Page 1
Instruction Manual 818
2/02
VeriFlame Single Burner
Monitoring System
Model 5600
Version 1.21
Modulation Model
Purge ModelNo Purge Model
Page 2
COPYRIGHT
Cop yright 1997 by Ec lips e Combusti on, Inc. All rights r eserved wo rldwide. Thi s
publication is protected by federal regulation and shall not be copied,
distributed, transmitted, transcribed or translated into any human or computer
language, in an y form or by an y means, t o an y third parties, without the express
written consent of Ecli pse Combustion, Inc., Rockford, Illinois, U.S.A .
DISCLAIMER NOTICE
LIABILITY AND
WARRANTY
In accordance with the manufacturer’s policy of continual product improv ement,
the product presented in this brochure is subject to change without notice or
obligation.
The material in this manual is believed adequate for the intended use of the
product. If the product is used for purposes other than those specified herein,
confirmation of validity and suitability must be obtained. Eclipse Combustion,
Inc. warrants that the product itself does not infringe upon any United States
patents. No further warranty is expressed or implied.
We have made every effort to make this manual as accurate and complete as
possible. Should you find errors or omissions, please bring them to our attention
so that we may correct them. In this way we hope to improve our product
documentation for the benefit of our customers. Please send y our corr ections
and comments to our Marketing Communications Manager.
It must be understood that Eclipse Combustion’s liability for its products,
whether due to breach of warranty, negligence, strict liability, or otherwise , is
limited to the furnishing of burner monitoring system replacement parts and
Eclipse Combustion will not be liable for any other injury, loss, damage or
expenses, whether direct or consequential, including but not limited to loss of
use, income of, or damage to material arising in connection with the sale,
installation, use of, inability to use or the repair or replacement of Eclipse
Combustion’s products.
Eclipse Combustion, Inc., for a period of one year from shipment, warrants each
V eri-Flame burner monitoring system to the original pur chaser to be fr ee fr om
defects in material and workmanship under normal use as defined hereafter.
Any operation expressly prohibited in this Guide, any adjustment or assembly
procedures not recommended or authorized in these instructions, shall void
the warranty.
Eclipse V eri-Flame Instruction Manual 818-2/02
2
Page 3
About this manual
AUDIENCE
SCOPE
DOCUMENT
CONVENTIONS
This manual has been written for the people who select and install the product
and the technicians who work on it. They are expected to ha v e previous experience with this kind of equipment.
This manual contains essential information for the proper installation and operation of the Eclipse Veri-Flame Burner Monitoring System.
Following the instructions in this manual should assur e trouble-free installation
and operation of the monitoring system. Read this manual carefully . Mak e sure
that you understand its structur e and contents. Obe y all the safety instructions.
Do not deviate from any instructions or application limits in this manual without written consent from Eclipse Combustion, Inc.
If you do not understand any part of the information in this manual, do not
continue. Contact your Eclipse sales office or Eclipse Combustion, Inc., Rockford, Illinois.
There are se veral special symbols in this document. Y ou must kno w their meaning
and importance.
The explanation of these symbols follows. Please read it thoroughly.
Danger:
Indicates hazards or unsafe practices which WILL result in severe
personal injury or even death.
Only qualified and well trained personnel are allowed to carry out
these instructions or procedures.
Act with great care and follow the instructions.
Warning:
Indicates hazards or unsafe practices which could result in severe
personal injury or damage.
Act with great care and follow the instructions.
Caution:
Indicates hazards or unsafe practices which could result in damage to the machine or
minor personal injur y.
Act carefully.
Note:
Indicates an important par t of the text.
Read the text thoroughly.
Eclipse V eri-Flame Instruction Manual 818-2/02
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Page 4
HOW TO GET HELP
If you need help, you can contact your local Eclipse Combustion sales office.
You 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
http://www.eclipsenet.com
@eclipsenet.com
Eclipse V eri-Flame Instruction Manual 818-2/02
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Page 5
Table of Contents
1
2
3
4
About this manual.....................................................................................
Table of contents........................................................................................
Introduction....................................................................................................
Product Description...........................................................................................
Specifications ...............................................................................................
Introduction............................................................................................................
Specifications ..........................................................................................................
Dimensions .............................................................................................................
DIP Switch Selection ..............................................................................
Introduction............................................................................................................
DIP Switch Location.............................................................................................
DIP Switch Access.................................................................................................
No Purge DIP Switch Settings ...........................................................................
Modulation & Purge DIP Switch Settings........................................................
Function Summary ..........................................................................................
Introduction............................................................................................................
Standard Features..................................................................................................
Combustion Air Flow Check.........................................................................
Main Fuel Valve Closed switch......................................................................
Low Fire Start ...................................................................................................
High Fire/High Fire Purge Check .................................................................
Recycle Mode....................................................................................................
Pilot T est Mode.................................................................................................
Interrupted or Intermittent Pilot.................................................................
Post Purge..........................................................................................................
Spark, Pilot Flame & Main Flame Separation .............................................
System Error & Lockout Conditions...........................................................
High to Low Fire Purge Modulation Capability with High to Low
Fire Position Switch Interlocks.....................................................................
3
5
8
8
9
9
9
9
12
12
12
12
12
13
14
14
14
14
14
14
14
14
14
15
15
15
15
16
Eclipse V eri-Flame Instruction Manual 818-2/02
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Page 6
Optional Features .................................................................................................
4
Pilot Test Mode Sequence ..............................................................................
Air Switch Input Hold .....................................................................................
Remote Display & Power Supply..................................................................
Status Lights & Push-buttons..............................................................................
Interlocks Closed.............................................................................................
Air Failure ..........................................................................................................
System Error .....................................................................................................
Burner On..........................................................................................................
Flame Failure .....................................................................................................
Low Fire..............................................................................................................
High Fire.............................................................................................................
Auto.....................................................................................................................
Test/Reset...........................................................................................................
16
16
16
16
17
17
17
17
17
17
17
17
17
17
System Installation...................................................................................
5
Introduction............................................................................................................
Interlocks and Limit Switch Input .....................................................................
Combustion Air Switch Input.............................................................................
Ignition Wiring........................................................................................................
Low Fire Input........................................................................................................
Main V alve Closed switch ....................................................................................
High Fire Input .......................................................................................................
Remote Reset ........................................................................................................
Remote Display & Power Supply.......................................................................
Purge and No Purge Wiring Diagram (Figure 5.1)........................................
Modulation Wiring Diagram (Figure 5.2) ........................................................
Typical Connections for all Models (Figure 5.3)............................................
Sensor Installation ....................................................................................
6
Introduction............................................................................................................
Sensor Wiring.........................................................................................................
Flame Rods .............................................................................................................
Scanners...................................................................................................................
Scanner Sighting Considerations.......................................................................
Test Procedures...........................................................................................
7
Introduction............................................................................................................
Flame Signal Strength ...........................................................................................
Minimum Pilot Test................................................................................................
Pilot Flame Failure Test ........................................................................................
Main Flame Failure Test........................................................................................
Spark Sighting Test.................................................................................................
Limits & Interlock Tests .......................................................................................
18
18
18
18
18
19
19
19
19
19
20
20
21
24
24
24
25
25
25
26
26
26
26
27
27
27
27
Eclipse V eri-Flame Instruction Manual 818-2/02
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Page 7
Maintenance & Troubleshooting....................................................
8
Introduction............................................................................................................
Maintenance............................................................................................................
Monthly Checklist .................................................................................................
Yearly Checklist .....................................................................................................
Troubleshooting.....................................................................................................
LED Status ..............................................................................................................
LED Status & Conditions for No Purge Models (Table 8.1) ......................
LED Status & Conditions for Purge Models (Table 8.2)..............................
LED Status & Conditions for Modulation Models (Table 8.3) ...................
28
28
28
28
28
29
30
30
31
32
9
Remote Display Messages...................................................................
Introduction............................................................................................................
Veri-Flame Operating Sequence (Table 9.1) ...................................................
Remote Display Diagnostic Messages (Table 9.2) .........................................
Appendix...........................................................................................................
Conversion Factors ..............................................................................................
Illustrated Parts List..............................................................................................
33
33
34
38
41
41
42
Eclipse V eri-Flame Instruction Manual 818-2/02
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Page 8
Introduction
1
PRODUCT
DESCRIPTION
The Eclipse Combustion Veri-Flame Single Burner Monitoring System controls
the start-up sequence and monitors the flame of single gas, oil, or combination
gas/oil burners. There are thr ee differ ent models to the Veri-Flame line: the no
purge, the purge and the modulation models. Each model f eatures field selectable trial for ignition (TFI). Each model is also available for use with four types
of flame sensor: ultraviolet (UV), self-check UV, infrared (IR) and flame rod.
