Instruction Manual 818
2/02
VeriFlame Single Burner
Monitoring System
Model 5600
Version 1.21
Modulation Model
No Purge Model
Purge Model
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About this manual
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 expe-
rience with this kind of equipment.
AUDIENCE
SCOPE
This manual contains essential information for the proper installation and op-
eration of the Eclipse Veri-Flame Burner Monitoring System.
Following the instructions in this manual should assure trouble-free installation
and operation of the monitoring system. Read this manual carefully. Make sure
that you understand its structure and contents.Obey all the safety instructions.
Do not deviate from any instructions or application limits in this manual with-
out 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., Rock-
ford, Illinois.
There are several special symbols in this document. You must know their meaning
and importance.
DOCUMENT
CONVENTIONS
The explanation of these symbols follows. Please read it thoroughly.
Danger :
Indicates hazards or unsafe practices which W ILL result in severe
personal injury or even death.
O nly qualified and well trained personnel are allowed to carry out
these instructions or procedures.
Act with great care and follow the instructions.
W arning:
Indicates hazards or unsafe practices which could result in severe
personal injury or dam age.
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.
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If you need help, you can contact your local Eclipse Combustion sales office.
You can also contact Eclipse Combustion, Inc. at:
HOW TO GET HELP
1665 Elmwood Road
Rockford, Illinois 61103 USA
Phone: 815-877-3031
Fax: 815-877-3336
E-mail: eclipse@eclipsenet.com
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Table of Contents
About this m anual.....................................................................................
3
5
Table of contents ........................................................................................
Introduction ....................................................................................................
8
8
1
2
Product Description ...........................................................................................
Specifications ...............................................................................................
Introduction ............................................................................................................
Specifications ..........................................................................................................
Dimensions .............................................................................................................
9
9
9
9
3
4
DIP Switch Selection ..............................................................................
Introduction ............................................................................................................
DIP Switch Location .............................................................................................
DIP Switch Access.................................................................................................
No Purge DIP Switch Settings ...........................................................................
Modulation & Purge DIP Switch Settings ........................................................
12
12
12
12
12
13
Function Summary ..........................................................................................
Introduction ............................................................................................................
Standard Features..................................................................................................
Combustion Air Flow Check.........................................................................
Main FuelValve Closed switch ......................................................................
Low Fire Start ...................................................................................................
High Fire/High Fire Purge Check .................................................................
Recycle Mode ....................................................................................................
Pilot Test 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 .....................................................................
14
14
14
14
14
14
14
14
14
15
15
15
15
16
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Optional Features .................................................................................................
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
4
System Installation ...................................................................................
Introduction............................................................................................................
Interlocks and Limit Switch Input .....................................................................
Combustion Air Switch Input .............................................................................
Ignition Wiring........................................................................................................
Low Fire Input ........................................................................................................
Main Valve 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) ............................................
18
18
18
18
18
19
19
19
19
19
20
20
21
5
Sensor Installation ....................................................................................
Introduction............................................................................................................
Sensor Wiring.........................................................................................................
Flame Rods .............................................................................................................
Scanners...................................................................................................................
Scanner Sighting Considerations .......................................................................
24
24
24
25
25
25
6
7
Test Procedures...........................................................................................
Introduction............................................................................................................
Flame Signal Strength ...........................................................................................
Minimum Pilot Test ................................................................................................
Pilot Flame Failure Test ........................................................................................
Main Flame Failure Test ........................................................................................
Spark Sighting Test .................................................................................................
Limits & Interlock Tests .......................................................................................
26
26
26
26
27
27
27
27
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Maintenance &Troubleshooting ....................................................
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
8
9
Rem ote Display Messages...................................................................
Introduction............................................................................................................
Veri-Flame Operating Sequence (Table 9.1) ...................................................
Remote Display Diagnostic Messages (Table 9.2) .........................................
33
33
34
38
Appendix ...........................................................................................................
Conversion Factors ..............................................................................................
Illustrated Parts List ..............................................................................................
41
41
42
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Introduction
1
The Eclipse CombustionVeri-Flame Single Burner Monitoring System controls
PRO DUCT
DESCRIPTIO N
the start-up sequence and monitors the flame of single gas, oil, or combination
gas/oil burners. There are three different models to theVeri-Flame line: the no
purge, the purge and the modulation models. Each model features field select-
able 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-Flam e No Purge and Purge models are available in three different
series—5602, 5603 and 5605.The 5602 Series is UL listed, CSA certified, 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-Flam e Modulation model is available in two different series: 5602
and 5603.Both series are capable 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 certifica-
tions.
Figure 1 .1 Veri-Flame Single Burner Monitoring System (Purge Unit Shown)
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Specifications
2
This section gives a detailed overview of Veri-Flame specifications and dimensions.
INTRODUCTION
Specifications
PARAMETER
DESCRIPTIO N
-
Supply
• Series 5602 & 5605: 120VAC ( 10%, 15%), 50/60 Hz standard.
+
-
Series 5603: 240VAC ( 10%, 15%), 50/60 Hz standard.
+
Internal power consumption: 12VA (excluding external connected loads).
Unit
Veri-Flame
90˚ U.V. Scanner
U.V. Scanner
NEMA4 UV Scanner
I.R. Scanner
UV/IR Scanner
Self-Check U.V.
Remote Display
Remote Display
Model Nos.
All Models
5600-90A
5600-91
5600-91N4
5600-92B
5600-92SC
5602-91
Temperature Range
-40˚ to +60˚C (-40˚ to +140˚F)
Temperature Ranges
-20˚ to +60˚C
-20˚ to +125˚C
-20˚ to +125˚C
(0˚ to 140˚F)
(0˚ to +257˚F)
(0˚ to +257˚F)
-40˚ to +110˚C (-40˚ to +230˚F)
-20˚ to +80˚C
-20˚ to +60˚C
0˚ to 50˚C
(0˚ to +176˚F)
(0˚ to +140˚F)
(32˚ to 122˚F)
(32˚ to 122˚F)
5602DB
5602DBP
0˚ to 50˚C
Flame Failure Response
Trial For Ignition (TFI)
3 seconds ±0.5 seconds.
