Beruflich Dokumente
Kultur Dokumente
Preface
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FLAME SAFEGUARD & COMBUSTION CONTROLS
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FLAME SAFEGUARD & COMBUSTION CONTROLS
FLAME SAFEGUARD
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FLAME SAFEGUARD & COMBUSTION CONTROLS
to fine-tune these sensors to meet the ever- purge, low fire start, check fuel-valve closed,
increasing demands for safety in the industry. post-purge and other functions.
Both residential and commercial FSG products
TYPES are designed with single burner appliances such
as furnaces and boilers in mind. These
There are many types of flame safeguard appliances require that the flame safeguard
controls designed for use in residential, control properly sequences the operation of the
commercial and industrial applications. burner system: energizing the combustion air
Residential FSG controls generally rely on a blower motor, purging the combustion chamber
thermocouple inserted into the pilot flame. The of any combustibles, opening pilot fuel valve and
heat in the thermocouple generates just enough energizing ignition, establishing main flame and
voltage to hold in a magnetic coil, which holds in monitoring flame for failure. All components
a spring-loaded plunger inside the automatic gas must be energized in the proper sequence to
valve allowing gas flow to the burner. The prevent unburned fuel from accumulating in the
plunger is manually pushed in and the pilot lit, equipment where it could cause a hazardous
followed by a short period of time for the condition. It continuously senses presence or
thermocouple to start generating enough current absence of flame while controlling the operation
to hold in the plunger. This system requires that and sequence of all components on the burner
the pilot flame is on at all times whether the in the proper order.
burner is on or off. As this wastes fuel, more
modern residential equipment utilize an Industrial FSG controls generally operate in a
automatic pilot light on-demand via spark multi burner environment. This environment
ignition combined with flame-rod flame places different demands on flame safeguard
detection. controls, the most important of which is the
ability of the flame detection system to
discriminate between its targeted flame and
other flames sharing the combustion chamber.
Programming and sequencing logic in a multi
burner appliance generally resides in a burner
management system (BMS) which may be in the
form of a programmable logic controller (PLC) or
a relay logic panel, or a combination of both. A
separate Fireye bulletin “Flame Safeguard
Controls in Multi Burner Environments”,
publication WV-96, deals with this subject in
detail.
COMBUSTION
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The above three products of combustion are achieving optimum results in any of these
chemical compounds. They are made up of functions. The following lists some variations of
molecules in which elements are combined in burner types found:
certain fixed proportions. As per the law of
science, matter is neither created nor destroyed a) Gaseous fuel fired:
in the process of combustion, and the heat given a) Natural draft burner
off in any combustion process is merely excess b) Inspirating burner
energy which the molecules are forced to c) Balanced draft burner
liberate because of their internal make-up. d) Induced draft burner
Stoichiometric combustion is obtained when no e) Forced draft burner
fuel or air goes unused during the combustion
process. Mixing and burning exactly the right Liquid fuel fired: (forced or balanced draft)
proportions of fuel and oxygen so nothing is left a) Mechanically atomized.
over does this. Combustion with too much b) Air atomized
(excess) air is said to be lean or oxidizing. The c) Steam atomized
excess air or oxygen plays no part in the
combustion process. In fact it reduces the Final fuel delivery and combustion-air & fuel
efficiency. The visual effect is a short and clear mixing varies dependent on the burner types as
flame. Combustion with too much fuel is said per the following examples:
to be rich or reducing, producing incomplete a) Gun type (gas or oil)
combustion. The visual effect is a long and b) Cane (spud) type (gas)
sometimes smoky flame. The oxygen supply c) Ring type (gas)
for combustion generally comes from the d) Rotary cup type (oil)
ambient air. Because air contains primarily
(78%) nitrogen, the required volume of air is
generally much larger then the required volume
of fuel. Primary air is air that is mixed with the
fuel before or within the burner's fuel delivery
system. Secondary air is usually brought in
around the burner's fuel delivery system and
spun through a diffuser or turning vane system
in order to optimize air-fuel mixing. Tertiary air is
air brought in downstream of the secondary air
and is sometimes used to control the shape of
the flame envelope, and/or to control flame
temperature on low-NOx burners.
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A burner must be equipped with a monitoring its viscosity in order to facilitate pumping and
and control system to assure safe and reliable straining.
operation throughout its intended use.
Complexity of this system is in relation to Btu/Lb Kcal/Kg
complexity of the process at hand and can vary Fuel (Btu/Gal) (Kcal/L)
from a single burner firing a single fuel, to a multi Burned
Gross Net Gross Net
burner environment where many burners are
operating into a common combustion chamber Blast
and a multiple choice of fuels are burned. The furnace 1,179 1,079 665 599
gas
larger the burner input, or heat release of a
burner, does not necessarily mean the more Coke oven
18,595 16,634 10,331 9,242
gas
complex the monitoring and control system
needs to be. Natural
21,830 19,695 12,129 10,943
gas
Conditions effecting complexity of control Propane
systems for burners are generally stipulated by: 21,573 19,886 11,986 11,049
gas
a) Type of process.
b) Type of burner. Oil #2
18,993 17,855 10,553 9,920
(137,080) (128,869) (9,130) (8,583)
c) Multi or single burner environment.
d) Multi or single fuel operation.
18,126 17,277 10,071 9,599
e) Safety hazard of fuel burned Oil #6 (153,120) (145,947) (10,198) (9,720)
f) Local codes and standards.
g) Redundancy and reliability factors. Coal 14,030 12,900 3,500 3,100
h) Continuous or intermittent burner operation.
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FLAME ROD
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electrodes were placed in a flame and a voltage The large grounding electrode generally forms
was applied, a current would be conducted part of the burner’s fuel-nozzle, helping to
between the two rods (flame rods). Naturally the stabilize and hold the flame firmly in place.
positively charged ions would flow to the Flame rods are simply small diameter metal rods
negatively charged rod. In order to use this supported by an insulator in order to be able to
process to determine presence of flame and to mount it such that the tip-end of the rod can
prevent the potential hazard of a high resistance project into the flame. Flame rods typically are
short to ground effectively simulating flame made of a material called Kanthal, a high
signal, the flame current is rectified. temperature alloy capable of operating in
temperatures of up to 2400 degree F. or 1300-
degree C. Other materials for even higher
temperature ratings such as Globar, a ceramic
material, are also available.
