General Installation Instructions - Lesman Instrument ... · PDF fileIn cases where replacement Flow Controller air and/or fuel sensor probes (with their attached elec-tronics) need

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MUNCIE, INDIANA, USAINDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.

Page 7200-S-1SMARTFIRE™ Intelligent Combustion Control

General Installation Instructions

4/03

Please read all installation and start-upinstructions prior to working with theSMARTFIRE™ Intelligent Combustion ControlSystem. A view port providing a clear view ofthe entire flame is strongly recommended.

The SMARTFIRE™ Intelligent CombustionControl System accounts for a portion of thetotal combustion system. The sizing andinstallation instructions for other componentssuch as burners, blowers, and regulators canbe found in the corresponding sections of theMaxon catalog.

Do not discard packing material until all partshave been identified. Collect the fiveSMARTFIRE™ components required for controlling aburner (or zone of burners):1. Interface Panel (includes the Burner Brain, User

Interface Terminal, and 24 VDC Power Supply)2. Air Valve Actuator3. Fuel Valve Actuator4. Air Flow Controller (comprised of a sensor probe

and attached electronics in a flow body)5. Fuel Flow Controller (comprised of a sensor

probe and attached electronics in a flow body)

A typical SMARTFIRE™/burner/piping layout isshown below.

Verify that all Maxon System Numbers andBurner Model Identifiers are the same. Becauseall SMARTFIRE™ Systems are pre-configured at thefactory for a given burner system, this installationstep is very important to ensure proper operation.

Typical SMARTFIRE™/Burner/Pipetrain Layout

BurnerAct

Gas

Air and Gas Supplied byConventional Pipe Train

Assembly

FlowAct

Air

Flow

Burner Brain

Interface Panel

UserDisplay

24 VDCSupply

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Page 7200-S-2 SMARTFIRE™ Intelligent Combustion Control

The SMARTFIRE™ System can be installed as anew or retrofit system. Installation is straightforwardand can be accomplished in a working day for mostapplications. The major tasks involve installing thefour field devices and mounting the SMARTFIRE™Interface Panel. These tasks are described in thefollowing sections:• Mechanical Installation Instructions

(pages 7200-S-3 to 5)• Electrical Installation Instructions

(pages 7200-S-6 to 15)

The Interface Panel and the four field devices canbe installed in any sequence.

Before performing the installation steps described inthese sections, please note the following generalguidelines and safety instructions:• Validate the air and fuel flow measurements

during commissioning by using the pressures atthe burner.

• The SMARTFIRE™ Interface Panel must bemounted in a protected enclosure.

• Check for air and fuel leaks before the burner isstarted.

• CAUTION: Never place hands or fingers in theValve Actuators/Valve Assemblies.

• If the piping requirements outlined in the Me-chanical Installation Instructions (Page 7200-S-3)cannot be achieved within the User’s allocatedspace for the combustion system, call MaxonSMARTFIRE™ Support at 800-652-3553 (withinthe United States or Canada).

• Eliminate any construction debris from the fueland air pipetrains before installing the FlowControllers to prevent blockages in the flowconditioning screens.

• Verify that the combustion air blower is properlyfiltered. (Proper filtering ensures that the airsensing probe of the SMARTFIRE™ FlowController is not contaminated by particulatematter or water.)

• Verify that the gas regulator is sized for both themaximum and minimum fuel flow required by theburner and/or application.

After the installation steps are completed, follow theSMARTFIRE™ checkout and startup proceduresprovided in the Start-up and Operation Instructions(Page 7200-S-16 to 21).

WARNINGThe SMARTFIRE™ System is not a safety

device. The System provides cross-limited air/fuel ratio control and performs many redun-dant and physically diverse diagnostic testsduring operation. However, in accordance withNFPA (National Fire Protection Agency) guide-lines and other local and national safety codes,the User should provide appropriate safetyequipment such as flame safeguard, hightemperature limits, oxygen sensors, or redun-dant air and fuel flow sensors, as required.

General Installation Instructions

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Page 7200-S-3

Mechanical Installation Instructions

SMARTFIRE™ Intelligent Combustion Control

RequirementsWhen installing the SMARTFIRE™ Air and Fuel

Flow Controllers and the Air and Fuel Valve Actua-tors, please note the following:• The arrow on the side of each Flow Controller

should be oriented in the direction of flow.• The Flow Controllers and the Valve Actuators can

be mounted in any orientation.• Refer to the Electrical Installation Instructions

(pages 7200-S-6 to 7200-S-15) for cable andwiring requirements for each of the field devices.Maintain proper wire color code for 24 Volt DCPower and Data Communication Signals.

In cases where replacement Flow Controller airand/or fuel sensor probes (with their attached elec-tronics) need to be installed in their respective flowbodies, loosen the compression fitting sufficiently toinsert the sensor probe and alignment pin into theflow body. The probe assembly should sit flushagainst the flow body’s horizontal mounting flangeand should not be cocked at an angle. The compres-sion fitting is then tightened.

The following piping guidelines for theSMARTFIRE™ field devices ensure that the gas andair flow can be properly measured and controlled.Flow control accuracy is essential for optimum burnerperformance. If the piping requirements outlinedin the Air Piping Guidelines and/or Gas PipingGuidelines cannot be achieved within the spaceallocated for the combustion system, call MaxonSMARTFIRE™ Support at 800-652-3553 (withinthe United States or Canada).