The Veri-Flame No Purge and Purge models are a vailable in three different
series—5602, 5603 and 5605. The 5602 Series is UL listed, CSA cer tified, FM
approved and IRI acceptable; the 5605 Series is UL listed, FM approved and IRI
acceptable. The 5603 Series is for 240VAC applications not requiring US or
Canadian certifications.
The Veri-Flame Modulation model is available in two different series: 5602
and 5603. Both series are ca pable of modulation (high and low fire purging). The
5602 Series is UL listed, CSA certified, FM approved and IRI acceptable. The
5603 Series is for 240VAC applications not requiring US or Canadian certifications.
Figure 1.1
Veri-Flame Single Burner Monitoring System
(Purge Unit Shown)
Eclipse V eri-Flame Instruction Manual 818-2/02
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Page 9
Specifications
2
INTRODUCTION
This section gives a detailed overview of Veri-Flame specifications and dimensions.
Specifications
P
ARAMETER
Supply • Series 5602 & 5605: 120 VAC (+10%, -15%), 50/60 Hz standard.
Series 5603: 240 VAC (+10%, -15%), 50/60 Hz standard .
Internal power consumption: 12 VA (excluding external connected loads).
Temperature Ranges
Flame Failure Response 3 seconds ±0.5 seconds.
Trial For Ignition (TFI)
Unit Model Nos. Temperature Range
Veri-Flame All Models -40˚ to +60˚C (-40˚ to +140˚F)
90˚ U.V. Scanner 5600-90A -20˚ to +60˚C (0˚ to 140˚F)
U.V. Scanner 5600-91 -20˚ to +125˚C (0˚ to +257˚F)
NEMA4 UV Scanner 5600-91N4 -20˚ to +125˚C (0˚ to +257˚F)
I.R. Scanner 5600-92B -40˚ to +110˚C (-40˚ to +230˚F)
UV/IR Scanner 5600-92SC -20˚ to +80˚C (0˚ to +176˚F)
Self-Check U.V. 5602-91 -20˚ to +60˚C (0˚ to +140˚F)
Remote Display 5602DB 0˚ to 50˚C (32˚ to 122˚F)
Remote Display 5602DBP 0˚ to 50˚C (32˚ to 122˚F)
No Purge & Purge Models:
Series 5602 & 5603: five or 10 seconds selectable.
Series 5605: ten or 15 seconds selectable.
Modulating Model: 5 or 10 seconds selectable
D
ESCRIPTION
Pilot Interrupt (if selected) 10 seconds.
Purge Time Selectable from 0-225 seconds in 15 second increments.
UL, CSA
Inductive Load
175VA
Relay Contact Rating
Output Ratings
(maximum total connected
load not to exceed 15 amps)
Output Ratings
(maximum total connected
load not to exceed 15 amps)
for
120 V A C
240 V AC
for
Function
Gas Valve 3, 5 175VA, 1/10 HP 10 amps
Ignition 4 375 VA 10 amps
Motor or Contactor
Control Signal
Function
Valves, Ignition
Motors or Contactor
Alarm
Control
Terminals
8 470 VA, 1/2 HP 16 amps
A, 10, 11, 12, 13
Terminals
3, 4, 5,
8
A
10, 11, 12, 13 5
(continued onto next page)
Eclipse V eri-Flame Instruction Manual 818-2/02
Relay Contact Rating
Resistive Load
10 amps
Resistive Load
5 amps
16 amps
5 amps
amps
9
Page 10
Specifications (continued)
PARAMETER DESCRIPTION
Approvals • No Purge & Purge Models:
(See chart below.)
Shipping Weight •1.4 kilograms (3 lbs.) for all Veri-Flame models.
Series 5602: UL listed, CSA certified, FM approved and IRI acceptable.
Series 5603: No approvals.
Series 5605: UL listed, FM approved and IRI acceptable.
• Modulating Models:
Series 5602: UL recognized (must be mounted in panel), CSA certified, FM
approved and IRI acceptable.
Series 5603: No approvals.
•0.9 kilograms (2 lbs.) for Models 5602-10 & 5602-10-1 bases.
•1.2 kilograms (2.6 lbs.) for Model 5602-40 base.
Approval Information
UL Listed, Guide No. MCCZ, File MH12613
UL Recognized, Guide No. MCCZ2, File MH12613
CSA Certified, Class No. 2632 01, File 37456
Dimensions
FM Approved, Class No. 7610, Report 1Y2A4.AF
Veri-Flame Unit/All Models
76mm
(3")
133mm
(5-1/4") Square
Veri-Flame Bases/Purge & No Purge Models
Model Number 5602-10 Model Number 5602-10-1
5.5mm
(7/32") Dia.
127mm
(5")
Square
Mounting
Holes (4)
Knockouts
(10) for
13mm (1/2"
Conduit
127mm
(5")
Square
10
38mm
(1-1/2")
102mm
(4") Square
13mm
(1/2")
Eclipse V eri-Flame Instruction Manual 818-2/02
102mm
(4") Square
124mm
(4-7/8")
19mm
(3/4")
38mm
(1-1/2")
Page 11
Dimensions (continued)
Veri-Flame/Modulating Model with Base Model Number 5602-40
24mm
(15/16")
171mm
(6-3/4")
25mm
(1")
12345678AD 11121310S2 S1
40mm
(1-9/16")
116mm
(4-9/16")
10mm (3/8")
213mm (8-3/8")
5mm (3/16")
Remote Display Model Number 5602-DB
102mm
(4") Square
*
54mm
(2-1/8")
Mounting
Bracket &
Screw (2)
*
= Alternate Mounting Locations
*
24VDC Power Supply for Remote Display 5602-DB
44mm
(1-3/4")
70mm
(2-3/4")
79mm
(3-1/8")
Remote Display Model Number 5602-DBP
102mm
(4") Square
54mm
(2-1/8")
*
89mm
(3-1/2")
Square
Wiring
Terminal
89mm
(3-1/2")
Square
Ground
Screw
Contrast
Adjustment
Screw
15-pin Port
Terminal
Mounting
Bracket &
Screw (2)
*
Wiring
= Alternate Mounting Locations
*
Terminals (2)
Eclipse V eri-Flame Instruction Manual 818-2/02
Ground
Screw
Contrast
Adjustment
Screw
15-pin Port
Terminal
11
Page 12
DIP Switch Selection
3
INTRODUCTION
DIP Switch Location
DIP Switch Access
No Purge
DIP Switch Settings
This section details the location, selection and description of the Veri-Flame
DIP switches, which allow for sequence and timing functions as well as system configuration.
Caution
T o avoid electric shock, shut off the power supply when installing or remo ving any control
device. Flame monitoring systems must be installed by a qualified, licensed technician.
All of the DIP switches are located in the back of each V eri-Flame unit (see Figure 3.1 on page 13, or the photograph on page 8).
To gain access to the DIP switches, the V eri-Flame must be separated from the
back box (for visual reference, please refer to “Dimensions” on page 10). This
separation will expose the DIP switches on the back of the Veri-Flame unit.
No Purge models of the Veri-Flame only use three of the eight DIP switches, as
shown in the labels in Figure 3.2 on page 13. They are as follows:
SW1: Recycling mode selection (On=Recycling; Off=Non-recycling)
SW2: Pilot selection (On=Intermittent, where pilot remains on during burner cycle;
Off=Interrupted, where pilot valve closes after main burner is established).
SW3: Trial-for-ignition (TFI) range selection ( For 5602/5603 units: On =10
seconds; Off=5 seconds. For 5605 units: On=10 seconds; Off=15 seconds).
Modulation & Purge
DIP Switch Settings
12
Modulation and purge models of the Veri-Flame use all of the eight DIP switches,
as illustrated in Figure 3.2 on page 13. They are as follows:
SW1: Recycling mode selection (On=Recycling; Off=Non-recycling)
SW2: Pilot selection (On=Intermittent, where pilot remains on during burner cycle;
Off=Interrupted, where pilot valve closes after main burner is established).
SW3: Trial-for-ignition (TFI) range selection (For 5602/5603 units: On=10 seconds;
Off=5 seconds. For 5605 units: On=10 seconds; Off=15 seconds).
SW4 through 7: Purge time selection. T otal purge time is the sum of each s witch
selected.
SW8: Post purge selection. (On=15 second post purge).
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 13
Close-up of DIP switches on
back side of all Veri-Flame models.
Figure 3.1
No Purge Models
Purge Models
Modulation Models
DIP Switch Location
Figure 3.2
DIP Switch Labels with Selections
Eclipse V eri-Flame Instruction Manual 818-2/02
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Page 14
Function Summary
4
INTRODUCTION
STANDARD FEATURES
Interlocks and Limit
Switch Input (Terminal 7)
Combustion Air
Switch Input (Terminal 6)
This section describes the features of the V eri-Flame. It is broken into three categories:
Standard features, Optional features and the LED Indicator Lights on the front cover.