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Advantages of flame rod applications: the rod directly above the burner assembly is
a) Location sensitive. Flame rod detectors least favored as this may allow it to prove a lazy
prove the flame with extreme location upward bending inadequate flame.
sensitivity. The flame must be where the
relative small rod can be in contact with it. Some atmospheric burner assemblies use a
This is most useful in controlling for runner type pilot, a pilot that is used to light off
example, that a pilot flame is detected only more than one burner. It may consist out of a
when it is at the optimum location to reliably tube with holes drilled along its side through
ignite the main burner. Flexibility in placing which fuel gas is burned. An assembly such as
the rod can assure this. Also, this location this requires it to be proven at its ignition source
sensitivity will detect flame lift-off and as and also at the extreme end of the runner pilot.
such can be used to prevent unstable flame A thermocouple may be used to prove the pilot
conditions for both pilot and main flames. at the ignition source and a flame rod may be
b) Fast response time. The relative low cost used to prove it at its extreme, with the flame rod
flame rod system has been put to use system in charge of main fuel.
replacing many, and sometimes working as
an auxiliary to, slow responding bi-metal and On some direct fired air handling units burners
thermocouple based systems. are installed which are of significant length
c) Fail-safe system. Using electronics, this requiring the main flame to be detected at the
system responds safely to abnormal end farthest away from the ignition source. This
conditions such as open or short circuits, also has proven to be an ideal job for flame rod
leakage to ground, all causing the system to systems.
fail-safe.
INSTALLATION AND APPLICATION
Ideally, the flame rod is mounted vertically
alongside its vertical burner nozzle with only the The Fireye part number 69ND1 flame rod is a
tip bent in to make contact with the flame spark plug type unit consisting of ½” NPT mount,
envelope. When installing a flame rod on a a Kanthal flame rod, a glazed porcelain
horizontally orientated burner assembly, care insulating rod holder and a spark plug connector
must be given to favor installing the rod on either for making the electrical connection. The 69ND1
one of the sides of the burner or directly below, is available in 12”, 18” or 24” lengths.
with the tip bent up to make contact. Installing
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The flame rod may be located to monitor only wire runs can be up to 200 feet long. Do not
the gas pilot flame or both the gas pilot and main share the flame rod wire with ignition wires
gas flames. It is mounted on a ½” NPT coupling. in same conduit.
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insufficient visible light for detection. In applying tube electrodes. Generally the voltage supplied
these detectors, special attention must be given to the tube is AC. (DC voltage may also be used
to: along with a square pulse generator). Voltage
1) As with all optical detectors, the cell must across the electrodes will go to zero for each
have full view of the flame monitored. half cycle of AC, allowing the tube to restore
2) Care should be given to protect it from itself to a non-ionized or quenched state. On the
possible visible light emitted by hot next voltage half cycle the current is re-
refractory or other sources. established across the electrodes in order to fire
3) The detector must be protected from if UV radiation is present.
ambient temperatures in excess of 165 F
(74 C).
4) Proper wire must be used to connect the
detector. Temperatures above 125 F (52 C)
may require specially protected wiring.
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the detectors' count goes to zero except for very The shutter opens and closes continuously,
infrequent firings, inherent in this type of design, effectively blocking the UV radiation for a brief
to which the system does not respond. UV period (0.25 to 0.75 sec. depending on design,
flame detectors are designed to respond to UV but less than the FFRT). The FSG system
sources in a flame, however it is possible for the drives the scanner self-check shutter
detector to respond to other sources of UV mechanism and checks for the scanner's pulse
radiation such as: Hot refractory well above count to stop during the shutter-closed period.
3000 degree F, also spark-ignition, welding arcs, Scanner pulse counts detected during the
halogen light, etc. Care should be taken to shutter closed time causes the system to react
avoid picking up unwanted signal from any of to scanner self-check failure; by shutting off fuel
these sources at, or near the burner-front. Ultra and going to lockout. When using UV tube-type
violet detection tubes can deteriorate due to flame detectors, a scanner with self-check
degeneration of the special gas inside the tube. feature is mandatory for burners or appliances
The cause of this could be over-heating the that are designed for continuous operation.
tube, subjecting the tube to excessive voltages
or subjecting the tube to excessive UV radiation
for long periods of time. Tubes deteriorated in
this way can operate in a random failure mode;
sometimes firing continuously after having
started and failing to quench, or sometimes firing
inconsistently causing nuisance shutdowns.
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This ability of the flame scanner to pick up flame spectrum. Where the detector is sighted at the
flicker frequency can be adversely affected by ignition zone of the targeted flame, it is not
over-powering low frequency radiation from uncommon to find that the lowest frequencies
furnace background. increase dramatically in a "flame off" condition.
This is due to the ignition zone of the targeted
flame "masking" the bright background low
frequency radiation while the targeted flame is
on. Upon disappearance of the targeted flame
this background radiation comes into full view.
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TROUBLE SHOOTING AND TESTING OF 6. Faulty detector rod (flame rod), cell
FLAME DETECTORS. (infrared) or tube (UV).
7. Excessive detector temperatures.
Any flame detector system must be thoroughly 8. Detector location.
inspected and tested prior to putting the system
into permanent service. The following is a HOT REFRACTORY SATURATION TEST
suggested listing of tests used to assure a safe
system of flame detection: Performed to insure that hot refractory does not
1. Flame signal measurement (required for all blind or saturate the detector, preventing it from
types of flame detectors). sighting radiation from the targeted flame.
2. Hot refractory saturation test (required for a) Start burner.
infrared flame detectors). b) Monitor flame while heating refractory.