Air Piping GuidelinesAir piping between the combustion blower and the

burner should be constructed using the followingguidelines:• Locate the SMARTFIRE™ Air Valve Actuator at a

maximum distance of 10 blower outlet diametersfrom the combustion blower. This configurationprevents blower pulsation (effects) created by theblower and air piping at low flow rates.

• If Maxon is not supplying the blower, the Usershould contact the blower manufacturer for themaximum recommended distance (for a specificpipe diameter) between the blower outlet and acontrol valve (i.e., the SMARTFIRE™ Air ValveActuator) to prevent Helmholtz effect.

• The SMARTFIRE™ Air Flow Controller is in-stalled downstream of the air valve actuator. Itrequires a total straight piping run of 14 flow bodydiameters (including approximately 4 diametersfor the Flow Controller) to ensure accurate airflow control. See installation schematic on page7200-S-4:

1. A minimum of seven (7) “straight” diameters arerequired upstream of the Air Flow Controller.

Minimum length of pipe =7 x the air flow body diameter

“Straight” diameter piping is defined as samediameter pipe with no elements such as valves,flanges, orifice plates, or bends within the speci-fied pipe length.

2. Exceed the above minimum requirement by asmany straight diameters as space permits (i.e.,maximize the number of straight diametersupstream of the Air Flow Controller). This lengthensures that the air stream can be properlyconditioned and measured by the Air FlowController.

3. A minimum of three (3) “straight” diameters arerequired downstream of the Air Flow Controller.

Minimum length of pipe =3 x the air flow body diameter

• Because the blower is rotational machinery,dampening pads for the blower stand and aflexible (bellows-type or braided stainlesshose) connection from the blower discharge tothe air piping are recommended.

4/03

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SMARTFIRE™ Air Piping Specification

Note 1: For Maxon blowers, piping distance between the blower and the control valve must not exceed 10 timesthe blower outlet diameter. For non-Maxon blowers, contact the blower manufacturer for the maximumrecommended length for the blower outlet size to prevent Helmholtz effects.

Note 2: Piping diameters should match the Flow Controller’s IDNote 3: Maximize the straight length of Dimension C (space permitting)Note 4: Piping sections dimensioned C and D are customer-supplied

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See Note 1

Blower

C B

See Note 2

A

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Valve MARTS

AssemblyIREF

See Notes 3 & 4 See Note 4

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Gas Piping Guidelines

Gas piping between the fuel train and burnershould be constructed using the following guidelines:• Locate the SMARTFIRE™ Fuel Flow Controller

downstream of the gas regulator and upstream ofthe gas valve actuator.

• The SMARTFIRE™ Fuel Flow Controller requiresa total straight piping run of 14 flow body diam-eters (including approximately 4 diameters for theFlow Controller) to ensure accurate fuel flowcontrol. See installation schematic below:1. A minimum of five (5) “straight” diameters are

required upstream of the Fuel Flow Controller.

Minimum length of pipe =5 x the fuel flow body diameter

“Straight” diameter piping is defined as samediameter pipe with no elements such asvalves, flanges, orifice plates, or bends withinthe specified pipe length.

2. Exceed the above minimum requirement byas many straight diameters as space permits(i.e., maximize the number of straight diam-eters upstream of the Fuel Flow Controller).This length ensures that the gas stream canbe properly conditioned and measured by theFuel Flow Controller.

3. A minimum of five (5) “straight” diameters arerequired downstream of the Fuel FlowController.

Minimum length of pipe =5 x the fuel flow body diameter

Note 1: Piping diameters should match the Flow Controller’s IDNote 2: Maximize the straight length of Dimension C (space permitting)Note 3: Piping sections dimensioned C and D are customer-supplied

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4/03

SMARTFIRE™ Gas Piping Specification

D

See Note 1

Gas Line

CSee Notes 2 & 3

B DSee Note 3

A See Note 1

SMARTFIRE FlowController Assembly

SMARTFIRE Valve Assembly

To Burner

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Electrical Installation Instructions

System Wiring Requirements

The following block diagram indicates the majorsources and destinations of the electrical wiringrequired by the SMARTFIRE™ System. The Systemwiring is divided into the following four categories:• Burner management AC control wiring to/from

the SMARTFIRE™ Burner Brain.• Current loop (4-20 mA) control and monitoring

wiring from a User’s temperature controller and/or DCS system to the SMARTFIRE™ BurnerBrain.

A complete set of wiring schematics de-scribing how SMARTFIRE™ is interfaced to a“typical” burner management system isshown in the following pages.

• Network wiring from the SMARTFIRE™ BurnerBrain to the SMARTFIRE™ Field Devices.

• Power and network wiring between theSMARTFIRE™ Burner Brain and the 24VDCPower and the User Display. These connectionsare factory wired on the SMARTFIRE™ InterfacePanel.

