Fireye BurnerPRO Manual

Fireye BurnerPRO Manual

Microprocessor-based integrated burner management control
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DESCRIPTION
The Fireye BurnerPRO is a compact, microprocessor based, primary flame safeguard control system
designed to provide the proper burner sequencing, ignition and flame monitoring for on-off, multi-
stage, or modulating burners used in commercial heating and process equipment firing oil and gas
fuels. The BurnerPRO flame safeguard offers two built-in amplifiers, which allows for use in UV
only, FR only, and UV+FR applications. Flame monitoring for UV is accomplished by using avail-
able UV scanners: UV90L, UV1AL & UV5. Flame monitoring for FR version is accomplished by
using available ionization rod: 69ND1. The FR amplifier circuitry is subjected to permanent self-
checking, which allows it for use in applications that require burner cycle that runs for more than 24
hours. When operated as a UV control, the system is considered non-permanent, which requires a
burner recycle at least once every 24 hours.
The valve proving feature checks for leakage through the safety shutoff valves prior to burner start-
up or immediately after a burner shutdown. The Modbus interface provides the ability to write cus-
tom timing parameters, as well as reading status information during burner operation.
Through seven SMART LEDs, the control provides current operating status and lockout information
in the event of a safety shutdown. Refer to the BurnerPRO ordering information section in this docu-
ment for the various combinations of control functions and timings.
A complete BurnerPRO system includes the BP110/230, flame scanner and wiring base. The Burn-
erPRO performs a safe-start check on every burner cycle. If flame is detected prior to a start or
during the purge cycle, the fuel valves are not energized and the control locks out. The 'POC' input
is also monitored to verify that the main fuel valves are always in the proper state prior to the start of
a burner cycle. The LEDs & alarm terminal are used to annunciate the presence of a lockout condi-
tion.
Expanded functions of the BurnerPRO:
Non-volatile lockout capability
Air-flow proving, Gas valve proving, & Modbus access
A run/check feature allows the operator to stop the program sequence in different
positions (Purge, Ignition, PTFI, MTFI, AUTO) for system troubleshooting
Modbus, Remote and local Reset ability
Two built-in amplifiers (UV, FR, UV+FR) for flexibility in applications
Smart LEDs provide on board diagnostic lockout information
Extended temperature operation (-40°C to 60°C)
High capacity relay contacts
®
FIREYE
BurnerPRO
MICROPROCESSOR-BASED
INTEGRATED BURNER
MANAGEMENT CONTROL
with UV & FR Flame Amplifiers,
Valve Proving Feature and Modbus Interface
BP-1003
SEPTEMBER 21, 2018
®
1

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Table of Contents
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Summary of Contents for Fireye BurnerPRO

  • Page 1 Through seven SMART LEDs, the control provides current operating status and lockout information in the event of a safety shutdown. Refer to the BurnerPRO ordering information section in this docu- ment for the various combinations of control functions and timings.
  • Page 2: Table Of Contents

    BURNERPRO SPECIFICATIONS........
  • Page 3: Burnerpro Specifications

    ® BURNERPRO SYSTEM SPECIFICATION Supply Voltage: BP110 110 VAC (+20%, -15%) 50/60 Hz, single phase BP230 230 VAC (+10%, -15%) 50/60 Hz, single phase Power Consumption: 7 VA Temperature Rating: Operating: -40°C to +60°C (-40°F to 140°F) Storage: -50°C to +85°C (-58°F to 185°F) Flame Amplifier Rating: UV: Terminals 22 &...
  • Page 4 OPERATIONAL TIMINGS The BurnerPRO is pre-programmed from the factory with a set of operational timings necessary for the safe operation of the burner system. However, operational timings can be modified via the mod- bus port.
  • Page 5: Part Numbers And Approvals

    ® PART NUMBERS AND APPROVALS Table 2: Agency Approvals Fireye Part Number Control BP110UVFR-SxM BP110UVFR-SxMP BP110UVFR-S1M BP110UVFR-S1MP BP110UVFR-S2M BP110UVFR-S2MP BP110UVFR-S3M BP110UVFR-S3MP BP110UVFR-S4M BP110UVFR-S4MP BP110UVFR-S5M BP110UVFR-S5MP BP110UVFR-S6M BP110UVFR-S6MP BP230UVFR-SxM BP230UVFR-SxMP BP230UVFR-S1M BP230UVFR-S1MP BP230UVFR-S2M BP230UVFR-S2MP BP230UVFR-S3M BP230UVFR-S3MP Wiring Base 60-2981-1 Scanners UV90L-1...
  • Page 6: Ordering Information