3. Hot refractory hold-in test (required for c) Note if any decline in flame signal as
visible light and infrared flame detectors). refractory heats.
4. Ignition spark sensing test (required for d) If signal declines, detector likely sights
ultraviolet flame detectors). refractory. Try re-sighting scanner to see
5. Ignition interference test (required for flame little or no refractory. If not possible try
rod type detectors). placing an orifice in front of scanner lens to
6. Pilot turndown test (required for all flame reduce field of vision. Alternately, changing
detector types, when used to detect pilot to a UV scanner may resolve this problem.
flame).
HOT REFRACTORY HOLD-IN TEST
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c) Monitor for any flame signal during ignition d) Reduce fuel supply to the pilot burner until
spark period. flame signal is at its minimum (see technical
d) There should be no signal what so ever. bulletin of FSG control for this information).
e) If any signal, take corrective action: Either This is the minimum pilot detectable.
re-sight the detector, or shield the detector e) Light off main fuel and insure that the main
from the spark via a metal shield at ignition flame lights off promptly and smoothly
electrode. (within 1 second).
f) If light off appears to be delayed, re-sight
IGNITION INTERFERENCE TEST detector so that a larger minimum pilot flame
is required.
The ignition interference test is done on any g) Repeat test until main lights smoothly with
flame rod system. It serves to determine minimum pilot.
whether or not ignition interference is creating a h) After completion of test, restore pilot flame
false flame signal from electrical noise, created to its normal capacity.
by the ignition and superimposed on the flame
rod system. Note that this can be either additive
or subtractive to the flame signal.
a) Start normal burner cycle.
b) Monitor flame signal during, and after spark
ignition.
c) If a noticeable difference is observed,
ignition interference is experienced and the
following may help to alleviate
a) Check for proper grounding area.
b) Maintain maximum distance between
ignition electrode and flame rod.
c) Check ignition electrode(s) spacing (1/16”
to 3/32”)
d) Replace deteriorated ignition / flame rod
leads.
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Swivel mounts are used to simplify scanner little of this purge/cooling air; 4 SCFM or
sighting. They are available for ½” and 1” NPT 113L/min is recommended.
scanner mountings and are bolted to the burner Fireye self check scanners are provided with a
front. The scanner sight-tube is threaded into the 3/8 “ NPT purge air opening. Infrared, 48PT2
swivel mount, with the scanner mounted at the and UV, UV1A scanners need to have fittings
other end. When satisfactory aiming is achieved, installed on the sight tube arrangement to suit.
the swivel mount’s locking bolts are tightened.
Purging air is used to prevent the sight tube Fig. 24 Water-cooled sight tube for ½ inch
from becoming obstructed by dust or dirt and mount scanners.
also serves to keep the scanner cool.
For large multi burner furnace installations The copper tees need the end-stops located
scanner cooling air fan assemblies may be inside the female ½ inch connections removed
used. These fans provide ambient air at a few in order to allow a ½ inch copper tube to run
inches of water column above furnace pressure uninterrupted from the sight tube end to scanner
and this air is distributed to all scanners via end. This arrangement can easily be adjusted to
cooling air piping. On smaller installations be used with 1 inch mount scanners also.
instrument-air is often used. Scanners need very
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COMMON TERMS IN FLAME SAFEGUARD Standing Pilot, or continuous pilot, is a pilot that
burns regardless of whether the burner is firing
Flame failure response time (FFRT) is the time or not. Generally these pilots are used in
from loss of flame, to the closure of fuel valve(s). atmospheric burner systems and most often
This may vary from 4 seconds (maximum) to need to be manually lit. In any event, a standing
less than 1 second. The control may respond pilot must be monitored by a flame detection
by recycling or re-lighting the burner, or by going system.
into a safety lockout requiring manual reset.
FLAME SAFEGUARD CONTROLS
Prepurge is required to provide a complete air
change to the combustion chamber. A prepurge A flame Safeguard system consists of a flame
time is a period of time after the combustion air safeguard control, also called flame relay, and a
fan has been started and proven, (sometimes flame detector. The primary functions of a flame
the combustion air damper is driven and proven safeguard control is to:
to the high purge position) during which the 1. Properly sequence the burner’s operation
combustion chamber and flue gas passages are through its start up, running cycle and its
provided with minimum of four complete air shutdown.
changes. 2. Provide flame supervision, de-energizing the
fuel supply valves within the flame failure
Pilot Trial For Ignition time (PTFI) is the response time if flame is no longer detected.
maximum time allotted for the system to 3. Monitor the safety interlocks before and
establish and detect the pilot flame during start during the operation of the burner.
up. Failure to establish the pilot flame within the 4. Provide “safe start check”, during which the
selected PTFI will cause the flame safeguard control prevents a burner start up if flame
system to lockout on safety, requiring a manual signal is present prior to its next cycle.
reset.
OPERATING INTERLOCK CIRCUIT
Main Trial For Ignition time (MTFI) is the
maximum time during which both the pilot and The operating interlock circuit, when closed,
main fuel safety valve(s) are permitted to be cycles the burner on and off. Burner cycling, or
open before the pilot valve is de-energized and operation, i.e. call for heat, or call for steam, is
the flame safeguard system is to supervise the provided by the Controller. The controller is the
main flame alone. device which cycles the burner, for example: An
aquastat for hot water systems, an area
Post Purge time is a short period of time (10 – thermostat for commercial heating systems, or a
15 sec.) after the a burner cycle during which pressure sensor for steam boilers. The
the combustion air fan continues to operate, controller is wired into the operating interlock
evacuating products of combustion from the circuit. Other devices such as a low water cut-
furnace area. off, or remote setpoint control, are sometimes
also wired into the operating interlock circuit,
TYPES OF PILOT BURNERS preventing the burner from operating unless the
device allows it, and recycling the burner when
Interrupted Pilot: is a pilot that is ignited during the condition is met.
each burner cycle and withdrawn after
establishing main flame, at the end of MTFI. RUNNING INTERLOCK CIRCUIT
Intermittent Pilot: is a pilot that is ignited with The running interlock circuit, when closed,
each cycle and remains on throughout the entire insures the operating limits of all safety devices
running cycle and is terminated the same time wired into it are met. The term “running interlock
as the main flame at the completion of each circuit” refers to the fact that some of the safety
cycle. In order to have an MTFI period, the devices being checked are not into play until the
burner must utilize an interrupted pilot, unless flame safeguard control has started its cycle. For
two separate flame detectors are used; one for example, the combustion air fan is first turned on
pilot and one for main. by the control and then its proper operation is
verified via an “air-proving device”.