J10

24VDC J1

Gas Flow J7

Spare J2

Display J3

Air Valve J4

Gas Valve J5

Air Flow J6

4-20 mA I/O J9

RS232 J8

J12

J11

s

USER DISPLAY

24VDCSUPPLY

GAS FLOWCONTROLLER

AIR FLOWCONTROLLER

GASVALVE

ACTUATOR

AIRVALVE

ACTUATOR

AIR & GAS FLOWRATE MONITORS

AIR & GAS VALVE POSITION MONITORS

FIRING RATE SOURCE

User 4-20mA Inputs & OutputsSMARTFIRE™ Interface Panel

SMARTFIRE™ Field Devices(Network Cabling)

BURNER START/STOPCONTROL SOURCE

(120VAC RELAYCOIL DRIVES)

BURNER START/STOP CONTROL MONITOR

(120VAC SPSTRELAY CONTACTS)

User Burner Management System

BU

RN

ER

BR

AIN

Relay In

pu

tsR

elay Ou

tpu

tsR

elay Ou

tpu

ts

RS232 J8

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TO: 200

15

15

19

19

18

18

17

19

18

2

2

17 2

4

4

8

3

4

4

5

2

17

13 13

2

2

1312

4 4

Lockout Interlocks

Indicates TemperatureControl Enabled

IndicatesPurge Complete

IndicatesSystem Purging

Lockout Interlocks

Indicates InterlocksProven

To Line 302(SMARTFIRE J10-2)

Continued on Line 200



Proof ofClosure

20

15

14

12

Control PanelPower

Neutral

LockoutInterlocks

(L1)

13

4

Request forHeat

6

L2

7

HoneywellFlame SafeguardRM7800E-1010

FSG106

J11-1

See Line 307

J11-2

SMARTFIRE Ready

120/1/60

➤

➤

➤

Purging

LT109X1 X2

A

4

Blocking ValveVCS-1

BV303

116

115

114

113 7 8

4111

112

110

87Main Valve

VCS-1

MV301

15 15

2

16

Temperature ControlEnabled

LT115X1 X2

G

Purge Complete

LT112X1 X2

B

102 5Combustion Air Pressure Switch

CAP102

RemoteBurner Start

CR3087 4

109

108

107

106

105

104

103

Customer Interlocks #2



9

1

1

101

100OFF ON

SS1003 4

887 766Low Gas

Pressure Switch

LGP102

High GasPressure Switch

HGP102

10 109 11

InterlocksProven

LT106X1 X2

W

10 AMP

FU100

Control PanelPower On

LT100X1 X2

G2

2

High TemperatureLimit

HTL400

2 3

Jumper all unused limits and interlocks

Field wiring shown forblock and bleed valve

arrangement



4/03

Typical SMARTFIRE™ Wiring Schematic

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Page 7200-S-8



Typical SMARTFIRE™ Wiring Schematic (Continued)

29 29 2

25

22

22 21

25

20 23

25 26

2

2

Remote Alarm

2

Main Valves9

Provides True Indication of Pilot Status

UVD208

White (L2)

White (S)

SMARTFIRE Enable Ignition

(DDL Cable)

Keyboard DisplayModule

See Line 309

J11-5 J11-6

Flame Detector22G

F

Yellow

Blue

Interrupted Pilot

(15 sec.)

Ignition(10 sec.)

Low FirePosition

5

18

21

8

SMARTFIRE Enable Purge

See Line 308

J11-3 J11-4Alarm

Continued From Line 116

High FirePosition

19

RM7800E1010FSG106

HoneywellFlame Safeguard

3

Flame Detector

IndicatesPilot is On

HoneywellSelf Checking Flame DetectorC7061A-1012

Pilot Valve

Indicates an AlarmCondition Exists

ShutterThis device is externally mounted to the

nclosure door, and is ated for NEMA 4 nvironment

Ignition cable to the spark electrode must be run in separate conduit

Wire to the detector should be #14AWG Type 600V insulated wire or equal. Wire must not be in the same conduit with power wiring.

29 2

CR211A B

2

XFMR203

28

GND

27

24

Pilot Valve

PV206

25 2

Pilot On

LT205X1 X2B

SP204

CR2117 4

2

Alarm

LT201X1 X2

R

Jumper

23

23

2

2

To enable shut-off valve power

CR

Spark IgnitionTransformer

54

123

Spark Plug

Spark IgnitionTransformer

205

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Page 7200-S-9



7/08

Typical SMARTFIRE™ Wiring Schematic (Continued)

SMARTFIREUser Interface

MAXON P/N 59829 cable used for connections to valve actuators and Flow Controllers. Apply color code: +24VDC, White/OrangeGND, OrangeData A, White/BlueData B, Blue

2

2

SMARTFIREGas FlowController

SMARTFIREGas ValveActuator

SMARTFIREAir FlowController

SMARTFIREAir ValveActuator

2

2

1AIN0+2

43

AIN0-

AIN1-AIN1+

65

7AOUT1+AOUT0-AOUT0+

J91

217

2 Relay ret

SMARTFIRE BURNER BRAIN

LN

PE

120 VAC

(+)(+)

(-)(-)

24 VD

C

9

1110

AOUT3+AOUT2-AOUT2+

12

21

RXTX

AOUT3-

43

5

CTSRTSCOM

1+24VDC

Reservedfor futureSMARTFIREuse

12

2

GND

GND+24VDC

412GND

+24VDCDATA BDATA A 3

3

14

+24VDC

DATA ADATA B

2

43

GND

DATA BDATA A

J10

(Inpu

t rel

ay c

oils

ref t

o re

lay

ret)