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
10 seconds.
Pilot Interrupt (if selected)
Purge Time
Selectable from 0-225 seconds in 15 second increments.
UL, CSA
Relay Contact Rating
Resistive Load
Terminals
Function
Gas Valve
Inductive Load
175VA, 1/10 HP
375 VA
for
Output Ratings
120 VAC
3, 5
4
10 amps
10 amps
(maximum total connected
load not to exceed 15 amps)
Ignition
Motor or Contactor
8
470 VA, 1/2 HP
175VA
16 amps
10 amps
Control Signal
A, 10, 11, 12, 13
Relay Contact Rating
Resistive Load
Terminals
Function
Valves, Ignition
Motors or Contactor
Alarm
Output Ratings for 240 VAC
(maximum total connected
load not to exceed 15 amps)
3, 4, 5,
5 amps
16 amps
5 amps
5 amps
8
A
10, 11, 12, 13
Control
(continued onto next page)
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Specifications (continued)
PARAMETER
DESCRIPTIO N
• No Purge & Purge Models:
Approvals
(See chart below.)
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.
Shipping Weight
• 1.4 kilograms (3 lbs.) for allVeri-Flame models.
• 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 Inform ation
UL Listed, Guide No. MCCZ, File MH12613
UL Recognized, Guide No. MCCZ2, File MH12613
CSA Certified, Class No. 2632 01, File 37456
FM Approved, Class No. 7610, Report 1Y2A4.AF
Veri-Flam e Unit/All Models
Dim ensions
76mm
(3")
133mm
(5-1/4") Square
Veri-Flam e Bases/Purge & No Purge Models
Model Number 5602-10
Model Number 5602-10-1
5.5mm
(7/32") Dia.
Mounting
Holes (4)
127mm
(5")
127mm
(5")
Square
Square
Knockouts
(10) for
13mm (1/2"
Conduit
19mm
(3/4")
38mm
(1-1/2")
102mm
(4") Square
13mm
(1/2")
102mm
(4") Square
124mm
(4-7/8")
38mm
(1-1/2")
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Dim ensions (continued)
Veri-Flam e/Modulating Model with Base Model Num ber 5602-40
24mm
(15/16")
171mm
(6-3/4")
25mm
(1")
1
2
3
4
5
6
7
8
A
D
S2 S1 10 11 12 13
40mm
(1-9/16")
10mm (3/8")
5mm (3/16")
213mm (8-3/8")
116mm
(4-9/16")
Rem ote Display Model Num ber 5602-DB
89mm
(3-1/2")
Square
102mm
(4") Square
54mm
(2-1/8")
*
Ground
Screw
Mounting
Bracket &
Screw (2)
Contrast
Adjustment
Screw
*
Wiring
Terminal
15-pin Port
Terminal
= Alternate Mounting Locations
24VDC Power Supply for Rem ote Display 5602-DB
*
44mm
70mm
(1-3/4")
(2-3/4")
79mm
(3-1/8")
Rem ote Display Model Num ber 5602-DBP
89mm
(3-1/2")
Square
102mm
(4") Square
54mm
(2-1/8")
*
Ground
Screw
Contrast
Adjustment
Screw
Mounting
Bracket &
Screw (2)
*
Wiring
Terminals (2)
15-pin Port
Terminal
= Alternate Mounting Locations
*
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DIP Switch Selection
3
This section details the location, selection and description of the Veri-Flame
DIP switches, which allow for sequence and timing functions as well as sys-
tem configuration.
INTRODUCTION
Caution
To avoid electric shock,shut off the power supply when installing or removing 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 eachVeri-Flame unit (see Fig-
ure 3.1 on page 13, or the photograph on page 8).
DIP Switch Location
DIP Switch Access
To gain access to the DIP switches, the Veri-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:
No Purge
DIP Switch Settings
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 and purge models of theVeri-Flame use all of the eight DIP switches,
as illustrated in Figure 3.2 on page 13. They are as follows:
Modulation & Purge
DIP Switch Settings
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. Total purge time is the sum of each switch
selected.
SW8: Post purge selection. (On=15 second post purge).
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Figure 3.1 DIP Switch Location
Close-up of DIP switches on
back side of all Veri-Flame models.
Figure 3.2 DIP Switch Labels with Selections
No Purge Models
Modulation Models
Purge Models
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Function Summary
4
This section describes the features of theVeri-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 for sequence diagrams.
INTRODUCTION
The following function features are standard on theVeri-Flame models as noted:
STANDARD FEATURES
This input is considered the normal operation control or run input to theVeri-
Flame system. Interlocks are generally pressure or temperature switches which,
when activated, start the burner. Limit switches are generally pressure, tempera-
ture and other switches which, when activated, stop the burner. The interlocks and
limit switches are wired in series. A break in this circuit will shut the burner down,
but will not produce an alarm.
Interlocks and Lim it
Switch Input (Term inal 7)
For purge and m odulation m odels: This input is for monitoring the
combustion air switch separately from other interlocks and limits. TheVeri-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.
Com bustion Air
Switch Input (Term inal 6)
The input will be proven open before start-up and after shutdown. If the input is
improperly powered before the fan output is energized, the system error light will
blink. The input must de-energize within 30 seconds or theVeri-Flame will lockout.
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.
Main FuelValve Closed
Switch (Term inalV)
Purge and No-Purge m odels: 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.
Low Fire Start
For m odulation m odels: when wired, the system checks for the low fire start
position prior to light-off.
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For m odulation m odels: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.
Main FuelValve Closed/
High Fire Purge Check
(Term inal D)
For all m odels: when selected,theVeri-Flame will restart the sequence after
flame or air failure. The recycle mode allows the system to re-initiate the start-
up 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 for
another recycle. At no time will the system recycle in the event of pilot flame
fail.
Recycle Mode
For all m odels: this mode is entered by depressing theTEST/RESET button on
the front cover. In the pilot test mode,theVeri-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.
Pilot Test Mode
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 rem ains lit) and restart the sequence.
Test Mode
(Button In)
Run Mode
(Button Out)
Interrupted or
Interm ittent Pilot
For all m odels: 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.
