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Fireye BurnerPRO - User Manual

Fireye BurnerPRO
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1
®
DESCRIPTION
The Fireye BurnerPRO is a compact, microprocessor based, primary flame safeguard control system
designed to provide the proper burner sequencing, ignition and flame monitoring for on-off, multi-
stage, or modulating burners used in commercial heating and process equipment firing oil and gas
fuels. The BurnerPRO flame safeguard offers two built-in amplifiers, which allows for use in UV
only, FR only, and UV+FR applications. Flame monitoring for UV is accomplished by using avail-
able UV scanners: UV90L, UV1AL & UV5. Flame monitoring for FR version is accomplished by
using available ionization rod: 69ND1. The FR amplifier circuitry is subjected to permanent self-
checking, which allows it for use in applications that require burner cycle that runs for more than 24
hours. When operated as a UV control, the system is considered non-permanent, which requires a
burner recycle at least once every 24 hours.
The valve proving feature checks for leakage through the safety shutoff valves prior to burner start-
up or immediately after a burner shutdown. The Modbus interface provides the ability to write cus-
tom timing parameters, as well as reading status information during burner operation.
Through seven SMART LEDs, the control provides current operating status and lockout information
in the event of a safety shutdown. Refer to the BurnerPRO ordering information section in this docu-
ment for the various combinations of control functions and timings.
A complete BurnerPRO system includes the BP110/230, flame scanner and wiring base. The Burn-
erPRO performs a safe-start check on every burner cycle. If flame is detected prior to a start or
during the purge cycle, the fuel valves are not energized and the control locks out. The ‘POC’ input
is also monitored to verify that the main fuel valves are always in the proper state prior to the start of
a burner cycle. The LEDs & alarm terminal are used to annunciate the presence of a lockout condi-
tion.
Expanded functions of the BurnerPRO:
Non-volatile lockout capability
Air-flow proving, Gas valve proving, & Modbus access
A run/check feature allows the operator to stop the program sequence in different
positions (Purge, Ignition, PTFI, MTFI, AUTO) for system troubleshooting
Modbus, Remote and local Reset ability
Two built-in amplifiers (UV, FR, UV+FR) for flexibility in applications
Smart LEDs provide on board diagnostic lockout information
Extended temperature operation (-40°C to 60°C)
High capacity relay contacts
FIREYE
®
BurnerPRO
MICROPROCESSOR-BASED
INTEGRATED BURNER
MANAGEMENT CONTROL
with UV & FR Flame Amplifiers,
Valve Proving Feature and Modbus Interface
BP-1003
SEPTEMBER 21, 2018

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Summary

BurnerPRO Control Description

BurnerPRO System Specifications

BurnerPRO Operational Timings

BurnerPRO Part Numbers and Approvals

Agency Approvals Overview

Overview of agency approvals including UL, CE, DIN DVGW, and DIN Geprüft.

BurnerPRO Product Certifications

Ordering Information Details

Detailed table listing BurnerPRO part numbers with corresponding series and features.

BurnerPRO Wiring Base

Fireye Scanner Selection Guide

BurnerPRO Mounting Recommendations

Wiring Base Mounting Guidelines

Guidelines for mounting the wiring base using specified screw sizes.

Grounding Wire Connection Instructions

Instructions for properly connecting the grounding wire to the wiring base.

BurnerPRO Wiring Base Dimensions

Mounting Hole and Knockout Locations

Diagram showing mounting hole locations and knockout hole specifications.

Side Views and Installation Notes

Left and right side views of the wiring base with installation notes.

BurnerPRO Terminal Wiring Guide

BurnerPRO Installation Procedure

General Installation Requirements

Wiring compliance, torque, limits, interlocks, and wire routing recommendations.

Maximum Wire Lengths

Specifies maximum lead wire lengths for inputs and flame detector wires.

BurnerPRO LED Indicators and Status

Status LED Descriptions

Detailed explanation of each status LED and its meaning during operation.

SMART LED Functionality

Describes the SMART LEDs' role in displaying flame strength in check mode.

BurnerPRO LED Run-time Status Indicator

LED Status Interpretation Table

Table mapping LED states to operational status, fault, or lockout conditions.

Fireye Flame Scanners

UV Scanner Installation Guidelines

General instructions for mounting UV scanners, including positioning and sealing.

UV Scanner Wiring and Installation

UV Scanner Wiring Specifications

Instructions for selecting wire and routing scanner wires, including conduit requirements.

69 ND1 Flame Rod Installation

Flame Rod Mounting Instructions

Guidelines for positioning the flame rod relative to the pilot and main flame.