    BurnerPRO Single Burner Control, 230VAC 50/60Hz, User defined timings, with UV & FR amplifiers, Modbus BP230UVFR-SxMP BurnerPRO Single Burner Control, 230VAC 50/60Hz, User defined timings, with UV & FR amplifiers, Modbus & VP BP230UVFR-S1M BurnerPRO Single Burner Control, 230VAC 50/60Hz, Series 1 timings, with UV & FR amplifiers, Modbus BP230UVFR-S1MP BurnerPRO Single Burner Control, 230VAC 50/60Hz, Series 1 timings, with UV &...
  • Page 7 ® BurnerPRO Wiring Base 60-2981-1 Standard base with terminal block and knockouts, 4.2”L x 4.2”W x 1.22”H 61-7429-1 Grounding wire/leash, 10” length SCANNER SELECTION FIREYE P/N DESCRIPTION BULLETIN UV SCANNER UV90L-1 UV scanner, Front and side (90 ) lateral view, terminal block hook-up...
  • Page 8: Installation

    Refer to Figure 2 for mounting dimensions. Grounding Wire Each BurnerPRO control is fitted with a grounding wire. Attach the open end of the grounding wire to a ground terminal on the wiring base (see figure 2 below). Undo the screw terminal with a screw- driver and place the ground lug over the terminal.
  • Page 9 Fireye cannot accept any liability for any consequences resulting from inappropriate, negligen or incorrect installation, commissioning or adjustment of operating parameters of the equipment. BurnerPRO does not have any user serviceable parts. If the unit has a problem, return the unit to your local distributor, or contact Fireye directly.
  • Page 10: Terminal Wiring

     TABLE 4: TERMINAL WIRING Terminal No. Type Description Rating Power Line voltage supply 110VAC (+20%, -15%), 50/60Hz 230VAC (+10%, -15%), 50/60Hz single phase Power Line voltage common Output Alarm See Load Ratings Output Lockout Limits 110/230 VAC, 1mA Input Recycle Limits 110/230 VAC, 1mA Output...
  • Page 11: Procedure

    PRO is designed to operate in a maximum 90% relative humidity environment. Do not install the BurnerPRO where it can be subjected to vibration in excess of 0.5G continuous maximum vibration. Allow at least one inch clearance (2.5 cm) around control for service and installation.
  • Page 12: Led Indicators

     LED INDICATORS The BurnerPRO control module has seven (7) LED indicator lights to annunciate the operating status of the control, as well as provide the reason for the last lockout condition. The "Open Damper" and "Close Damper" LEDs provide easy set-up of the modulating motor end switches. Each LED has a graphic symbol to describe its function (see Table below).
  • Page 13: Led Run-Time Status Indicator

    ® Table 6: LED Run-time Status Indicator OPERATION OPEN CLOSED AUTO IGNITION FLAME STATUS LED ● = ON DAMPER DAMPER ICON OFF / NO POWER NOT READY / Green DIAGNOSTICS READY / ● Green STANDBY ● CHANGING ● Green Blinking Blinking (note 3) ●...
  • Page 14: Flame Scanners

    To increase scanner sensitivity with UV1AL scanner, a quartz lens permits location of the scan- ner at twice the normal distance. Use 1/2” x 1 1/2” pipe nipple between UV1AL scanner and the coupling. Request the assistance of any Fireye field office for recommendations of a proper scanner instal- lation on a non-standard application.
  • Page 15: Wiring - Uv Scanners

    ® TYPICAL SCANNER INSTALLATIONS SCANNER DO NOT EXTEND FORCED MORE THAN CLEAN AIR HALF-WAY INTO (FROM DISCHARGE OF FAN) REFRACTORY DO NOT EXTEND MORE THAN HALF-WAY INTO REFRACTORY The maximum UV signal INSULATING TUBING from a flame is found in the first one-third of the visible SEALING UNION FORCED...
  • Page 16: Installation - 69Nd1 Flame Rod

