Fireye D30 series manual

£
D-30
AUGUST 22, 2005
SOLID STATE
BURNER MANAGEMENT
CONTROLS
SERIES D30
®
APPROVED
DESCRIPTION
Fireye Series D30 Burner Management Controls provide ignition and main flame failure protection
for automatically ignited oil, gas and combination fuel burners. In conjunction with limit-operating
controls and interlock devices it automatically programs, with solid state timing logic, the burner/
blower motor, ignition, and main fuel valve(s). The control cycles automatically when the operating
control closes and following a power interruption, but must be manually reset following a safety
shutdown.
The start-up programming includes a safe start check on each start. If flame signal (real or simulated)
is detected, the ignition will not be energized and safety lockout will occur. Terminals are provided
for a main fuel valve proof of closure interlock, which must be closed before start-up and during
prepurge. Proof of the low fire start position is required before ignition. An interlock circuit is provided for air flow switches, fuel pressure switches etc. which must be closed during the prepurge and
firing period. The control system de-energizes all fuel valves within four seconds following flame
failure. An alarm circuit actuates audible and visual alarms following a safety lockout.
Plug-in amplifier modules permit the selection of Ultraviolet, repetitive self-check Ultraviolet,
AUTOCHECK infrared, or Rectification methods of flame detection. For increased safety and reliability, Fireye 72D1R1-3 AUTOCHECK infrared amplifiers (using the pulsing flame signal) and
72DUVS-45UV5 Ultraviolet amplifier-scanner (using a scanner shutter) check the function of the
flame detecting system for any component failure during each burner firing cycle. Meter test jacks
on each amplifier module provide flame signal readout with a DC voltmeter.
The solid state programmer is a plug-in module. A test switch permits the operator to stop the programming before energizing the main fuel valves, for test purposes.
The complete control incorporates plug-in design for easy installation. All flame scanners are miniaturized. Fireye D30 Series controls directly replace similar Fireye C-Series models.
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SPECIFICATIONS
Supply Voltage:
120V (Max. 132V, Min. 102V) 50/60 Hz.
Power Consumption:
Operating 20VA
Maximum simultaneous connected load:
2000VA
Humidity:
85% RH max. Non-Condensing
OPERATING TEMPERATURE LIMITS:
PRODUCT
MAX.
MIN.
Control-Amplifier-Programmer
140qF (60qC)
- 40qF/C
UV1A, UV2, UV8A, UV90 Scanner
200qF (93qC)
- 40qF/C
45UV5 Scanner
200qF (93qC)
- 40qF/C
48PT2 Scanner
140qF (60qC)
- 40qF/C
69ND1 Flame Rod (TIP 2460qF)
1500qF (816qC)
- 40qF/C
Humidity 85% RH MAX. NON-Condensing
MAXIMUM LOAD RATING FOR SERIES D30 CONTROLS
Terminal
Typical Load
A
Maximum Rating @120V -60Hz
X, 5, 6
(Individually or
Combined)
Pilot Valve(s) and
Ignition Transformers
50VA Pilot Duty (solenoid valves) plus
500VA (Transformer)
125VA Pilot Duty (solenoid valve) plus
250VA (Transformer)
7
Main Fuel Valve(s)
250VA Pilot Duty (Solenoid Valve)
1250VA Opening. 500VA holding
(Motorized Valve) plus 65VA Pilot
Duty (solenoid valve)
M
Burner/Blower Motor
9.8 F.L.A.
58.8 L.R.A.
250VA Pilot Duty
(motor starter coil)
Alarm
B
Alternate Rating @120V -60Hz
50VA Pilot Duty
A
Terminal ratings may be selected from either column A or B:
(selecting the rating from the column for each terminal which best applies to the connected load on that terminal).
APPROVALS
Underwriters Laboratories Inc.
Listed: Guide MCCZ, File Mp1537
Underwriters Laboratories, Inc.
Recognized: Guide MCCZ2, File MP1537
Canadian Standards Association:
Certified: LR7989
Factory Mutual System:
Approved: Report (J.I.) 1C1A1.AF
Three LED lights on the Fireye chassis provide the following indication:
•
•
•
2
Air Flow — lights when interlock circuit is closed.
TFI — lights during pilot trial-for-ignition period.
Fireye — lights when flame is detected.