Post Purge
For purge and m odulation m odels: 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 Flam e &
Main Flam e Separation
For all m odels: during the trial for ignition period (TFI), the pilot valve and
ignition coil remains energized. At the end of the TFI, the pilot flame remains
on and the ignition coil is de-energized. After a five second delay to prove the
pilot flame, the main gas valve is energized.
System Errors &
Lockout Conditions
A system error (illuminated by the red “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 pressed 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 m odels).
2) Welded internal contacts or other malfunctions in theVeri-Flame (for all
m odels).
3) Main fuel valve (for all m odels)–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.
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4) Low fire fail (for m odulating m odel)–low fire switch open prior to trial
System Errors &
Lockout Conditions
(Continued)
for ignition.
5) High fire fail (for m odulating m odel)–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 m odulation m odels) – 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 m odels) 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 m odels) 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 m odels);
b) electrical interference on the sensor wiring (for all m odels);
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 m odels).
10) Air flow switch closed before start-up (for purge and modulation models).
High to Low Fire Purge
Modulation Capability
with High to Low Fire
Position Switch Interlocks
For m odulation m odels: the modulation feature incorporates a high fire purge
time and a low fire purge time into the purge sequence. This feature allows the
Veri-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
SW5 ................................30 seconds
SW6 ................................60 seconds
SW7 ............................. 120 seconds
The selected times are additive and apply 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
Internal Contact Connections
Power Off
Terminal 10 (Common)
Terminal 11 (Auto)
Power On, Limits Open
Purge To High Fire
Purge To Low Fire
Automatic Modulation
Alarm and Lockout
Terminal 10 (Common)
Terminal 10 (Common)
Terminal 10 (Common)
Terminal 10 (Common)
Terminal 10 (Common)
Terminal 12 (Low Fire)
Terminal 13 (High Fire)
Terminal 12 (Low Fire)
Terminal 11 (Auto)
Terminal 12 (Low Fire)
The Automatic step occurs when the burners are operating and allows the
burner firing rate to be controlled by an automatic temperature controller.
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The following features are available on select models, or when optional equipment
is purchased.
OPTIO NAL FEATURES
Air Switch Input Hold
For purge/m odulation m odels: holds the sequence indefinitely until air switch
input is confirmed without affecting the air failure function and causing a lockout.
Rem ote Display &
Power Supply
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.
Manual Reset on
Power O utage
This optional feature requires a reset on initial application 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 theTEST/RESET push-button are located on the front
cover of the Veri-Flame. This section describes their respective functions.
STATUS LIGHTS
PUSH-BUTTON
&
For all m odels: 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“PilotTest
Mode” on page 15).
Interlocks Closed
For purge and m odulation m odels: this red LED illuminates whenever com-
bustion air is lost during the operational cycle of the Veri-Flame.
Air Failure
For all m odels: this red LED illuminates when a system error is detected (see
“System Errors & Lockout Conditions” on pages 15-16).
System Error
For all m odels: this red LED illuminates when a pilot or main flame fails.
Flam e Failure
Low Fire
For m odulation m odels: this yellow LED illuminates during the low fire pe-
riod of the purge cycle.
For m odulation m odels: this red LED illuminates during the high fire period
of the purge cycle.
High Fire
Auto
For m odulation m odels: this green LED illuminates during the automatic pe-
riod which occurs 20 seconds after the main valve is energized.
For all m odels: this push-button is used to activate the pilot test mode or to
reset the Veri-Flame unit.
Test/Reset
Flam e Signal
For all m odels: this red LED is located behind the signal test port and illumi-
nates when a flame signal is present.
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System Installation
5
In this section, the necessary procedures are detailed to integrate aVeri-Flame into a
burner system; Figures 5.1 and 5.2 illustrate the various terminal strips mentioned.
INTRODUCTION
Note:
Shut off the power supply before theVeri-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 monitoring
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 for 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.
Interlocks and
Lim it Switch Input
Com bustion Air
Switch Input
For purge and m odulation m odels: Wire any switches and contacts in
series to this terminal for proving air flow function and relating to the air failure
light. Power must not be immediately present at terminal 6 when power is first
applied to terminals 1 or 7.
If this terminal is not used,place a jumper between the combustion blower out-
put (terminal 8) and the air switch input (terminal 6).
If the combustion air blower is controlled outside of theVeri-Flame system,then
a three way 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 switch could be wired between the combustion
blower output and the air switch input. Connecting the air switch in this man-
ner will satisfy the open contact (air short) check on the switch.
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Route ignition wiring a sufficient distance from all sensors and other low volt-
age wiring to avoid electrical interference, which may cause erratic operation
of theVeri-Flame system. Keep the high voltage wire run from the ignition trans-
former as short as possible. The best condition is to mount the ignition trans-
former 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.
Ignition W iring
For m odulation m odels: it is possible to wire the system for checking low
fire start position prior to pilot ignition.To use this feature, the low fire start
switch must be connected between terminal 3 and the pilot valve (see Figure
5.2). On direct spark burners, a by-pass contact must be wired around the low
fire switch, see relay and contact CR in Figure 5.3.
Low Fire Input
The system can be wired to check for the main valve closed switch on the main
gas valve prior to start-up and after the end of the burner cycle.
Main Valve
Closed Switch
For purge and no purge m odels: the main valve closed switch must be con-
nected to TerminalV and the jum per in the base m ust be cut (see Figure
5.4 on page 22).
For m odulation m odels: the main valve closed switch 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 jum per in the base m ust be
cut.
For m odulation m odels: the system can be wired to check for high purge
position during the high fire purge portion of the sequence. To use this fea-
ture, the red jum per 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 termi-
nals 1 and D. Please note that the yellow jumper on the base has no effect
whether cut or intact.
High Purge Input
This feature permits remote mounting of a switch to reset the Veri-Flame.To
use this feature,a normally closed remote reset switch 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.