Grounding Surface Requirements

Importance of adequate grounding surface for flame rod signal strength.

Flame Rod Wiring and Maintenance

Flame Rod Wiring Requirements

Wiring requirements for flame rectification systems, including insulation resistance.

Flame Rod Maintenance Procedures

Routine cleaning and replacement recommendations for the flame rod and insulator.

BurnerPRO System Operation Modes

Control Reset Functionality

Describes the two methods for resetting the control after a lockout.

Check Mode Operation Guide

Explains the CHECK MODE feature for set-up, start-up, and troubleshooting.

BurnerPRO Operational Sequence Flowchart

Sequence States and Transitions

Diagram detailing states like Power On, Initial System Check, Purge, Ignition, Trials, and Shutdown.

BurnerPRO Sequence State Explanations

Power On and System Check

Explains the initial power application and the internal Power-On Self-Test (POST).

Preconditions and Purge Cycle

Details preconditions for startup, call for heat, and the purge cycle steps.

Ignition and Trial Phases

Describes the ignition process, pilot trial, and main trial phases.

Burner Cycle Progression States

Pilot Trial and Main Trial Details

Explains the pilot trial, main trial, and flame signal verification.

Modulation, Shutdown, and Lockout

Details release to modulation, shutdown sequence, and lockout conditions.

Valve Proving System Operation

Describes the function and process of the valve proving system.

BurnerPRO Sequence Timing Diagram

Timing Legend and Definitions

Defines the timing parameters (t1, t3, t4, etc.) and sequence stages (A, B, C, D).

BurnerPRO Expanded Timings Table

BurnerPRO Operating Controls Functions

Limit Switches Explained

Details the function of Recycle and Non-Recycle/Lockout limit switches.

Proof of Closure and Purge Interlocks

Explains the Proof of Closure (POC) and Purge Interlock functions.

Running Interlocks Description

Describes various running interlocks for proper burner operation.

BurnerPRO External Actuator Interfacing

Direct Interfacing with Actuators

Diagram and explanation for direct line voltage interfacing with actuators.

Non-Direct Interfacing with Actuators

Diagram and explanation for low voltage interfacing using interposing relays.

BurnerPRO Example Wiring Diagrams

Modulating Burner Wiring (Interrupted Pilot, Valve Proving)

Wiring diagram for a modulating burner with interrupted pilot and valve proving.

BurnerPRO Example Wiring Diagrams (Continued)

Direct Ignition Burner Wiring (Non-Valve Proving)

Wiring diagram for a direct ignition burner without valve proving.

BurnerPRO Example Wiring Diagrams (Further Continued)

Modulating Burner Wiring (Intermittent Pilot, Non-Valve Proving)

Wiring diagram for a modulating burner with intermittent pilot, non-valve proving.

BurnerPRO Communications Protocol

Modbus RTU Message Format

Details the message format for Modbus RTU communication with the BurnerPRO.

Modbus Communication Setup

Information on Modbus port, physical connection, and required kits.

BurnerPRO Modbus Connection Diagram

Interface Board and Adapters Diagram

Diagram illustrating the connection between BurnerPRO, ED610 board, and UC485 adapter.

BurnerPRO Modbus Message Table

Static and User Command Data Registers

Map of registers for controlling burner operation, reset, and configuration.

Read-Only Data Registers

Map of registers for reading burner state, actuator position, and ignition status.

BurnerPRO Modbus Message Table (Continued)

AUTO, Recycle Limit, and POC Registers

Register mapping for AUTO drive state, Recycle Limit, and POC terminal status.

Timer and Counter Registers

Register mapping for various timers and counters like CAST, CAP, POC, and Check Mode.

BurnerPRO Modbus Message Table (Further Continued)

Operating Frequency and Burner Counts Registers

Register mapping for operating frequency, burner cycle count, and flame timers.

Lockout History and Count Registers

Register mapping for lockout count and detailed lockout history.

BurnerPRO Valve Proving System

Valve Proving Setup Methods

Describes single and dual pressure switch setups for valve proving.

BurnerPRO Valve Proving Details

Pressure Switch Selection Criteria

Steps for selecting and setting pressure switches for valve proving.

Two-Valve System Proving Wiring

Wiring and operation of a two-valve system for proving gas valve closure.

BurnerPRO Valve Proving Sequence Steps

Valve Proving Test Execution

Detailed steps for executing the valve proving test, including leak checks.

Calculating Valve Proving Test Times

Valve Proving Test Time Formula

Formula and variables for calculating test times based on pressure and volume.

Leakage Rate Standards

Specifies leakage rate standards for valve proving systems per EN 1643 and FM 7400.