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Plug-in Module Retainer
Chassis Retaining Screw
Test Jack Black (-)
Check-Run Test Switch
Plug-in Flame Amplifier
Cover Retainer
Lock-out Switch
LED Indicators
Plug-in Programmer
Test Jack Red (+)
DESCRIPTION OF FIREYE D-30 SYSTEM COMPONENTS
Control
Part Numbers
Control Chassis and Cover
70D30
Plug-in Program Module
71D81-15 Second purge
71D80-30 Second purge
71D90-90 Second purge
Plug-in Amplifier module
and Flame Scanner
Amplifier
Flame Scanner
72DRT1
Rectification
69ND1-1000K4 1/2" mount - 12" flamerod
69ND1-1000K6 1/2" mount - 18" flamerod
69ND1-1000K8 1/2" mount - 24" flamerod
72D1R1 infra-red (IR) AUTOCHECK
71DIR3 for specific applications (see note below)
48PT2-1003 1/2" straight mount 96" cable
48PT2-9003 1/2" angle mount 96" cable
48PT2-1007 1/2" straight mount 48" cable
48PT2-9007 1/2" angle mount 48" cable
72DUV1
Ultraviolet (UV)
UV1A3
UV1A6
UV2
UV8A
1/2" mount 36" cable
1/2" mount 72" cable
3/8" mount 36" cable
90q head 1/2" NPT mount,
72" unshielded leads.
UV90-3, -6, -9 90º side opening, 36”
(900mm), 72" (1800mm),
or 108" (2700mm) cable
45UV3-1050
3/4” mount, cast aluminum
housing, 8’ wire.
72DUVS4: Ultraviolet Repetitive Self-Check 2-4 sec. FFRT.
72DUVS1T: Ultraviolet Repetitive Self-check 1 sec. FFRT.
45UV5-1009
Wiring Base
60-1386-2
60-1466-2
1" mount, 72" wire leads
Standard base for surface mounting
Open base for cabinet mounting.
NOTE: Infra-red “Autocheck” amplifier module 72D1R3 may be specified for burner applications firing special fuel such as sawdust,
sander dust, low BTU gas.
The 72D1R3 is not to be used on any liquid fuel fired burner since it may result in malfunctions causing
damage to property and/or injury to personnel.
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ORDERING INFORMATION
Each complete Fireye Series D30 system includes:
1.
2.
3.
4.
5.
A control chassis and cover.
A plug-in Programmer.
A plug-in Amplifier.
A flame scanner.
A wiring base.
To specify a control system which provides 30 seconds prepurge, with infrared (AUTOCHECK)
flame detection for surface mounting, select the following:
70D30 Control and Cover
71D80 Programmer
72D1R1 Amplifier
48PT2 Flame Scanner (specify length and mount)
60-1386 Wiring Base
REMOVING OLD CLIP
REPLACING NEW CLIP
Note: When a Fireye C-Series unit is replaced with a D-Series unit, the chassis retaining clip (for
quarter turn fastener) in the wiring base must be replaced with a threaded clip that is supplied with
each D-Series control.
Fireye Series D30 controls supersede similar Fireye C-Series controls and are directly plug-in interchangeable.
CAUTION: While all controls in the D-Series are mechanically interchangeable in that they
mate with a common wiring base, you should select the correct model for your application.
Inappropriate application of a control could result in an unsafe condition hazardous to life
and property. Selection of a control for a particular application should be made by a competent professional, such as a boiler/burner service technician licensed by a state or other governmental agency.
INSTALLATION
CAUTION: Installer must be a trained safety control technician. Verify that Electrical
Power is disconnected before starting installation.
Follow the burner manufacturer’s instructions, if supplied. Otherwise proceed as follows:
Wiring Base
Mount the control wiring base on the burner or on a panel. The location should be free from excessive vibration and within the specified ambient temperature rating. The base may be mounted in any
angular position.
All wiring should comply with applicable electrical codes and be suitable for 75qC min. The terminals in the wiring base permit a variety of connection methods — wire loop, eyelet, lug or quick connect. A green grounding terminal is provided for equipment bonding. Circuit recommendations are
provided later in this document. Consult with the factory for assistance with non-standard applications.
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ELECTRICAL RATINGS
VA ratings (not specified as pilot duty) permit the connection of transformers and similar devices
whose inrush current is approximately the same as their running current.
