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FireStar
User Manual
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Maxim FireStar User Manual

FIRESTAR VER. 1.0 – 3-May-2011
UNDERSTANDING THE FIRESTAR CONTROL PANEL
Before operating the FIRESTAR Control Panel, become familiar with the information the control panel provides and the procedures for making changes to settings. The control panel has been programmed with factory default settings. If ne-tuning is desired, refer to the appropriate section of these operating instructions for more information.
1. During normal operation, the LED display indicates the actual temperature of the system water. Other information will also be displayed on the LED display depending on settings, modes, etc. The Water Temp button may be used to display the water temperature setting or, used in conjunction with the and buttons, to change the water temperature setting.
100%
Feed Rate
60%
65% 20%
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4
2
3
5
6
FireStar Control Panel
Operating Instructions and Controller Variables
Software Version 1.0
1-2 FIRESTAR VER. 1.0 – 3-May-2011
2. The Fan Set button may be used in conjunction with the three mode (HI / NORMAL / IDLE) and buttons to change the fan speed for each mode.
3. The Ignition button starts the Gas Ignitor and may be used to enable/disable the Auto Relight mode.
4. The feed rate settings in each of the three modes (HI / NORMAL / IDLE) may be changed here. During operation, the light bar will indicate the feed rate setting for the mode the controller is currently in. May also be used in conjunction with the Fan Set button to change the fan speed for each mode.
5. The Auger Jog button may be used to manually control the burner and transfer augers and/or to enable Clean Out mode. The Auger light is on any time the augers are running.
6. The Power button is used to turn the FIRESTAR control on and off. It does not disable all electrical power to the furnace.
INITIAL START-UP
NOTE: Before starting the furnace, make sure that (1) there is adequate clean, dry fuel in the hopper or supply bin; (2) the proper amount of Corrosion Inhibitor has been added and the water level is full; (3) the main electrical power supply to the furnace is on and (4) the gas supply for the Gas Ignitor and the Honeywell gas valve are both turned on.
1. Press the Power button. Upon startup, the lights on the control panel and the LED display will cycle through a lamp test and then go off. The LED display will indicate the actual system water temperature.
2. Fuel must be present in the burn chamber for the system to burn properly. To deliver fuel to the burn chamber, start the transfer and burner augers by pressing and holding the Auger Jog button. Continue to hold the Auger Jog button until fuel enters the burn chamber.
3. To start the Gas Ignitor, press and hold the Ignition button until the LED display indicates and the burner fan starts. During ignition, the ignition light will stay on.
FIRESTAR VER. 1.0 – 3-May-2011
4. Press the Ignition button twice within one second to enable the Auto Relight function. The Auto Relight Enabled light will turn on.
NOTE: If during ignition the LED display indicates and the ignition light is off, check the gas supply.
HOW THE GAS IGNITOR STARTS
The ignition process is a series of steps that automatically occur to ensure the Gas Ignitor starts properly before the system begins to operate. During ignition, the following will take place:
1. The burner fan will start to provide air for combustion.
2. Once the pressure switch senses air ow, it will energize the gas ignition module.
3. Both the transfer and burner augers run, delivering fuel to the burn chamber.
4. The gas ignition module ignites the gas burner to start burning the fuel in the burn chamber.
5. The gas burner will continue to burn until the burn chamber reaches a high enough temperature to sustain burning the fuel, at which time the controller will turn off the gas burner.
HOW THE BURNER OPERATES
To best utilize the fuel and obtain the most efciency, the controller automatically changes from NORMAL to HI mode when the water temperature drops and then back to NORMAL once the water temperature rises. When the water temperature reaches the water temperature setting, the controller will change to IDLE mode. The controller will again change to NORMAL mode when the water temperature drops. This cycle repeats as necessary to maintain the system water temperature.
1-4 FIRESTAR VER. 1.0 – 3-May-2011
CHANGING FIRESTAR CONTROL PANEL SETTINGS
NOTE: Until you become familiar with the operation of your FIRESTAR control panel, consult your Central Boiler dealer before making changes to the factory default settings.