J8J1

3

5

4

18

32

19

6

7

8

9

33

Select B

Select A

Modulation enable

Main valve on

Drive to light off

Spare Input

Alarm Reset

J7J5

J6

10

1

2

3

4

13

4

20

12

Spare Input

SMARTFIRE ready

SMARTFIRE ready ret

Enable purge

Enable purge ret

Drive to max air AOUT1- 8

4

From line 215

300

301

32

BV303

12

4

4 10303

4

305

304

VCS-2Blocking Valve

Contacts closewhen valve starts open

307

306

308

302

To Line 201

To Line 104

From Line 201

From Line 104

From Line 115

From Line 112

From Line 109

SMARTFIREAlarm Reset

PB7053 4

GND+24VDC

DATA A

SHLDDATA B

123

GND+24VDC

DATA A

1

32GND

DATA A

+24VDC4DATA B

4

21

GND+24VDCDATA B

43

DATA BDATA A

CR2CR3

CR1

CR5

CR6CR4

J4J3J11

(N.0

. out

put r

elay

con

tact

pai

rs)

J2

5

6

7

8

21

22

9

10

114

Select B ack ret

Select B ack

Alarm 1

Select A ack ret

Enable ignition ret

Select A ack

Enable ignition

SW

2

J12

(N.0

. out

put r

elay

con

tact

pai

rs)

12

13

14

4

34

35

16

15

Spare output ret

Spare output

Alarm 1 ret

Alarm 2

Alarm 2 ret

SW

1

310

309

4

312

311

34

35

2

2Alarm 2

LT713X1 X2

R

313

315

314

Alarm 1

LT712X1 X2

R

4

316

To Line 204

From Line 205

Reserved for future SMARTFIRE use

4/20 mA output, mass flow gas

4/20 mA output, mass flow air

4/20 mA output, gas valve position

4/20 mA output, air valve position

4/20 mA temperature control input

+24VDCGNDDATA A

SHLDDATA B

+24VDCGNDDATA ADATA BSHLD+24VDCGNDDATA ADATA BSHLD+24VDCGNDDATA ADATA BSHLD

Optional Telephone GatewayMaxon P/N 1055838

Split Ferrite, 2-turns, line/neutral, Steward #28A2024-OA

Data BData A

RJ11 To Telephone Service

120VAC to 24VDC Supply

Indicates external wiring

Indicates terminals and wiring in Maxon Control Panel

OrangeWeidmullerBLA 5.08Series Connector

Split

Fer

rite,

1-tu

rn

Stew

ard

#28A

2024

-OA

Flow

Con

trol N

etw

ork

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Page 7200-S-10



Field Device Wiring Requirements

A four-conductor cable with an outer shield isrequired between the SMARTFIRE™ Burner Brain andeach of the four SMARTFIRE™ field devices (four fieldcables are required, one for each field device). A fifthcable of the same type is provided (pre-wired) with theInterface Panel. It connects the Burner Brain to theUser Interface Terminal. An optional sixth cable can berun for connection to a remote display or to connect toa telephone gateway for remote monitoring by Maxonfield support personnel.

The recommended cable can be purchased fromMaxon (P/N 59829) in a 500-foot spool, or it can besupplied in longer lengths (Connect-Air P/N W22P-1005)by contacting the following manufacturer.

Connect-Air International, Inc.4240 “B” Street NWAuburn, Washington 98001Phone: 800-247-1978

The shields of each field cable should be terminatedjust as the cable enters the enclosure that houses theInterface Panel. Shield wire length should not exceed2 inches.

Maxon recommends all SMARTFIRE™ field devicecables be routed through a dedicated conduit or at leastone that carries only low voltage, instrumentationsignals.

Typically, flex conduit is used at each field device.The flex conduits feed a common steel conduit or cabletray that is run to the combustion panel. TheSMARTFIRE™ control cable conduit(s) should notshare the same conduit with any AC wiring or be inclose proximity to the burner ignition cable. All wiringshould be done in accordance with all applicablelocal and national electric codes.

The maximum total length of the recommendedMaxon cable (P/N 59829) must be:• Less than a total length of 1100 feet• No single cable run to a SMARTFIRE™ Flow

Controller, remote User Display Terminal, or DigitalGateway greater than 300 feet

• No single cable run to a SMARTFIRE™ ValveActuator greater than 100 feet.

If any single cable run to a SMARTFIRE™ ValveActuator exceeds 100 feet in length but is less than300 feet, Belden Cable #3086A should be ordered.Belden product distribution information is available at1-800-BELDEN-1 or www.belden.com.

If a single cable run to any SMARTFIRE™ devicemust exceed 300 feet, call the Maxon ProductSupport Team at 1-800-652-3553 within the UnitedStates or Canada.

The Burner Brain diagram on the following pageshows all input/output terminations to the User’sburner management system and field device cableterminations for the SMARTFIRE™ Valve Actuatorsand Flow Controllers. The tables on pages 7200-S-12 through 7200-S-15 explain the function of allinputs and outputs and network wiring color code.

It is the responsibility of the User to ensurethat Maxon’s SMARTFIRE™ Burner Brain iswired correctly to the proper burner start-upsequencing logic and combustion safety inter-locks as required by local and national safetycodes.

The User’s burner management system andall related electrical control drawings thatincorporate Maxon’s SMARTFIRE™ CombustionControl System should be reviewed by qualifiedpersonnel knowledgeable in all relevant safetyand industrial combustion requirements.

Maintain the integrity of the MAXON enclosureby using NEMA 4X or IP66 rated dust- and water-tight electrical connectors. Use cable-sealing gripsand strain-relief loops for any cord or cable. Useinternal sealing materials on all conduit connec-tions. Moisture can have a harmful effect ondevice internals if permitted to enter through wiringconnectors. Ensure that the device connection isnot at a low point of the conduit to avoid conden-sation run-off into the housing; install a drip loop ifnecessary. Make sure that the access cover plateis in place and securely fastened. All cover screwsshould be tightened using an alternate cross-corner tightening pattern. Cover screws should bechecked periodically to ensure adequate sealingprotection.

