CaptiveAire M4RT1 Installation Manual

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JANUARY 29, 2007

M-4000

FIREYE

M4RT1

FLAME SAFEGUARD CONTROLS

WARNING: Selection of this control for a particular application should be made by a com­petent professional, licensed by a state or other government agency. Inappropriate application
of this product could result in an unsafe condition hazardous to life and property.

DESCRIPTION

The Fireye® M4RT1 Flame Safeguard Control is a compact burner management system. It is
designed to provide automatic ignition and continuous flame monitori ng for commercial sizes of
heating and process burners that use gaseous fuels.

Flame monitoring is accomplished by a Flame Rod detector, the built in amplifier and programmer.
Control functions and timing are factory set with onboard jumpers. Functions such as recycle/non­recycle, purge timing, and pilot trial for ignition (P.T.F.I.) time are determined by the jumpers. Flame
Failure Response Time (F.F.R.T.) is fixed at three seconds. LED indicator lights indicate the operat­ing status of the control.

In the event of ignition failure, or following a safety shutdo wn, the unit locks out, activating an
alarm circuit. Cycling the power OFF and back on will reset the control. A manual reset option can
be special ordered. Remote reset (via remote pushbutton) is also available as a special order option.
A detailed description of the programmer sequence is found later in this document. Test jacks are
provided to permit flame signal measurement during operation.

The M4RT1 control incorporates a safety checking circuit that is operative on each start. If flame
(real or simulated) is detected prior to a start or during the purge, the fuel valves will not be ener­gized, and the unit will lock out.

All M4RT1 controls do not require a wiring base due to the terminals included on the relay board.
See INST ALLATION OF CONTROL, SCANNERS, AND FLAME DETECTORS (page 2) for tem­perature and wiring requirements.

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SPECIFICATIONS

Supply:

120V (min. 102, max. 132) 50/60 Hz

Table 1: AMBIENT TEMPERATURE LIMITS

MAXIMUM MINIMUM

Control 140°F (60°C) - 40°F (- 40°C)

Flame Rod
(Tip 2460 F)

Power Consumption: 12 VA (Operating)
Shipping Weight (Approx.): 2.2 lbs. (1.4kg)

Table 2: LOAD RATINGS

Fireye Terminal Typical Load Maximum Rating & 120V 60 Hz

3 or 4

Individual or combined

5 Main Fuel Valve(s)

8 Motor or contactor

A Alarm 50 VA, pilot duty

1500°F (816°C) - 40°F (- 40°C)

Pilot valve(s)

Solenoid valve

Ignition Transformer

Minimum load requirement = 100mA

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125 VA pilot duty (solenoid valve) plus
250 VA (Transformer)

125 VA pilot duty (solenoid) or
25 VA pilot duty (solenoid) and
400 VA (opening) motorized

Motor normally energized and de-energized by the
operating control whose rating must be suitable. Termi­nal 8 rated to de-energize 9.8 FLA, 58.8 LRA, on safety
lockout.

APPROVALS

Underwriters Laboratories Inc.

Recognized Components Guide MCCZ2
File MP1537

ORDERING INFORMATION

CONTROL:

M4RT1 120 VAC (min.102, max 132) Supply, 50 Hz/60 Hz.

FLAME DETECTORS:

69ND1-1000K4 12 inch flame rod, 1/2” NPT connector
69ND1 -1000K6 18 inch flame rod, 1/2” NPT connector

69ND1-1000K8 24 inch flame rod, 1/2” NPT connector

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INSTALLATION OF CONTROL, SCANNERS, AND FLAME DETECTORS

Wiring Base

Mount the control in an enclosure/burner panel that provides the proper protection fo r the control.
The location should be free from moisture, excessive vibration and within the specified ambient tem­perature rating. The control may be mounted in any angular position.

All wiring should comply with applicable electrical codes, regulations, and local ordinances. Use
moisture resistant wire suitable for at least 90 degrees C. Circuit recommendations are found on
pages 10 through 11. Consult the factory for assistance with non-standard applications.

