Eclipse Combustion VeriFlame Single Burner Monitoring System manual

Modulation Model Purge Model No Purge Model Instruction Manual 818 2/02 V er iFlame Single Bur ner Monitor ing System Model 5600 V ersion 1.21[...]

2 Eclipse V e ri-Flame Instruction Manual 818 -2/02 Cop y r igh t 1 997 b y Ec li ps e C ombustion, In c . All rights r es er v ed w orl dwide. Thi s p u b l i c a t i o n i s p r o t e c t e d b y f e d e r a l r e g u l a t i o n a n d s h a l l n o t b e c o p i e d , dis trib uted , tr ansmit ted, transcrib e d or tra nslated in to an y human o[...]

3 Eclipse V er i-Flame Instruction Manual 818 - 2/02 A UDIENCE S COPE D OCUMENT C ONVENTIONS This man ual has been written for the people who select and install the product and the technicians who w ork on it. They ar e expected to ha v e previous expe- rience with this kind of equipment. This man ual contains essential information for the proper i[...]

4 Eclipse V eri-Flame Instruction Manual 818 -2/02 H OW TO GET HELP If you need help , you can contact y our local Eclipse Combustion sales office. Y ou can also contact Eclipse Combustion, Inc . at: 1665 Elmwood Road Rockford, Illinois 61103 USA Phone: 815-877-3031 Fax: 815-877-3336 E-mail: eclipse @ eclipsenet.com http://www .eclipsenet.com[...]

5 Eclipse V er i-Flame Instruction Manual 818 - 2/02 About this manual ..................................................................................... 3 T ab le of contents ........................................................................................ 5 Introduction ...................................................................[...]

6 Eclipse V eri-Flame Instruction Manual 818 -2/02 Optional Featur es ................................................................................................. 16 Pilot T est Mode Sequence .............................................................................. 16 Air Switch Input Hold .................................................[...]

7 Eclipse V er i-Flame Instruction Manual 818 - 2/02 Maintenance & T r oub leshooting .................................................... 28 Introdu ction ............................................................................................................ 28 Maintenance ..................................................................[...]

8 Eclipse V eri-Flame Instruction Manual 818 -2/02 The Eclipse Combustion V eri-Flame Single Burner Monitoring System contr ols the start-up sequence and monitors the flame of single gas, oil, or combination gas/oil burners. There ar e thr ee different models to the V eri-Flame line: the no purge, the purge and the modulation models. Each model fea[...]

9 Eclipse V er i-Flame Instruction Manual 818 - 2/02 Specifications I NTRODUCTION Specifications This section giv es a detailed ov er view of V eri-Flame specifications and dimensions. 2 (continued onto next page ) P ARAMETER D ESCRIPTION Supply • Series 5602 & 5605: 1 20 V A C ( + 10%, - 15%), 50/60 Hz standard. Series 5603: 240 V AC ( + 10%[...]

10 Eclipse V eri-Flame Instruction Manual 818 -2/02 Specifications (continued) P ARAMETER D ESCRIPTION Approvals • No Purge & Purge Models: Series 5602: UL listed, CSA cer tified, FM approv ed and IRI acceptable. Series 5603: No appr ovals. Series 5605: UL listed, FM appro v ed and IRI acceptable . • Modulating Models: Series 5602: UL r eco[...]

11 Eclipse V er i-Flame Instruction Manual 818 - 2/02 Dimensions (continued) * * 171mm (6-3/4") Veri-Flame/Modulating Model with Base Model Number 5602-40 Remote Display Model Number 5602-DB Contrast Adjustment Screw Ground Screw 15-pin Port Terminal Wiring Terminal 54mm (2-1/8") 102mm (4") Square 89mm (3-1/2") Square Mounting B[...]

12 Eclipse V eri-Flame Instruction Manual 818 -2/02 I NTRODUCTION DIP Switch Location DIP Switch Selection This section details the location, selection and description of the V eri-Flame DIP switches, which allow for sequence and timing functions as well as sys- tem configuration. Caution T o avoid electr ic shock, shut off the po wer supply when i[...]