Water Temperature
Normally the system water temperature will be displayed. To display the water temperature setting, press the Water Temp
button. The default setting is 175˚F-185˚F. To raise the water
temperature setting, press and hold the Water Temp button; then press the button. To lower the water temperature setting, press and hold the Water Temp button; then press the button. The water temperature setting can be set between 150˚F and 195˚F.
HI, NORMAL and IDLE modes
Changes in system heat load, fuel quality and a number of other conditions may make it desirable to change the feed rate to the burner in one or more of the three operating modes (HI / NORMAL / IDLE).
To view the current feed rate setting:
During operation, the light bar will indicate the feed rate setting for the mode the controller is currently in.
To view all feed rate settings:
1. Press any of the or buttons for the HI, NORMAL or IDLE modes. The light bars will display the current feed rate settings.
To change the feed rate settings:
1. In each mode (HI / NORMAL / IDLE), you can press the button to decrease the feed rate setting or press the button to increase the feed rate setting. The new feed rate setting will be displayed on the light bar.
Fan Set
If the feed rate is changed for any mode (HI / NORMAL / IDLE), it may be necessary to change the burner fan speed for that mode to optimize burner operation. In IDLE mode, the fan only runs when the Auger light is on.
FIRESTAR VER. 1.0 – 3-May-2011
To view the current fan speed settings:
1. Press and hold the Fan Set button. The light bars will display the current fan speed settings.
To change the fan speed settings:
1. Press and hold the Fan Set button; then press the or button for the respective mode to decrease or increase the fan speed setting. Decreasing the setting (fewer lights on the light bar) lowers the fan speed. Increasing the setting (more lights on the light bar) increases the fan speed.
Auto Relight
When the auto relight function is enabled, the controller continuously monitors the burner temperature. If at any time the burner temperature is less than the burner temperature setting (which is set at the factory) and the controller is in NORMAL or HI mode, the controller will automatically change to Ignition mode in an attempt to relight and raise the burner temperature.
NOTE: A drop in burner temperature may be caused by wet or contaminated fuel or by an extended IDLE mode time, for example.
If after three Ignition mode cycles, the burner temperature does not rise above the burner temperature setting, all outputs will be disabled, the Auto Relight Enabled light will ash, and the LED display will indicate to notify that the burner re has gone out.
NOTE: Before resetting the controller after the auto relight function has failed, be sure to nd the cause of the burner not being operational (e.g., wet or contaminated fuel, mechanical problem, etc.).
WARNING
Do not attempt any service on the burner without rst disconnecting the main power supply to the furnace. Make
sure there is no hot ash in the burn chamber or furnace.
The controller will maintain the system in a disabled condition and the Auto Relight Enabled light will continue to ash until one of the following occurs:
1. Press and hold the Ignition button for 15 seconds.
2. Press the Power button to turn off the controller; then press again to turn on the controller.
1-6 FIRESTAR VER. 1.0 – 3-May-2011
3. The main power to the furnace is turned off and then on again.
To enable the Auto Relight function:
1. Press the Ignition button twice within one second. When enabled, the Auto Relight Enabled light will turn on.
Clean Out mode
Situations may arise when it becomes necessary to empty all of the fuel from the burner auger (e.g., for service, at the end of season, etc.). In the Clean Out mode, the transfer auger is disabled. The burner will operate normally until the burner auger is empty and the re goes out.
To start Clean Out mode:
1. Press the Auger Jog button three times within two seconds. The Clean Out mode light will turn on and the transfer auger will be disabled. To speed the process, press and hold the Auger Jog button.
To cancel Clean Out mode:
1. Press the Auger Jog button three times within two seconds. The Clean Out mode light will turn off and the burner and transfer augers will run as normal.
To reset auger and fan settings to factory default settings:
1. Press the Power button to turn off the controller; then, while pressing and holding the IDLE mode and buttons, press the Power button to turn on the controller.
To reset all controller settings to factory default settings and perform Self-Test:
1. Press the Power button to turn off the controller; then, while pressing and holding the Water Temp and buttons, press the Power button to turn on the controller. All settings will be reset to the factory default settings and the controller will perform a Self-Test.
