£ MC-5000 OCTOBER 7, 2008 FIREYE MODULAR MicroM FLAME SAFEGUARD CONTROLS APPROVED WARNING: Selection of this control for a particular application should be made by a competent professional, licensed by a state or other government. Inappropriate application of this product could result in an unsafe condition hazardous to life and property.
£ MEC230 type chassis include the MEP100, MEP 200 and MEP500 series. Programmers for use with the MEC320 and MEC480 type chassis include the MEP300, MEP400 and MEP600 series. Some programmer modules are equipped with a series of dipswitches to select Purge Timing, Pilot Trial for Ignition (PTFI) timing, Proof of Air flow open at start, Post Purge, Recycle and Non-Recycle operation.
£ Table 2: LOAD RATINGS: All Ratings are 120V, 60 Hz Fireye Terminal Typical Load Maximum Rating @120V 60 Hz 3 or 4 Individual or combined Pilot valve(s) Solenoid valve Ignition Transformer 5 Main Fuel Valve(s) 125 VA pilot duty (solenoid) or 25 VA pilot duty (solenoid) and 400 VA (opening) motorized, 250 VA hold 8 Motor or contactor Terminal 8 rated to energize and de-energize 9.8 FLA, 58.8 LRA on safety lockout.
£ MOUNTING BASE 3/16” DIA. MOUNTING HOLES (4) S1 7 KNOCKOUTS (12) FOR 1/2” CONDUIT S2 8 3 5 3/16” 2/N 5 4” A 4 P0 6 1 3/16” MOUNTING HOLES (4) 1/2” 5 3/16” 5 5/16” 13/16” HEX (20.6) 2 3/8” (60.3) 4” 1/2” (12.7) 3/8” PIPE THREAD 36” (1m APPROX.) FLEXIBLE CABLE UV2 UV SCANNER 1/2”-14 NPT ”L” LENGTH AS SPECIFIED: 12”, 18”, 24” (304.8, 457.2, 609.6) 2” (50.8) 69ND1 FLAME ROD 1.406" (35.7MM) 1” DIA (25.4) UV90 MOUNTING BLOCK (Included with Scanner) 1.48" (37.6MM) 1.90 (48.
£ WARNING: This equipment is a Class B digital apparatus which complies with the Radio Interference Regulations, CRC c.1374. CAUTION: Published load ratings assume that no control be required to handle inrush current more often than once in 15 seconds. The use of control switches, solenoids, relays, etc. which chatter will lead to premature failure.
£ ORDERING INFORMATION MEC120 MEC120R MEC120D MEC120RD MEC120C MEC120RC MEC230 MEC230RC MEC320 MEC320R MEC320D MEC320RD MEC320C MEC320RC MEC320TS MEC480 MEC480RC MEP100 MEP101 MEP102 MEP103 MEP104 MEP105 MEP106 MEP107 MEP108 MEP109 MEP100P MEP130 MEP230 MEP230H MEP235 MEP236 MEP237 MEP238 MEP290 MEP560 MEP561 MEP562 MEP564 MEP536 MEP537 MicroM Chassis Types (For use with MEP1XX, MEP2XX, and MEP5XX, includes dust cover) 120 VAC input with standard plug-in board.
£ MEP300 MEP304 MEP335 MEP397 MEP696 MEP697 MEUV1 MEUV4 MEUVS1 MEUVS4 MERT1 MERT4 MEIR1 MEIR4 MECD1 MECD4 MEDC2 MicroM Programmer Models (For use with MEC320 and MEC 480 Chassis) Relight operation, 10 sec. fixed PTFI, 5 sec.pilot proving period, 5 second MTFI. lockout on flame fail during PTFI, pilot proving and MTFI. Recycle on air flow open. No post purge. Reset on line voltage. Non-recycle on flame fail, 5 sec. purge, 10 sec.fixed PTFI, 5 sec. pilot proving, 10 sec.
£ Accessories ED510 Two line by 16 character, back lit LCD display with keypad. ED580-2, -4, -8 Remote display cable with RJ45 connection in 2, 4 or 8 foot long lengths. To be used with the appropriate daughter board. EC485 RS232 to RS485 converter with power supply and RJ12 jack. UC485 USB to RS485 converter. Supplied with USB cable. SMDK-1004 Serviceman’s display kit used for diagnosing MicroM system. Consists of ED510 equipped with back plate, MED daughter board and ED580-4.