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FIREYE, M SERIES II
Programmer modules may be equipped with
Fireye, Modular M Series II controls are of solid dipswitches to select Purge timing, Pilot Trial for
state design and provide a multitude in basic Ignition (PTFI) timing, and Recycle or Non-
styles of functions. The M Series II is a Recycle operation. The M Series II has a clear
compact, modular design flame safeguard plastic window covering all dipswitches, which
control, designed to provide automatic ignition must be in the closed and permanently locked
and flame monitoring for commercial heating position in order for the programmer to be
and process burners. Interchangeable operational. Programmer modules are also
programmer and flame amplifier modules allow provided with LED indicator lights characterizing
for versatility in selection of control functions, the operating status of the control.
timing, and flame detector types. The
programmer module determines control The following components are required for a
functions. Detector type and flame failure complete system.
response time (FFRT) are determined by the 1. Control Chassis
amplifier module. 2. Amplifier Module
3. Programmer Module
4. Wiring Base
5. Flame detector
Fuse Jumper
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Fireye, Micro M Series controls are of This remains true even if power was removed
microprocessor based design and, as with the M and later restored during a lockout condition.
Series II, are a modular burner management Lockout codes are described in detail in the
system designed to provide automatic ignition Micro M technical bulletin MC-5000.
and continuous flame monitoring for commercial There is also provision for “Smart Reset”, in
sizes of heating and process equipment firing where the control’s remote reset terminals of
any type of fuel. The Micro M design is multiple units can be wired parallel to a common
backward compatible to the wiring base of push button. Useful in a multi burner system
existing UVM, TFM and M Series II controls. The where the controls are mounted in a common
Micro M incorporates smart diagnostic LED’s panel. The Smart Reset function allows, when
causing the programmer’s LED’s to illuminate in the remote reset push button is energized for
a coded sequence identifying the reason for the between 3 and 5 seconds, to reset only those
lockout. controls which are in lockout condition, without
affecting those which are in normal operation.
The Micro M control is also compatible with the
Fireye alpha numeric display module, part no.
ED510, which can be remote-mounted for
permanent use via a remote mount kit part no.
129-145, or can be used hand-held as a service
tool to retrieve important service related
information.
Serial communications are available via either a
Modbus driver, or a Fireye E500
communications interface.
The Micro M series control provides for greater
flexibility in flame detector selection. In addition
to the standard UV1A non self-check UV, and
Flame Rod applications, this control is also
compatible with 45UV5-1009 self-check UV
scanners, 48PT2 Infra Red scanners, and
Cadmium Sulfide detectors.
Amplifier modules are selected based on type of
flame detector and required flame failure
response time (FFRT).
Programmer modules are equipped with smart
LED’s and may be equipped with dipswitches to
select Purge timing. Pilot Trial for Ignition (PTFI)
timing, and Recycle or Non Recycle operation.
A “Burn-in Time” , at which the dipswitch setting
become permanently stored, occurs after 8
hours of continuous operation of the control.
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TROUBLE SHOOTING M SERIES CONTROL • Defective ignition transf. (Check for spark).
• Incorrect spark-gap at igniter assembly.
No voltage at term. L1 – L2 • Incorrect location of spark electrode tips in
• Electrical supply switched off. relation to pilot burner.
• Blown fuse or tripped breaker. • Incorrect wiring of pilot components.
• Bent Tab on bottom of control.
• Loose connection. Pilot fails to be detected, PTFI LED on for 10
• Wiring error. seconds, followed by lockout. Yet visual
presence of flame.
Improper voltage at term. L1 – L2 • Flame detector not detecting flame.
• Min. operating voltage 102vac • Inadequate pilot flame.
• Max. operating voltage 132vac • Improper amplifier module installed.
• Flame rod not making contact with flame.
No voltage at term. 7 • Defective flame rod. (porcelain)
• Burner on/off switch off. • Grounding surface of pilot assembly too
• Operating or limit control open. small (corroded). Replace pilot burner. See
• Loose connection. page 8
• Wiring error. • Incorrect detector wiring.
• (Flame rod system). No ground-path from
Voltage at term. 7 but not term. 8 pilot burner to FSG control. Provide ground
• Control is in lockout.(Alarm LED on) wire from control chassis to pilot assembly.
• False flame signal detected (Flame LED is Provide ground to terminal S1.
on). Check for false flame being detected, or • Flame detector dirty.
possibly incorrect scanner wiring causing • Incorrect line of sight for flame detector.
electrical noise. • Unstable pilot flame.
• Defective UV tube giving false flame signal. • Defective flame detector or amplifier
• Defective control chassis. module.
Voltage at term. 7 but not term. 6 It takes seconds before the pilot flame is
• Interlock(s) wired between term. 8 and 6 detected after pilot valve and ignition
open. (Airflow LED remains off) transformer are energized.
• Wiring error. • Incorrect location of spark electrode tips in
relation to pilot burner.
Control locks out before prepurge begins. • Incorrect (too high) fuel pressure.
• Prove Airflow (Term. 8 – 6) open on start is • Incorrect primary air adjustment on pilot
selected “enabled” via its dipswitch. burner.
It seems prepurge is too long. Main flame fails to establish after PTFI
• Check dipswitch settings on programmer • Run check switch in “check” (500 series
module. programmer modules only)
• Main, manual shut off valve closed.
PTFI starts, PTFI LED on programmer • Defective main safety shutoff fuel valve.
module lights, but no power on term. 3 & 4. • Improper fuel pressure.