2. During the Self-Test, the following will occur:
a. The LED display will rst indicate the burner temperature,
then the water temperature and nally the center section of the display digits will ash.
FIRESTAR VER. 1.0 – 3-May-2011
b. The system will operate in HI mode for 10 seconds.
c. The ignition process will begin (see How the Gas Ignitor
Starts). The system will operate in NORMAL mode for 1 minute.
d. After a delay of 10 seconds, all outputs will be disabled
and the controller will shut off.
DISPLAY READOUT DEFINITIONS
Low Water Alarm
High Water Temperature
Back Burn Alarm
Fire Out Alarm
Control Panel Locked
Control Panel Unlocked
Gas Mode
Alarms
If any of the following alarms occur, system operations will be halted until the cause of the alarm is corrected:
Low Water: the LED display will ash until the water level is above the sensor. Refer to the furnace owner's manual for procedure to correct low water situation.
High Water Temperature: the LED display will ash until the water temperature drops below 195˚F.
Back Burn: the LED display will ash if the controller detects a high temperature in the burner auger area, even if the control panel is turned off. Everything but the burner auger will be disabled. The burner auger will run for two minutes, pause for 10 minutes, and continue as required. The Back Burn alarm will not stop until the controller detects that the temperature has dropped.
1-8 FIRESTAR VER. 1.0 – 3-May-2011
Fire Out: the LED display will ash until the cause of the Fire Out alarm is corrected and the controller is reset. To clear the Fire Out alarm, turn the controller off and on again or press and hold the Ignition button. This will enable Auto Relight to attempt lighting the burner again.
Controller Lock
The controller can be locked at any time to prevent unauthorized operation. After locking the controller while turned off, it will not be possible to start the controller or change any settings until it is unlocked. The controller may also be locked while it is operating. After locking the controller while turned on, it will not be possible to turn the controller off or change settings.
To lock the controller:
Rapidly press the Water Temp button four times. The LED display will indicate for ve seconds.
To unlock the controller:
Rapidly press the Water Temp button four times. The LED display will indicate for several seconds.
Power Off
To turn the controller on or off, press and hold the Power button for at least one second. After turning off the controller, release the Power button for at least one second before turning power back on.
Power Outage
In the event of a power outage, the controller is programmed to return to its previous state. If the system was powered on, it will automatically restart. If enabled prior to the power outage, Auto Relight will be enabled once power returns.
Troubleshooting/System Restarting
If there appears to be a system error, attempt to restart the system. If a standard restart fails to correct an apparent error, shut off the main power at the source for one minute and then try again.
FIRESTAR VER. 1.0 – 3-May-2011
FOR DEALER USE ONLY
CHANGING FIRESTAR CONTROLLER VARIABLES
Software Version 1
The FIRESTAR control relies on several variables for operation. The control panel has been programmed with factory default settings. If ne-tuning is desired, the variables can be changed.
To enter Setup mode:
Press and hold the Water Temp button for 20 seconds until the LED display changes from the water temperature to a "1."
Changing Control Variables:
While in Setup mode, select the control variable you want to change (see Selecting Control Variables). To make changes, press the Water Temp button. The current value is displayed. Press the or buttons to modify the setting. Press the Water Temp button to accept the value and return to the selection menu.
Selecting Control Variables:
There are 10 variables that may be changed within the Setup mode. To select a variable while in Setup mode, press the Water Temp or buttons until the number representing the variable appears in the display. The following list indicates each variable's number, name, the default factory settings, and a brief description of the function.
1. Water Temperature Setpoint: 175-185 (˚F)
When the water temperature is above this setting, the control
will change to IDLE mode.
2. IDLE to NORMAL Differential: 2 (˚F)
When the water temperature is less than the Water
1-10 FIRESTAR VER. 1.0 – 3-May-2011
3. NORMAL to HI Differential: 2 (˚F)
When the water temperature is less than the Water Temperature Setpoint minus the IDLE to NORMAL Differential minus the NORMAL to HI Differential, the controller will change from NORMAL mode to HI mode. For example, with the default factory settings, the controller will change from NORMAL mode to HI mode when the water temperature is less than 185˚F – 2˚F – 2˚F (or 181˚F).