Refer to Figure 5.5 f or sequence diagrams.
The following function features are standar d on the V eri-Flame models as noted:
This input is considered the normal operation control or run input to the VeriFlame system. Interlocks are generally pressure or temperature switches which,
when activated, start the burner . Limit switches are generally pressure, temperature and other switches which, when activated, stop the burner . The interlocks and
limit switches are wir ed in series. A break in this cir cuit will shut the burner down,
but will not produce an alarm.
For purg e and modulation models: This input is for monitoring the
combustion air switch separately fr om other interlocks and limits. The Veri-Flame
checks the air flow switch input is open before start-up, closed during operation,
and open again at burner shutdown, thus preventing operation with an air switch
that is defective, maladjusted or jumped. This input has about a 2 second delay to
filter out and ignore a momentary interruption.
The input will be proven open bef or e start-up and after shutdown. If the input is
improperly pow ered befo re the fan output is energized, the system error light will
blink. The input must de-energize within 30 seconds or the Veri-Flame will lockout.
Main Fuel Valve Closed
Switch (Terminal V)
Low Fire Start
14
After the fan output has energized, the air switch input must be made within 10
seconds. If not proven, then the system will lockout, the alarm output and the air
failure light will come on. However, if the unit has the optional air switch input
hold feature, the sequence is held indefinitely without causing a lockout. When the
air switch input is made, then the sequence continues.
If the air switch opens during the main firing cycle, the system will either lockout
or recycle, depending on the DIP switch recycle selection.
Purge and No-Purge models: the Veri-Flame can be interlocked with the
main valve closed switch. This feature checks the switch position before
start-up and after shutdown to insure proper valve operation when the
jumper on the base is cut.
For modulation models: when wired, the system checks for the low fire start
position prior to light-off.
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 15
Main Fuel Valve Closed/
High Fire Purge Check
(Terminal D)
For modulation models: This feature 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 are both made at the end of the high fire purge.
Recycle Mode
Pilot T est Mode
Test Mode
(Button In)
Run Mode
(Button Out)
Interrupted or
Intermittent Pilot
Post Purge
For all models: when selected, the V eri-Flame will restart the sequence after
flame or air failure. The recycle mode allows the system to re-initiate the startup sequence automatically provided the main burner has been operating for
at least 35 seconds. If the pilot flame fails to light during recycling, the system
will lock out and annunciate a pilot flame fail. If the recycle is successful and
the main burner is operational for at least 35 seconds, the system is ready f or
another recycle. At no time will the system recycle in the event of pilot flame
fail.
For all models: this mode is entered by depr essing the TEST/RESET button on
the front cover. In the pilot test mode, the V eri-Flame will hold the sequence once
the pilot flame is established (i.e., the main valve is not energized). When in the
pilot test mode, the green “Interlocks Closed” light blinks.
To exit the pilot test mode, simply push the TEST/RESET button again and the
Veri-Flame will exit the pilot test mode (the green “Interlocks Closed” light
stops blinking but remains lit) and restart the sequence.
For all models: pilot mode is selected using the DIP switch SW2. An inter-
rupted pilot shuts off 10 seconds after the main valve opens. An intermittent
pilot continues during the entire main flame firing cycle.
For purge and modulation models: post purge is enabled by DIP switch
SW8. A post purge maintains the combustion air fan output for 15 seconds
after the interlocks and limit switch input have opened.
Spark, Pilot Flame &
Main Flame Separation
System Errors &
Lockout Conditions
For all models: during the trial f or ignition period (TFI), the pilot valve and
ignition coil remains energized. At the end of the TFI, the pilot flame r emains
on and the ignition coil is de-energized. After a five second delay to prov e the
pilot flame, the main gas valve is energized.
A system error (illuminated b y the r ed “System Error” LED on the front cover)
prevents gas ignition. The unit will continue its sequence after the error is cleared.
A lockout condition energizes the alarm output and de-energizes the gas valve
and ignition outputs. The unit must be reset to clear the alarm and start the
sequence. To reset, the button must be pr essed twice so that the button is in
the out position.
The following system errors result in immediate lockout conditions:
1) Wiring error which puts external voltage on the output terminals (for
all models).
2) W elded internal contacts or other malfunctions in the Veri-Flame (for all
models).
3) Main fuel valve (for all models)–open after cycle shutdown or before
start-up. The system error light blinks twice and then remains on. The
fan output terminal 8 will energize.
Eclipse V eri-Flame Instruction Manual 818-2/02
15
Page 16
System Errors &
Lockout Conditions
(Continued)
4) Low fire fail (for modulating model)–low fire switch open prior to trial
for ignition.
5) High fire fail (for modulating model)–high fire switch is not closed at the
end of high fire purge.
The following situations will result in a lockout condition:
6) Air failure (for purge and modulation models) – loss of combustion air
anytime during the operational cycle. The Air Failure LED will be on for this
condition. (See “Recycle Mode”).
7) Pilot flame fail (for all models) loss of flame during the trial for pilot ignition
period. The Flame Failure LED will be on for this condition.
8) Main flame fail (for all models) loss of flame during the main burner trial for
ignition or run period (recycling not selected). The Flame Failure LED will be
on for this condition.
The following result in lockout conditions after 30 seconds, the system error
light blinks about 14 times and then remains on:
9) If a flame is detected out of sequence, which may be caused by:
a) a faulty scanner (for all models);
b) electrical interference on the sensor wiring (for all models);
c) a flame exists in the burner or in the line of sight of a scanner , due to
a gas leak, product fire or other condition (for all models).
10) Air flow switch closed before start-up (f or purge and modulation models).
High to Low Fir e Purg e
Modulation Capability
with High to Low Fire
P osition Switch Interlocks
For modulation models: the modulation featur e incorporates a high fire purge
time and a low fire purge time into the purge sequence. This feature allows the
V eri-Flame to sequence internal dry contacts which can be used by the customer
requiring a high fire purge of the combustion chamber before ignition.
The high fire and low fire purge times are selectable by means of DIP switches
(see Section 3, “DIP Switch Settings” on page 12):
SW4................................15 seconds SW6 ................................60 seconds
SW5................................30 seconds SW7 ............................. 120 seconds
The selected times are additive and appl y to both the high fire and low fire purge
times (that is, high and low fire times are always identical).
The modulation terminals will sequence as follows:
Sequence Step
Power Off Terminal 10 (Common) Terminal 11 (Auto)
Power On, Limits Open Terminal 10 (Common) Terminal 12 (Low Fire)
Purge To High Fire Terminal 10 (Common) Terminal 13 (High Fire)
Purge To Low Fire Terminal 10 (Common) Terminal 12 (Low Fire)
Automatic Modulation Terminal 10 (Common) Terminal 11 (Auto)
Alarm and Lockout Terminal 10 (Common) Terminal 12 (Low Fire)
Internal Contact Connections
The Automatic step occurs when the burners are operating and allows the
burner firing rate to be controlled by an automatic temperature controller.
16
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 17
OPTIONAL FEATURES
The following features are a vailable on select models, or when optional equipment
is purchased.
Air Switch Input Hold
Remote Display &
Power Supply
Manual Reset on
Power Outage
S
T A TUS LIGHTS
P
USH-BUTTON
&
For purge/modulation models: holds the sequence indefinitely until air switch
input is confirmed without affecting the air failure function and causing a lock out.
Two models of remote display are available. The model 5602DB operates
on 24VDC and has no keypad. The model 5602DBP operates on
120VAC and has a keypad for reset function. The display is door panel
mounted and features a liquid crystal display in a ¼ DIN housing. The
unit connects to the Veri-Flame by a cable to the flame signal test jack,
and receives a serial communication on each sequence state change. The
display incorporates the following functions:
1) Provides status messages for the Veri-Flame sequence (see
section 9).
2) Indicates lockout conditions when they occur, as well as the
amount of time into the sequence when the lockout occurred
(see section 9).
3) Provides continuous monitoring of the burner’s flame signal
strength and run time during main burner operation.
This optional feature requires a reset on initial a pplication of power or after an
interuption of power. The system error light blinks rapidly (about 4 times per
second) and a remote display will show “PUSH RESET TO START”. The reset
button must be pressed in and out to start
All of the status lights and the TEST/RESET push-button are located on the front
cover of the Veri-Flame. This section describes their respective functions.
Interlocks Closed
Air Failure
System Error
Flame Failure
Low Fire
High Fire
Auto
Test/Reset
For all models: this green LED illuminates when the operation limits are made.
These limits are wired in series to terminal 7. This input becomes energized to
begin the burner sequence. When in the test mode, this LED blinks (see “Pilot Test
Mode” on page 15).
