is the pressure regulator. The setting of
this regulator determines the operating pressure of the entire system, with a
maximum of 100 psi. In general, more pressure makes bigger and hotter flame
effects. At about 70 psi, the system will produce the largest flame it is capable of
producing. Increasing pressure beyond 70 psi will not necessarily increase the
flame height. You should use the lowest pressure setting that will achieve the
desired effect. For operation beyond the aforementioned pressure range, or for
additional or replacement hoses please contact Sigma Services, Inc.

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4.1.9 CABLES
The multi-pin cables connect the burner head and the E-STOP valves to the
control panel. They are keyed so they can only be plugged in correctly. Take
precautions to prevent these cables from getting damaged. Any damaged cables
must be repaired or replaced immediately. For replacement cables or extension
cables, please contact Sigma Services, Inc.
4.1.10 FUEL SOURCE
The fuel source for the FireFly system is propane vapor. This can be drawn from
many different sizes of propane tanks. The most common tank size is a 20-
pound tank most frequently used in residential barbecue grills. Other sizes will
work, however. Some venues will request that you limit the propane supply
inside the building to 5 pounds. For this usage, a 5-pound tank can be obtained
from many sources, including camping supply stores. Keep the propane tank
away from sources of heat. As the tank heats up, the vapor pressure of the
propane inside rises. The relationship between temperature and pressure is
illustrated on a graph in the technical section of this manual.
4.1.11 STRIKING THE SYSTEM
After using the system, you must render it safe before packing it or leaving
it unattended:
• First, the hoses and valve train must be drained of the remaining
fuel. At each propane tank, turn off the tank valve. At the flame
control panel, ARM each Burner Head and FIRE the main effect
until the flame has consumed all of the remaining gas.
• Second, disable the system electrically. At the flame control panel,
press the ESTOP button and remove the key. Disconnect the
system from electrical power. Disconnect the cables from the
control panel.
• Third, remove the fuel source. Disconnect the hoses and the
propane tanks and store in an approved location.
CAUTION: The Burner head(s) will be very HOT!!! Allow it to cool before
handling, packaging or placing in close proximity to flammable materials.
4.1.12 REPAIR and MAINTENANCE