4. Restart Time: 1 (minute)
Time that must pass before the controller will change from NORMAL mode to HI mode, even if the water temperature is low enough and the burner temperature is high enough.
5. Burner Temperature Setpoint: 300 (˚F)
When operating in NORMAL or HI mode, the controller constantly checks the burner temperature. If the burner temperature is below the Burner Temperature Setpoint, the controller will immediately change from HIGH mode to NORMAL mode. If Auto Relight is enabled, Gas Ignition is started.
6. Gas Differential: 100 (˚F)
7. Gas Burn Time: 10 (minutes)
8. Fire Out Time: 5 (minutes)
FIRESTAR VER. 1.0 – 3-May-2011
9. Water Temp Offset: 0 (˚F)
Providing a means of manually calibrating the water temperature, the Water Temp Offset is the number of degrees that will be added or subtracted from all temperature readings.
10. Burner Differential: 50 (˚F)
The Burner Differential can only be set as high as the Gas Differential setting.
To exit Setup mode:
Wait 15 seconds (while not pressing any buttons) and the controller will automatically exit Setup mode.
FIRESTAR VER. 1.2 – 3-May-2011
UNDERSTANDING THE FIRESTAR CONTROL PANEL
Before operating the FIRESTAR Control Panel, become familiar with the information the control panel provides and the procedures for making changes to settings. The control panel has been programmed with factory default settings. If ne-tuning is desired, refer to the appropriate section of these operating instructions for more information.
1. During normal operation, the LED display indicates the actual temperature of the system water. Other information will also be displayed on the LED display depending on settings, modes, etc. The Water Temp button may be used to display the water temperature setting or, used in conjunction with the and buttons, to change the water temperature setting.
100%
Feed Rate
60%
65% 20%
1
4
2
3
5
6
FireStar Control Panel
Operating Instructions and Controller Variables
Software Version 1.2
2-2 FIRESTAR VER. 1.2 – 3-May-2011
2. The Fan Set button may be used in conjunction with the three mode (HI / NORMAL / IDLE) and buttons to change the fan speed for each mode.
3. The Ignition button starts the Gas Ignitor and may be used to enable/disable the Auto Relight mode.
4. The feed rate settings in each of the three modes (HI / NORMAL / IDLE) may be changed here. During operation, the light bar will indicate the feed rate setting for the mode the controller is currently in. May also be used in conjunction with the Fan Set button to change the fan speed for each mode.
5. The Auger Jog button may be used to manually control the burner and transfer augers and/or to enable Clean Out Mode. The Auger light is on any time the augers are running.
6. The Power button is used to turn the FIRESTAR control on and off. It does not disable all electrical power to the furnace.
INITIAL START-UP
NOTE: Before starting the furnace, make sure that (1) there is adequate clean, dry fuel in the hopper or supply bin; (2) the proper amount of Corrosion Inhibitor has been added and the water level is full; (3) the main electrical power supply to the furnace is on and (4) the gas supply for the Gas Ignitor and the Honeywell gas valve are both turned on.
1. Press the Power button. Upon startup, the lights on the control panel and the LED display will cycle through a lamp test and then go off. The LED display will indicate the actual system water temperature.
2. Fuel must be present in the burn chamber for the system to burn properly. To deliver fuel to the burn chamber, start the transfer and burner augers by pressing and holding the Auger Jog button. Continue to hold the Auger Jog button until fuel enters the burn chamber.
3. To start the Gas Ignitor, press and hold the Ignition button until the LED display indicates and the burner fan starts. During ignition, the ignition light will stay on.
FIRESTAR VER. 1.2 – 3-May-2011
4. Press the Ignition button twice within one second to enable the Auto Relight function. The Auto Relight Enabled light will turn on.
NOTE: If during ignition the LED display indicates and the ignition light is off, check the gas supply.