£ WARNING: Installer must be trained and qualified. Follow the burner manufacturer’s instructions, if supplied. Otherwise, proceed as follows: INSTALLATION OF CONTROL, SCANNERS AND FLAME DETECTORS Wiring Base Mount the wiring base on the burner or on a panel. The location should be free from excessive vibration and within the specified ambient temperature rating. The base may be mounted in any angular position. All wiring should comply with applicable electrical codes, regulations and local ordinances.
£ INSTALLING THE PROGRAMMER AND AMPLIFIER MODULES WARNING: Remove power from the control before proceeding. FIGURE 1. . AMPLIFIER PROGRAMMER Select the appropriate programmer and amplifier modules for your application. Remove the dust cover from the chassis. Insert the amplifier module into the slot in the corner of the chassis and gently push the module into position. Insert the programmer module into the slot at the right side of the chassis and gently push the module into position.
£ FIGURE 2. Replaceable Fuse Location PROGRAMMER DIPSWITCH SETTINGS NOTE: The dipswitch settings become permanently stored within the programmer’s eeprom memory after 8 hours of continuous electrical operation. The first 8 hours of continuous operation is determined from the value of system hours being accumulated by the MicroM. System hours are stored to memory (eeprom) automatically every 1,000 minutes or at the occurrence of a lockout.
£ Once the switches are set, they become permanently stored after 8 hours of continuous operation or they can be manually set through the use of the optional ED510 display. Refer to the section using the optional ED510 display for detailed information. Where applicable, each MicroM programmer is shipped with dip-switch 6 set to non-recycle on flame fail, dipswitch 4 set to 5 second PTFI time, and dipswitches 1 & 2 set to the longest purge time. FIGURE 3.
£ PTFI: This LED is illuminated only during the pilot trial for ignition period and the stabilization period when so equipped. Flame: This LED is on whenever a flame signal is detected, and the control is not in a locked out state. Alarm: This LED flashes when an alarm condition is detected and is used as an address indicator (see communication). During an alarm condition, the Alarm LED is made to flash at approximately a 1 second rate.
£ DIAGNOSTIC MESSAGES - TROUBLESHOOTING GUIDE Check Programmer POSSIBLE CAUSE SOLUTION Voltage on Terminal 5 at improper time. Inspect wiring to main fuel valve Welded watchdog relay Replace MEC chassis Internal diagnostic failure Replace MEP programmer Check Chassis Voltage on Terminal 3 or 4 at improper time. Inspect wiring to pilot valve and igniter.
£ Safety Shutdown In the event pilot flame is not detected at the end of the 10 second PTFI period, the pilot gas valve and spark ignition are de-energized. A safety lockout occurs which de-energizes the burner motor and energizes the lockout alarm relay circuit, lighting the Alarm LED, 15 seconds after the safety lockout occurs. Manual reset is required.
£ following a post purge of 30 seconds and a safe start check. Failure to ignition spark on the second attempt results in safety lockout. MEP100P The MEP100P programmers provides a fixed 15 second post purge period upon detection of the operating Control (1-7) or Air Flow switch (7-6) opening.
£ If non-recycle operation is selected, in the event of a main flame failure, power is removed from Terminal 3 and Terminal 5. The control will enter a forced post purge period of 15 seconds, after which the Alarm LED is illuminated and the alarm relay is energized putting power on Terminal A. The MEP230H programmer operates the same as the MEP230 with the exception of an additional 8 second pilot stabilization.
£ TYPE MEP236 PROGRAMMING SEQUENCE L1/7 ON INTERLOCK AIR FLOW PROVEN FIRING PERIOD PURGE COMPLETE L1/7 OFF 8 T E R M I N A L S 3 PILOT SELECTABLE POST PURGE SELECTABLE PURGE 4 IGNITER 5 MAIN VALVE SELECTABLE PTFI 5 OR10 SEC MFSP* 6 SEC *MAIN FLAME STABILIZATION PERIOD Terminal #5 is energized 3 seconds after the flame is detected. Selectable Recycle/Non-Recycle operation on loss of flame after flame is proven. Igniter remains on for 6 seconds after main valve opened.
