Eclipse Combustion 6500 User Manual
Instruction Manual
No. 826, 05/03
Bi-Flame
Dual Burner Monitoring System
Model 6500
Version 1.8
COPYRIGHT
Copyright 2003 by Eclipse Combustion. All rights reserved
worldwide. This publication is protected by federal regulation and
shall not be copied, distributed, transmitted, transcribed or
translated into any human or computer language, in any form or
by any means, to any third parties, without the express written
consent of Eclipse Combustion.
DISCLAIMER NOTICE
LIABILITY AND
WARRANTY
In accordance with the manufacturer’s policy of continual product
improvement, 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 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 your corrections 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, for a period of one year fr om shipment, warrants
each Bi-Flame burner monitoring system to the original purchaser to
be free from 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.
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Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
About this manual
AUDIENCE
IMPORTANT NOTICES
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 have previous experience with this kind of equipment.
• Read this manual carefully. Make sure that you understand the
structure and contents of this manual.
• Obey all the safety instructions.
• Do not deviate from any instructions or application limits in this
manual without written consent from Eclipse Combustion.
• If you do not understand any part of the information in this
manual, do not continue. Contact your Eclipse sales office or
Eclipse Combustion.
There are several special symbols in this document. You must know
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 injur y 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 injury.
Act carefully.
Note:
Indicates an important part of the text.
Read the text thoroughly.
Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
3
Table of Contents
2
3
1
About this manual....................................................................
Table of contents.......................................................................
Introduction...................................................................................
Product Description..........................................................................
Specifications ..............................................................................
Introduction...........................................................................................
Specifications .........................................................................................
Dimensions ............................................................................................
Modules Description ..............................................................
Introduction...........................................................................................
Module Description and Identification ...........................................
Relay Module.........................................................................................
Logic Module.........................................................................................
Power Module.......................................................................................
Sensor Module......................................................................................
Remote Display ....................................................................................
3
4
7
7
8
8
8
9
10
10
10
10
10
10
11
11
4
4
DIP Switch Selection .............................................................
Introduction...........................................................................................
DIP Switch Location............................................................................
DIP Switch Access................................................................................
S2 DIP Switch Settings........................................................................
S4 DIP Switch Settings........................................................................
S6 DIP Switch Settings........................................................................
Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
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12
12
12
13
13
13
5
6
Function Summary..................................................................
Introduction...........................................................................................
Standard Features.................................................................................
Combustion Air Flow Check Terminal............................................
Main Fuel Valve Proof-of-Closure Terminal....................................
Low Fire Start T erminal ......................................................................
High Fire/High Fire Purge Check Terminal.....................................
Recycle Mode........................................................................................
Pilot Test Mode .....................................................................................
Interrupted or Intermittent Pilot.....................................................
Spark, Pilot Flame & Main Flame Separation .................................
Auxiliary Inputs.....................................................................................
History Log............................................................................................
Modulation Contacts...........................................................................
Valve Leak Sensing Device .................................................................
Remote Display Unit...........................................................................
RS232/RS485 Communication Interfaces ......................................
Logic Module Status Lights & Push-buttons ..................................
Limits.......................................................................................................
Air ............................................................................................................
Purge .......................................................................................................
Burner On..............................................................................................
Fault .........................................................................................................
Alarm.......................................................................................................
Low Fire..................................................................................................
High Fire.................................................................................................
Scan..........................................................................................................
Enter........................................................................................................
Reset........................................................................................................
System Faults.........................................................................................
System Lockout Conditions ..............................................................
14
14
14
14
14
14
14
15
15
15
15
16
16
17
18
19
19
19
19
20
20
20
20
20
20
20
20
20
20
21
21
System Installation..................................................................
Introduction...........................................................................................
Interlocks and Limit Switch Input ....................................................
Combustion Air Switch Input............................................................
Ignition Wiring.......................................................................................
Communication Wiring ......................................................................
Power Supply.........................................................................................
Low Fire Input.......................................................................................
Main Valv e Proof-of-Closure..............................................................
High Fire Input ......................................................................................
Auxiliary Inputs.....................................................................................
Remote Reset .......................................................................................
Remote Display ....................................................................................
Terminal Strips Identification & Location (Figure 6.1) ................
Wiring Diagram & Connections–Main Chassis (Figure 6.2) ........
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22
22
22
23
23
23
23
23
23
23
23
24
25
26
5
7
Sensor Installation ...................................................................
Introduction...........................................................................................
Sensor Wiring........................................................................................
Flame Rods ............................................................................................
Scanners..................................................................................................
Scanner Sighting Considerations......................................................
27
27
27
28
28
29
8
9
10
Test Procedures ...............................................................................
Introduction...........................................................................................
Flame Signal Strength ..........................................................................
Minimum Pilot Test...............................................................................
Pilot Flame Failure Test .......................................................................
Main Flame Failure Test.......................................................................
Spark Sighting Test................................................................................
Limits & Interlock Tests ......................................................................
Maintenance & Troubleshooting ..............................................