VA pilot duty ratings permit the connection of relays, solenoid valves, lamps, etc. whose total operating load does not exceed the published rating and whose total inrush current does not exceed 10
times the rating. Running and locked rotor ratings are intended for motors. VA and VA pilot duty
loads may be added to a motor load provided the total load does not exceed the published rating.
CAUTION: Published load ratings assume that no contact be required to handle inrush current more often than once in 15 seconds. The use of control switches, solenoids, relays, etc.
which chatter will lead to premature failure of switches in the Fireye control. Similarly, the
contacts cannot be expected to handle short circuit currents without damage. It is important
to run through a test operation (with fuel shut off) following the tripping of a circuit
breaker, a blown fuse or any known instance of chattering.
INSTALLING THE PROGRAMMER AND AMPLIFIER MODULES
To assemble or disassemble a control and its plug-in modules, place the unit on a work bench,
remove the two module retainer hold-down screws and lift off the module retainer. The module
retainer cannot be removed if the control is secured into a wiring base. Insert the appropriate amplifier module in the slots at the left side of the unit and gently push the module into position.
Insert the appropriate programmer module in the slots at the right side of the unit and gently push the
module into position. Replace the Module retainer and tighten the two hold-down screws. The unit
cannot be installed on a wiring base if the module retainer is not in place.
BEFORE INSTALLING THE CONTROL
CAUTION: Assure that electric power is shut off.
Verify that the supply voltage connected to terminals L1, L2 is 120 volts AC nominal. Test the electrical field wiring for short circuits and grounds. The recommended method requires the use of an
ohmmeter set on its lowest resistance scale.
1.
2.
Touch the meter probes together and calibrate it accurately to assure a reliable test.
Disconnect the neutral wire (L2) from the control system at the power source. Clip one meter
test lead to the grounded green terminal on the lower right side of the wiring base and with the
other probe touch every other terminal. At no time should the meter read other than infinity.
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3.
Reconnect the neutral wire (L2) at the power source. Remove the test probe from the grounded
terminal and reconnect it to terminal L2 in the wiring base. With the other probe, touch each terminal. It is normal to obtain a resistance reading on the meter at some terminals during this test
as there are resistive loads (coils-transformers-lamps, etc.) connected whose normal DC resistance may be less than 5 ohms. However, at no time should the test meter read zero ohms.
4.
If either a ground or a short circuit is detected, it must be eliminated before the control is
plugged into the wiring base and power turned on. Otherwise, the control may be destroyed or
improper operation may occur.
INSTALLING THE CONTROL
CAUTION: Assure that electric power is shut off.
1.
2.
6
Check the electrical tabs on the bottom of the chassis — if they are bent out of position, reposition them with your fingers using the angle on the bottom of the red tag shipped with the control
as a guide.
Insert the slots at the bottom of the assembled control in the tabs on the wiring base. Push the
control into position. Insert a screwdriver through the hole in the top of the control and tighten
the retaining screw.
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INSTALLATION - UV SCANNERS
Where possible, obtain the Burner Manufacturer’s Instructions for mounting the scanner. This information is available for most standard burners manufactured. The scanner mounting should comply
with the instructions that follow.
1.
2.
3.
4.
Position the UV1, UV2, UV8A scanner within 36 inches of the flame to be monitored, the
45UV5 within 72 inches, closer if possible.
Select a scanner location that will remain within the ambient temperature limits of the UV scanner. If cooling is required, use an insulating coupling (Fireye P/N 35-69 for UV1, UV2, UV8A
scanners, P/N 35-127-1 for 45UV5) to reduce conducted heat.
The UV1, UV2, UV8A, 45UV5 scanners are designed to seal off the sight pipe up to 1 PSI pressure. Higher furnace pressures should be sealed off. To seal off positive furnace pressure up to
100PSI for UV1, UV2, UV8A scanners, install a quartz window coupling (P/N 60-1257). For
45UV5 scanners, use P/N 60-1199 coupling. Add cooling air to reduce the scanner sight pipe
temperature.