For purge and modulation models: this r ed LED illuminates whenever combustion air is lost during the operational cycle of the Veri-Flame.
For all models: this r ed LED illuminates when a system error is detected (see
“System Errors & Lockout Conditions” on pages 15-16).
For all models: this red LED illuminates when a pilot or main flame fails.
For modulation models: this yellow LED illuminates during the low fir e pe-
riod of the purge cycle.
For modulation models: this red LED illuminates during the high fire period
of the purge cycle.
For modulation models: this green LED illuminates during the automatic pe-
riod which occurs 20 seconds after the main valve is energized.
For all models: this push-button is used to activate the pilot test mode or to
reset the Veri-Flame unit.
Flame Signal
For all models: this red LED is located behind the signal test port and illumi-
nates when a flame signal is present.
Eclipse V eri-Flame Instruction Manual 818-2/02
17
Page 18
System Installation
5
INTRODUCTION
Interlocks and
Limit Switch Input
Combustion Air
Switch Input
In this section, the necessary procedures ar e detailed to integrate a V eri-Flame into a
burner system; Figures 5.1 and 5.2 illustrate the various terminal strips mentioned.
Note:
Shut off the power supply before the V eri-Flame is removed or replaced from the base.
Caution:
Installation and maintenance must conform with the National Electrical Code and all
other national and local codes and authorities having jurisdiction. Flame monitor ing
systems must be installed by a qualified, licensed technician.
Wire external interlock, control, and limit switches in series to this input. Guard
against induced voltage levels to wiring connected to this input. In some extreme
wiring runs, reduction of induced voltages may require a load (relay or light) connected
to terminal 7 to avoid system error lockouts. This input is the power source f or the
valve and ignition output terminals. Be sure all switches wired to this input can handle
the current required by the total of all loads connected to terminals 3, 4,and 5.
For purge and modulation models: Wire any switches and contacts in
series to this terminal for proving air flow function and r elating to the air failure
light. P ower must not be immediately pr esent at terminal 6 when power is first
applied to terminals 1 or 7.
18
If this terminal is not used, place a jumper betw een the combustion blower output (terminal 8) and the air switch input (terminal 6).
If the combustion air blower is contr olled outside of the Veri-Flame system, then
a three wa y solenoid valve must be connected between the air switch port and
the blower sensing port. The valve de-energized state should vent the switch
to ambient pressure. The energized state then connects the air switch to the
blower sensing port. Power the valve from the blower ouput terminal 8. If
accepted by local codes, the air s witch could be wired between the combustion
blower output and the air switch input. Connecting the air switch in this manner will satisfy the open contact (air short) check on the switch.
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 19
Ignition Wiring
Route ignition wiring a sufficient distance from all sensors and other low voltage wiring to avoid electrical interference, which may cause erratic operation
of the Veri-Flame system. K eep the high voltage wire run from the ignition transformer as short as possible. The best condition is to mount the ignition transformer close to the burner and keep a low impedance path from the burner
ground to the case of the transformer. Make sure the high voltage lead and
ground return paths do not create a loop antenna around the Veri-Flame and
sensor wiring.
Low Fire Input
Main Valve
Closed Switch
High Purge Input
For modulation models: it is possible to wire the system for checking low
fire start position prior to pilot ignition. To use this feature, the low fire star t
switch must be connected between terminal 3 and the pilot valve (see Figure
5.2). On dir ect spark burners, a by-pass contact must be wired ar ound the low
fire switch, see relay and contact CR in Figure 5.3.
The system can be wired to check for the main valve closed s witch on the main
gas valve prior to start-up and after the end of the burner cycle.
For purge and no purge models: the main valv e closed switch must be connected to Terminal V and the jumper in the base must be cut (see Figure
5.4 on page 22).
For modulation models: the main valve closed s witch must be wired in se-
ries between the air flow switch and the high purge damper switch (see Figure
5.1 on page 20). To use this feature , the jumper in the base must be
cut.
For modulation models: the system can be wired to check for high purge
position during the high fire purge portion of the sequence. To use this feature, the r ed jumper in the base m ust be cut and the high purge position
switch must be connected from terminal 6 to D. If this feature is not used, the
jumper in the base remains intact or a jumper must be installed between terminals 1 and D. Please note that the yellow jumper on the base has no effect
whether cut or intact.
Remote Reset
Remote Display &
P o wer Supply
This feature permits remote mounting of a switch to reset the Veri-Flame . To
use this feature, a normally closed remote reset s witch must be wired so power
is interrupted to terminal 1. When it is depressed or actuated, the connection
to terminal 1 is momentarily interrupted and resets the Veri-Flame.
Identify the model of remote display (see page 11) and wir e according to figur e
5.3. Mount through a ¼ DIN cutout using the two supplied brackets in either
the top and bottom or the side slots. Locate the displa y and wiring to minimize
electrical interference. Applying and disconnecting the display power supply
should coincide with power to terminal 1 of the Veri-Flame. Use the appropriate cable (Eclipse part #20318) to connect to the test jack and to the S2 terminal of the Veri-Flame wiring base. Do not attempt to parallel the test jack signal
to other devices when using a remote displa y. The LCD display contrast can be
adjusted on the back with a small blade screwdriver.
Eclipse V eri-Flame Instruction Manual 818-2/02
19
Page 20
Figure 5.1
No Purge and Purge Wiring Diagrams
15 A
Fuse
On/Off
No Purge Models
5602/5605:
120 VAC
50/60 HZ
Interlocks & Limits
Proof of
Closure
A
V
S1
S2
G
240 VAC
50/60 HZ
1
2
3
4
5
7
5603:
Piloted Burner
Pilot
Ignition
Main
Alarm
15 A
Fuse
On/Off
Purge Models
5602/5605:
120 VAC
50/60 HZ
Air Flow Switch
Interlocks
& Limits
Proof of Closure
A
V
S1
S2
G
240 VAC
50/60 HZ
1
2
3
4
5
6
7
8
5603:
Piloted Burner
Pilot
Ignition
Main
Fan
Alarm
15 A. Fuse
Air Flow
Interlocks
& Limits
Proof of
Closure
5602/5605:
120 VAC
50/60 HZ
On/Off
Cut Red
Jumper
To Activate
Terminal D.
High Purge
Damper
Switch
Figure 5.2
1
2
3
4
5
6
7
8
A
D
S2
S1
Common
10
Automatic
11
Low Fire
12
High Fire
13
G
Modulation Wiring Diagram
5603:
240 VAC
50/60 HZ
Flame
Sensor
Terminals
Low Fire Proving
Alarm
See the “High to
Low Fire Purge
Modulation
Capability” section
on page 16 for
contact connections.
Pilot
Ignition
Main
Fan
20
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 21
Figure 5.3
r
Typical Connections For All Models
Model 5602 DB
24 VDC Remote Display
24V G GTx Rx
Cable
#20318
NG
120/240VAC
S1
S2
Power
Supply
#20317
Blue (Signal)
Yellow (Neutral)
PLUG
Self Check U.V. 5602-91
(Requires 5602-91-7 cable)
2
1
S1
S2
A
B
C
D
Flame Signal
Test Jack
To S2
Veri-Flame
U.V
or
I.R.
Model 5602 DBP
120 VAC Remote Display
12V
12V
+
-
Tx
Cable
#20318
Solid State U.V. /I.R.
S1
S2
G
White
Black
Shield
Direct Spark
3
4
MAIN
IGNITION
5
Note: Intermittent pilot must
be selected, DIP-SW2 = ON
Rx
Scanner
Neutral
120V
120V
L
N
to 120 VAC
R1 R2
G
To 1
PLUG
Flame Signal
Test Jack
To S2
Veri-Flame
Flame RodU.V. /I.R.
S1
Blue
Flame Rod
S2
Direct Spark with
Low Fire Start
3
Low Fire Proving
CR
4
5
Note: Intermittent pilot must be selected, DIP-SW2 = ON
CR is a control relay used to bypass the low fire switch afte
the burner is lit.
CR
MAIN
IGNITION
Neutral
Notes for Figures 5.1, 5.2 & 5.3:
1. Ground, shielding and conduit must not be connected to terminal S2.
2. Control circuit wires must meet 90°C (194°F) specification minimum and must
be No. 16 AWG or larger and in accordance with all applicable codes.
3. Flame sensor wires must be individually run in their own separate conduit;
flame sensor wires C ANNOT be run together in a common conduit or wireway (See Section 6).
4. Flame signal should read between 4 and 10 VDC with a digital volt meter. Drop
off is approximately 4.0 VDC . Positive test jack point is on the cover marked
“Flame Signal” with negative point being the ground.