• Fuse is blown (Inside program module for • Main valve opening causes fuel pressure
MC120, on chassis for MEC120 type limits (high or low) to trip.
control). • Wiring error to main fuel valve.
Pilot fails to establish, PTFI LED on for 10 Main flame lights, but goes out when pilot
seconds, followed by lockout. No visual flame is shut off (500 series program
presence of flame. modules only)
• Fuel supply shut off. • Main burns off-ratio. Main fuel pressure too
• Air in fuel line (needs purging) high.
• Defective pilot valve. • Main burner improperly adjusted.
• Incorrect fuel pressure (check pilot reg.) • Scanner does not detect main flame.
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Figure 44 is an example of a control wiring When the dampers are fully open, the damper
arrangement for an air make up unit. Air make end-switch closes and will provide voltage to the
up units are generally mounted on the roof of the motor starter coil, starting the blower motor.
building and are provided with a remote control Outside air is now forced into the building.
panel which is located inside the building for To heat the make up air, close the heat switch.
ease of operating the equipment. All other This will energize the flame safeguard control by
equipment shown is located on the unit. powering its terminal 7 and 1, and a control
Fused, 3 phase power is run to a disconnect, sequence will begin as described in figure 41
which generally is attached to the outside of the Temperature control is achieved via a direct
unit. From the disconnect, the 3 phase power acting control valve having a capillary tube in the
wires are run to the motor starter/overloads, and discharge duct.
on to the blower motor. A step-down Prepurge is not required in air make up
transformer provides 120vac control-voltage; L1 equipment, as large amounts of air are moved
(hot) and L2 (neutral). From the transformer, L1 across the burner area at all times.
is run through a fuse and connected to the fan
switch located in the remote control panel.
To operate, close the fan switch. The inlet
damper motor opens and exhaust interlocks, are
checked.
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Figure 45 is an example of a control wiring All limits wired between terminals 8 and 6 must
arrangement for a small power burner mounted be satisfied and a control sequence will begin as
on a steam boiler. Fused control voltage (L1) is described in figure 43
wired to terminal 1 from where it is run to the Two stage firing control is achieved via separate
boiler on/off switch. From the switch a wire is controller (not shown).
run to the boiler operating control and
terminated at terminal 7, completing L1 to 7.
Running interlocks are shown wired between
terminals 8 and 6, some of these such as low
water cut-off may be found wired in series with
the operating control between terminals 1 and 7.
To operate, close the on/off switch. On a call for
steam and with other limits wired into the 1 to 7
circuit satisfied, terminal 8 will become
energized, starting the combustion air blower.
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FLAME SAFEGUARD & COMBUSTION CONTROLS
D Series Amplifiers
• 72D1R1 Infrared, 2-4 sec. FFRT
• 72D1R1T Infrared, 1 sec. FFRT
• 72D1R3 Infrared, 2-4 sec. FFRT for solid
fuel only.
• 72D1R3T Infrared, 1 sec. FFRT for solid
fuel only.
• 72DRT1 Flame Rod, 2-4 sec. FFRT
• 72DRT1T Flame Rod, 1 sec. FFRT
• 72DUV1 UV, 2-4 sec. FFRT
• 72DUVS4 UV Self-Check, 2-4 sec. FFRT
• 72DUVS1T UV Self-Check, 1 sec. FFRT
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FLAME SAFEGUARD & COMBUSTION CONTROLS
Fig. 49
A 70D10 and 70D20 control chassis is equipped Terminal Test-Points Run Check Switch
with five LED indicator lights each of which are Fig. 50
labeled:
1. Blower – Lights when blower circuit is
energized (Terminal M). For trouble shooting the control there are
voltage test-point for each terminal. These are
2. Purge – Lights when firing rate motor is identified and located on the edge of the chassis
driven to high fire (prepurge) position board, see figure 50.
(Terminals 10 – X).
When trouble shooting be sure that:
3. TFI – Lights during trail for ignition
4. Fireye – Lights when flame is detected. 1. Wiring is accordance with instructions
5. Auto – Lights when firing rate motor is 2. Contact tabs on bottom of chassis are not
released to modulate (Terminals 10 – 11). bent out of position.
3. Chassis is firmly secured in wiring base.
FLAME SIGNAL STRENGTH 4. The Run-Check switch is in the desired
position.
Test Jacks are provided on the front of the 5. The correct amplifier module is installed for
amplifier module to accommodate measuring the flame detector used.
the flame signal strength using a 1,000 ohm/volt 6. The flame detector is clean.
(or greater) DC voltmeter, or a digital meter with 7. The lock-out switch is reset.
an input impedance of 500K ohms or greater.
Normal flame signal strength reads 18 – 25vdc
Flame Relay drop-out is approximately 5vdc
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TROUBLE SHOOTING D SERIES CONTROL 70D10 only: Modulator driven to high, but no
further progress in program sequence.
No voltage at term. L1 – L2 (Blower and Purge LED’s on).
(All LED’s off) • High fire purge interlock end-switch not
• Electrical supply switched off. made. Terminals D - 8
• Blown fuse or tripped breaker.
• Bent tab on bottom of control. Modulator driven to low, but no further
• Loose connection. progress in program sequence.
• Wiring error. (Blower LED on).
• Low fire end-switch not made.
Improper voltage at term. L1 – L2 Terminals M - D
• Min. operating voltage 102vac
• Max. operating voltage 132vac PTFI starts, TFI LED on programmer module
lights, but no power on term. 5 & 6, Control
No voltage at term. 13 locks out.
• Burner on/off switch off. • Replace 70D control chassis.
• Operating or limit control open.
• Loose connection. Pilot fails to establish, Blower and TFI LED’s
on for 10 seconds, followed by lockout. No
• Wiring error.
visual presence of flame.
No voltage at term. 3 • Fuel supply shut off.
(All LED’s off) • Air in fuel line (needs purging)
• Fuel valve’s “proof of closure” switch open. • Defective pilot valve.