HOW THE GAS IGNITOR STARTS
The ignition process is a series of steps that automatically occur to ensure the Gas Ignitor starts properly before the system begins to operate. During ignition, the following will take place:
1. The burner fan will start to provide air for combustion.
2. Once the pressure switch senses air ow, it will energize the gas ignition module.
3. Both the transfer and burner augers run, delivering fuel to the burn chamber.
4. The gas ignition module ignites the gas burner to start burning the fuel in the burn chamber.
5. The gas burner will continue to burn until the burn chamber reaches a high enough temperature to sustain burning the fuel, at which time the controller will turn off the gas burner.
HOW THE BURNER OPERATES
To best utilize the fuel and obtain the most efciency, the controller automatically changes from NORMAL to HI mode when the water temperature drops and then back to NORMAL once the water temperature rises. When the water temperature reaches the water temperature setting, the controller will change to IDLE mode. The controller will again change to NORMAL mode when the water temperature drops. This cycle repeats as necessary to maintain the system water temperature.
2-4 FIRESTAR VER. 1.2 – 3-May-2011
CHANGING FIRESTAR CONTROL PANEL SETTINGS
NOTE: Until you become familiar with the operation of your FIRESTAR control panel, consult your Central Boiler dealer before making changes to the factory default settings.
Water Temperature
Normally the system water temperature will be displayed. To display the water temperature setting, press the Water Temp button. The default setting is 175˚F. To raise the water temperature setting, press and hold the Water Temp button; then press the
button. To lower the water temperature setting, press and hold
the Water Temp button; then press the button. The water temperature setting can be set between 150˚F and 195˚F.
Wood/Corn Mode
The controller's default setting is Corn Mode. In this mode, the auger will run for 3 seconds when delivering fuel. The controller may also be set to Wood Mode. In this mode, the auger will run for 5 seconds when delivering fuel.
To view the current fuel type setting:
1. Press and hold the HI and buttons. The NORMAL light bar will display the current fuel type setting. If the top half of the light bar is lit, the controller is in Corn Mode. If the bottom half of the light bar is lit, the controller is in Wood Mode.
To change the fuel type setting:
1. Press and hold the HI and buttons; then press the Normal or button to change between Corn and Wood modes. Once selection is made, let go of all buttons.
HI, NORMAL and IDLE Modes
Changes in system heat load, fuel quality and a number of other conditions may make it desirable to change the feed rate to the burner in one or more of the three operating modes (HI / NORMAL / IDLE).
To view the current feed rate setting:
During operation, the light bar will indicate the feed rate setting for the mode the controller is currently in.
To view all feed rate settings:
1. Press any of the or buttons for the HI, NORMAL or IDLE
modes. The light bars will display the current feed rate settings.
FIRESTAR VER. 1.2 – 3-May-2011
To change the feed rate settings:
1. In each mode (HI / NORMAL / IDLE), you can press the button to decrease the feed rate setting or press the button to increase the feed rate setting. The new feed rate setting will be displayed on the light bar.
Fan Set
If the feed rate is changed for any mode (HI / NORMAL / IDLE), it may be necessary to change the burner fan speed for that mode to optimize burner operation. In IDLE mode, the fan only runs when the Auger light is on.
To view the current fan speed settings:
1. Press and hold the Fan Set button. The light bars will display the current fan speed settings.
To change the fan speed settings:
1. Press and hold the Fan Set button; then press the or button for the respective mode to decrease or increase the fan speed setting. Decreasing the setting (fewer lights on the light bar) lowers the fan speed. Increasing the setting (more lights on the light bar) increases the fan speed.
Auto Relight
The auto relight function in enabled by default. When the auto relight function is enabled, the controller continuously monitors the burner temperature. If at any time the burner temperature is less than the burner temperature setting (which is set at the factory) and the controller is in NORMAL or HI mode, the controller will automatically change to Ignition mode in an attempt to relight and raise the burner temperature.
NOTE: A drop in burner temperature may be caused by wet or contaminated fuel or by an extended IDLE mode time, for example.
If after three Ignition mode cycles, the burner temperature does not rise above the burner temperature setting, all outputs will be disabled, the Auto Relight Enabled light will ash, and the LED display will indicate to notify that the burner re has gone out.