5. Purge time, TFI, intermittent/interrupted pilot, and rec yc le/non-recyc le selections
are made with a DIP switch located on the rear plate of the control unit.
6. Neutral must be grounded.
Eclipse V eri-Flame Instruction Manual 818-2/02
21
Page 22
Figure 5.4
Purge and No Purge Bases
Model Number 5602-10
P3
P2
5
6
S2
S1
7
8
P1
Gnd
n
3
4
V
2
1
A
NOTE: Ground Terminal
not present in plastic base.
Model Number 5602-40
3
2
1
1
3
2
1
Jumper
6
P3
4
P2
6
P1
4
Gnd
Model Number 5602-10-1
3
6
2
1
1
3
2
1
5
6S2S17 8A1 2V 4 3
P3
4
P2
6
P1
4
Jumper
Modulating Base
1
1
J2J1
Internal Diagram
Purge & No-purge
P1 P1
5
P1
P3
P3
P2
P2
6
3
1
Fan
Alarm
Fault
J1
Supervisor
Flame Signal
1
7
V
6
2
S2
S1
Note: No purge models do not use 6 & 8.
Internal Diagram
Modulation Model
P1 P1
5
1
6
Alarm
Fault
P1
3
7
22K
22K
D
P3
6
2
P2
2
2
Fan
P3
4
Red
Pilot
Ign
Main
Supervisor
P1
P3
P3
P3
1
2
4
6
5
3
Pilot
Ign
Main
Amplifier
8
A
3
4
5
P1
P3
P3
P3
1
8
2
A
4
6
3
4
5
3
5
Jack
22
Jumper
Gnd
1 2 3 4 5 6 7 8 A D 11 12 1310S2 S1
Eclipse V eri-Flame Instruction Manual 818-2/02
10
S2
S1
P2
1
J2
4
Flame Signal
Amplifier
Jack
J2
Auto
2
11
J2
Low
1
12
J2
High
3
13
Page 23
Figure 5.5
Sequence Diagrams
Outputs
Inputs
Outputs
Inputs
Terminal
1
3
4
5
7
V
Terminal
1
3
4
5
8
6
7
V
Function
Control Power
Pilot Valv e
Ignition
Main Valv e
Interlocks
POVC
Function
Control Power
Pilot Valv e
Ignition
Main Valv e
Fan
Air Switch
Interlocks
POVC
Recycle
Pilot Off
(Interr
Pilot Off
End
upted)
Permitted
Firing
Cycle
(Intermittent)
Recycle
Pilot Off
(Intermittent)
Post
Purge
15 Sec
End
Pilot Off
35 Seconds
Main
Trial
10 Sec
TFI
Pilot
Trial
(Interrupted)
Flame
Check
5 Sec
Permitted
Firing
Cycle
35 Seconds
Main
Trial
10 Sec
Start
Flame
TFI
Check
Pilot
Trial
Air Proven
Start
10
Sec
Purge
Outputs
Inputs
Continuity
Between
Modulation
Terminals
Terminal
1
3
4
5
8
6
7
D
3
10 to 12
10 to 13
10 to 11
Function
Control Power
Pilot Valv e
Ignition
Main Valv e
Fan
Air Switch
Interlocks
High Fire & POVC
Low Fire Switch
Low Fire Purge
High Fire Purge
Automatic
Start
Air Proven
10
Sec
High Fire
Purge
Low Fire
Purge
TFI
Pilot
Trial
Flame
Check
5 Sec
Eclipse V eri-Flame Instruction Manual 818-2/02
Pilot Off
(Interrupted)
Main
Trial
10 Sec
20 Seconds
35 Seconds
Firing Cycle
Recycle
Permitted
Pilot Off
(Intermittent)
Post
Purge
15 Sec
End
23
Page 24
Sensor Installation
6
INTRODUCTION
Sensor Wiring
This section describes the proper wiring, installation and sighting considerations for
all sensors that can be used with a Veri-Flame.
Warning
Incorrect sensor installation ma y cause the sensor to g enerate a
false flame signal, possibly resulting in the collection of unburned
fuel in the combustion chamber. This unburned fuel cr eates the
potential for explosions which can result in injuries, death and
property damage. Be certain that the flame sensor detects acceptable pilot and main flames only.
Route sensor wiring a sufficient distance from ignition and other high voltage
or high current wiring to avoid electrical interference. Interference from
ground currents, nearby conductors, radio-fr equency emitters (wireless divices),
and inverter drives can induce false flame signals. Shielded cables can help reduce interference with the shield connected to ground at the contr ol end only.
The wire type and its capacitance (picofarads or microfarads) to ground may
cause low signal problems, so a grounded shield may decr ease the signal due to
the cable’s internal capacitance. Multiple U.V. tube-type sensor leads run together without shielding may interfere or “cross talk”, so the shield or flexible
armor must be grounded to prevent this situation. For flame rod sensor runs
approximately 100 feet (30 meters) or greater, use Eclipse part number 21741
coax cable. To achieve the maximum wiring distance, the shield should not be
grounded (keep in mind that an ungrounded shield provides less protection
against electrical interference).
Flame Rods
24
Note:
n
Flame rods should be used only on gas burners. They accumulate soot on oil burners, causing nuisance shutdowns and unsafe operating conditions.
See the burner manufacturer’s literature for flame rod mounting location. When
installing flame rods, please consider the following:
Eclipse V eri-Flame Instruction Manual 818-2/02
Unshielded sensor wiring must not be run in common with other wires; it
must be run in separate conduit. Use #14 to #18 AWG wire suitable for
90°C (194°F) and 600 volt insulation. Multiple unshielded flame sensor
wiring must not be run together in a common conduit or wireway. Multiple
shielded flame sensor cables can be run in a common conduit.
Page 25
Figure 6.1 Flame Rod Position
WRONG
Rod Detects
Weak Pilot
PILOT
CORRECT
Rod Detects
Only Strong
Pilot Flame
1) Keep the flame rod as short as possible and at least 13 mm (1/2") away from
any refractory .
2) Position the rod into the side of both the pilot and main flames, preferably
at a descending angle to minimize drooping of the flame rod against burner
parts, as shown in Figure 6.1. Flame rod position must adequately detect
the pilot flame at all burner draft conditions. Extend the rod 13 mm (1/2")
into nonluminous flames, such as blue flames from burning an air/gas mixture. For partially luminous flames, such as atmospheric air/gas mixtures,
place the rod at the edge of the flame.
3) Provide a burner/flame grounding area that is at least four times greater than the
flame rod area contacting the flame. The flame r od/burner ground ratio and position of the rod in the flame may need adjustment to yield maximum flame signal
strength.
4) Ignition interference from the spark plug may increase or decrease the flame
signal strength. Reversing the ignition transformer primary leads may reduce
this effect. Changing the spark gap or adding gr ounding area between the flame
rod and spark plug may eliminate the interference.
Scanners
Scanner Sighting
Considerations
Figure 6.2 U.V. Scanner Sighting
MAIN
BURNER
Scanner
Sight
Line
SCANNER
1/3 of
Flame Length
Warning
Use only Eclipse scanner models as listed in the Illustrated Parts
List at the end of this document.
When installing scanners, please consider the following:
1) Position the scanner within 457 mm (18") of the flame. Consult factor y for
longer distances.
2) Bushing threads are 1/2 inch F.N.P.T. for all scanner models except 5602-91
which has 1 inch F.N.P.T. bushing threads.
3) The ambient temperature limits of each scanner varies; check the literatur e for
the specific scanner model. For higher temperatures, use Eclipse heat block
seal 23HBS for ½” N.P.T . scanners and if necessary, add cooling purge air.
4) An optional magnifying lens may also be used to increase the flame signal strength
in difficult sighting situations.
Aim scanners at the third of the flame closest to the burner nozzle, as shown in
Figure 6.2 (oil flames typically hav e less UV radiation in the outer flame). The scanner should view the intersection of the pilot and main flames. When sighting scanners, please consider the following:
1) Sight the scanner away from the ignition spark. Sighting the spark or its reflections from burner internals can cause nuisance shutdowns during burner ignition. If necessary, use a scanner orifice to reduce spark pickup.
2) Do not allow the scanner to detect a pilot flame that is too small to ignite the
main burner.
3) Perform a minimum pilot test when installing or adjusting any pilot or main
burner system; see “Minimum Pilot Test” on page 26.
4) I.R. scanner model 5600-92B is ideal f or oil flame applications. When used, aim
the I.R. scanner at the outer oil flame for flickering detection.
Eclipse V eri-Flame Instruction Manual 818-2/02
25
Page 26
Test Procedures
7
INTRODUCTION
Flame Signal Strength
Minimum Pilot Test
This section describes the test procedures that must be performed after installation to insure that the Veri-Flame is operating pr operly; these procedures are
mandatory.