• System has no POC switch and no jumper • Incorrect fuel pressure (check pilot reg.)
installed at terminals 3 – 13 • Defective ignition transf. (Check for spark).
• Bent tab on bottom of control. • Incorrect spark-gap at igniter assembly.
• Incorrect location of spark electrode tips in
Blower motor does not start. relation to pilot burner.
(Blower and Purge LED’s on) • Incorrect wiring of pilot components.
• Control is in lockout.
• Motor three-phase power off. Pilot fails to be detected, Blower and TFI
• Defective motor or contactor. LED’s on for 10 seconds, followed by
• Bent tab on bottom of control. lockout. Yet visual presence of flame.
• Defective control chassis. • Flame detector not detecting flame.
• If no voltage at term. M, replace chassis. • Inadequate pilot flame.
• Improper amplifier module installed.
Blower runs, but control locks out before • Flame rod not making contact with flame.
end of purge. • Defective flame rod. (porcelain)
(Blower, Airflow and Fireye LED’s on). • Grounding surface of pilot assembly too
• False flame is detected. small (corroded). Replace pilot burner. See
• Check for actual flame being detected. page 8
• Check for incorrect scanner wiring causing • Incorrect detector wiring.
electrical noise, causing false signal. • (Flame rod system). No ground-path from
• Defective UV tube giving false flame signal. pilot burner to FSG control. Provide ground
• Defective amplifier module. wire from control chassis to pilot assembly.
• Provide ground to terminal S2.
• Flame detector dirty.
Blower runs, purge is not initiated, 70D10 • Incorrect line of sight for flame detector.
locks out, 70D20 does not. • Unstable pilot flame.
(Airflow LED remains off) • Defective flame detector or amplifier
• Interlock(s) wired between term. 3 and P module.
open.
• Wiring error.
• Bent tab on bottom of control.
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FLAME SAFEGUARD & COMBUSTION CONTROLS
It takes seconds before the pilot flame is Reposition detector for more angular view if
detected after pilot valve and ignition possible.
transformer are energized. • Pilot burner “pulled away” from flame rod by
• Incorrect location of spark electrode tips in main burner firing. (Flame rod systems on
relation to pilot burner. natural draft burners).
• Incorrect (too high) fuel pressure. • Power spike, unnoticed by FSG but closing
• Incorrect primary air adjustment on pilot fuel solenoid valves.
burner. • Operating, or running interlock limit “weak”
causing short drop in voltage, unnoticed by
Main flame fails to establish after PTFI FSG but closing fuel solenoid valves.
(Blower, TFI and Fireye LED’s on) • Insufficient grounding to control wiring base.
• Run check switch in “check” (located in • Flame detector wiring in common conduit.
programmer modules ) Should be in separate conduit.
• Main, manual shut off valve closed. • Interference by x-rays or extreme sources of
• Defective main ESD fuel valve. electrical noise.
• Improper fuel pressure. • Defective main safety shutoff valve.
• Main valve opening causes fuel pressure • Defective main gas regulator.
limits (high or low) to trip.
• Wiring error to main fuel valve. SPECIFICATIONS:
Main flame lights, but goes out when pilot Supply Voltage: 120vac (max. 132, Min.
flame is shut off. 102vac)
(Blower LED on) Pwr Consumption: 20VA operating
• Main burns off-ratio. Main fuel pressure too Max. connected load: 2000VA
high. Temp. Rating: Max. 125 F, Min. –40 F
• Main burner improperly adjusted. Max. load ratings for:
• Scanner does not detect main flame. • Term. 5 & 6 (ind. or combined) 550Va
• • Term. 7: 250Va (Pilot duty)
Flame Signal diminishes with time after main • Term. M: 9.8 F.L.A. 58.8 L.R.A.
burner lights. • Term. 10-11-12-X: 125Va Pilot duty
• Main burns off-ratio. Main fuel pressure too • Term. A: 50Va pilot duty
high.
• Main burner improperly adjusted.
• Infrared detector saturates. (see page 16)
• Bad UV tube in ultraviolet flame detector.
• Steam atomization blocks flame signal. (UV
detector on steam atomized oil burner).
Reposition detector for more angular view if
possible.
• Pilot burner “pulled away” from flame rod by
main burner firing. (Flame rod systems on
natural draft burners).
• Excessive scanner temperatures.
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FLAME SAFEGUARD & COMBUSTION CONTROLS
FLAME MONITOR during pre-purge and trial for ignition timings are
determined by the choice of programmer
module. Amplifier modules are selected based
on flame detector used.
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FLAME SAFEGUARD & COMBUSTION CONTROLS
AMPLIFIER MODULES
Note 1:
The E1R2 has increased sensitivity,
Amplifier modules used in conjunction with the which may result in unsafe operation if
Flame Monitor System are selected based on not properly applied. Increased
the type of flame detector. sensitivity implies that far less infrared
The amplifier module is installed in the third set radiation intensity is required as
of guide channels found in the Flame Monitor received from the flame envelope to be
Chassis, where it is clearly marked “Amplifier accepted as flame on. Only special
Module”. applications can operate safely with this
There is a total selection of six amplifier amplifier. Consult factory before using.
modules. The following table assists in clarifying Note 2:
the specifics of each. The E1R3 does not provide oil spray
rejection protection, which may result in
unsafe operation if not properly applied.
Oil Spray Rejection implies that the
system responds to any significant
change in level of flame-brightness,
such as a flame out condition where oil
continues to be sprayed in front of
bright, hot refractory. Consult factory
before using.
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FLAME SAFEGUARD & COMBUSTION CONTROLS
Fig. 57 Flame Monitor Programmer Programmers for the Flame Monitor system are
selection chart designated with prefix “EP” or “EPD”.
PROGRAMMERS
The programming module is the hearth of the EP programmers are designed to receive the
system. Figure 57 represents a chart of the ED510 display module “snapped into the face of
most common programmers and lists the the module.
programming sequence. EPD programmers are designed with an integral
Note that programming functions in the LED display and are compatible to be used with
sequence may be selectable via dipswitches an additional remotely mounted ED510 display
located on the module. module.