2-6 FIRESTAR VER. 1.2 – 3-May-2011
NOTE: Before resetting the controller after the auto relight function has failed, be sure to nd the cause of the burner not being operational (e.g., wet or contaminated fuel, mechanical problem, etc.).
WARNING
Do not attempt any service on the burner without rst disconnecting the main power supply to the furnace. Make
sure there is no hot ash in the burn chamber or furnace.
The controller will maintain the system in a disabled condition and the Auto Relight Enabled light will continue to ash until one of the following occurs:
1. Press and hold the Ignition button for 15 seconds.
2. Press the Power button to turn off the controller; then press again to turn on the controller.
3. The main power to the furnace is turned off and then on again.
To enable/disable the Auto Relight function:
1. Press the Ignition button twice within one second. When enabled, the Auto Relight Enabled light will turn on.
Clean Out Mode
Situations may arise when it becomes necessary to empty all of the fuel from the burner auger (e.g., for service, at the end of season, etc.). In the Clean Out Mode, the transfer auger is disabled. The burner will operate normally until the burner auger is empty and the re goes out.
To start Clean Out Mode:
1. Press the Auger Jog button four times within two seconds. The Clean Out Mode light will turn on and the transfer auger will be disabled. To speed the process, press and hold the Auger Jog button.
To cancel Clean Out Mode:
1. Press the Auger Jog button four times within two seconds. The Clean Out Mode light will turn off and the burner and transfer augers will run as normal.
FIRESTAR VER. 1.2 – 3-May-2011
NOTE: If not cancelled, Clean Out Mode will run for 30 minutes. After 30 minutes the Clean Out Mode light will turn off and the burner and transfer augers will run as normal.
To reset auger and fan settings to factory default settings:
1. Press the Power button to turn off the controller; then, while pressing and holding the IDLE mode and buttons, press the Power button to turn on the controller.
To reset controller settings to factory default settings and perform Self-Test:
1. Press the Power button to turn off the controller; then, while pressing and holding the Water Temp and buttons, press the Power button to turn on the controller. Controller settings will be reset to the factory default settings, the LED display will ash and the controller will perform a Self­Test.
NOTE: To reset ALL settings to factory default, it is necessary to reset both the auger and fan settings and the controller settings using the procedures above.
2. During the Self-Test, the following will occur:
a. The LED display will rst indicate the burner
b. The system will operate in HI mode for 10 seconds.
c. The ignition process will begin (see How the Gas Ignitor
d. After a delay of 10 seconds, all outputs will be disabled
and the controller will shut off.
2-8 FIRESTAR VER. 1.2 – 3-May-2011
DISPLAY READOUT DEFINITIONS
Low Water Alarm
High Water Temperature
Back Burn Alarm
Fire Out Alarm
Control Panel Locked
Control Panel Unlocked
Gas Mode
Alarms
If any of the following alarms occur, system operations will be halted until the cause of the alarm is corrected:
Low Water: the LED display will ash until the water level is above the sensor. Refer to the furnace owner's manual for procedure to correct low water situation.
High Water Temperature: the LED display will ash until the water temperature drops below 195˚F.
Back Burn: the LED display will ash if the controller detects a high temperature in the burner auger area, even if the control panel is turned off. Everything but the burner auger will be disabled. The burner auger will run for two minutes, pause for 10 minutes, and continue as required. The Back Burn alarm will not stop until the controller detects that the temperature has dropped.
Fire Out: the LED display will ash until the cause of the Fire Out alarm is corrected and the controller is reset. To clear the Fire Out alarm, turn the controller off and on again or press and hold the Ignition button. This will enable Auto Relight to attempt lighting the burner again.
FIRESTAR VER. 1.2 – 3-May-2011
Silent Fire Out: the IDLE light bar will ash until the water temperature drops low enough and at least 30 seconds in IDLE mode pass.
NOTE: When operating in IDLE mode, if the burner temperature falls below 2/3 the Burner Temperature Setpoint, the controller will go into Silent Fire Out mode. The augers and fan will turn off and the IDLE light bar will ash until the water temperature falls below the Water Temperature Setpoint
and at least 30 seconds have passed.