Insert the positive probe of
point on the front cover of the Veri-Flame; connect the negative probe to
ground. A good flame signal strength will read between 6 and 11 VDC; an ything below 4 VDC is inadequate . Also, the red LED inside the test point
illuminates when a flame signal is indicated.
Run the following test procedures to ensure that the sensor will not detect a
pilot flame too small to reliably light the main flame:
1) Manually shut off the fuel supply to the burner, but not to the pilot.
2) Star t the system normally.
3) To enter the pilot test mode, depress the test/reset button located in the
lower right corner on the front cover.
4) The control will hold the operating sequence at the pilot flame step. Measure signal strength as described above.
5) Reduce pilot fuel until the flame relay drops out. Increase pilot fuel until the
flame signal is greater than 4 VDC , and flame relay just manages to pull in.
This is the minimum pilot. If you don’t think this flame will be able to safely
light the main burner, realign the sensor so that it requires a larger pilot
flame and repeat steps 2 through 5.
6) Push the test/reset button located in the low er right corner on the front cover
to exit the test mode (reset) and begin the normal start-up sequence again.
7) When the sequence reaches the main flame trial for ignition, smoothly restore the fuel supply to the burner. If the main burner does not light within
five seconds, immediately shut off the burner supply to shut down the system. Realign the sensor so that it requir es a larger pilot flame. Repeat steps
1 through 6 until the main burner lights off smoothly and reliably.
a 0-15 VDC , digital volt meter into the test
26
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 27
Pilot Flame Failure Test
1) Manually shut off the fuel supply to the pilot and the main burner.
2) Place system in pilot test mode (please refer 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
the problem and correct it before resuming normal operation.
Main Flame Failure Test
(For Interrupted Pilot Systems)
Spark Sighting Test
Limits & Interlock Tests
1) Manually shut off the fuel supply to the main burner but not to the pilot.
2) Star t the system normally. This should ignite the pilot and lock out* after
pilot interruption. If the system does not lock out, the controller is detecting a false flame signal (see Section 6). Find the problem and correct it before resuming normal operation.
1) Manually shut off the fuel supply to the pilot and the main burner.
2) Star t the system normally.
3) Measure the flame signal as described in “Flame Signal Strength” in this section.
4) If a flame signal greater than 4 VDC is measured for more than three seconds during the trial for ignition, then the sensor is picking up a signal from
the spark plug; see “Sensor Wiring” on page 24.
Periodically check all interlock and limit switches by manually tripping them
during burner operation to make sure they cause the system to shut down.
Warning
Never operate a system that is improperly adjusted or has faulty interlocks or limit switches. Always replace faulty equipment with ne w
equipment before resuming operation. Operating a system with defective safety equipment can cause e xplosions, injuries, and property
damage.
* Indicated by the illuminated red “Flame Failure” LED on the Veri-Flame front cover.
Eclipse V eri-Flame Instruction Manual 818-2/02
27
Page 28
Maintenance & Troubleshooting
8
INTRODUCTION
MAINTENANCE
Monthly Checklist
This section is divided into two parts:
• The first part describes the maintenance procedures.
• The second part describes tr oubleshooting procedur es, from identifying problems to interpreting the operating conditions by the lit LEDs on the front co ver .
Prev entativ e maintenance is the k e y to a r eliable, safe and efficient system. The
core of any preventive maintenance program is a list of periodic tasks.
In the paragraphs that follow are suggestions for a monthl y list and a yearl y list.
Note:
The monthly list and the yearly list are an aver age interval. If your envir onment is dirty,
then the intervals may be shorter.
Caution:
Turn off power before disconnecting or installing sensors , controls or modules.
1. Inspect flame-sensing devices for good condition and cleanliness. Keep scanner lenses clean with a soft, damp cloth, since small amounts of dust will measurably reduce the flame signal strength. Wash the flame rod electrode and
insulator with soap and water, then rinse and dry thoroughly.
2. Test all the alarm systems for proper signals.
Yearly Checklist
28
3. Check ignition spark electrodes and check proper gap.
4. Test interlock sequence of all safety equipment as described on page 27:
manually make each interlock fail, noting what related equipment closes or
stops as specified by the manufacturer.
Test flame safeguard by manually shutting off gas to the burner.
1. Test (leak test) safety shut-off valves for tightness of closure.
2. Test pressure switch settings by checking switch movements against pressure setting and comparing with actual impulse pressure.
3. Visually check ignition cable and connectors.
4. Make sure that the following components are not damaged or distorted:
• the burner nozzle
• the spark plugs
• the flame sensors
• the flame tube or combustion block of the burner
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 29
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
Cannot initiate start sequence
Main valve is not closed.
Air pressure switch has not made
contact.
High gas pressure switch has tripped.
Low gas pressure switch has tripped.
Malfunction of flame safeguard system
such as a shorted-out flame sensor or
electrical noise in the sensor line.
Purge cycle not completed.
Check main valve closed switch.
No voltage on V (or D).
Check air pressure switch adjustment.
Check air filter.
Check blower rotation.
Check outlet pressure from blower.
No voltage on 6 after 8 is on.
Check incomming gas pressure; adjust gas
pressure if necessary.
Check pressure switch setting and
operation.
No voltage to 7.
Check incomming gas pressure; adjust gas
pressure if necessary.
Check pressure switch setting and
operation.
No voltage to 7.
Have qualified electrician investigate and
rectify.
Check switch settings.
Check air switch.
Scrambled messages on remote display.
“UNSAFE AIR SHORT” message
appears on display.
Burner flame fails but no flame
failure indication occurs.
Voltage reading greater than
15VDC at “Test Point” on
eri-Flame faceplate.
V
Main power is off.
No power to control unit.
Electrical interference.
Improperly adjusted air switch.
Air switch either shorted or wired
wrong.
A faulty scanner.
Improperly connected sensor wires.
Electrical interference from other
current carrying wires.
Improper grounding.
Make sure power is on to control system.
Call qualified electrician to investigate.
Check grounding in system.
Separate communication cable.
Move ignition circuit.
Check air switch settings.
Check wiring to air switch.
Check scanner as explained in checklists in
“Maintenance” portion of this Section.
Check wiring diagram on page 20 or 21 as
well as appropriate sensor information in
Section 6.
Check Note information on page 24
regarding sensor wiring.
Check grounding of neutral at control
power transformer.
Eclipse V eri-Flame Instruction Manual 818-2/02
29
Page 30
LED STATUS
This section describes the status of operating conditions based on the LED or
combination of LEDs which are lit on the front cov er of each Veri-Flame model.
Table 8.1
LED Status & Conditions for Veri-Flame No Purge Models
LED(S) LIT POSSIBLE CAUSES
INTERLOCKS CLOSED
SYSTEM ERROR
FLAME FAILURE
1) The interlocks are closed (normal operation), power on terminal 7.
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 sensor wires, flame signal light is on.
4) Voltage wired into terminals 3, 4 or 5.
5) Internal relay contacts welded.
6) Internal controller failur e.
7) Main valve closed switch defective, no power to V.
1) Pilot flame is not established in selected TFI.
2) Main flame is not established in selected TFI.
3) Main flame fails within 35 seconds of TFI.
4) Flame failed during operation in non-recycle mode.
5) Flame failed 35 seconds after TFI and was not established after try in recycle mode.
30
No Purge Model
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 31
Table 8.2
LED Status & Conditions for V eri-Flame Purg e Models
LED(S) LIT POSSIBLE CAUSES
INTERLOCKS CLOSED
SYSTEM ERROR
FLAME FAILURE
AIR FAILURE
1) The interlocks are closed (normal operation), power on terminal 7.
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 sensor wires, flame signal light is on.
4) Voltage wired into terminals 3, 4 or 5.
5) Internal rela y contacts welded.
6) Internal controller failur e.
7) Air flow s witch closed bef ore start-up.
8) Main fuel valve switch opens after shutdown or befor e start-up , no power to V.
1) Pilot flame is not established in selected TFI.
2) Main flame is not established in selected TFI.
3) Main flame fails within 35 seconds of TFI.
4) Flame failed during operation in non-recycle mode.
5) Flame failed 35 seconds after TFI and was not established after one try in recycle mode.
1) Air flow switch not closed within ten seconds of start-up.
2) Air flow switch is open during timing cycle.
3) Air flow s w itch is open during firing cycle.
Purge Model
Eclipse V eri-Flame Instruction Manual 818-2/02
31
Page 32
T able 8.3
LED Status & Conditions for Veri-Flame Modulation Models
LED(S) LIT POSSIBLE CAUSES
INTERLOCKS CLOSED 1) The interlocks are closed (normal operation), power on terminal 7.
SYSTEM ERROR 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 sensor wires, flame signal light is on.