Rem ote Reset
Rem ote Display &
Power Supply
Identify the model of remote display (see page 11) and wire according to figure
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 display and wiring to minimize
electrical interference. Applying and disconnecting the display power supply
should coincide with power to terminal 1 of theVeri-Flame. Use the appropri-
ate cable (Eclipse part #20318) to connect to the test jack and to the S2 termi-
nal of theVeri-Flame wiring base. Do not attempt to parallel the test jack signal
to other devices when using a remote display. The LCD display contrast can be
adjusted on the back with a small blade screwdriver.
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Figure 5.1 No Purge and Purge W iring Diagram s
Purge Models
No Purge Models
5602/5605:
120 VAC
50/60 HZ
5603:
240 VAC
50/60 HZ
5602/5605:
120 VAC
50/60 HZ
5603:
240 VAC
50/60 HZ
15 A On/Off
Fuse
15 A On/Off
Fuse
1
2
3
4
1
2
Piloted Burner
Piloted Burner
Pilot
Ignition
Main
Pilot
Ignition
Main
3
4
Air Flow Switch
5
6
5
Interlocks & Limits
7
A
V
7
8
Interlocks
& Limits
Alarm
Fan
Proof of
Closure
A
S1
S2
Alarm
Proof of Closure
V
S1
S2
G
G
Figure 5.2 Modulation W iring Diagram
5602/5605:
120 VAC
50/60 HZ
5603:
240 VAC
50/60 HZ
On/Off
15 A. Fuse
1
2
3
4
5
Low Fire Proving
Pilot
Ignition
Main
Cut Red
Jumper
To Activate
Terminal D.
Air Flow
6
7
Interlocks
& Limits
Fan
8
A
Alarm
D
Proof of
Closure
High Purge
Damper
Switch
Flame
Sensor
Terminals
S2
S1
10
11
12
13
Common
See the “High to
Automatic
Low Fire
High Fire
Low Fire Purge
Modulation
Capability” section
on page 16 for
contact connections.
G
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Figure 5.3 Typical Connections For All Models
Model 5602 DBP
120 VAC Rem ote Display
Model 5602 DB
24 VDC Rem ote Display
12V
-
120V
L
12V
+
120V
N
24V G Tx Rx
G
G
Tx Rx
R1 R2
To 1
Cable
#20318
to 120 VAC
PLUG
Flame Signal
Test Jack
Cable
#20318
Flame Signal
Test Jack
PLUG
To S2
To S2
Veri-Flame
Veri-Flame
Power
Supply
#20317
N
G
120/240VAC
U.V. / I.R.
Solid State U.V. / I.R.
Flam e Rod
Blue
White
S1
S2
Flame Rod
U.V
or
I.R.
S1
S2
S1
Blue (Signal)
Scanner
Black
S2
Yellow (Neutral)
Shield
G
Self Check U.V. 5602-91
(Requires 5602-91-7 cable)
Direct Spark with
Low Fire Start
Direct Spark
Low Fire Proving
A
B
C
D
2
1
3
MAIN
3
4
5
MAIN
CR
IGNITION
S1
S2
IGNITION
4
5
Neutral
Note: Intermittent pilot must
be selected, DIP-SW2 = ON
CR
Neutral
Note: Intermittent pilot must be selected, DIP-SW2 = ON
CR is a control relay used to bypass the low fire switch after
the burner is lit.
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 CANNOT be run together in a common conduit or wire-
way (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 recycle/non-recycle selections
are made with a DIP switch located on the rear plate of the control unit.
6. Neutral must be grounded.
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Figure 5.4 Purge and No Purge Bases
Internal Diagram
Purge & No-purge
Model Num ber 5602-10
Model Num ber 5602-10-1
P1
5
P1
1
Fan
8
1
7
2
6
P1
4
P3
6
P3
5
Alarm
Fault
P3
A
3
Pilot
Ign
P1
3
3
6P3
5
6
3
4
V
2
1
2
4
1
1
J1
4
Jumper
S2
S1
7
P2
6
Main
P3
3
P3
P3
P2
5
3
2
1
V
6
P2
P1
4
8
A
P1
Jumper
Supervisor
2
Gnd
Gnd
S2
S1
Jack
Flame Signal
Amplifier
P2
1
5
6 S2 S1 7 8 A 1 2 V 4 3
NOTE: Ground Term inal
nnot present in plastic base.
Note: No purge models do not use 6 & 8.
Modulating Base
Internal Diagram
Modulation Model
Model Num ber 5602-40
P1
5
P1
1
Fan
1
7
8
6
2
Red
1
P1
4
P3
6
P3
5
P3
3
Alarm
Fault
3
2
1
6
1
A
3
J1
J2
Pilot
Ign
P1
3
P3
4
4
22K
22K
1
P2
Main
P3
4
5
D
6
6
3
2
1
P3
2
P1
4
P2
2
Supervisor
2
S2
S1
Jack
Jumper
Flame Signal
Amplifier
P2
1
J2
Auto
2
J2
1
J2
3
11
12
13
Low
High
Gnd
J2
4
1 2 3 4 5 6 7 8 A D S2 S1 10 11 12 13
10
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Figure 5.5 Sequence Diagram s
Term inal
Function
Control Power
Pilot Valve
Ignition
1
3
4
5
7
V
O utputs
Inputs
MainValve
Interlocks
POVC
Flame
Check
Recycle
35 Seconds
TFI
Permitted
Main
Trial
10 Sec
Pilot
Trial
Firing
Cycle
Term inal
Function
Control Power
Pilot Valve
Ignition
1
3
4
5
8
6
7
V
O utputs
Inputs
MainValve
Fan
Air Switch
Interlocks
POVC
Flame
Check
5 Sec
Recycle
Permitted
10
Sec
35 Seconds
TFI
Post
Purge
15 Sec
Main
Trial
10 Sec
Firing
Cycle
Pilot
Trial
Purge
Term inal
Function
Control Power
Pilot Valve
Ignition
1
3
4
5
8
6
7
O utputs
Inputs
MainValve
Fan
Air Switch
Interlocks
D
3
High Fire & POVC
Low Fire Switch
Continuity
Between
Modulation
Term inals
10 to 12 Low Fire Purge
10 to 13 High Fire Purge
10 to 11
Automatic
10
Sec
Main
Trial
Flame
Firing Cycle
Post
Purge
15 Sec
Check
5 Sec
TFI
Recycle
Permitted
10 Sec
High Fire
Purge
Pilot
Trial
Low Fire
Purge
20 Seconds
35 Seconds
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Sensor Installation
6
This section describes the proper wiring,installation and sighting considerations for
all sensors that can be used with aVeri-Flame.