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Page 7200-S-11



Burner Brain Interconnect Diagram

4/03

RELAY RET

DRIVE TO MAX AIR

DRIVE TO LIGHTOFF

MAIN VALVE ON

MODULATION ENABLE

SELECT A

SELECT B

ALARM RESET

SPARE INPUT

N/C

SMARTFIRE READY

SMARTFIRE READY RET

ENABLE PURGE

ENABLE PURGE RET

ENABLE IGNITION

ENABLE IGNITION RET

SELECT A ACK

SELECT A ACK RET

SELECT B ACK

SELECT B ACK RET

ALARM 1

ALARM 1 RET

ALARM 2

ALARM 2 RET

SPARE OUTPUT

SPARE OUTPUT RET

AIN0 +AIN0 –AIN1 +AIN1 –AOUT0 +AOUT0 –AOUT1 +AOUT1 –AOUT2 +AOUT2 –AOUT3 +AOUT3 –

+24VDCGNDDATA ADATA B



+24VDCGND

TXRXCTSRTSCOM




123456789

101112

12345

12

1234

1234

1234

1234

1234

1234

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

J10

24VDC J1

Gas Flow J7

Spare J2

Display J3

Air Valve J4

Gas Valve J5

Air Flow J6

4-20 ma I/O J9

RS232 J8

J12

J11

Relay Inputs

Relay O

utputsR

elay Outputs

BU

RN

ER

BR

AIN

mA

mCORPORATION





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Start-up and Operation Instructions

Checkout before Start-up

After the SMARTFIRE™ System has been in-stalled and before power is applied, follow thecheckout procedure listed below:1. Verify that all Maxon system numbers and burner

model identifiers on the device labels are thesame. Because all SMARTFIRE™ systems arepreconfigured at the factory for a specific burnerconfiguration, this verification is very important.It ensures that the proper components areinstalled.

2. Verify the Air Flow Controller and Air ValveActuator are installed in the air pipetrain and theGas Flow Controller and Gas Valve Actuator areinstalled in the gas pipetrain.

3. Verify the proper connection of theSMARTFIRE™ READY output contact to the start-up and running interlock of the User’s burnermanagement system. With no AC power appliedto the SMARTFIRE™ Interface Panel, theSMARTFIRE™ READY output should provide anopen contact to the burner management permis-sive circuit.

4. Verify that all other required terminations havebeen made at the Burner Brain.

5. Verify the connections and color coding conven-tion on all control cable wiring at eachSMARTFIRE™ field device and the Burner Brain.

6. On the Interface Panel with power off, measurethe resistance between earth ground and each ofthe four signals wired to each field device: 24VDC, GND, Data-A, and Data-B. The resistanceshould indicate an open circuit (i.e., a resistancevalue of several Mega-Ohms). If the resistancevalue does not indicate an open circuit, it is likelythat there is a short circuit in the cabling betweenthe field devices and the Burner Brain. Discon-nect each cable and determine where the shortcircuit exists.

7. Perform all required prestart-up checkout proce-dures for the installed burner, pipetrain, and theburner management system.

Once these checks have been completed, theSMARTFIRE™ System is ready to operate in con-junction with the User’s installed burner managementsystem.

Start-up Procedure

During start-up, the SMARTFIRE™ Systemresponds to commands supplied by the burnermanagement system by moving its Air and Gas ValveActuators to appropriate positions and closingseveral output contacts to acknowledge specificconditions such as “maximum combustion air” and“low fire start” conditions.

Note: The SMARTFIRE™ System does notreplace, inhibit, or interfere with any of thesafety functions provided by the User’sflame relay or burner management system.

During the start-up sequence outlined below, if theUser Display shows an alarm indication, referencethe Troubleshooting section of these instructions(Page 7200-S-23) for appropriate action.

If the start-up sequence does not proceed asexpected, check if the required SMARTFIRE™ inputor output is powered and properly connected to theburner management system.

The following burner start-up procedure is drivenby the User’s burner management system:1. Apply 120VAC power to the 24VDC Supply of the

SMARTFIRE™ Interface Panel. After power isapplied, the User Display reads, “System Initializ-ing.” All SMARTFIRE™ output contacts areopened while the System performs initializationand self-diagnostic tasks. The System will closethe SMARTFIRE™ READY contact after approxi-mately 20 seconds if all the following conditionsare met:• The SMARTFIRE™ Flow Controllers and

Valve Actuators are communicating properly;• A fuel leak test passes (i.e., fuel flow less

than 1/20th the burner’s flow at high fire);• Both Valve Actuators are in their pre-defined

standby positions: and• The combustion-related data in the Burner

Brain are correct.

When the System completes initialization suc-cessfully, the User Display reads “SMARTFIRE™Ready ON, Waiting for Dr to Max” with no alarmconditions displayed. The SMARTFIRE™System is now waiting for the burner manage-ment command to drive to a maximum air condi-tion for purging.

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Before proceeding, press the Menu key of the UserDisplay until the Burner Configuration Data screenis shown. Verify that the burner type and capacitydata match the installed burner. If the displayeddata do not match the installed burner, discon-tinue the start-up and call Maxon.