4) Voltage wired into terminals 3, 4 or 5.
5) Internal relay contacts welded.
6) Internal controller failur e.
7) Air flow s witch closed bef ore start-up.
8) High purge damper switch and/or main fuel valve s witch opens during start-up.
9) Low fire switch not made before TFI.
FLAME FAILURE
AIR FAILURE
INTERLOCKS CLOSED and
AUTO
INTERLOCKS CLOSED
and HIGH FIRE
INTERLOCKS CLOSED and
LOW FIRE
1) Pilot flame is not established in selected TFI.
2) Main flame is not established in selected TFI.
3) Main flame fails within 35 seconds of TFI.
4) Flame failed during operation in non-recycle mode.
5) Flame failed 35 seconds after TFI and was not established after try in recycle mode.
1) Air flow switch not closed within ten seconds of start-up.
2) Air flow switch is open during timing cycle.
3) Air flow s w itch is open during firing cycle.
1) Burner in run mode, firing rate determined by automatic contr oller (normal operation).
1) Purge high sequence (normal operation).
1) Purge low sequence (normal operation).
32
Modulation Model
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 33
Remote Displa y Messages
9
INTRODUCTION
This section covers how the optional remote display is used with the Veri-Flame .
The remote display provides LCD messages which monitor the status of the V eriFlame’ s functions as well as any lock out conditions. This section is divided into two
parts or tables:
• The first table describes the start-up and shutdown monitoring sequences of the
V eri-Flame and how the pr ogress (or halt) of the sequence can be monitored b y
the messages on the remote display.
• The second table alphabetically lists and explains the diagnostic messages which
can appear on the remote display.
Eclipse V eri-Flame Instruction Manual 818-2/02
33
Page 34
REMOTE DISPLAY
NORMAL MESSAGE
REVISION X.X
ERROR MESSAGE #1
UNSAFE FLAME ON
Table 9.1
V eri-Flame Operating Sequence
PO WER ON
Was internal saf e start check successful?
YES NO
EXTERNAL INTERLOCK CHECKS
Is flame signal present?
YES NO
Various lockout messages
Is main valve closed switch made?*
Fan is energized. If signal is eliminated within 30 seconds, sequence continues. If not, then . .
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFE FLAME ON
XX:XX:XX LOCK OUT
Alarm energized.
FOR PURGE & MODULATING
ERROR MESSAGE #1
UNSAFE AIR SHORT
If switch is opened within 30
seconds, sequence continues. If
not, then . . .
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFE AIR SHORT
XX:XX:XX LOCK OUT
Alarm energized.
NORMAL MESSAGE
SAFE START OK
Check_Sum = XX
NORMAL MESSAGE
FAN ENERGIZED
Fan output is energized; modulator is sent to low fire.
Is voltage present at air flow switch?
YES NO
Is voltage present at interlock switch?
YES NO
ERROR MESSAGE
LIMITS OPEN
TIME = XXXX:XX:XX
Holds until answer is yes.
YES NO
ERROR MESSAGE
MAIN VALVE FAIL
XX:XX:XX LOCK OUT
34
BURNER START-UP
(see next page)
* Applies to purge and no purge models only.
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 35
Table 9.1
V eri-Flame Operating Sequence (continued)
BURNER START-UP
Is voltage pr esent at air flow switch
within ten seconds?
NO PURGE MODELS
PURGE MODELS
NORMAL MESSAGE
AIR PROVEN
Purge based on selected time.
NORMAL MESSAGE
PILOT TRIAL FOR
IGNITION
Spark and pilot valve energized
for selected trial for ignition.
Is voltage present at air switch . . .
YES NO
ERROR MESSAGE
AIR NOT PR OVEN
XX:XX:XX LOCK OUT
MODULATION MODELS
NORMAL MESSAGE
AIR PROVEN
NORMAL MESSAGE
PURGE TO HIGH FIRE
Modulator sent to high fire for
selected purge time.
NORMAL MESSAGE
PURGE TO LOW FIRE
Modulator sent to low fire for
selected purge time.
Is voltage present at air switch . . .
YES NO
ERROR MESSAGE
AIR NOT PR OVEN
XX:XX:XX LOCK OUT
Is voltage present
at high purge switch?
YES NO
ERROR MESSAGE
HI DAMPER FAIL
XX:XX:XX LOCK OUT
Is low fire switch closed?
YES NO
ERROR MESSAGE
LOW FIRE FAIL
XX:XX:XX LOCK OUT
PILOT FLAME ON
NORMAL MESSAGE
Flame signal detected
NORMAL MESSAGE
PILOT FLAME XX.XV
TIME = XXXX:XX:XX
Spark turns off at end of TFI;
sequence delayed 5 seconds.
NORMAL MESSAGE
MAIN FLAME ON
Is pilot flame signal present?
YES NO
Is main flame signal present?
YES NO
Is flame signal present?
(see next page)
Eclipse V eri-Flame Instruction Manual 818-2/02
PILOT FLAME FAIL
ERROR MESSAGE
XX:XX:XX LOCK OUT
ERROR MESSAGE
MAIN FLAME FAIL
XX:XX:XX LOCK OUT
35
Page 36
Table 9.1
Veri-Flame Operating Sequence (continued)
BURNER START-UP (continued)
Is flame signal present?
YES
NO
MAIN FLAME FAIL
ERROR MESSAGE
XX:XX:XX LOCK OUT
MAIN FLAME ON
NORMAL MESSAGE
PILOT OFF
Pilot will shut off 10 seconds
after main flame is energized.
MODULATION MODELS
PURGE & NO PURGE MODELS
MAIN FLAME ON
NORMAL MESSAGE
IF Interrupted Pilot is selected IF Intermittent Pilot Is Selected
AUTOMATIC
MODULATION
Modulator sent to automatic 20
seconds after main valve is
energized.
NORMAL MESSAGE
MODULATION MODELS
NORMAL MESSAGE
BURNER ON XX.XV
TIME = XXXX:XX:XX
Main flame of burner is proven.
Flame signal = XX.XVolts DC;
elapsed time is shown in hours:
minutes:seconds.
Is flame signal present?
YES
NO
PURGE & NO PURGE MODELS
MAIN FLAME ON
NORMAL MESSAGE
Was the main flame on more
than 35 seconds?
YES
NO
ERROR MESSAGE
AIR FAILURE
RECYCLING
Unit returns to beginning
sequence.
36
Is air switch signal on?
YES
Is recycle selected?
YES
NO
NO
ERROR MESSAGE
AIR FAILURE
XX:XX:XX LOCKOUT
Is recycle selected?
Was the main flame on more
than 35 seconds?
YES
NO
ERROR MESSAGE
MAIN FLAME FAIL
RECYCLING
Unit returns to beginning
sequence.
Eclipse V eri-Flame Instruction Manual 818-2/02
YES
NO
ERROR MESSAGE
MAIN FLAME FAIL
XX:XX:XX LOCKOUT
Page 37
Table 9.1
Veri-Flame Operating Sequence (continued)
BURNER SHUTDOWN
Shutdown is started by opening
the operating interlock circuit.
Is voltage pr esent at interlocks?
Continued operation.
NORMAL MESSAGE
POST PURGE
XX
Fuel valves de-energized; fan
energized for 15 seconds.
FOR PURGE & MODULATING
ERROR MESSAGE #1
UNSAFE AIR SHORT
If switch is opened within 30
seconds, sequence continues. If
not, then . . .
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFE AIR SHORT
XX:XX:XX LOCK OUT
Alarm energized.
YES NO
Is post purge selected?
YES NO
Is main valve closed switch made?*
YES NO
Is voltage pr esent at air flow switch?
YES NO
ERROR MESSAGE #1
UNSAFE FLAME ON
Fan is energized. If signal is eliminated within 30 seconds, sequence continues. If not, then . .
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFE FLAME ON
XX:XX:XX LOCK OUT
Alarm energized.
MAIN V ALVE FAIL
ERROR MESSAGE
XX:XX:XX LOCK OUT
Fan energized; alarm sounds.
Is flame signal present?
YES NO
NORMAL MESSAGE
LIMITS OPEN
TIME = XXXX:XX:XX
* Applies to purge and no purge models only.
Eclipse V eri-Flame Instruction Manual 818-2/02
37
Page 38
Table 9.2
Remote Display Diagnostic Messages (Listed Alphabetically)
MESSAGE TYPE EXPLANATION
AIR FAILURE
XX:XX:XX LOCKOUT
AIR FAILURE
RECYCLING
AIR NOT PROVEN
XX:XX:XX LOCKOUT
AIR PROVEN
AUTOMATIC
MODULATION
BURNER ON XX.XV
TIME=XXXX:XX:XX
D-INTERNAL FAIL
XX:XX:XX:XX LOCKOUT
FAN ENERGIZED
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 air failure (see “Recycle Mode” on page 14).