INTRODUCTION
Warning
Incorrect sensor installation may cause the sensor to generate a
false flame signal, possibly resulting in the collection of unburned
fuel in the combustion chamber. This unburned fuel creates the
potential for explosions which can result in injuries, death and
property damage. Be certain that the flame sensor detects ac-
ceptable pilot and main flames only.
Sensor W iring
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-frequency emitters (wireless divices),
and inverter drives can induce false flame signals. Shielded cables can help re-
duce interference with the shield connected to ground at the control end only.
The wire type and its capacitance (picofarads or microfarads) to ground may
cause low signal problems,so a grounded shield may decrease the signal due to
the cable’s internal capacitance. Multiple U.V. tube-type sensor leads run to-
gether 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).
Note:
n
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.
Flame rods should be used only on gas burners. They accumulate soot on oil burn-
ers, causing nuisance shutdowns and unsafe operating conditions.
Flam e Rods
See the burner manufacturer’s literature for flame rod mounting location. When
installing flame rods, please consider the following:
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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 mix-
ture. For partially luminous flames, such as atmospheric air/gas mixtures,
place the rod at the edge of the flame.
Figure 6.1 Flame Rod Position
W RO NG
Rod Detects
Weak Pilot
CO RRECT
Rod Detects
Only Strong
Pilot 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 rod/burner ground ratio and posi-
tion of the rod in the flame may need adjustment to yield maximum flame signal
strength.
PILOT
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 grounding area between the flame
rod and spark plug may eliminate the interference.
W arning
Scanners
Use only Eclipse scanner m odels as listed in the Illustrated Parts
List at the end of this docum ent.
When installing scanners, please consider the following:
1) Position the scanner within 457 mm (18") of the flame. Consult factory 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 literature 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 have less UV radiation in the outer flame). The scan-
ner should view the intersection of the pilot and main flames. When sighting scan-
ners, please consider the following:
Scanner Sighting
Considerations
Figure 6.2 U.V. Scanner Sighting
1) Sight the scanner away from the ignition spark. Sighting the spark or its reflec-
tions from burner internals can cause nuisance shutdowns during burner igni-
tion. If necessary, use a scanner orifice to reduce spark pickup.
1/3 of
Flame Length
MAIN
BURNER
2) Do not allow the scanner to detect a pilot flame that is too small to ignite the
main burner.
SCANNER
Scanner
Sight
Line
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 for oil flame applications. When used,aim
the I.R. scanner at the outer oil flame for flickering detection.
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Test Procedures
7
This section describes the test procedures that must be performed after instal-
lation to insure that theVeri-Flame is operating properly; these procedures are
mandatory.
INTRODUCTION
Insert the positive probe of a 0-15 VDC, digital volt meter into the test
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 11VDC; any-
thing below 4 VDC is inadequate. Also, the red LED inside the test point
illuminates when a flame signal is indicated.
Flam e Signal Strength
Run the following test procedures to ensure that the sensor will not detect a
pilot flame too small to reliably light the main flame:
Minim um Pilot Test
1) Manually shut off the fuel supply to the burner, but not to the pilot.
2) Start 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. Mea-
sure 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 4VDC, 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 lower 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 re-
store 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 sys-
tem. Realign the sensor so that it requires a larger pilot flame. Repeat steps
1 through 6 until the main burner lights off smoothly and reliably.
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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).
Pilot Flam e Failure Test
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.
1) Manually shut off the fuel supply to the main burner but not to the pilot.
Main Flam e Failure Test
(For Interrupted Pilot Systems)
2) Start the system normally. This should ignite the pilot and lock out* after
pilot interruption. If the system does not lock out, the controller is detect-
ing a false flame signal (see Section 6). Find the problem and correct it be-
fore resuming normal operation.
1) Manually shut off the fuel supply to the pilot and the main burner.
2) Start the system normally.
Spark Sighting Test
3) Measure the flame signal as described in“Flame Signal Strength” in this section.
4) If a flame signal greater than 4VDC is measured for more than three sec-
onds 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.
Lim its & Interlock Tests
Warning
Never operate a system that is im properly adjusted or has faulty in-
terlocks or lim it switches. Always replace faulty equipm ent with new
equipm ent before resum ing operation. O perating a system with de-
fective safety equipm ent can cause explosions, injuries, and property
dam age.
* Indicated by the illuminated red “Flame Failure” LED on the Veri-Flame front cover.
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Maintenance &Troubleshooting
8
This section is divided into two parts:
INTRODUCTION
• The first part describes the maintenance procedures.
• The second part describes troubleshooting procedures,from identifying prob-
lems to interpreting the operating conditions by the lit LEDs on the front cover.
Preventative maintenance is the key to a reliable, safe and efficient system. The
core of any preventive maintenance program is a list of periodic tasks.
MAINTENANCE
In the paragraphs that follow are suggestions for a monthly list and a yearly list.
Note:
The monthly list and the yearly list are an average interval. If your environment 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 scan-
ner lenses clean with a soft, damp cloth, since small amounts of dust will mea-
surably reduce the flame signal strength. Wash the flame rod electrode and
insulator with soap and water, then rinse and dry thoroughly.
Monthly Checklist
2. Test all the alarm systems for proper signals.
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.
Yearly Checklist
2. Test pressure switch settings by checking switch movements against pres-
sure 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
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TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
SO LUTIO N
Check main valve closed switch.
No voltage onV (or D).
Cannot initiate start sequence
Main valve is not closed.
Check air pressure switch adjustment.
Check air filter.
Check blower rotation.
Check outlet pressure from blower.
No voltage on 6 after 8 is on.
Air pressure switch has not made
contact.
Check incomming gas pressure; adjust gas
pressure if necessary.
High gas pressure switch has tripped.
Low gas pressure switch has tripped.
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.