Install the scanner on a standard NPT pipe (UV1 and UV8A - 1/2", UV2-3/8", 45UV5-1")
whose position is rigidly fixed. If the scanner mounting pipe sights through the refractory, do not
extend it more than halfway through. Swivel flanges are available if desired (P/N 60-302 for
UV1, UV2, UV8A scanners, P/N 60-1664-3 for 45UV5). The sight pipe must permit an unobstructed view of the pilot and/or main flame, and both pilot and main flames must completely
cover the scanner field of view.
CAUTION: The scanner must not sight the ignition spark directly, or any part of the
burner that can reflect the spark back to the scanner. The scanner must not see a pilot
flame that is too small to reliably ignite the main flame.
6. Smoke or unburned combustion gases absorb ultraviolet radiation. On installations having negative pressure combustion chambers, a small hole drilled in the UV1, UV2 and UV8A sight pipe
will assist in keeping the pipe clean and free from smoke. The 45UV5 has a 3/8" plug in the
mounting flange that can be removed. For positive pressure furnaces, provide clean air to pressurize the sight pipe, if necessary.
7. Two UV1, UV2 and UV8A scanners may be installed on one burner if it is necessary to view
two areas to obtain reliable detection of the flame. They should be wired in parallel. Only one
repetitive self-checking 45UV5-1009 scanner may be installed on a burner.
8. To increase the scanner sensitivity with UV1, UV2 and UV8A scanners, a union with quartz lens
(P/N 60-1290) permits location of the scanner at twice the normal distance. Use 1/2" x 3/8"
bushing on UV2 installations. Install a 1/2" x 1 1/2" nipple between the scanner and the union.
Request the assistance of any Fireye field office for recommendations on proper scanner installation
for a non-standard application
5.
SCANNER MUST HAVE UNOBSTRUCTED
VIEW OF FLAME
FLAME MUST COMPLETELY COVER
SIGHT OPENING
NOT THIS
NOT THIS
NOT THIS
NOT THIS
BUT THIS
BUT THIS
Since oil and gas flames radiate more ultraviolet energy from the base of the flame than from further
out in the flame, this fact should be taken into consideration when installing the scanner sight pipe.
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TYPICAL SCANNER INSTALLATIONS
SCANNER
DO NOT EXTEND
MORE THAN
HALF-WAY INTO
REFRACTORY
FORCED
CLEAN AIR
(FROM DISCHARGE
OF FAN)
DO NOT EXTEND MORE THAN
HALF-WAY INTO REFRACTORY
A
The maximum UV signal from a flame
is found in the first one-third of the visible flame taken from the point where
the flame begins. The scanner sight
pipe should be aimed at this area.
B
SELECT SCANNER LOCATION (A OR B) THAT GIVES THE
BEST VIEW OF THE PILOT FLAME.
INSULATING
TUBING
SEALING
UNION
FORCED
AIR
EXTEND SIGHTING TUBE
6”(1524) OR 8”(2032)
METHODS OF COOLING SCANNER
OPERATION — 45UV5 SELF-CHECKING UV SCANNER
Self-checking ultraviolet scanners should be used in applications where burner firing operation is
continuous or where the burner is on for long periods of time without recycling. In addition, ultraviolet self-checking systems are mandatory in some locations.
The operation of this type of system consists of maintaining the flame scanning capability at all times
while also proving that the ultraviolet tube is firing properly. This is done periodically by mechanically closing off the sight of the UV tube and checking to make sure that the flame signal goes away.
A shutter assembly in the 45UV5 scanner performs this function. The diagram below explains the
process further.
If the shutter assembly in the scanner fails, the tube is faulty, or there is insufficient power to the
scanner, the control will LOCKOUT. The ultraviolet tube is replaceable (P/N 4-314-1).
A lockout will result if a minimum signal is detected for three consecutive shutter closed periods.
SHUTTER OPEN
3.7 SEC.
SHUTTER CLOSED
0.4 SEC.
TIME
Wiring — UV Scanners
To connect the scanner to the control, the UV1 and UV8A scanners are supplied with 36" or 72" of
flexible cable. The UV2 comes with 36" of flexible cable, to connect the scanner to the control. The
45UV5-1009 is supplied with four 72" lead wires. Install them in a suitable length of flexible armor
cable and connect it to the control. A conduit connector is supplied with the scanner. Connect black
wires (shutter) to terminals L1, L2; red wires (UV tube) to terminals S1, S2.
Use the following instructions if the scanner wiring must be extended. Scanner wires should be
installed in a separate conduit. The wires from several scanners may be installed in a common conduit.