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FLAME SAFEGUARD & COMBUSTION CONTROLS
UP
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FLAME SAFEGUARD & COMBUSTION CONTROLS
WIRING
Figures 60 and 61 show generic wiring Figure 62 shows the wiring for a proportioning
schematics for flame monitor. Needless to say, controller with slide wire (135 ohm)
each application has its peculiarity and style. But potentiometer system. A potentiometer, or
these diagrams, in conjunction with the flame variable resistor, consists of a fine wire wound
monitor “control sequence diagram”, give a clear around a core (term. W – B). A wiper rests on
indication of the function of each terminal at this assembly and moves along the windings.
specific periods in the control sequence. Use The wiper is connected to terminal R. As the
these schematics in conjunction with the wiper moves back and forth (as determined
equipment’s wiring diagram. mechanically by the process demand), the
resistance between R and W, and between R
FIRING RATE MOTOR CIRCUIT and B changes. If the wiper moves toward W,
the resistance between R and B increases, and
the reverse is true, in that if the wiper moves
toward B, the resistance between R and W
increases. The modulating motor has a similar
feed back potentiometer, which works in
conjunction with a balancing relay. The unequal
currents flowing through each side of the
balancing relay will cause the relay to pivot ,
engaging the appropriate motor windings.
Increasing resistance in the B wire of the motor
circuit will cause the motor to drive to the low, or
closed position. Increasing the resistance to the
W wire of the motor circuit will cause the motor
to drive to the high or open position. As is clear
from figure 62, resistance between R and B, or
R and W are manipulated by the Flame
Monitor’s firing rate motor switching circuit,
causing the desired effect during the control
sequence.
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FLAME SAFEGUARD & COMBUSTION CONTROLS
Communications Maintenance
When interfacing Fireye controls to a Periodically, the spark electrode should be
communication system, be it an E500, PLC or inspected for proper gapping and cracked
other microprocessor based device, ferrite cores ceramics. At ignition time, the high energy from
should also be utilized. Fireye supplied ED512 the ignition transformer will attempt to conduct to
cables provide the ferrite cores attached to the the point of least resistance and with an
cables. For longer runs beyond the lengths of improper spark gap, where the conduction takes
ED512, proper twisted shielded pair cable must place will no longer be controlled. The VA rating
be utilized. In a multi-drop system, the shields of the control transformer must be sized to
should be tied together within a cabinet and not handle the inrush currents of the pilot solenoid
to any ground point. The shield at the source and ignition transformer at PTFI and the then the
end of the cable of the multi-drop connection inrush currents of the main fuel valve assembly
can then be terminated to ground. Source end is at MTFI time. Inspect neatness of wiring in
defined as the originating end of the junction boxes and cabinets. It is best to have
communication system Care must be taken not connections short and direct and also not having
to route communication cables in close proximity wires bunched up and tied off. Also connections
to any starter motor contactor located in the should be periodically inspected for tightness
control panel or across any high voltage ignition and corrosion.
wires.
Refer to Fireye bulletin E-8002 for proper
installation.
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KEYPAD
SCRL
• Used to advance through and display
operational information associated with the
control, including various sub-menus. Treat Fig.72 EPD programmer module LED indicator
it like a “NEXT” key. Where ever you are in lights. Shown here with description added above
a menu, pressing this key will “scroll” you to each.
the next item.
RESET EPD style programmers are provided with a
• Press to reset the control after a lockout series of seven LED indicator lights to
condition has occurred. The control will annunciate the current operating status. Figure
reset, and if conditions allow, the next 72 shows the symbols of each LED with a
operating cycle will start. Sub-menus also description above.
make use of this key for things like unit Alarm: lights when unit is in lockout
(Communication) address, and customized Fan: Lights when blower motor is energized.
messages. Open Damper: Blinks when damper is driven to
MODE high purge position, lights constant when high
• Use this key to change mode, from standard purge limit is made (Term. D – 8).
menu to a sub-menu. Any time a small right Close Damper: Blinks when damper is driven to
pointing arrow appears at the end of a menu low fire position, lights constant when high purge
item i.e. “LOCKOUT HISTORY”, you can limit is made (Term. M - D).
press the MODE key to enter this sub-menu, Ignition: Blinks during PTFI, Lights constant
or to exit back to the standard menu. during MTFI
Auto: Lights when MTFI complete and control
EPD STYLE PROGRAMMER MODULES releases to automatic (Terminals 10 – 11 made),
blinks when RUN/CHECK switch is in Check
mode during Run period.
Flame: Lights whenever flame is detected.
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FLAME SAFEGUARD & COMBUSTION CONTROLS
FLAME MONITOR MESSAGES CHECK AMPLIFIER : High electrical noise. Check phase on
L1/L2 is the same as on the control's
interlock circuits. Defective amplifier ?.
As previously mentioned, a key feature of the Defective IR scanner cell ?. See page
56
Flame Monitor is its diagnostic capabilities.
CHECK CHASSIS : Voltage on terminal 7 at improper
Below is a listing of all known and available time? Defective Chassis ? Defective
messages at the time of writing. These have programmer ?
been arranged in alphabetic order for ease of CHECK EXPANSION : Expansion module part no. E300
locating each. MODULE failed. Replace E300
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FLAME SAFEGUARD & COMBUSTION CONTROLS
HIGH OIL PRESSURE : This is a message selected from the PROGRAM SETUP : From here press MODE key to display
E300 message menu and refers to a details on operating parameters of
limit in either circuit L1 - 13, or 3 - P programmer and amplifier module.