Malfunction of flame safeguard system
such as a shorted-out flame sensor or
electrical noise in the sensor line.
Have qualified electrician investigate and
rectify.
Check switch settings.
Check air switch.
Purge cycle not completed.
Main power is off.
Make sure power is on to control system.
Call qualified electrician to investigate.
No power to control unit.
Check grounding in system.
Separate communication cable.
Move ignition circuit.
Scrambled messages on remote display. Electrical interference.
Improperly adjusted air switch.
Air switch either shorted or wired
wr ong.
“UNSAFE AIR SHORT” message
appears on display.
Check air switch settings.
Check wiring to air switch.
Burner flame fails but no flame
failure indication occurs.
Check scanner as explained in checklists in
“Maintenance” portion of this Section.
A faulty scanner.
Check wiring diagram on page 20 or 21 as
well as appropriate sensor information in
Section 6.
Improperly connected sensor wires.
Electrical interference from other
current carrying wires.
Check Note information on page 24
regarding sensor wiring.
Voltage reading greater than
15VDC at “Test Point” on
Veri-Flame faceplate.
Check grounding of neutral at control
power transformer.
Improper grounding.
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This section describes the status of operating conditions based on the LED or
combination of LEDs which are lit on the front cover of eachVeri-Flame model.
LED STATUS
Table 8.1 LED Status & Conditions for Veri-Flame No Purge 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 “runaway”, 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 failure.
7) Main valve closed switch defective, no power to V.
1) Pilot flame is not established in selected TFI.
FLAME FAILURE
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.
No Purge Model
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Table 8.2 LED Status & Conditions for Veri-Flame Purge 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 “runaway”, 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 failure.
7) Air flow switch closed before start-up.
8) Main fuel valve switch opens after shutdown or before start-up, no power to V.
1) Pilot flame is not established in selected TFI.
FLAME FAILURE
AIR FAILURE
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 switch is open during firing cycle.
Purge Model
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Table 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 “runaway”, 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 failure.
7) Air flow switch closed before start-up.
8) High purge damper switch and/or main fuel valve switch opens during start-up.
9) Low fire switch not made before TFI.
1) Pilot flame is not established in selected TFI.
FLAME FAILURE
AIR FAILURE
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 switch is open during firing cycle.
1) Burner in run mode, firing rate determined by automatic controller (normal operation).
1) Purge high sequence (normal operation).
INTERLOCKS CLOSED and
AUTO
INTERLOCKS CLOSED
and HIGH FIRE
1) Purge low sequence (normal operation).
INTERLOCKS CLOSED and
LOW FIRE
Modulation Model
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Remote Display Messages
9
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 Veri-
Flame’s functions as well as any lockout conditions. This section is divided into two
parts or tables:
INTRODUCTION
• The first table describes the start-up and shutdown monitoring sequences of the
Veri-Flame and how the progress (or halt) of the sequence can be monitored by
the messages on the remote display.
• The second table alphabetically lists and explains the diagnostic messages which
can appear on the remote display.
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Table 9.1 Veri-Flame Operating Sequence
POW ER ON
Was internal safe start check successful?
NORMAL MESSAGE
REMOTE DISPLAY
REVISIO N X.X
YES
NO
Various lockout messages
EXTERNAL INTERLOCK CHECKS
Is flam e signal present?
ERROR MESSAGE #1
YES
NO
Is main valve closed switch made?*
UNSAFE FLAME O N
YES
NO
Fan is energized. If signal is elimi-
nated within 30 seconds, se-
quence continues. If not, then . .
Is voltage present at air flow switch?
FOR PURGE & MODULATING
ERROR MESSAGE #1
YES
NO
UNSAFE AIR SHO RT
ERROR MESSAGE
MAIN VALVE FAIL
XX:XX:XX LOCKOUT
If switch is opened within 30
seconds, sequence continues. If
not, then . . .
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFE FLAME ON
XX:XX:XX LOCKOUT
Alarm energized.
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFEAIR SHORT
XX:XX:XX LOCKOUT
Alarm energized.
Is voltage present at interlock switch?
NORMAL MESSAGE
SAFE START O K
Check_Sum = XX
YES
NO
ERROR MESSAGE
LIMITS OPEN
TIME = XXXX:XX:XX
Holds until answer is yes.
NORMAL MESSAGE
FAN ENERGIZED
Fan output is energized; modu-
lator is sent to low fire.
BURNER START-UP
(see next page)
* Applies to purge and no purge models only.
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Table 9.1 Veri-Flame Operating Sequence (continued)
BURNER START-UP
Is voltage present at air flow switch
within ten seconds?
NO PURGE MODELS
PURGE MODELS
MODULATION MODELS
Is voltage present at air switch . . .
NORMAL MESSAGE
YES NO
AIR PROVEN
Is voltage present at air switch . . .
ERROR MESSAGE
NORMAL MESSAGE
AIR NOT PROVEN
XX:XX:XX LOCKOUT
YES NO
AIR PROVEN
NORMAL MESSAGE
PURGE TO HIGH FIRE
Purge based on selected time.
ERROR MESSAGE
AIR NOT PROVEN
XX:XX:XX LOCKOUT
Modulator sent to high fire for
selected purge time.
Is voltage present
at high purge switch?
NORMAL MESSAGE
YES
NO
PURGE TO LOW FIRE
Modulator sent to low fire for
selected purge time.
ERROR MESSAGE
HI DAMPER FAIL
XX:XX:XX LOCKOUT
Is low fire switch closed?
NORMAL MESSAGE
PILOT TRIAL FO R
IGNITIO N
YES
NO
ERROR MESSAGE
Spark and pilot valve energized
for selected trial for ignition.
LOW FIRE FAIL
XX:XX:XX LOCKOUT
Is pilot flam e signal present?
NORMAL MESSAGE
ERROR MESSAGE
YES
NO
PILOT FLAME O N
PILOT FLAME FAIL
XX:XX:XX LOCKOUT
Flame signal detected
NORMAL MESSAGE
PILOT FLAME XX.XV
TIME = XXXX:XX:XX
Spark turns off at end of TFI;
sequence delayed 5 seconds.