     INSTALLATION - 69ND1 FLAME ROD The 69NDl flame rod proves a gas pilot flame and/or main gas flame. It is a spark plug type unit. It consists of 1/2' “NPT” mount, a KANTHAL flame rod, a glazed porcelain insulating rod holder and a spark plug connector for making electrical connections.
  • Page 17: Wiring - Flame Rod

    ® WIRING - FLAME ROD For proper operation of flame rectification systems, it is necessary to maintain at least 20 megohms insulat- ing resistance in the flame rectification circuit. The scanner should be wired using metal cable or rigid conduit. High voltage wiring must not be installed in the same conduit with scanner wiring.
  • Page 18: System Operation

    RESET The BurnerPRO control provides two methods of resetting the control in the event of a safety lockout: The push button reset and terminal 21 remote reset. Both reset methods can be used to stop the control in its firing sequence at anytime to force a user/emergency lockout.
  • Page 19: Operational Sequence Diagram

    ® FIGURE 3. OPERATIONAL SEQUENCE 32:(5 21 32:(5(' 1(875$/ 32:(5(' ,1,7,$/ 6<67(0 &+(&. ,QWHUQDO 3RZHU2Q 6HOI7HVW 6+87'2:1    2873876 $5( 2)) 3RVW 3XUJH 7LPHU &RXQWGRZQ      2873876 $5( 2)) 5(/($6( 287387 ,6 2)) (&2120< 287387 ,6 21 0,1,080 287387 ,6 212))
  • Page 20: Explanation Of Sequence States

     NOTES: 1)Presence of flame at this point results in a lockout. 2)When CAST (terminal 13) is open and POC (terminal 12) is open at this point, control locks out after 10 minutes. When CAST is open and POC is closed, control remains in same state indefinitely. 3)Control locks out if FEEDBACK (terminal 8) is not present after 10 minutes.
  • Page 21 ® 10) PILOT TRIAL (1st safety time) The control turns on the pilot flame by energizing terminal 17. The MAIN direct output (terminal 18) is also energized for systems that implement direct light-off of the main flame during pilot. The control doesn't check for flame during this phase as the flame may not be fully established. 11) PILOT TRIAL (1st safety time) The ignition transformer is turned off.
  • Page 22: Sequence Timing

     FIGURE 4.
  • Page 23 ® Table 3: Table 7: EXPANDED TIMINGS TABLE Times are in seconds BURNERPRO SERIES TIMINGS TIMING DESCRIPTION Purge time Pre-ignition time (direct fired) Pre-ignition time (piloted) Ignition safety time (direct ignition) TSA’ Ignition safety time (PTFI) Interval between voltage on Pilot/Main Fuel Direct and Main Fuel Piloted 11.5...
  • Page 24: Description Of Functions Of Operating Controls

     DESCRIPTION OF FUNCTIONS OF OPERATING CONTROLS 1. Limit Switches: These are generally pressure, water level or temperature activated. There are two types which are: a. Recycle - when it is desired to start the burner or a call for heat is present, the limit switch closes causing the burner start-up sequence to begin.
  • Page 25: Connection To An External Actuator

    CONNECTION TO AN EXTERNAL ACTUATOR BurnerPRO is designed to interface with an external actuator. It offers direct interfacing to common actuators that support line voltage signaling (see figure below). It can also be wired with low voltage actuators with the...
  • Page 26: Example Wiring 1

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  • Page 27: Example Wiring 2

    ®...
  • Page 28: Example Wiring 3

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  • Page 29: Communications

    / display. As shipped the baud rate is 9600. Communication to the BurnerPRO control is made through the RJ45 port located on the side of the control. Since the RJ45 port is not compliant with a standard network Ethernet pinout, it’s highly recommended that an ED610 breakout board be utilized to gain physical access to the modbus com- munication signals.
  • Page 30: Modbus Connection Diagram