13 Eclipse V er i-Flame Instruction Manual 818 - 2/02 Close-up of DIP switches on back side of all V eri-Flame models. Figure 3. 1 DIP Switch Location Figure 3. 2 DIP Switch Labels with Selections No Purge Models Purge Models Modulation Models[...]

14 Eclipse V eri-Flame Instruction Manual 818 -2/02 I NTRODUCTION Function Summar y S T AND ARD FEA TURES 4 This section describes the featur es of the V eri-Flame. It is br ok en into thr ee categories: Standard f eatur es, Optional features and the LED Indicator Lights on the front co ver . Refer to Figur e 5.5 f or sequence diagrams. The followi[...]

15 Eclipse V er i-Flame Instruction Manual 818 - 2/02 F or modulation models: This f eature is enabled when the jumper on the base is cut. The system checks that the high fire position switch and the main valve closed switch ar e both made at the end of the high fire purge. F or all models: when selected, the V eri-Flame will r estar t the sequence[...]

16 Eclipse V eri-Flame Instruction Manual 818 -2/02 F or modulation models: the modulation f eature incorporates a high fir e purge time and a low fir e purge time into the purge sequence. This f eatur e allows the V eri-Flame to sequence internal dr y contacts which can be used b y the customer requiring a high fir e purge of the combustion chambe[...]

17 Eclipse V er i-Flame Instruction Manual 818 - 2/02 S T A TUS L IGHTS & P USH - BUTT ON All of the status lights and the TEST/RESET push-button ar e located on the fro nt cover of the V eri-Flame. This section describes their r espectiv e functions. For all models: this green LED illuminates when the operation limits ar e made. These limits a[...]

18 Eclipse V eri-Flame Instruction Manual 818 -2/02 System Installation In this section, the necessar y pr ocedures are detailed to integrate a V eri-Flame into a burner system; Figur es 5.1 and 5.2 illustrate the various terminal strips mentioned. Note: Shut off the power supply befor e the V eri-Flame is removed or replaced from the base. Caution[...]

19 Eclipse V er i-Flame Instruction Manual 818 - 2/02 Ignition Wiring Lo w Fire Input Main V alve Closed Switch High Purge Input Remote Reset Route ignition wiring a sufficient distance fr om all sensors and other low v olt- age wiring to a void electrical interference, which ma y cause erratic operation of the V eri-Flame system. K eep the high vo[...]

20 Eclipse V eri-Flame Instruction Manual 818 -2/02 Figure 5. 1 No Purg e and Purg e Wiring Diagrams No Purg e Models Purg e Models Figure 5. 2 Modulation Wiring Diagram On/Off 15 A Fuse 7 S1 S2 V 1 2 Alarm Interlocks & Limits 3 4 5 On/Off 15 A Fuse A Piloted Burner Pilot Ignition Main Piloted Burner Pilot Ignition Main 7 S2 S1 1 2 Alarm Interl[...]

21 Eclipse V er i-Flame Instruction Manual 818 - 2/02 Notes f or Figur es 5.1, 5.2 & 5.3: 1. Ground, shielding and conduit must not be connected to terminal S2. 2. Control circuit wir es must meet 90°C (194°F) specif ication minimum and must be No. 16 A WG or larger and in accor dance with all applicable codes. 3. Flame sensor wir es must be [...]

22 Eclipse V eri-Flame Instruction Manual 818 -2/02 Figure 5. 4 Purge and No Purge Bases Model Number 5602-10 Model Number 5602-10-1 5 6 S2 S1 7 8 3 4 V 2 1 A 5 6S 2 S 1 7 8 A 1 2 V 4 3 P3 P2 P1 Gnd Gnd P3 P1 P2 Jumper Jumper 1 2 3 4 5 6 7 8 A D 11 12 13 10 S2 S1 J2 J1 1 1 Modulating Base Jumper P3 P2 P1 6 4 6 4 3 1 2 3 1 2 1 6 4 6 4 3 1 2 3 1 2 1 [...]