WARNING: Installer must be trained and qualified. Follow the burner manufacturer's in­structions, if supplied. Otherwise, proceed as follows.

WARNING: Controls require safety limits utilizing isolated mechanical contacts. Solid state
limit switches are not acceptable and should not be used due to their high leakage currents.

WARNING: Remove power from the control before proceeding.

Replaceable Fuse

The M4RT1 is designed with a field replaceable fuse. The fuse is located on the printed circuit
board. The fuse will blow as a result of an overload conditio n on Terminals 3, 4 or 5. To replace the
fuse, remove power from the system. Using a small screwdriver or similar tool, remove th e fuse
from its holder. Install a Fireye replacement fuse (P/N 23-176) or equivalent 8 amp fuse (e.g. Lit­tlefuse 225008P, 8 amp, 125V).

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WARNING: Turn off the power when installing or removing the control.

INSTALLATION - 69ND1 FLAME ROD

The 69ND1 flame rod proves a gas pilot flame and/or main gas flame. It is a spark plug type unit
consisting of
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

The following instructions should be observed:

1. Keep flame rod as short as possible.

2. Keep flame rod at least

3. Flame rod should enter the pilot flame from the side so as to safely prove an adequate pilot

flame under all draft conditions.

4. If the flame is nonluminous (air and gas mixed before bu rning), the electro de tip should ext end

at least

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/2″ NPT mount, a KANTHAL flame rod, a glazed porcelain insulating rod holder and

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/2″ into the flame, but not more than halfway through.

CORRECT
POSITION

OF ROD

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/2″ NPT coupling.

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/2″ from any refractory.

WRONG POSITION

OF ROD

INADEQUATE FLAME

PILOT BURNER

CORRECT POSITION

OF PILOT FLAME

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5. If the flame is partly luminous, the electrode tip should extend only to the edge of the flame. It is

not necessary to maintain absolutely uninterrupted contact with the flame.

6. It is preferable to angle the rod downward to minimize the effect of sagging and to prevent it

from coming in contact with any object.

7. An adequate grounding surface for the flame must be provided. The grounding surface in actual

contact with the flame must be at least four times greater than the area of the portion of the
flame rod in contact with the flame. It is essential to adjust the flame rod and ground area ratio
to provide a minimum signal reading of 6.0 VDC.

Note: Interference fr om the ignition spark can alter the true signal reading by adding to, or subtract­ing from it. This trend sometimes may be reversed by interchanging the primary wires (line voltage)
to the ignition transformer . This interfer ence can also be r educed by the addition of grounded shield­ing between the flame rod and ignition spark.

8. Proven types of flame grounding adapters, as shown below, may be used to provide ad equate

grounding surface. High temperature stainless steel should be used to minimize the effect of
metal oxidation. This assembly may be welded directly over the pilot or main burner nozzle.

WIRING OF FLAME RODS

For proper operation of flame rectification systems, it is necessary to maintain at least 20 megohms
insulating resistance in the flame rectification circuit.

1. The scanner should be wired using metal cable or rigid conduit.

2. High voltage wiring must not be installed in the same conduit with scanner wiring.

Selection of Scanner Wire

1. Use #14, 16, or 18 gauge wire with 90 C, 600 volt insulation for up to 20 feet distance.

2. The type of insulation used with flame rectification is i mportant, since it must protect against

current leakage resistance to ground. Use Belden 8254-RG62 Coaxial Cable (or equal) for runs
greater than 20 feet. Maximum wiring run not to exceed 100 feet.

MAINTENANCE

Type 69ND1 Flame Rod

The flame rod and its insulator should be kept clean by washing routinely with soap and water. Rods
should be routinely replaced as they oxidize.

Flame Signal Strength

Routine observation of the flame signal strength will forewarn any deterioration in the capability of
the flame detector or its application.

BOMB FIN

GROUNDING

ASSEMBLY

THREADED ROD

ASSEMBLY

Periodic Safety Check

It is recommended that a procedure be established to test the complete flame safeguard system at
least once a month. This test should verify the proper operation of all limit switches and safety inter­locks as well as flame failure protection and fuel safety shutoff valve tightness.

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