Valve Proving Test Time Calculation Example

Example Calculation and Rounding

Provides an example calculation for test times and rounding recommendations.

BurnerPRO Lockouts and Resetting

Control Reset Methods

Describes push button and remote terminal methods for resetting the control.

LED Error;Lockout Codes Overview

Explains how LEDs indicate lockout reasons and the limits on remote reset attempts.

BurnerPRO LED Error;Lockout Codes

Lockout Code Mapping (1-32)

Table mapping LED patterns to specific fault conditions and lockout reasons.

BurnerPRO LED Error;Lockout Codes (Continued)

Lockout Code Mapping (33-63)

Table mapping LED patterns to specific fault conditions and lockout reasons.

BurnerPRO Lockout Code Explanations

Fault Code Explanations (1-36)

Provides possible remedies for lockout codes 1 through 36.

BurnerPRO Lockout Code Explanations (Continued)

Fault Code Explanations (37-63)

Provides possible remedies for lockout codes 37 through 63.

Fireye Product Warranty Information

Warranty Terms and Limitations

Details the warranty period, replacement/repair options, and exclusions.

Summary

BurnerPRO Control Description

BurnerPRO System Specifications

BurnerPRO Operational Timings

BurnerPRO Part Numbers and Approvals

Agency Approvals Overview

Overview of agency approvals including UL, CE, DIN DVGW, and DIN Geprüft.

BurnerPRO Product Certifications

Ordering Information Details

Detailed table listing BurnerPRO part numbers with corresponding series and features.

BurnerPRO Wiring Base

Fireye Scanner Selection Guide

BurnerPRO Mounting Recommendations

Wiring Base Mounting Guidelines

Guidelines for mounting the wiring base using specified screw sizes.

Grounding Wire Connection Instructions

Instructions for properly connecting the grounding wire to the wiring base.

BurnerPRO Wiring Base Dimensions

Mounting Hole and Knockout Locations

Diagram showing mounting hole locations and knockout hole specifications.

Side Views and Installation Notes

Left and right side views of the wiring base with installation notes.

BurnerPRO Terminal Wiring Guide

BurnerPRO Installation Procedure

General Installation Requirements

Wiring compliance, torque, limits, interlocks, and wire routing recommendations.

Maximum Wire Lengths

Specifies maximum lead wire lengths for inputs and flame detector wires.

BurnerPRO LED Indicators and Status

Status LED Descriptions

Detailed explanation of each status LED and its meaning during operation.

SMART LED Functionality

Describes the SMART LEDs' role in displaying flame strength in check mode.

BurnerPRO LED Run-time Status Indicator

LED Status Interpretation Table

Table mapping LED states to operational status, fault, or lockout conditions.

Fireye Flame Scanners

UV Scanner Installation Guidelines

General instructions for mounting UV scanners, including positioning and sealing.

UV Scanner Wiring and Installation

UV Scanner Wiring Specifications

Instructions for selecting wire and routing scanner wires, including conduit requirements.

69 ND1 Flame Rod Installation

Flame Rod Mounting Instructions

Guidelines for positioning the flame rod relative to the pilot and main flame.

Grounding Surface Requirements

Importance of adequate grounding surface for flame rod signal strength.

Flame Rod Wiring and Maintenance

Flame Rod Wiring Requirements

Wiring requirements for flame rectification systems, including insulation resistance.

Flame Rod Maintenance Procedures

Routine cleaning and replacement recommendations for the flame rod and insulator.

BurnerPRO System Operation Modes

Control Reset Functionality

Describes the two methods for resetting the control after a lockout.

Check Mode Operation Guide

Explains the CHECK MODE feature for set-up, start-up, and troubleshooting.

BurnerPRO Operational Sequence Flowchart

Sequence States and Transitions

Diagram detailing states like Power On, Initial System Check, Purge, Ignition, Trials, and Shutdown.

BurnerPRO Sequence State Explanations

Power On and System Check

Explains the initial power application and the internal Power-On Self-Test (POST).

Preconditions and Purge Cycle

Details preconditions for startup, call for heat, and the purge cycle steps.

Ignition and Trial Phases

Describes the ignition process, pilot trial, and main trial phases.

Burner Cycle Progression States

Pilot Trial and Main Trial Details

Explains the pilot trial, main trial, and flame signal verification.

Modulation, Shutdown, and Lockout

Details release to modulation, shutdown sequence, and lockout conditions.

Valve Proving System Operation

Describes the function and process of the valve proving system.