£ A “run-check” switch is also provided to assist in testing size, position and stabilization of pilot in conjunction with the flame detector, For the MEP560 and MEP562, after pilot flame is detected, the control enters an 8 second pilot stabilization period with Terminal 3 and Terminal 4 energized. At the expiration of the stabilization period, Terminal 5 is energized.
£ TYPE MEP562 PROGRAMMING SEQUENCE L1/7 ON INTERLOCK AIR FLOW PROVEN FIRING PERIOD PURGE COMPLETE L1/7 OFF 8 T E R M I N A L S SELECTABLE PURGE 3 SELECTABLE POST PURGE PTFI 5 OR10 SEC 4 STABLIZATION PERIOD 8 SEC MTFI 10 SEC 5 Pilot stabilization timing begins as soon as flame is proven. Lockout on loss of air flow (interlock circuit) after flame is proven. Lockout on flame fail. MEP300/MEP600 SERIES This programmer type must be used with the MEC320 or MEC480 type chassis.
£ TYPE MEP304 PROGRAMMING SEQUENCE L1/7 ON T E R M I N A L S INTERLOCK AIR FLOW PROVEN FIRING PERIOD PURGE COMPLETE L1/7 OFF 8 POST PURGE 5 SECOND PURGE 3 10 SEC PTFI 4 5 SEC PILOT PROVING 10 SEC MTFI INTERRUPTED PILOT 5 0 Second post purge on operating control open. 15 Second post purge on flame fail. Non-recycle operation on flame fail. Recycle operation on air flow failure.
£ TYPE MEP397 PROGRAMMING SEQUENCE L1/7 ON T E R M I N A L S INTERLOCK AIR FLOW PROVEN FIRING PERIOD PURGE COMPLETE L1/7 OFF 8 POST PURGE 1 5 SECOND PURGE 3 7 SEC PTFI 4 5 SEC PILOT PROVING 5 SEC MTFI INTERRUPTED PILOT 5 0 Second post purge on operating control open. 15 Second post purge of flame fail during PTFI, Proving and MTFI. Lockout on flame fail during PTFI, Proving and MTFI. Relight operation on main flame fail. Recycle operation on air flow failure.
£ TYPE MEP697 PROGRAMMING SEQUENCE L1/7 ON T E R M I N A L S INTERLOCK AIR FLOW PROVEN FIRING PERIOD (AUTO) PURGE COMPLETE L1/7 OFF 8 3 SELECTABLE PURGE 4 SELECTABLE POST PURGE 5 SEC 5/10 SEC PILOT SELECTABLE PROVING PTFI 5 SEC MTFI INTERRUPTED PILOT 5 MODULATE CONTACTS Lockout on flame fail. Lockout on air flow switch opening while main flame energized. Recycle/Non-recycle dipswitch controls lockout on air flow switch not closing 10 seconds into purge.
£ Function Any MicroM chassis type with the appropriate plug-in board installed provides remote reset capabilities in the event of a lockout condition. A remote reset switch consists of a dry contact such as a remote momentary push-button wired to the two (2) terminals located on the plug-in board as shown in Figure 5. The reset switch will also force the MicroM to recycle if depressed and released during the purge or run period.
£ MicroM will reset from the lockout state only. This is especially useful where, through the use of remote reset daughter boards, all reset inputs can be connected together to a common reset pushbutton or intelligent device (PLC). If the push button is depressed as described above it will only cause the unit that is in lockout to reset and not effect any other units.
£ OPERATING STATUS (Standby, Purge, PTFI, Auto, etc.) ADDITIONAL INFORMATION ON OPERATING STATUS (Flame Signal Strength, Cause of current Lockout, etc.) OR PURGE STARTING BURNER 00:05 BURNER HISTORY (SCRL key required) (Burner Cycles, Burner Lockouts, etc.) OR SUB-MENU HEADINGS (SCRL and MODE keys required) (Lockout History, Program Setup, etc.
£ LOCKOUT HISTORY The sub-menu “LOCKOUT HISTORY” will display the last six (6) lockouts, along with the burner cycle and burner hour when the lockout occurred. When the MODE key is pressed, the screen will display the most recent lockout condition and the number of that lockout (e.g. LO #127 represents the 127th lockout of that control). The SCRL key will display the Burner Hour, followed by the Burner Cycle when the lockout occurred.