Introduction...........................................................................................
Maintenance...........................................................................................
Monthly Checklist ................................................................................
Yearly Checklist ....................................................................................
Troubleshooting....................................................................................
Remote Display Messages...........................................................
Introduction...........................................................................................
Bi-Flame Operating Sequence (Table 10.1) ...................................
Remote Display Diagnostic Messages (Table 10.2)......................
30
30
30
30
31
31
31
31
32
32
32
32
33
34
35
35
36
40
Appendix .............................................................................................
Conversion Factors .............................................................................
Illustrated Parts List.............................................................................
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Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
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43
44
Introduction
1
PRODUCT
DESCRIPTION
The Eclipse Combustion Bi-Flame Burner Monitoring System
controls the start-up sequence and monitors the flame of two
individual gas, oil, or combination gas/oil burners connected to a
common valve train. Its dynamic on-board testing checks for
faulty relays, proof of valve closure, high and low fire switch
interlocks, and shorted air switch.
The microcomputer based system features a plug-in modular
design so any of the circuit board modules attached to the
motherboard can be replaced when power is removed. Its DIP
switches allow sequence and timing functions, as well as system
configuration. It is also capable of modulation (high and low fire
purging) and monitoring up to four auxiliary inputs, history
logging, and interfacing to valve leakage detection devices. It is UL
recognized, FM approved and CSA certified.
Figure 1.1
Bi-Flame Burner Monitoring System
Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
7
Specifications
2
INTRODUCTION
Specifications
Parameter Description
Supply •120 VAC (+10%, -15%), 50/60 Hz standard.
Internal power consumption: 24VA
Temperature Ranges Unit Model Nos. Temperature Range
Bi-Flame 6500 -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 -40˚ to +125˚C (-40˚ to +257˚F)
NEMA4 UV Scanner 5600-91N4 -20˚ to +125˚C (0˚ to 257˚F)
Self-Check U.V. 5602-91 -40˚ to +60˚C (-40˚ to +140˚F)
Remote Display 6000D 0˚ to 50˚C (32˚ to 122˚F)
Flame Failure Response • 3 seconds ±0.5 seconds.
TFI/Pilot Interrupt • 5, 10 or 15 seconds selectable.
Purge Time • Modulating: selectable from 0-225 seconds in 15 second increments,
or 0-15 minutes in 1 minute increments
• Process: selectable from 0-15 minutes in 1 minute increments,
or 0-60 minutes in 4 minute increments.
This section gives a detailed overview of Bi-Flame specifications and
dimensions.
Contact Ratings @ 120 VAC Function Affected Terminals Inductive Load Resistive Load
(maximum total connected Output Relay J2-4 through J2-8 1/3 HP 10 amps
load not to exceed 15 amps) Output Relay J2-3 1/2 HP 15 amps
Modulation J3-1 through J3-4 1/3 HP 10 amps
Approvals • UL Recognized; File MP1537 (category MCCZ2)
• FM Approved; J.I. 2Y3A5.AF (class 7610)
• CSA Certified; File 007989-0-000 (class 2632-01, 2642-01)
Shipping Weight • 2.7 kilograms (6 lbs.)
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Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
DIMENSIONS
Main Chassis
Mounting
Holes (4)
5 mm
(3/16") Dia.
183 mm
(7-3/16")
140 mm
(5-1/2")
237 mm
(9-5/16")
Remote Display
102 mm
(4") Square
229 mm
(9")
270 mm
(10-5/8")
(Shown with remote keypad and reset)
54 mm
(2-1/8")
Mounting
Bracket &
Screw (2)
Mounting
Bracket
Slot (4)
21 mm
(13/16")
15-pin
Port
Terminal
89 mm
(3-1/2") Square
Contrast
Adjustment
Slot
Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
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Modules Descr iption
3
INTRODUCTION
MODULE DESCRIPTION
AND
IDENTIFICATION
Relay Module Location
In this section, you will find descriptions of the various modules
which comprise the Bi-Flame dual burner flame monitoring system,
whether standard or optional items.
Relay Module
The relay module contains the output relays which provide power
for operating the ignition coil, pilot valve, main valve, combustion
fan and alarm. This module is mounted in the first position on the
left of the motherboard closest to the output terminals.
Logic Module
The logic module houses the microcomputer which provides all
the sequential logic and safety start-up and shutdown circuitry. On
the front of this module is the reset, scan and enter push-buttons,
and status lights. This module is mounted in the second position
from the left of the motherboard next to the relay module.
Power Module
10
The power module supplies the power required for the electronic
circuitry. It is mounted in the motherboard to the right of the logic
module. The green LED on the front indicates that power is on to
the Bi-Flame.
Logic Module Location
Power Module Location
Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
Sensor Module Location
Sensor Module
The sensor module is the flame sensing module of the Bi-Flame. It is
mounted in the furthest right position of the mother board.
On the front of the sensor module are two “Flame On” LED’s, which
illuminate when a flame is detected at the corresponding burner.