Controller Lock
The controller can be locked at any time to prevent unauthorized operation. After locking the controller while turned off, it will not be possible to start the controller or change any settings until it is unlocked. The controller may also be locked while it is operating. After locking the controller while turned on, it will not be possible to turn the controller off or change settings.
To lock the controller:
Rapidly press the Water Temp button four times. The LED display will indicate for ve seconds.
To unlock the controller:
Rapidly press the Water Temp button four times. The LED display will indicate for several seconds.
Power Off
To turn the controller on or off, press and hold the Power button for at least one second. After turning off the controller, release the Power button for at least one second before turning power back on.
Power Outage
In the event of a power outage, the controller is programmed to return to its previous state. If the system was powered on, it will automatically restart. If enabled prior to the power outage, Auto Relight will be enabled once power returns.
Troubleshooting/System Restarting
If there appears to be a system error, attempt to restart the system. If a standard restart fails to correct an apparent error, shut off the main power at the source for one minute and then try again.
2-10 FIRESTAR VER. 1.2 – 3-May-2011
FOR DEALER USE ONLY
CHANGING FIRESTAR CONTROLLER VARIABLES
Software Version 1.2
The FIRESTAR control relies on several variables for operation. The control panel has been programmed with factory default settings. If ne-tuning is desired, the variables can be changed.
To enter Setup mode:
Press and hold the Water Temp button for 7 seconds until the LED display changes from the water temperature to a "1."
Changing Control Variables:
While in Setup mode, select the control variable you want to change (see Selecting Control Variables). To make changes, press the Water Temp button. The current value is displayed. Press the or buttons to modify the setting. Press the Water Temp button to accept the value and return to the selection menu.
Selecting Control Variables:
There are 11 variables that may be changed within the setup mode. To select a variable while in Setup Mode, press the Water Temp or buttons until the number representing the variable appears in the display. The following list indicates each variable's number, name, the default factory settings, and a brief description of the function.
1. Water Temperature Setpoint: 175 (˚F)
When the water temperature is above this setting, the control
will change to IDLE mode.
2. IDLE to NORMAL Differential: 2 (˚F)
When the water temperature is less than the Water
FIRESTAR VER. 1.2 – 3-May-2011
3. NORMAL to HI Differential: 2 (˚F)
When the water temperature is less than the Water Temperature Setpoint minus the IDLE to NORMAL Differential minus the NORMAL to HI Differential, the controller will change from NORMAL mode to HI mode. For example, with the default factory settings, the controller will change from NORMAL mode to HI mode when the water temperature is less than 185˚F – 2˚F – 2˚F (or 181˚F).
4. Restart Time: 10 (minutes)
Time that must pass before the controller will change from NORMAL mode to HI mode, even if the water temperature is low enough and the burner temperature is high enough.
5. Burner Temperature Setpoint: 300 (˚F)
When operating in NORMAL or HI mode, the controller constantly checks the burner temperature. If the burner temperature is below the Burner Temperature Setpoint, the controller will immediately change from HIGH mode to NORMAL mode. If Auto Relight is enabled, Gas Ignition is started.
NOTE: Burner Temperature Setpoint + Gas Differential can never exceed 470˚F. For example, at default settings, Burner Temperature Setpoint can only be increased to a maximum of 370 (Burner Temperature Setpoint of 370˚F + Gas Differential of 100˚F = 470˚F). Lowering Gas Differential will allow a higher Burner Temperature Setpoint to be set.
NOTE: When operating in IDLE mode, if the burner temperature falls below 2/3 the Burner Temperature Setpoint, the controller will go into Silent Fire Out mode. The augers and fan will turn off and the IDLE light bar will ash until the water temperature falls below the Water Temperature Setpoint and at least 30 seconds have passed.
6. Gas Differential: 100 (˚F)
2-12 FIRESTAR VER. 1.2 – 3-May-2011
7. Gas Burn Time: 10 (minutes)
8. Fire Out Time: 5 (minutes)
9. Water Temp Offset: 0 (˚F)
Providing a means of manually calibrating the water temperature, the Water Temp Offset is the number of degrees that will be added or subtracted from all temperature readings.