Lockout For purge & modulation models: Combustion air flow limit
switch did not make within ten seconds of fan being energized.
Status For purge & modulation models: Combustion air flow limit
switch closed within ten seconds of fan being energized.
Status For modulation models only: Modulating motor is sent to au-
tomatic operation.
Status Main flame of burner is proven in the automatic modulation mode;
flame strength is XX.XV (volts DC). Elapsed time is shown in
hours:minutes:seconds.
Lockout For modulation models only: Internal control failure; replace
controller.
Status For purge & modulation models: Blower motor is energized
at the start of pre-purge.
FLAME FAILURE
XX:XX:XX LOCKOUT
HI DAMPER/POVC
XX:XX:XX LOCKOUT
K-INTERNAL FAIL
XX:XX:XX LOCKOUT
L-INTERNAL FAIL
XX:XX:XX LOCKOUT
LIMITS OPEN
TIME=XXXX:XX:XX
LOW FIRE FAIL
XX:XX:XX LOCKOUT
MAIN FLAME FAIL
XX:XX:XX LOCKOUT
MAIN FLAME FAIL
RECYCLING
Lockout Main flame lost during operation in the automatic modulation mode.
Burner number (X) given of failed unit.
Lockout For modulation models only: High damper or high purge rate
switch did not make at the end of pre-purge to high fire.
Lockout Internal control failure; replace controller.
Lockout Internal control failure; replace controller.
Status The controller has completed its internal checks and is standing by
for the interlocks to close.
Lockout For modulation models only: Low fire switch is open just prior
to pilot trial for ignition.
Lockout Main flame was not established during the main burner trial for
ignition.
Status Main flame lost during automatic modulation; control will recycle
once if “recycle” has been selected.
38
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 39
Table 9.2
Remote Display Diagnostic Messages (continued)
MESSAGE TYPE EXPLANATION
MAIN FLAME ON
MAIN FLAME ON
PILOT OFF
MAIN VALVE FAIL
XX:XX:XX LOCKOUT
NO PURGE SELECT
XX:XX:XX LOCKOUT
PILOT FLAME FAIL
XX:XX:XX LOCKOUT
PILOT ON
PILOT TRIAL FOR
IGNITION
POST PURGE
Lockout Main valve has been energized and main flame proven during trial
for ignition.
Status 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 models: No purge time was selected;
lockout prior to purge to high fire.
Lockout Pilot flame was not established during the pilot trial for ignition.
Status Pilot flame is proven; transformer is de-energized; remaining count-
down for pilot trial for ignition is.
Status Pilot valve and ignition transformer are energized; countdown for
pilot trial for ignition begins.
Status For purge & modulation models: 15 second post purge is
started on burner shutdown.
PROGM SWITCH ERR
XX:XX:XX LOCKOUT
PURGE TO HIGH
FIRE
PURGE TO LOW
FIRE
RELAY FAIL
XX:XX:XX LOCKOUT
SAFE START OK
UNSAFE AIR SHORT
UNSAFE AIR SHORT
XX:XX:XX LOCKOUT
Lockout DIP switch improperly set or changed during cycle.
Status For modulation models only: Modulating motor is sent to high
fire.
Status For modulation models only: Modulating motor is sent to low
fire.
Lockout Internal relay(s) fail initial check. Check ratings. If lockout still oc-
curs after overload is eliminated, replace control.
Status Control has completed internal safe-start check.
Status For purge & modulation models: Combustion air switch is closed
before start-up or after shutdown; control holds start-up until switch
reopens; if interlocks close before switch opens, alarm is energized.
Lockout For purge & modulation models: Same conditions as above,
except the interlocks close before the switch reopens, causing a
lockout and the alarm being energized.
Eclipse V eri-Flame Instruction Manual 818-2/02
39
Page 40
Ta ble 9.2
Remote Display Diagnostic Messages (continued)
MESSAGE TYPE EXPLANATION
UNSAFE FLAME ON
UNSAFE FLAME ON
XX:XX:XX LOCKOUT
UNSAFE–FLM–PURGE
UNSAFE–FLM–PURGE
XX:XX:XX LOCKOUT
V–INTERNAL FAULT
XX:XX:XX LOCKOUT
WATCHDOG FAIL
XX:XX:XX LOCKOUT
XXXXXXX
XXXXXTESTXX
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 cause has not been corrected
within 30 seconds, resulting in a lockout and the alarm being energized.
Hold For purge & modulation models: Flame signal—actual, induced,
or runaway scanner—is detected during the selected purge time
period. 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 For purge & modulation models: Same conditions as above,
except the cause has not been corrected within 30 seconds, resulting
in a lockout and the alarm being energized.
Lockout Internal control failure; replace controller.
Lockout Internal control failure; replace controller.
Status In combination with other messages, shows the control is in the
minimum pilot test mode.
40
Eclipse V eri-Flame Instruction Manual 818-2/02
Page 41
Appendix
CONVERSION
FACTORS
Metric to English.
FROM TO MULTIPLY BY
cubic meter (m3) cubic foot (ft3) 35.31
cubic meter/hour (m
degrees Celsius (°C) degrees Fahrenheit (°F) (°C x 1.8) + 32
kilogram (kg) pound (lb) 2.205
kilowatt (kW) Btu/hr 3414
meter (m) foot (ft) 3.28
millibar (mbar) inches water column ("wc) 0.401
millibar (mbar) pounds/sq in (psi) 14.5 x 10
millimeter (mm) inch (in) 3.94 x 10
Metric to Metric.
3
/h) cubic foot/hour (cfh) 35.31
FROM TO MULTIPLY BY
kiloPascals (kPa) millibar (mbar) 10
meter (m) millimeter (mm) 1000
millibar (mbar) kiloPascals (kPa) 0.1
-3
-2
millimeter (mm) meter (m) 0.001
English to Metric.
FROM TO MULTIPLY BY
Btu/hr kilowatt (kW) 0.293 x 10
cubic foot (ft3) cubic meter (m3) 2.832 x 10
cubic foot/hour (cfh) cubic meter/hour (m3/h) 2.832 x 10
degrees Fahrenheit (°F) degrees Celsius (°C) (°F – 32) ÷ 1.8
foot (ft) meter (m) 0.3048
inches (in) millimeter (mm) 25.4
inches water column ("wc) millibar (mbar) 2.49
pound (lb) kilogram (kg) 0.454
pounds/sq in (psi) millibar (mbar) 68.95
Eclipse V eri-Flame Instruction Manual 818-2/02
-3
-2
-2
41
Page 42
ILLUSTRATED PARTS
LIST
1
2
3
4
5
Pos.
No.
Categor
Sensors
(1)
(2)
(3)
(4)
y
Straight U.V. scanner 5600-91 49600-91
1
NEMA 4 U.V. scanner 5600-91N4 20898
2
90˚ U.V. scanner 5600-90A 49600-90
I.R. scanner 5600-92B 49600-92
3
Self-check scanner 5602-91 49602-91
4
Solid-state U.V./I.R. scanner 5600-92SC 21349
5
10-foot cable for self-check scanner 5602-91-7 49602-91-7
Scanner support (max. temp. 220˚F)
6
6
Scanner support (max. temp. 475˚F)
Magnifying lens assembly 5600-98 49600-98
7
Lens, magnifying 49600-99
Lens, non-magnifying
8
Insulated coupling 5600-99 49099
Cable, coax, RG62A/U for flame rod 21741
Internal terminal base, metal 5602-10 49602-10
9
Exposed terminal base, metal 5602-10-1 49602-10-1
10
Internal terminal base, plastic 22194
Adapter Base RA890 5602-12 49602-12
Bases
Test
Display
For 90º U.V. scanner (Model No. 5600-90A), I.R. scanner (5600-92B), and solid state U.V./I.R. scanner (5600-92SC)
For magnifying lens assembly (Model No. 5600-98), and self-check scanner (5602-91)
Used to test modulation controls on tester (Model No. 5602) above.
To be used with 20316 display only (not 20896).
Adapter Base R4795 5602-14 49602-14
11
Modulation base 5602-40 49602-40
Screw, mounting to plastic base 22110
Screw, mounting to metal base 22385
Tester for Veri-Flame units 5602 49602
Relay module
Remote display, 24V 5602 DB 20316
12
Remote display, 120VAC with keypad 5602 DBP 20896
Power supply, 24VDC 20317
Cable for remote display 20318
Description
(1)
(1)
(2)
(3)
(4)
Model
Number
5600-90A SS 20722
5600-90A SSH 20723
5602-10-P
5602-40-4 49240-2
Part
Number
18165
Instruction Manual 818 2/02
6
9
7
11
8
12
10
Litho in USA
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