Directly below the “Flame ON” LED are “Flame Fail” LED’s, which
energize to show the first burner to lose its signal.
The sensor module incorporates test point connection jacks in the
front of the unit. Using these, the flame signal strength of each burner
can be measured using a 0-15 VDC, one meg ohm/v olt meter as
explained and shown in “Flame Signal Strength” on page 30.
Remote Display
The remote display provides alphanumeric messages which indicate
burner status as well as annunciate lockout condition in the Bi-Flame
system. It also provides remote reset, a keypad and history logging
capability.
A cable connects the remote display to the motherboard; this cable is
available in six and 10 feet lengths.
Remote Display
Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
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DIP Switch Selection
INTRODUCTION This section details the location, selection and description of the
Bi-Flame DIP switches, which allow for sequence and timing functions as well as system configuration.
Caution:
To avoid electric shock, shut off the power supply when installing
any control device. Flame monitoring systems must be installed
by a qualified, licensed technician.
4
DIP SWITCH LOCA TION
DIP SWITCH ACCESS
All of the DIP switches are located in the logic module, which is
mounted in the second position from the left of the motherboard
next to the relay module (see page 10 for logic module location).
To gain access to the DIP switches, remove the circuit board
cover. To do this, remove the four screws which hold the cover to
the motherboard. Remove the cover by lifting up and off of the circuit boards. The logic module is the second board from the left.
Gently pull the logic module with a rocking motion to disengage
the terminal pins at the module base. The photo below sh ows
the DIP switch locations.
ON/OFF
S6
S4
12
S2
Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
DIP SWITCH SETTINGS
S2 DIP Switches
ON/OFF
8
50/60Hz
7
—
6
—
5
S6
S4
S2
8
7
6
S2
5
4
S2 Modulation Purge Time, S4 - 8 = ON
8
7
6
S2
5
4
S2 Process Purge Time, S4 - 8 = OFF
Number
4
3
2
1
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
of
PAF
MOD/PROC
TFI
—
LEAK 110/40
—
—
—
BLOWER
P
U
R
G
E
PILOT IMIT/IRPT
RECYCLE
DIP Switch Functions
ON
OFF
—
X4
120 sec.
Time
60 sec.
Not
30 sec.
Added
15 sec.
ON
OFF
—
X4
8 min.
Time
4 min.
Not
2 min.
Added
1 min.
X4
120/8
60/4
30/2
15/1
TFI
The S2 DIP switches permit programming of timing and sequence
functions of the Bi-Flame.
Note:
The S2 DIP switch settings at left are for illustrative purposes
only; the actual settings of any of these switches will be
determined by your system conditions.
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: T rial-for -ignition (TFI) range selection; used with SW7 of the S4
DIP switch. See the table at left for proper selection.
SW4 through 8: Purge time selection; switch in off position selects
indicated purge time. Selected purge times are additive. See
illustration at left for exact times.
S4 DIP Switches
SW1: Fan operation on flame failure (on = fan turns off; off = fan stays
on).
SW5: Leak test time (on=110 seconds; off=40 seconds).
SW7: T rial-for -ignition (TFI) range selection; used with SW3 of the S2
DIP switches. See the table at left for proper selection.
SW8: Purge mode; (on = modulation, off = process).
S6 DIP Switches
The S6 DIP switches are factory set for two burners. DO NOT
CHANGE. Any other setting will result in an “UNMATCH#” fault
condition.
SW6: Off, Not used.
SW7: Off, Not used.
SW8: Frequency Selection; (On = 50Hz, Off = 60 Hz)
THEN
SW3 of S2
If the
TFI
needed is:
5 seconds
10 seconds
15 seconds
DIP switch
must be
turned:
Off
Off
On
Trial-for-Ignition (TFI) Settings
AND
SW7 of S4
DIP Switch
must be
turned:
Off
On
Off or On
Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
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Function Summar y
5
INTRODUCTION This section describes the function features of the Bi-Flame that can
be found on the various terminal strips and the modules of the BiFlame.
Combustion Air Flo w Check Terminal
The Bi-Flame checks that the combustion air flow switch 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 jumpered.
Main Fuel Valve Proof-of-Closur e T erminal
The Bi-Flame checks that the main fuel valve is closed before startup and after burner shutdown. This ar rangement requir es a closed
position switch on the main fuel valve.
Low Fire Start Terminal
The system checks for the low fire start position prior to light-off. If
voltage is not present on this terminal within 15 minutes, the Bi-Flame
goes to lockout and alarm.
High Fire Purge Check Terminal
The system checks that the air modulation motor reached the high
fire position during high fire purge. The modulation motor or air
valve must be fitted with a high fire position switch, which is then
connected to the high fire check terminal. An air flow or pressure
switch that is set to prove sufficient purge air may be used instead
of the high fire position switch. If v oltage is not pr esent on this terminal within 15 minutes, the Bi-Flame goes to lockout and alarm.
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Eclipse Bi-Flame v1.8, Instruction Manual 826, 05/03
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