Is m ain flam e signal present?
NORMAL MESSAGE
ERROR MESSAGE
YES
NO
MAIN FLAME O N
MAIN FLAME FAIL
XX:XX:XX LOCKOUT
Is flam e signal present?
(see next page)
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Table 9.1 Veri-Flame Operating Sequence (continued)
BURNER START-UP (continued)
Is flam e signal present?
ERROR MESSAGE
NO
YES
MAIN FLAME FAIL
XX:XX:XX LOCKOUT
NORMAL MESSAGE
MAIN FLAME O N
NORMAL MESSAGE
NORMAL MESSAGE
MAIN FLAME O N
PILOT O FF
IF Interrupted Pilot is selected
IF Interm ittent Pilot Is Selected
MAIN FLAME O N
Pilot will shut off 10 seconds
after main flame is energized.
NORMAL MESSAGE
AUTO MATIC
MO DULATIO N
MODULATION MODELS
MODULATION MODELS
Modulator sent to automatic 20
seconds after main valve is
energized.
NORMAL MESSAGE
BURNER O N XX.XV
TIME = XXXX:XX:XX
PURGE & NO PURGE MODELS
PURGE & NO PURGE MODELS
Main flame of burner is proven.
Flame signal = XX.XVolts DC;
elapsed time is shown in hours:
minutes:seconds.
Is flame signal present?
NO
YES
Is air switch signal on?
Is recycle selected?
NO
NO
YES
YES
Was the main flame on more
than 35 seconds?
Is recycle selected?
NO
YES
NO
YES
Was the main flame on more
than 35 seconds?
ERROR MESSAGE
ERROR MESSAGE
MAIN FLAME FAIL
XX:XX:XX LO CKO UT
MAIN FLAME FAIL
RECYCLING
NO
YES
Unit returns to beginning
sequence.
ERROR MESSAGE
ERROR MESSAGE
AIR FAILURE
XX:XX:XX LO CKO UT
AIR FAILURE
RECYCLING
Unit returns to beginning
sequence.
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Table 9.1 Veri-Flame Operating Sequence (continued)
BURNER SHUTDOW N
Shutdown is started by opening
the operating interlock circuit.
Is voltage present at interlocks?
YES
NO
Continued operation.
Is post purge selected?
YES
NO
NORMAL MESSAGE
PO ST PURGE
XX
Fuel valves de-energized; fan
energized for 15 seconds.
Is m ain valve closed switch m ade?*
ERROR MESSAGE
YES
NO
MAIN VALVE FAIL
XX:XX:XX LOCKOUT
Fan energized; alarm sounds.
Is voltage present at air flow switch?
FOR PURGE & MODULATING
ERROR MESSAGE #1
YES
NO
Is flam e signal present?
UNSAFE AIR SHO RT
ERROR MESSAGE #1
YES
NO
If switch is opened within 30
seconds, sequence continues. If
not, then . . .
UNSAFE FLAME O N
Fan is energized. If signal is elimi-
nated within 30 seconds, se-
quence continues. If not, then . .
NORMAL MESSAGE
LIMITS OPEN
TIME = XXXX:XX:XX
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFEAIR SHORT
XX:XX:XX LOCKOUT
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFE FLAME ON
XX:XX:XX LOCKOUT
Alarm energized.
Alarm energized.
* Applies to purge and no purge models only.
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Table 9.2 Remote Display Diagnostic Messages (Listed Alphabetically)
MESSAGE
AIR FAILURE
TYPE
EXPLANATIO N
Lockout
For purge & m odulation m odels: Combustion air flow limit
XX:XX:XX LOCKOUT
switch opened for more than two seconds once initially proven.
AIR FAILURE
RECYCLING
Status
For purge & m odulation m odels: 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).
AIR NOT PROVEN
XX:XX:XX LOCKOUT
Lockout
Status
For purge & m odulation m odels: Combustion air flow limit
switch did not make within ten seconds of fan being energized.
For purge & m odulation m odels: Combustion air flow limit
AIR PROVEN
switch closed within ten seconds of fan being energized.
AUTOMATIC
MODULATION
Status
Status
For m odulation m odels only: Modulating motor is sent to au-
tomatic operation.
BURNER ON XX.XV
TIME=XXXX:XX:XX
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.
D-INTERNAL FAIL
XX:XX:XX:XX LOCKOUT
Lockout
Status
For m odulation m odels only: Internal control failure; replace
controller.
For purge & m odulation m odels: Blower motor is energized
FAN ENERGIZED
at the start of pre-purge.
FLAME FAILURE
XX:XX:XX LOCKOUT
Lockout
Lockout
Main flame lost during operation in the automatic modulation mode.
Burner number (X) given of failed unit.
HI DAMPER/POVC
For m odulation m odels only: High damper or high purge rate
XX:XX:XX LOCKOUT
switch did not make at the end of pre-purge to high fire.
K-INTERNAL FAIL
XX:XX:XX LOCKOUT
Lockout
Lockout
Internal control failure; replace controller.
Internal control failure; replace controller.
L-INTERNAL FAIL
XX:XX:XX LOCKOUT
Status
The controller has completed its internal checks and is standing by
for the interlocks to close.
LIMITS OPEN
TIME=XXXX:XX:XX
LOW FIRE FAIL
Lockout
For m odulation m odels only: Low fire switch is open just prior
XX:XX:XX LOCKOUT
to pilot trial for ignition.
MAIN FLAME FAIL
XX:XX:XX LOCKOUT
Lockout
Status
Main flame was not established during the main burner trial for
ignition.
MAIN FLAME FAIL
RECYCLING
Main flame lost during automatic modulation; control will recycle
once if “recycle” has been selected.
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Table 9.2 Remote Display Diagnostic Messages (continued)
MESSAGE
TYPE
EXPLANATIO N
Lockout
Main valve has been energized and main flame proven during trial
for ignition.
MAIN FLAME ON
MAIN FLAME ON
PILOT OFF
Status
Pilot valve is de-energized and main flame is on.
MAIN VALVE FAIL
XX:XX:XX LOCKOUT
Lockout
Lockout
Lockout
For purge and no purge m odels: Main valve closed switch is
open before start-up or after burner shutdown.