23 Eclipse V er i-Flame Instruction Manual 818 - 2/02 Figure 5. 5 Sequence Dia grams T erminal 1 3 4 5 8 6 7 V Function Control P ow er Pilot V alve Ignition Main V alve Fan Air Switch Interlocks PO VC Outputs Inputs Start Air Pr ov e n Flame Check 5 Sec Pilot T rial Main T rial 10 Sec End Pilot Off (Intermittent) Pilot Off (Interr upted) Firing Cy[...]

24 Eclipse V eri-Flame Instruction Manual 818 -2/02 Flame Rods This section describes the pr oper wiring, installation and sighting considerations for all sensors that can be used with a V eri-Flame . W arning Incorr ect sensor installation ma y cause the sensor to generate a false flame signal, possibly resulting in the collection of unburned fuel[...]

25 Eclipse V er i-Flame Instruction Manual 818 - 2/02 1) K eep the flame r od as short as possible and at least 13 mm (1/2") awa y from any refractory . 2) Position the r od into the side of both the pilot and main flames, pref erably at a descending angle to minimize dr ooping of the flame rod against burner parts, as sho wn in Figure 6.1. Fl[...]

26 Eclipse V eri-Flame Instruction Manual 818 -2/02 I NTRODUCTION Flame Signal Strength T est Pr ocedures 7 This section describes the test pr ocedures that must be perf ormed after instal- lation to insur e that the V eri-Flame is operating properly; these pr ocedures are mandatory . Insert the positive probe of a 0-15 VDC , digital volt meter int[...]

27 Eclipse V er i-Flame Instruction Manual 818 - 2/02 1) Man ually shut off the fuel supply to the pilot and the main burner . 2) Place system in pilot test mode (please r e fer to page 15). 3) Start the system normally . The controller should lock out*; if it doesn’ t, then the controller is detecting a false flame signal (see Section 6). Find t[...]

28 Eclipse V eri-Flame Instruction Manual 818 -2/02 I NTRODUCTION 8 This section is divided into tw o parts: • The first part describes the maintenance pr ocedures. • The second part describes troubleshooting pr ocedures, from identifying pr ob- lems to interpr eting the operating conditions by the lit LEDs on the fr ont cove r . Pre v entativ [...]

29 Eclipse V er i-Flame Instruction Manual 818 - 2/02 T R OUBLESHOO TING Check main valve closed switch. No voltage on V (or D). Check air pressure switch adjustment. Check air filter . Check blower rotation. Check outlet pr essur e from blow er . No voltage on 6 after 8 is on. Check incomming gas pressure; adjust gas pressur e if necessar y . Chec[...]

30 Eclipse V eri-Flame Instruction Manual 818 -2/02 LED S T A TUS This section describes the status of operating conditions based on the LED or combination of LEDs which are lit on the fr ont cov er of each V eri-Flame model. T able 8.1 LED Status & Conditions for V eri-Flame No Purge Models LED( S ) L IT P OSSIBLE C AUSES INTERLOCKS CLOSED SYS[...]

31 Eclipse V er i-Flame Instruction Manual 818 - 2/02 T able 8.2 LED Status & Conditions for V eri-Flame Purg e Models LED( S ) L IT P OSSIBLE C AUSES INTERLOCKS CLOSED SYSTEM ERR OR 1) The interlocks are closed (normal operation), pow er on terminal 7. 1) The flame detected is out of sequence , flame signal light is on. 2) The sensor is “run[...]

32 Eclipse V eri-Flame Instruction Manual 818 -2/02 T able 8.3 LED Status & Conditions for V eri-Flame Modulation Models Modulation Model LED( S ) L IT P OSSIBLE C AUSES SYSTEM ERR OR 1) The flame detected is out of sequence , flame signal light is on. 2) The sensor is “runawa y”, flame signal light is on. 3) Inductance is detected on senso[...]