BurnerPRO Sequence Timing Diagram

Timing Legend and Definitions

Defines the timing parameters (t1, t3, t4, etc.) and sequence stages (A, B, C, D).

BurnerPRO Expanded Timings Table

BurnerPRO Operating Controls Functions

Limit Switches Explained

Details the function of Recycle and Non-Recycle/Lockout limit switches.

Proof of Closure and Purge Interlocks

Explains the Proof of Closure (POC) and Purge Interlock functions.

Running Interlocks Description

Describes various running interlocks for proper burner operation.

BurnerPRO External Actuator Interfacing

Direct Interfacing with Actuators

Diagram and explanation for direct line voltage interfacing with actuators.

Non-Direct Interfacing with Actuators

Diagram and explanation for low voltage interfacing using interposing relays.

BurnerPRO Example Wiring Diagrams

Modulating Burner Wiring (Interrupted Pilot, Valve Proving)

Wiring diagram for a modulating burner with interrupted pilot and valve proving.

BurnerPRO Example Wiring Diagrams (Continued)

Direct Ignition Burner Wiring (Non-Valve Proving)

Wiring diagram for a direct ignition burner without valve proving.

BurnerPRO Example Wiring Diagrams (Further Continued)

Modulating Burner Wiring (Intermittent Pilot, Non-Valve Proving)

Wiring diagram for a modulating burner with intermittent pilot, non-valve proving.

BurnerPRO Communications Protocol

Modbus RTU Message Format

Details the message format for Modbus RTU communication with the BurnerPRO.

Modbus Communication Setup

Information on Modbus port, physical connection, and required kits.

BurnerPRO Modbus Connection Diagram

Interface Board and Adapters Diagram

Diagram illustrating the connection between BurnerPRO, ED610 board, and UC485 adapter.

BurnerPRO Modbus Message Table

Static and User Command Data Registers

Map of registers for controlling burner operation, reset, and configuration.

Read-Only Data Registers

Map of registers for reading burner state, actuator position, and ignition status.

BurnerPRO Modbus Message Table (Continued)

AUTO, Recycle Limit, and POC Registers

Register mapping for AUTO drive state, Recycle Limit, and POC terminal status.

Timer and Counter Registers

Register mapping for various timers and counters like CAST, CAP, POC, and Check Mode.

BurnerPRO Modbus Message Table (Further Continued)

Operating Frequency and Burner Counts Registers

Register mapping for operating frequency, burner cycle count, and flame timers.

Lockout History and Count Registers

Register mapping for lockout count and detailed lockout history.

BurnerPRO Valve Proving System

Valve Proving Setup Methods

Describes single and dual pressure switch setups for valve proving.

BurnerPRO Valve Proving Details

Pressure Switch Selection Criteria

Steps for selecting and setting pressure switches for valve proving.

Two-Valve System Proving Wiring

Wiring and operation of a two-valve system for proving gas valve closure.

BurnerPRO Valve Proving Sequence Steps

Valve Proving Test Execution

Detailed steps for executing the valve proving test, including leak checks.

Calculating Valve Proving Test Times

Valve Proving Test Time Formula

Formula and variables for calculating test times based on pressure and volume.

Leakage Rate Standards

Specifies leakage rate standards for valve proving systems per EN 1643 and FM 7400.

Valve Proving Test Time Calculation Example

Example Calculation and Rounding

Provides an example calculation for test times and rounding recommendations.

BurnerPRO Lockouts and Resetting

Control Reset Methods

Describes push button and remote terminal methods for resetting the control.

LED Error;Lockout Codes Overview

Explains how LEDs indicate lockout reasons and the limits on remote reset attempts.

BurnerPRO LED Error;Lockout Codes

Lockout Code Mapping (1-32)

Table mapping LED patterns to specific fault conditions and lockout reasons.

BurnerPRO LED Error;Lockout Codes (Continued)

Lockout Code Mapping (33-63)

Table mapping LED patterns to specific fault conditions and lockout reasons.

BurnerPRO Lockout Code Explanations

Fault Code Explanations (1-36)

Provides possible remedies for lockout codes 1 through 36.

BurnerPRO Lockout Code Explanations (Continued)

Fault Code Explanations (37-63)

Provides possible remedies for lockout codes 37 through 63.

Fireye Product Warranty Information

Warranty Terms and Limitations

Details the warranty period, replacement/repair options, and exclusions.

Fireye BurnerPRO Specifications

General IconGeneral
Operating Temperature-40°F to +140°F (-40°C to +60°C)
ApplicationCommercial and Industrial Burners
Flame DetectionUV, IR, or UV/IR
ApprovalsFM, CE
OutputRelay