£ SCRL UNIT ADDRESS 00 PRESS RESET TO ACCEPT SETTINGS Force storage of dipswitch settings before 8 hours time-out. MODE AUTO Mode key returns to normal run message. 45 SYSTEM INFO The sub-menu “SYSTEM INFO” allows the user to review information pertaining to the operation of the control (e.g. average main flame signal strength, status of the high fire and low fire end switches, etc.). The MODE key is used to enter the “SYSTEM INFO” sub-menu, and the SCRL key is used to advance.
£ 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 MicroM programmers, followed by a description where necessary.
£ Message 26 returns the current operating status as well as stored burner hours and burner cycles as a snapshot of the entire MicroM system. When all 9 words are requested, the data returned consists of STATUS, MSGN, FLAME, INPUTS, OUTPUTS, BNRMINS, and BNRCYCS. 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.
£ It is suggested that repeated polling interval not be less than 200 mSec per request. Requesting data such as burner minutes, system minutes and burner cycles be kept at a minimum due to the amount of processing time required to gather that data.
£ Table 2: Program Module Identification 32 Programmer Module Identifier MEP100 0H, 01H MEP101 0H, 02H MEP102 0H, 03H MEP103 0H, 04H MEP100P 0H, 05H MEP109 0H, 06H MEP130 0H, 08H MEP104 0H, 09H MEP105 0H, 0AH MEP106 0H, 0BH MEP107 0H, 0CH MEP108 0H, 0DH MEP230 1H, 01H MEP230H 1H, 02H MEP235 1H, 04H MEP236 1H, 05H MEP290 1H, 06H MEP238 1H, 09H MEP237 1H, 0AH MEP560 2H, 01H MEP561 2H, 02H MEP562 2H, 03H MEP536 2H, 04H MEP537 2H, 05H MEP300 0H, 01H MEP304
£ Table 3: Message Description DEC HEX MicroM Message 1 1 L1-7 OPEN 2 2 FALSE FLAME 3 3 STARTING BURNER 4 4 5 5 INTRLCK OPEN 6 6 LOCKOUT LINE FREQUENCY NOISE DETECTED 7 7 LOCKOUT FLAME FAIL - PTFI 8 8 UNIT ADDRESS 9 9 MTFI 10 0AH IGNITION TIMING 11 0BH 12 0CH FLAME SIGNAL 13 0DH CYCLE COMPLETE 14 0EH OFF 16 10H LOCKOUT AMPLIFIER HIGH COUNT FAIL 19 13H LOCKOUT FLAME FAIL – MTFI 20 14H LOCKOUT FALSE FLAME – STANDBY 21 15H LOCKOUT INTRLCK OPEN 22 16H LO
£ line of the display. Pressing and releasing the RESET key will cause the address to increment. The address after 31 is 0. The second method is to use the local reset located on the plug-in board. It is first necessary to open the operating control (L1-7) to have the MicroM in the IDLE or STANDBY position. Depressing the reset switch for greater than 10 seconds will cause the address of the MicroM to be displayed in a binary format on the LEDs located on the programmer board.
£ EXTERNAL METER CONNECTIONS The test jacks are located on the amplifier card. If external access is desired for a panel meter the shown below will assist you in locating the position to drill through on the front cover. The hole sizes should be large enough to accommodate the body of the meter probes. The tests accept meter probes up to .080” or 2mm diameter. 2.963 2 31/32 ADDING HOLES IN COVER TO ACCESS TEST JACKS 1.759 1 3/4 3.
£ 3. Observe the pilot flame signal on the test meter or the ED510 display. If the flame signal is below 4.0 volts DC or a reading of 10 on a remote display, re-adjust the pilot flame or realign the flame detector. WARNING: DO NOT TOUCH a flame rectification rod with power applied. 4. 5. When using UV detection, a test is required to verify that UV radiation from the ignition spark is not being detected. To accomplish this, manually shut off both the pilot and main fuels. Initiate a normal start-up.
£ NO HEAT MicroM SERVICE GUIDE O.C.