33 Eclipse V er i-Flame Instruction Manual 818 - 2/02 I NTRODUCTION 9 This section co vers how the optional remote displa y is used with the V eri-Flame . The remote displa y provides LCD messages which monitor the status of the V eri- Flame’ s functions as w ell as an y lock out conditions. This section is divided into two parts or tables: • T[...]

34 Eclipse V eri-Flame Instruction Manual 818 -2/02 T able 9.1 V eri-Flame Operating Sequence PO WER ON W as internal safe start check successful? EXTERNAL INTERLOCK CHECKS Is flame signal present? BURNER ST AR T -UP (see next page) YES NO YES NO YES NO YES NO V arious lockout messages Fan output is energized; modu- lator is sent to low fir e. YES [...]

35 Eclipse V er i-Flame Instruction Manual 818 - 2/02 T able 9.1 V eri-Flame Operating Sequence (continued) BURNER ST AR T -UP Is volta g e pr esent at air flo w switch within ten seconds? Is flame signal present? (see next page) Spark turns off at end of TFI; sequence dela y ed 5 seconds. Spark and pilot valve energized for selected trial for igni[...]

36 Eclipse V eri-Flame Instruction Manual 818 -2/02 T able 9.1 V eri-Flame Operating Sequence (continued) BURNER ST AR T -UP (continued) Is flame signal present? NO Modulator sent to automatic 20 seconds after main valve is energized. Pilot will shut off 10 seconds after main flame is energized. Main flame of burner is pro ven. Flame signal = XX.XV[...]

37 Eclipse V er i-Flame Instruction Manual 818 - 2/02 T able 9.1 V eri-Flame Operating Sequence (continued) BURNER SHUTDO WN Shutdo wn is started b y opening the operating interlock cir cuit. Is volta g e pr esent at interlocks? YES NO Fuel valves de-energized; fan energized for 15 seconds. Is main valve closed s witch made?* YES NO Is volta g e pr[...]

38 Eclipse V eri-Flame Instruction Manual 818 -2/02 Lockout For purge & modulation models: Combustion air flow limit switch opened for more than two seconds once initially proven. Status For purge & modulation models: Combustion air flow limit switch opened; if “recycle” has been selected, the Veri-Flame will restart the sequence after [...]

39 Eclipse V er i-Flame Instruction Manual 818 - 2/02 Lockout Main valve has been energized and main flame proven during trial for ignition. St at us Pilot valve is de-energized and main flame is on. Lockout For purge and no purge models: Main valve closed switch is open before start-up or after burner shutdown. Lockout For purge & modulation m[...]

40 Eclipse V eri-Flame Instruction Manual 818 -2/02 Hold Flame signal—actual, induced, or runaway scanner—is detected be- fore start-up or after shutdown. The fan is energized. If the cause is corrected within 30 seconds, as in afterburn, the control will turn off the fan and continue the sequence. Lockout Same conditions as above, except the c[...]

41 Eclipse V er i-Flame Instruction Manual 818 - 2/02 C ONVERSION F A CT ORS Appendix Metric to English. F ROM T O M UL TIPL Y BY cubic meter (m 3 ) cubic f oot (ft 3 ) 35.31 cubic meter/hour (m 3 /h) cubic foot/hour (cfh) 35.31 degr ees Celsius (°C) degrees Fahrenheit (°F) (°C x 1.8) + 32 kilogram (kg) pound (lb) 2.205 kilowatt (kW) Btu/hr 3414[...]

I LLUSTRA TED P AR TS L IST Litho in USA Instruction Manual 818 2/02 Straight U .V . scanner 5600-91 49600-91 NEMA 4 U .V . scanner 5600-91N4 20898 90˚ U .V . scanner 5600-90A 49600-90 I.R. scanner 5600-92B 49600-92 Self-check scanner 5602-91 49602-91 10-f oot cable f or self-chec k scanner 5602-91-7 49602-91-7 Scanner suppor t (max. temp . 220˚F[...]