2. The burner management system energizes theSMARTFIRE™ DRIVE TO MAX AIR input relay. (Ina mechanically controlled MICRO-RATIO®

system, this burner management commandwould be used to drive open the MICRO-RATIO®

valve motor.)3. When the SMARTFIRE™ DRIVE TO MAX input is

powered, the SMARTFIRE™ System preparesfor a purge cycle and displays, “Driving to MaxAir.” The SMARTFIRE™ ENABLE PURGE outputcontact is closed if all the following conditions aresatisfied:• Air Valve Actuator is opened to its full open

position;• A fuel leak check is passed;• Communications are tested, and• Air flow greater than one-half of the burner’s

maximum required air flow is measured.If the above conditions are satisfied, theSMARTFIRE™ System displays “Enable PurgeON, Waiting for Dr to Lightoff.” It then waits for alow fire start command from the burner manage-ment system.

4. The burner management system applies to 120VAC to the SMARTFIRE™ DRIVE TO LIGHTOFF

input signal. (In a mechanically controlledMICRO-RATIO® system, this burner managementcommand would be used to drive the MICRO-RATIO® valve to the minimum setting establishedby the mechanical linkage.)

5. When the SMARTFIRE™ DRIVE TO LIGHTOFF inputsignal is powered, the System prepares forburner management ignition trials. If all thefollowing conditions are satisfied, within approxi-mately 30 seconds, the SMARTFIRE™ ENABLE

IGNITION output contact is closed:• Air flow control is enabled and the starting air

flow is achieved;• Communications are tested; and• The Burner Brain verifies gas Valve Actuator

starting position (nominally 5 degrees).

If the above conditions are satisfied, theSMARTFIRE™ display shows “Enable Ignition ON,Waiting for Main Valve ON.” It then waits for theburner management system to prove pilot andbegin main flame trials.

6. The burner management system energizes theburner spark transformer and proves a pilotflame.

7. The burner management system begins mainflame trials. When this event occurs, the burnermanagement system (typically using switcheswithin the gas shut-off valve that close as thevalve begins to open) energizes theSMARTFIRE™ MAIN VALVE ON relay input.

8. When the SMARTFIRE™ MAIN VALVE ON input ispowered, the burner management system provesmain flame while the SMARTFIRE™ Systemperforms the following actions:• Closed loop control of fuel flow at the starting

flow setpoint after a 10-second fuel modulationdelay for the shut-off valve to fully open andthe fuel sensor to read properly;

• A 10-second firing rate delay timer is startedwhich allows the burner management systemto prove the main flame before theSMARTFIRE™ System can begin to adjustthe burner’s firing rate, and

• A ratio check and a test for theSMARTFIRE™ MODULATION ENABLE inputsignal is started after the firing rate delayexpires.

9. After the main flame establishment period (typi-cally 10 to 15 seconds), the burner managementsystem energizes the SMARTFIRE™ MODULATION

ENABLE relay input.10. When the SMARTFIRE™ MODULATION ENABLE

input is powered, SMARTFIRE™ begins to adjustthe burner’s firing rate based on the SMART-FIRE™ FIRING RATE input, a 4-20 mA signal fromthe User’s temperature or process controller.SMARTFIRE™ translates the Firing Rate signalinto air and fuel flow setpoints that are determinedby the Maxon burner model being used in theapplication. These setpoints are transmitted totheir respective Mass Flow Controllers, which, inturn, modulate the position of their respectiveValve Actuator through digital position commandssent over the control network.



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After the burner is lit, the SMARTFIRE™ Systemcontinuously tests for the following unsafe operatingconditions:

• An incorrect ratio;• Loss of communication to either Fuel or Air

Flow Controller;• Corrupted Burner Brain memory;• Improper Burner Brain program execution that

tests for the three previous fault conditions;and

• Fuel or air flow measurements that exceed therange of the sensor.

If the SMARTFIRE™ System detects any of thesefault conditions, it initiates a combustion systemshutdown by opening the SMARTFIRE™ READY

contact that is wired to the burner managementsystem’s running interlocks. When the interlockstring is opened, the burner management system de-energizes the main gas shut-off valves. ASMARTFIRE™ reset must be performed to allow are-start. This can be accomplished through thedisplay or by momentarily powering the alarm resetinput or repowering the SMARTFIRE™ System.

SMARTFIRE™ will return to the beginning of itsstart-up sequence if the burner management systeminitiated the shutdown event or if the main gas shut-off valve is closed at anytime. SMARTFIRE™detects a closed main gas shut-off valve through itsMAIN VALVE ON input signal.

Checkout after Start-up

Note: After the burner is running at minimumfire, perform the following checkout proceduresto ensure safe operation.

1. Verify that the SMARTFIRE™ READY output(used by the burner management system as aburner interlock) is operational by removing120VAC power to the SMARTFIRE™ System.The burner should shut-off when this test isperformed.

2. Restart the burner. If process temperature limitswill not be exceeded, place the User’s tempera-ture controller in manual mode and ramp theburner to approximately 25-50% capacity. After theburner reaches the requested firing rate, validateSMARTFIRE™ flow readings by measuring air andgas pressures at the taps typically provided at the

burner. Using the burner’s flow-versus-pressurecurves, verify that the flows calculated usingpressure are within 10% of the SMARTFIRE™ flowreadings available on the User Display.

3. If process temperature limits will not be exceeded,ramp the burner to maximum capacity and checkfor any fuel or air flow “high limit” alarms (i.e.,insufficient gas pressure or combustion blowercapacity).