    ...
  • Page 31 ®...
  • Page 32: Modbus Message Table / Map

     MODBUS MESSAGE TABLE / MAP Static and User command data Holding Message Word Response Value Register Address Requested 40001 Burner ON/OFF Enable or disable burner operation: 0x00 = Burner OFF 0x01 = Burner ON 40002 Lockout Reset Reset command: 0x00: Reset from lockout 0x01: Move to lockout 40003...
  • Page 33 ® 40207 AUTO Release to modulation drive state: 0x00: OFF 0x01: ON 40208 Recycle Limit Recycle limit terminal state: 0x00: OFF 0x01: ON 40209 Proof of closure terminal state: 0x00: OFF 0x01: ON 40210 CAST Combustion air switch test terminal state: 0x00: OFF 0x01: ON 40211...
  • Page 34 Lockout count Total system lockout count 40241 Lockout history 1 (most recent) 40245 Lockout history 2 BurnerPRO stores the last 10 lockout 40249 Lockout history 3 information. Each lockout history is stored 40253 Lockout history 4 using 4 words: Lockout history 5...
  • Page 35: Valve Proving

    ® VALVE PROVING The BurnerPRO offers an intelligent Valve Proving System (VPS). It checks the effective closure of auto- matic shut-off valves by measuring the pressure differential between two fuel shutoff valves during the test sequence. When active, it will open and close the main safety shutoff valves (double block valve arrange- ment) in the proper sequence and monitor the pressure in the gas pipe between the two safety shutoff valves (MV1 &...
  • Page 36: Pressure Switch Selection

    Proper hookup of terminal 12 & 15 inputs are required in order to properly operate the valve proving feature. The BurnerPRO is designed to allow valve proving to be performed at the beginning or at the end of a burner cycle.
  • Page 37: Proving Steps

    ® Proving steps: 1. Both safety shutoff valves are in the closed position at the start of valve proving sequence. 2. The downstream valve (MV2) is energized (open) for 3 seconds. Thus, evacuating the test space. 3. The downstream valve is closed after the evacuation time. 4.
  • Page 38: Calculating Valve Proving Test Times

     CALCULATING VALVE PROVING TEST TIMES The valve proving test times are expected to be calculated by using the following formula: Where: Test Time = Duration of proving time (in seconds) ∆P = Difference between inlet pressure and the switch point of pressure switch (English -- psi, Metric -- mbar) = Volume of test section (English -- ft , Metric -- dm...
  • Page 39 ® downstream valve. Assume a single pressure switch is installed and set to trip at 50% of the inlet pressure. Calculate the expected test times for such system. For the example above, round up TEST TIME 1 to 30 seconds and TEST TIME 2 to 35 seconds.
  • Page 40: Lockouts

    Depressing and releasing the reset button during run mode causes the control to go into lockout. • The BurnerPRO limits the amount of remote reset attempts to 5 tries in a 15 minutes window. • BURNERPRO LED ERROR / LOCKOUT CODES During an alarm condition, the status LED turns solid red.
  • Page 41: Lockout Led Error / Lockout Codes

    ® BurnerPRO LED ERROR / LOCKOUT CODES OPERATION OPEN CLOSED AUTO IGNITION FLAME STATUS LED ● = ON DAMPER DAMPER ICON MODBUS RESET ● LOCAL RESET ● CAB_FAULT ● ● SUPERVISORY MCU INPUT DIAG FAULT ● FLAME ROD FLAME LOSS MTFI ●...
  • Page 42 POC OPEN FAULT ● ● ● ● ● ● ● ● ● STRONG UV FLAME FAULT SPI CRC FAULT ● The table above shows the various required LED error/lockout codes displayed on the BurnerPRO after a fault or error has occurred.
  • Page 43: Lockout Code Explanation

    ® Table 9: LOCKOUT CODE EXPLANATION: FAULT POSSIBLE REMEDY MODBUS RESET Lockout issued via Modbus command. Reset control via modbus, terminal or local reset button. LOCAL RESET User initiated manual reset or faulty reset switch. CAB FAULT Air Prove [terminal 14] signal did not prove at the end of ignition safety time or loss of Air Prove signal during burner opera- tion SUPERVISORY MCU INPUT DIAG “System detected voltage on terminal 16, 17, 18, or 19 at the wrong time or voltage is not present when needed.
  • Page 44  FAULT POSSIBLE REMEDY INPUTS WAITING TIME FAULT System was unable to satisfy combustion air switch test and/or proof of closure during a burner sequence. Check wiring. Check air-flow switch. SUPV SW WDT RESET Internal software reset by Microcontroller. Contact distributor/factory if error persists. SUPV SW RESET Internal software reset by Microcontroller.
  • Page 45 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.

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