10. Burner Differential: 50 (˚F)
The Burner Differential can only be set as high as the Gas Differential setting.
11. Hardware Mode: 0 (Maxim)
NOTE: Setting #11 must correspond to the correct auger delay setting. Press and hold the HI and buttons. The IDLE light bar will display the current auger delay setting. If the top half of the light bar is lit, the controller is in the auger delay setting for the Maxim. If the bottom half of the light bar is lit, the controller is in the auger delay setting for the Bio­Advantage. Press the IDLE or buttons to modify the setting.
To exit Setup Mode:
Wait 15 seconds (while not pressing any buttons) and the controller will automatically exit Setup Mode.
FIRESTAR VER. 1.2 – 3-May-2011
TECHNICAL SPECIFICATIONS
These tables indicate the settings for the various modes and the corresponding values. Default values are shaded. For example, the value at setting 3 for Maxim IDLE mode fan voltage is 5.00 Volts.
TROUBLESHOOTING
Primary EEPROM Failure (System will attempt to auto­correct): If the system detects failed EEPROM hardware, it will
halt operations and ash "EEE." If this occurs, shut down the board and attempt both manual resets. If the problem persists, contact Central Boiler.
Secondary EEPROM Failure: If the EEPROM containing fan and auger settings has failed, the system will halt operations and the auger LEDs will illuminate as follows:
HI - Top half of light bar lit NORMAL - Bottom half of light bar lit IDLE - Top half of light bar lit
If this occurs, shut down the board and attempt both manual resets. If the problem persists, contact Central Boiler.
FIRESTAR VER. 1.3 – 3-May-2011
UNDERSTANDING THE FIRESTAR CONTROL PANEL
Before operating the FireStar Control Panel, become familiar with the information the control panel provides and the procedures for making changes to settings. The control panel has been programmed with factory default settings. If ne-tuning is desired, refer to the appropriate section of these operating instructions for more information.
1. During normal operation, the LED display indicates the actual temperature of the system water. Other information will also be displayed on the LED display depending on settings, modes, etc. The Water Temp button may be used to display the water temperature setting or, used in conjunction with the and buttons, to change the water temperature setting.
100%
Feed Rate
60%
65% 20%
1
4
2
3
5
6
FireStar Control Panel
Operating Instructions and Controller Variables
Software Version 1.3
3-2 FIRESTAR VER. 1.3 – 3-May-2011
2. The Fan Set button may be used in conjunction with the three mode (HI / NORMAL / IDLE) and buttons to change the fan speed for each mode.
3. The Ignition button starts the Gas Ignitor and may be used to enable/disable the Auto Relight mode.
4. The feed rate settings in each of the three modes (HI / NORMAL / IDLE) may be changed here. During operation, the light bar will indicate the feed rate setting for the mode the controller is currently in. May also be used in conjunction with the Fan Set button to change the fan speed for each mode.
5. The Auger Jog button may be used to manually control the burner and transfer augers and/or to enable Clean Out Mode. The Auger light is on any time the augers are running.
6. The Power button is used to turn the FireStar control on and off. It does not disable all electrical power to the furnace.
INITIAL START-UP
NOTE: Before starting the furnace, make sure that (1) there is adequate clean, dry fuel in the hopper or supply bin; (2) the proper amount of Corrosion Inhibitor has been added and the water level is full; (3) the main electrical power supply to the furnace is on and (4) the gas supply for the Gas Ignitor and the Honeywell gas valve are both turned on.
1. Press the Power button. Upon startup, the controller will display the software version number followed by a brief lamp test. The LED display will indicate the actual system water temperature.
2. Fuel must be present in the burn chamber for the system to burn properly. To deliver fuel to the burn chamber, start the transfer and burner augers by pressing and holding the Auger Jog button. Continue to hold the Auger Jog button until fuel enters the burn chamber.
3. To start the Gas Ignitor, press and hold the Ignition button until the LED display indicates and the burner fan starts. During ignition, the ignition light will stay on.
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