CHECK SYSTEM WIRING 6. 5. 3. 4. YES REPLACE MEC120 REPLACE MEC120 CHECK AIR FLOW SWITCH AND CHECK WIRING CHECK BLOWER SYSTEM NO IS 120VAC PRESENT 8-2? NO NO IS YES PROGRAMMER OR MC120 DEFECTIVE YES IS 120 VAC PRESENT 6-2? ON? BLOWER YES Verify that there is a solid earth ground wire brought to the panel that the Fireye base is mounted to.
£ Wiring Arrangements IMPORTANT: Use moisture resistant wire rated 90°C minimum. CAUTION: When powered, 560 VAC across S1, S2 with MEUV4, MEUV1, MEUVS4 and MEUVS1; 260 VAC across S1, S2 with MERT4 and MERT1. CAUTION: Control wiring procedures which deviate from those shown in the diagrams may bypass safety functions designed in the control. Check with the Fireye Representative before deviating from the recommended wiring diagrams.
£ WIRING ARRANGEMENT FOR PILOT IGNITED BURNERS AND PROVISION FOR MAIN FLAME STABILIZATION USING MEP236 SERIES PROGRAMMERS FIGURE 7.
£ WIRING ARRANGEMENT FOR PILOT IGNITED BURNERS AND INTERRUPTED PILOT USING MEP500 SERIES PROGRAMMERS FIGURE 9.
£ WIRING ARRANGEMENT FOR FLAME SWITCHES USING MEP100 PROGRAMMERS FIGURE 11. ENABLE/DISABLE INPUT FLAME SCANNER 6 7 H KL (WATCHDOG) 1 S2 S1 FLAME AMPLIFIER F1 120VAC 50/60Hz KA 2 N KB A KF-2 8 3 FLAME ROD ONLY KF-1 4 5 ISOLATED SWITCHED OUTPUTS REFER TO LOAD RATING V VOLTAGE SOURCE * FUSE F1 CAN BE REMOVED NOTE: Air Flow LED will blink while flame is detected and KF relay is energized. WIRING ARRANGEMENT FOR PILOT IGNITED BURNERS USING MEP300, MEP400 AND MEP600 SERIES PROGRAMMERS.
£ ALTERNATE WIRING ARRANGEMENT FOR MEP CONTROLS FIGURE 13. A. FOR MANUAL S1 A START-STOP STATION MAY BE ADDED TO REQUIRE OPERATOR START-UP EACH TIME THE BURNER FIRES. S2 3 PILOT VALVE 5 MAIN FUEL VALVE 4 IGNITION HOT 1 START ON-OFF STOP 7 BLOWER OR CONTACTOR LR-2 LR-1 LIMIT SW ALARM 8 2 NEUTRAL AIR FLOW SWITCH A LATCH RELAY COIL 6 SECOND STAGE FIRST STAGE B.
£ BACKWARD COMPATIBLE WIRING USING MEP100 AND MEP200 SERIES PROGRAMMERS (PILOT IGNITED BURNERS). FIGURE 14. AIR FLOW OPERATING CONTROL T INTERLOCK P FLAME SCANNER 6 7 H KL (WATCHDOG) 1 S2 KA 2 N KB A S1 FLAME AMPLIFIER F1 120VAC 50/60Hz KF-2 8 3 FLAME ROD ONLY KF-1 4 5 ** * PV ALARM MV INTERMITTENT PILOT VALVE BLOWER MOTOR OR CONTACTOR * For intermittent ignition, connect to terminal 3 ** Combined current from Terminal 8 must not exceed 9.
£ SUGGESTED GROUNDING RULES The MicroM system, being microprocessor based, requires a ground system that provides a zerovoltage reference. The voltage measured from L2 to all other terminals except L1 should be 0 volts. 1. 2. 3. 4. 5. 6. 7. The most effective ground is to run the ground wire in the same raceway as the hot and neutral from the main distribution service panel (not intermediate sub-panels) to the burner control panel and insure that this ground wire is well bonded to the control panel.
£ COMMUNICATIONS When interfacing Fireye controls to a communication system, be it an E500, PLC or other microprocessor based device, ferrite cores should also be utilized. Proper twisted shielded pair cable must be utilized. In a multi-drop system, the shields should be tied together within a cabinet and not to any ground point. The shield at the source end of the cable of the multi-drop connection can then be terminated to ground.