HIGH OIL : This is a message selected from the
TEMPERATURE E300 message menu and refers to a SCANNER NOISE : Electrical noise on scanner wiring.See
limit in either circuit L1 - 13, or 3 - P page 57 "Scanners"
HIGH PRESSURE : This is a message selected from the SHORT CIRCUIT : Short circuit, or excessive current
E300 message menu and refers to a TERM 5,6,7 detected on terminals 5, 6 or 7. See
limit in either circuit L1 - 13, or 3 - P page 40 "Before installing the control"
HIGH STACK : This is a message selected from the
TEMPERATURE E300 message menu and refers to a SYS HOURS : Number of hours the control has been
limit in either circuit L1 - 13, or 3 - P powered (L1 / L2)
HIGH : This is a message selected from the SYSTEM ERROR : Programmer module failure. Replace
TEMPERATURE E300 message menu and refers to a programmer module
limit in either circuit L1 - 13, or 3 - P SYSTEM INFO : From here press MODE key to display
HIGH WATER : This is a message selected from the details on operating parameters of the
E300 message menu and refers to a control.
limit in either circuit L1 - 13, or 3 - P UNIT ADDRESS : Run-Check switch placed in Check, L1
I.D. FAN INTLK : This is a message selected from the - 13 (operating control is open), press
E300 message menu and refers to a reset button here for one second
limit in either circuit L1 - 13, or 3 - P intervals to increase unit address
IGNITION TIMING : PTFI Started Flame not yet proven
L1 - 13 AUX. #1 : This is an E300 message and refers to WAITING FOR DATA : Communication between control and
OPEN a limit in circuit L1 - 13 display module is disrupted and needs
L1 - 13 AUX. #2 : This is an E300 message and refers to time to correct. Plugging in the ED510
OPEN a limit in circuit L1 - 13 display while control is powered may
cause this. Running ED580 cable with
L1 - 13 AUX. #3 : This is an E300 message and refers to
other power wiring also causes this.
OPEN a limit in circuit L1 - 13
See page 57 "Remote display"
L1 - 13 OPEN : Operating control open (L1 - 13) Removing and restoring power while
LINE FREQUENCY : Electrical noise detected on L1 and L2. ED510 is connected will recover
NOISE DETECTED Refer to page 56 proper operation.
LOCKOUT HISTORY : From here press MODE key to access
information on the last 6 lockouts
stored in memory.
LOW ATOMIZING : This is a message selected from the
PRESSURE E300 message menu and refers to a
limit in either circuit L1 - 13, or 3 - P
LOW FIRE PURGE : Modulator motor send low (10 - 12
made)
LOW FIRE SIGNAL : Run-Check switch placed in Check,
modulator driven to low position.
Flame signal strength is displayed
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Pilot fails to establish, Display reads PTFI for • Bad pilot burner assembly. Pilot should
10 seconds, followed by lockout. No visual remain stable when spark ignition is turned
presence of flame. off.
(Lockout PTFI Flame Fail)
• (Pilot) Fuel supply shut off. Main flame fails to establish after PTFI
• Air in fuel line (needs purging) (Lockout MTFI Flame Fail)
• Defective pilot valve. • Main, manual shut off valve closed.
• Incorrect fuel pressure (check pilot reg.) • Defective main ESD fuel valve.
• Defective ignition transf. (Check for spark). • Wiring error to main fuel valve.
• Incorrect spark-gap at igniter assembly. • Improper fuel pressure(s).
• Incorrect location of spark electrode tips in • Oil not atomized properly.
relation to pilot burner. • Oil nozzle (plugged) troubles.
• Incorrect wiring of pilot components. • Main valve opening causes fuel pressure
• Check for correct voltage at term. 5 or 6 limits (high or low) to trip.
during PTFI . If none, check for dirty or bent • Main valve opening causing pilot to bow out.
tab at bottom of control chassis. See figure • Main burner needs pilot burner. Goes out
48. Also check wiring base tabs. when pilot interrupted. Needs air, fuel, or air-
fuel ratio adjustment at light-off position.
Pilot fails to be detected, Display reads PTFI • Furnace pressure incorrect.
for 10 seconds, followed by lockout. Yet • Scanner detects pilot flame, but does not
visual presence of flame. detect main flame.
(Lockout PTFI Flame Fail)
• Flame detector not detecting flame. Flame Signal diminishes with time after main
• Inadequate pilot flame. burner lights.
• Improper amplifier module installed. • Main burner burns off-ratio.
• Flame rod not making contact with flame. • Main burner improperly adjusted.
• Defective flame rod. (porcelain) • Infrared detector saturates. (see page 16)
• Grounding surface of pilot assembly (Flame • Flame reduces flame flicker as flame
Rod) too small (corroded). Replace pilot temperatures increase (Applies to infrared
burner. See page 8 detection only).
• Incorrect detector wiring. See page 57 • Bad cell in infrared detector.
• (Flame rod system). No ground-path from • Bad UV tube in ultraviolet flame detector.
pilot burner to FSG control. Provide ground • Steam atomization blocks flame signal. (UV
wire from control chassis, terminal S2, to detector on steam atomized oil burner).
pilot assembly. Reposition detector for more angular view if
• Flame detector dirty. possible.
• Incorrect line of sight for flame detector. • Pilot burner “pulled away” from flame rod by
• Unstable pilot flame. main burner firing. (Flame rod systems on
• Incompatible flame detector for fuel used. natural draft burners).
• Defective flame detector or amplifier • Excessive scanner temperatures. Provide
module. cooling air to scanner.
• Electrical noise on scanner wiring.
It takes seconds before the pilot flame is
detected after terminal 5 and 6 are energized. Burner locks out on Flame Failure during
• Unstable pilot flame. main flame firing.
• Incorrect location of spark electrode tips in (Lockout Auto Flame Fail)
relation to pilot burner. • Main burns off-ratio. Main fuel pressure too
• Defective, weak, ignition transformer. high.
• No ground-path, ignition transformer-to- • Main burner improperly adjusted.
burner-front. • Infrared detector saturates. (see page 16)
• Incorrect (too high) fuel pressure. • Bad UV tube in ultraviolet flame detector.
• Incorrect primary air adjustment on pilot • Steam atomization blocks flame signal. (UV
burner. detector on steam atomized oil burner).
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