If an air flow limit is reached, check the specifica-tions of the installed combustion blower anddetermine if the blower is undersized.

If a fuel high limit is reached, increase the gasregulator pressure; reset the alarms with the UserDisplay (refer to the User Display Functionssection on the following page) and verify the highlimit alarm condition has been eliminated.

With the burner at maximum capacity, adjust thegas regulator pressure until the gas valve actua-tor position is between 50 and 60 degrees. If theblower is undersized or the available gas pres-sure is not adequate to reach the desired capac-ity, refer to the Maxon Field Configuration section(page 7200-S-21).

4. Ramp the burner back down to minimum fire andcheck for an air or fuel “low limit” alarm (i.e., thegas/air pressure may be too high or the installedvalve characteristics due to piping hydraulicsmay limit burner turndown). Readjust the gaspressure regulator, reset the alarms with the UserDisplay and repeat Steps 3 and 4.

If both maximum and minimum burner capacitiescannot be achieved due to pressure limitations orpressure losses in the piping, refer to the MaxonField Configuration section (Page 7200-S-21) topermanently modify the application’s capacitylimits. If the application capacity limits are notmodified, the SMARTFIRE™ System will auto-matically limit the maximum and minimum capaci-ties and run with the proper ratio. However, a “lowlimit” or “high limit” condition will be indicated untilpower is cycled or the alarms are reset.

5. After adjusting the gas pressure, turn the burner offand cycle power to SMARTFIRE™. This resetsthe flow checking function in the Burner Brain.This continuous, on-line checking function tests forreasonable flow measurements that are critical toproper operation of a burner system and detectionof flow sensor failures.



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6. For some applications, on-site adjustment of theair/fuel ratio is necessary to optimize emissions orfuel efficiency. Although the SMARTFIRE™System delivers high-precision, turnkey ratiocontrol performance, adjustment of the air/fuelratio is sometimes required due to variations ingas composition or piping configurations thatcause errors in flow measurements. This adjust-ment procedure can be accomplished by sourcetesting the burner system while trimming (in 1%steps) the entire air/fuel ratio curve using theUser Display. Refer to the User Display Func-tions section on page 7200-S-20 for instructions.

7. For applications that must optimize emissions orfuel efficiency over a significant turndown, the air/fuel ratio can also be trimmed in twenty 5%segments that cover 100% of the burner’s capac-ity. Maxon-trained personnel must perform thisadjustment capability using a PC andSMARTFIRE™ commissioning software.

Do not remove power from an air valve actuatorwhen both 1) the valve is open more than 30degrees, and 2) the blower is running. Prior topower loss, ensure that the valve position is lessthan 30 degrees open, and/or that the blower hasstopped. Failure to observe these precautions canresult in permanent damage to the valve actuator.



7/08

User Display Functions

The SMARTFIRE™ User Display is used to adjustair/fuel ratio, view start-up status, System perfor-mance, flow, alarm data, view and reset flow totals,perform valve diagnostics, and reset alarm andshutdown conditions. These functions can be easilyaccessed using the display’s MENU and BACK (orESCAPE) keys.

The table on the following page summarizes all UserDisplay functions and is organized in the order thatmenu items are accessed using the MENU andESCAPE keys. The up and down ARROW keys areused to scroll down sub-menus and increase ordecrease specific adjustable parameters such as air/fuel ratio.

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Maxon Field Configuration

Using a PC connected to the SMARTFIRE™control network and SMARTFIRE™ commissioningsoftware, Maxon field personnel can perform thefollowing field configuration functions:

• For applications that require on-site optimiza-tion of emissions or fuel efficiency over awide turndown, the air/fuel ratio can beadjusted in twenty 5% segments of burnerfiring capacity. The adjustments can be madeleaner or richer in 1% steps.

• Modify maximum, minimum, and startingfiring rates due to fuel pressure limitations,undersized combustion blower, under-estimated pressure losses in piping.

• Modify starting fuel valve position for applica-tions with long piping runs between the shut-off valve and the burner and have a burnermanagement system with a very short mainflame-establishment period.

See the Product Support section on page 7200-S-22 for information on Maxon SMARTFIRE™ Techni-cal Support.

Local and Remote Monitoring

Local monitoring of the SMARTFIRE™ Systemcan be accomplished by connecting a User’s DCS(Distributed Control System) or data acquisitionsystem. This monitoring may be required to meetlocal environmental regulations that mandate arecord of air/fuel ratio performance data in place ofcostly periodic or continuous emissions monitoring.Local SMARTFIRE™ monitoring may also be usefulto help determine the cause of a burner shutdown.

The most straightforward method for local monitor-ing is to connect the User’s monitoring system to thetwo alarm contacts and the four isolated 4-20 mAoutputs that represent fuel and air flow and fuel and airvalve position.

Remote diagnostic support by Maxon field personnelcan also be performed with an optional SMARTFIRE™telephone gateway (Maxon P/N 1055838) and a localtelephone line. This remote monitoring option allowstrained personnel to log diagnostic control data andhelp the customer diagnose a problem without an on-site service call.

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Maxon SMARTFIRE™ Telephone Gateway

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Maintenance

The SMARTFIRE™ System continuously monitorsits components for proper operation and alarms whenfailures or maintenance issues arise. Maxon recom-mends a minimum monthly check for alarm condi-tions that are indicated by SMARTFIRE™ alarmcontacts and by alarm messages on the User Inter-face Display.