£ than halfway through. Swivel flanges are available if desired (#60-302 for UV1A, UV2 Scanners, #60-1664-3 for 45UV5). The sight pipe must permit an unobstructed view of the pilot and/ or main flame, and both pilot and main flames must completely cover the scanner field of view. SCANNER MUST HAVE UNOBSTRUCTED VIEW OF FLAME NOT THIS 5. 6. NOT THIS FLAME MUST COMPLETELY COVER SIGHT OPENING BUT THIS NOT THIS NOT THIS BUT THIS Smoke or unburned combustion gases absorb ultraviolet energy.
£ OPERATION — 45UV5 SELF-CHECKING UV SCANNER Self-checking ultraviolet scanners should be used in applications where burner firing operation is continuous or where the burner is on for long periods of time without recycling. In addition, ultraviolet self-checking systems are mandatory in some locations. The operation of this type of system consists of maintaining the flame scanning capability at all times while also proving that the ultraviolet tube is firing properly.
£ INSTALLATION—INFRARED SCANNER TYPE 48PT2 Where possible, obtain the burner manufacturer’s instructions for mounting the scanner, otherwise proceed as follows: A single scanner is used to detect both pilot and main flames. The sight pipe on which the scanner mounts must be aimed so that the scanner sights a point at the intersection of main and pilot flames. Proper scanner positioning must assure the following: 1. 2. 3. 4. 5. 6. Reliable pilot flame signal. Reliable main flame signal.
£ INSTALLATION - 69NDl FLAME ROD The 69NDl flame rod proves a gas pilot flame and/or main gas flame. It is a spark plug type unit consisting of 1/2" NPT mount, a KANTHAL flame rod, a glazed porcelain insulating rod holder and a spark plug connector for making electrical connections. The 69ND1 is available in 12", 18" or 24" lengths. The flame rod may be located to monitor only the gas pilot flame or both the gas pilot and main gas flames. It is mounted on a 1/2" NPT coupling.
£ MAINTENANCE Type 48PT2 Infrared and Type UV1A, UV2 and 45UV5 Ultraviolet Scanners The viewing area of the scanner must be kept clean. Even a small amount of contamination will reduce the flame signal reaching the detector by a measurable amount. Wipe the viewing area routinely using a soft cloth dampened with concentrated detergent. — Type 48PT2 Scanners include a replaceable #4-263-1 Firetron cell. — Type 45UV5 Scanners include a replaceable #4-314-1 UV tube.
£ FIGURE 16. Mounting 45UV5 Scanner #60-1664 1” SWIVEL MOUNT AIR ENTRY (PURGE AND COOLING) #35-127 HEAT INSULATING NIPPLE #60-1664 1” SWIVEL MOUNT APERTURE #53-121 2.75” (70) RETAINER #34-181 STANDARD MOUNTING FOR TYPES OF SCANNERS #60-1664 1” SWIVEL MOUNT AIR/ENTRY (PURGE ABD COOLING) #35-127 HEAT INSULATING NIPPLE #35-127 HEAT INSULATING NIPPLE PURGE AIR ENTRY 2.75” (70) MOUNTING FOR HIGH TEMP.
£ FIGURE 18.
£ M-SERIES TO M-SERIES II TO MICROM CROSS REFERENCE LISTING M-SERIES M-SERIES II REPLACEMENT MODULES MicroM REPLACEMENT MODULES Part Number Chassis Amplifier Programme r Programmer Dipswitch #8 Chassis Amplifier Programmer Programmer Dipswitch #6 UVM1D MC120 MAUV1T MP100 N/A MEC120 MEUV1 MEP100 N/A UVM1F MC120 MAUV1 MP100 N/A MEC120 MEUV4 MEP100 N/A TFM1D MC120 MART1T MP100 See Note #1 MEC120 MERT1 MEP100 N/A TFM1F MC120 MART1 MP100 See Note #1 MEC120 MERT4 ME
£ 55
£ NOTICE When Fireye products are combined with equipment manufactured by others and/or integrated into systems designed or manufactured by others, the Fireye warranty, as stated in its General Terms and Conditions of Sale, pertains only to the Fireye products and not to any other equipment or to the combined system or its overall performance.