NO PURGE SELECT
XX:XX:XX LOCKOUT
For purge & m odulation m odels: No purge time was selected;
lockout prior to purge to high fire.
PILOT FLAME FAIL
Pilot flame was not established during the pilot trial for ignition.
XX:XX:XX LOCKOUT
PILOT ON
Status
Status
Status
Pilot flame is proven; transformer is de-energized; remaining count-
down for pilot trial for ignition is.
Pilot valve and ignition transformer are energized; countdown for
pilot trial for ignition begins.
PILOT TRIAL FOR
IGNITION
POST PURGE
For purge & m odulation m odels: 15 second post purge is
started on burner shutdown.
Lockout
DIP switch improperly set or changed during cycle.
PROGM SW ITCH ERR
XX:XX:XX LOCKOUT
Status
For m odulation m odels only: Modulating motor is sent to high
fire.
PURGE TO HIGH
FIRE
PURGE TO LOW
FIRE
Status
For m odulation m odels 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.
RELAY FAIL
XX:XX:XX LOCKOUT
SAFE START OK
Status
Status
Control has completed internal safe-start check.
UNSAFE AIR SHORT
For purge & m odulation m odels: 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.
UNSAFE AIR SHORT
XX:XX:XX LOCKOUT
Lockout
For purge & m odulation m odels: Same conditions as above,
except the interlocks close before the switch reopens, causing a
lockout and the alarm being energized.
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Table 9.2 Remote Display Diagnostic Messages (continued)
MESSAGE
TYPE
EXPLANATIO N
UNSAFE FLAME ON
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.
UNSAFE FLAME ON
XX:XX:XX LOCKOUT
Lockout
Hold
Same conditions as above, except the cause has not been corrected
within 30 seconds, resulting in a lockout and the alarm being energized.
UNSAFE–FLM–PURGE
For purge & m odulation m odels: 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 sec-
onds, as in afterburn, the control will turn off the fan and continue
the sequence.
Lockout
For purge & m odulation m odels: Same conditions as above,
except the cause has not been corrected within 30 seconds, resulting
in a lockout and the alarm being energized.
UNSAFE–FLM–PURGE
XX:XX:XX LOCKOUT
V–INTERNAL FAULT
XX:XX:XX LOCKOUT
Lockout
Lockout
Status
Internal control failure; replace controller.
Internal control failure; replace controller.
W ATCHDOG FAIL
XX:XX:XX LOCKOUT
XXXXXXX
XXXXXTESTXX
In combination with other messages, shows the control is in the
minimum pilot test mode.
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Appendix
Metric to English.
CONVERSION
FACTORS
FROM
cubic meter (m3)
cubic meter/hour (m3/h)
degrees Celsius (°C)
kilogram (kg)
TO
cubic foot (ft3)
cubic foot/hour (cfh)
degrees Fahrenheit (°F)
pound (lb)
MULTIPLY BY
35.31
35.31
(°C x 1.8) 32
+
2.205
3414
kilowatt (kW)
Btu/hr
meter (m)
foot (ft)
3.28
millibar (mbar)
millibar (mbar)
millimeter (mm)
inches water column ("wc)
pounds/sq in (psi)
inch (in)
0.401
14.5 x 10-3
3.94 x 10-2
Metric to Metric.
FROM
TO
MULTIPLY BY
kiloPascals (kPa)
meter (m)
millibar (mbar)
millimeter (mm)
kiloPascals (kPa)
meter (m)
10
1000
0.1
millibar (mbar)
millimeter (mm)
0.001
English to Metric.
FROM
TO
MULTIPLY BY
0.293 x 10-3
2.832 x 10-2
2.832 x 10-2
Btu/hr
kilowatt (kW)
cubic foot (ft3)
cubic foot/hour (cfh)
degrees Fahrenheit (°F)
foot (ft)
cubic meter (m3)
cubic meter/hour (m3/h)
degrees Celsius (°C)
meter (m)
–
(°F 32) ÷ 1.8
0.3048
25.4
inches (in)
millimeter (mm)
millibar (mbar)
kilogram (kg)
inches water column ("wc)
pound (lb)
2.49
0.454
68.95
pounds/sq in (psi)
millibar (mbar)
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ILLUSTRATED PARTS
LIST
Pos.
No.
Model
Part
Description
Straight U.V. scanner
NEMA 4 U.V. scanner
90˚ U.V. scanner
Number
Number
Category
5600-91
49600-91
20898
49600-90
49600-92
49602-91
21349
1
5600-91N4
5600-90A
5600-92B
5602-91
5600-92SC
5602-91-7
5600-90A SS
2
I.R. scanner
Self-check scanner
3
4
5
Solid-state U.V./I.R. scanner
10-foot cable for self-check scanner
Scanner support (max. temp. 220˚F)
Scanner support (max. temp. 475˚F)
Magnifying lens assembly
Lens, magnifying
1
49602-91-7
20722
(1)
(1)
6
6
Sensors
5600-90A SSH 20723
5600-98
7
49600-98
49600-99
18165
(2)
Lens, non-magnifying
2
8
Insulated coupling
5600-99
49099
Cable, coax, RG62A/U for flame rod
21741
Internal terminal base, metal
Exposed terminal base, metal
Internal terminal base, plastic
Adapter Base RA890
Adapter Base R4795
Modulation base
5602-10
5602-10-1
5602-10-P
5602-12
5602-14
5602-40
49602-10
49602-10-1
22194
49602-12
49602-14
49602-40
22110
9
10
3
Bases
11
12
Screw, mounting to plastic base
Screw, mounting to metal base
22385
Tester for Veri-Flame units
5602
5602-40-4
49602
49240-2
Test
(3)
Relay module
Remote display, 24V
5602 DB
5602 DBP
20316
20896
20317
20318
Remote display, 120VAC with keypad
Display
(4)
Power supply, 24VDC
4
Cable for remote display
(1)
(2)
(3)
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.
(4)
To be used with 20316 display only (not 20896).
5
6
7
11
8
9
12
10
Instruction Manual 818 2/02
Litho in USA
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