When alarms occur, the user should follow theTroubleshooting section of these instructions (Page7200-S-23) to determine if any maintenance action isrequired. For example, if a Flow Test or Flow LimitAlarm occurs, a flow limitation or sensing problemmay exist that requires cleaning of the combustionfan filter, removing debris in the flow conditioningscreens, or cleaning contaminates on the flow sensorprobe.

Maxon also recommends the calibration of theSMARTFIRE™ Air and Fuel Flow Controllers beverified at least every 5 years. This verification canbe accomplished in the field using the sensor valida-tion procedure described in the Start-up and Opera-tion section of these instructions (Page 7200-S-16 to21). For a more precise evaluation of sensor calibra-tion, the sensor probe assemblies can be removedfrom their flow bodies and shipped to Maxon Corpo-ration in Muncie, Indiana, for testing.

All maintenance work performed on the Fuel orAir Flow Controllers must be performed with theSystem turned off. Cleaning of the flow sensorprobes can be done with any solvent material suit-able for stainless steel. However, care should betaken not to bend the two small sensing probes. Re-validation of any flow sensor that has been cleanedor removed from its flow body is required before re-commissioning the combustion system.

If the SMARTFIRE™ System is applied in combus-tion systems with minimal combustion air filtering orwith fuel gas contaminants, the SMARTFIRE™ alarmcontacts should be monitored by the plant or processDCS system to alert personnel of improper operationand possible maintenance issues.

Product Support

Maxon Corporation provides 24-hour telephonesupport for all SMARTFIRE™ customers. If you havea question that relates to the installation, operation,or maintenance of the SMARTFIRE™ System,please call 800-652-3553 (within the United States orCanada) and your call will be answered immediatelyor returned as soon as possible.

Maintenance and Product Support

mCORPORATION



Troubleshooting


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4/03

mCORPORATION




Troubleshooting (Continued)

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mCORPORATION



Troubleshooting (Continued)


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4/03

mCORPORATION




SMARTFIRE™ Actuator Field Replacement Instructions

Actuator Removal

1. Verify that the SMARTFIRE™/Burner System iscompletely shut down and that the gas shut-offvalve is closed. DO NOT try to move the valvemanually with power on.

2. Remove the actuator access cover using an M3Allen wrench, and verify that there is no power tothe unit. The 3 lights (power, status, and diagnos-tic LEDs) should not be lit if power is off.

3. Record the wire color code sequence and thendisconnect the four lead wires from the terminalblock. Disconnect any conduit fittings.

4. Loosen the clamp collar set screw with a 3/16”Allen wrench.

5. Remove the four M6x1x18mm socket head capscrews connecting the actuator to the valveadapter with an M5 Allen wrench.

6. Remove the actuator by holding the actuatorhousing and pulling the actuator along the shaftaxis, away from the valve.

7. IMPORTANT: Move the valve to a fully closedposition using the hole below the clamp collar.

Actuator Reinstallation

1. Inspect the actuator shaft and verify that the 1/8”square ½” long key is completely seated in theshaft slot.

2. IMPORTANT: Verify that the clamp collar isloose and the valve is in a fully closedposition. The collar should have the screw headon the left when looking at the clamp with thecollar at the top.

3. Align the shaft key with the slot in the couplingand insert the shaft into the coupling. Turn theactuator housing as needed so the alignment pinon the actuator is aligned with the valve adapterhole (closest to the open face of the valveadapter).

Note: Older units may have an alignmentbushing in place of a dowel pin.

If you have an older unit, remove the dowel pinfrom the replacement actuator with a pair of pliersand proceed with installation. To confirm properorientation of the actuator to the adapter, verifythat the pinhole is over the adapter opening priorto bolting in place.

4. The parts are a clearance fit but should sliptogether with little force. Apply pressure until theactuator is flat against the adapter. (DO NOT applyexcessive force — if the valve adapter andactuator do not mate together, recheck that theclamp is loose and the key is pressed to thebottom of the key slot.) Verify that the actuator isseated flush to the valve adapter. Install the fourM6x1x18 mm socket head cap screws and torqueto 18 in-lbs. with an M4 Allen wrench.

5. Verify that the clamp collar is seated flush againstthe coupling shoulder. Tighten the socket head capscrew with a 3/16” Allen wrench and torque to 110in-lbs.

6. Remove the access cover using an M4 Allenwrench and make the necessary water-tightelectrical conduit connection. Connect the fourwires to the terminal strip per the original colorcode sequence. Connect the shield wire to theterminal strip, keeping it as short as possible.

7. Apply power to the SMARTFIRE™ System and,using the User Interface Display, verify that theactuator has power and is communicating withthe Burner Brain.

8. Reinstall the access cover and torque the fourfasteners to 18 in-lbs. using an M3 Allen wrench.

9. Run the actuator calibration function from the UserInterface Display main menu.

See next page for schematic of typical Valve/Actuator assemblies.

mCORPORATION




Typical Valve/Actuator Assembly1” through 4” valves

(2” valve shown)

4/03

Typical Valve/Actuator Assembly6” through 16” valves

(6” valve shown)

SMARTFIRE™ Actuator Field Replacement Instructions

mCORPORATION




Notes

Documents

General Installation Instructions - Lesman Instrument ... · PDF fileIn cases where replacement Flow Controller air and/or fuel sensor probes (with their attached elec-tronics) need