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1.
2.
Selection of Wire.
— Use #14, 16 or 18 wires with 75qC, 600 volt insulation for up to 100 foot distances (signal loss
approximately 20% at 100 feet).
— For extended scanner wiring up to 500 feet, and for shorter lengths to reduce signal loss, use a
shielded wire (Belden 8254-RG-62/U coaxial cable, or equivalent) for each scanner wire of
UV1, UV2 and UV8A and red wires of 45UV5-1009. The ends of the shielding must be taped
and not grounded.
— Asbestos insulated wire should be avoided.
— Multiconductor cable is not recommended without prior factory approval.
High voltage ignition wiring should not be installed in the same conduit with flame detector
wires.
INSTALLATION — INFRARED SCANNER TYPE 48PT2
Where possible, obtain the burner manufacturer’s instructions for mounting the scanner, otherwise
proceed as follows. A single scanner is used to detect both pilot and main flames. The sight pipe on
which the scanner mounts must be aimed so that the scanner sights a point at the intersection of main
and pilot flames. Proper scanner positioning must assure the following:
1.
2.
3.
4.
5.
6.
7.
8.
Reliable pilot flame signal.
Reliable main flame signal.
A pilot flame too short or in the wrong position to ignite the main flame reliably, must not be
detected.
Scanner must have unobstructed view of flame being monitored.
Flame being monitored must completely cover scanner field of view.
To avoid nuisance shutdowns, it is important to avoid sighting hot refractory and to keep scanner
temperature low (below 125qF).
When the proper position has been established, drill a hole through the furnace wall and install a
4" to 8" length of threaded black iron pipe on which to mount the 48PT2 scanner.
When a satisfactory sighting position has been confirmed by operating tests, the sight tube
should be firmly welded in place.
SCANNER MUST NOT
SIGHT REFRACTORY
SCANNER
LINE-OF-SIGHT
SCANNER TARGET
ABOVE REFRACTORY
COMBUSTION
CHAMBER
MAIN
CENTER LINE
OF MAIN FLAME
PILOT
BURNER
SCANNER
SCANNER
SIGHTING TUBE
Wiring
Attach the cable supplied with the scanner to a junction box. Splice the cable wires to a pair of wires
not smaller than #18. Install the complete run in a separate conduit to the control. Continuous conduit bonding between scanner and control is mandatory. Scanner may be located up to 100 feet
from control. Do not pass scanner wiring through any junction box containing other wires. Do not
run other wires through scanner conduit. Asbestos insulated wire should be avoided.
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Keeping the Scanner Cool
The Firetron Scanner (Temperature limit 125F) should never get too hot to grasp comfortable in the
hand. Keep the scanner cool by one or more of the following methods.
1.
2.
3.
4.
5.
Use 6” to 8” length of pipe between scanner and hot furnace front plate.
Use insulating nipple (Part No. 35-69) on the end of the iron pipe.
Force air into sighting tube.
Make sure sighting tube does not extend more than halfway into refractory wall.
Use Fireye sealing union (part #60-801) when using method 3 above.
INSTALLATION — 69ND1 FLAME ROD
The 69ND1 flame rod proves a gas pilot flame and/or main gas flame. It is a “spark plug” type unit
consisting of 1/2" NPT mount, a KANTHAL flame rod, a glazed porcelain insulating rod holder and
a spark plug connector for making electrical connection. The 69ND1 is available in 12", 18" or 24"
lengths. The flame rod may be located to monitor only the gas pilot flame or both the gas pilot and
main gas flames. It is mounted on a 1/2" NPT coupling.
1.
2.
3.
4.
5.
6.
7.
Keep flame rod as short as possible.
Keep flame rod at least 1/2" from any refractory.
Flame rod should enter the pilot flame from the side to safely prove an adequate pilot flame
under all draft conditions.
If the flame is non luminous (air and gas mixed before burning), the electrode tip should extend
at least 1/2" into the flame, but not more than half way through.
If the flame is partly luminous, the electrode tip should extend only to the edge of the flame. It is
not necessary to maintain absolutely uninterrupted contact with the flame.
It is preferable to angle the rod downward to minimize the effect of sagging and to prevent it
from coming in contact with any object.
An adequate grounding surface for the flame must be provided. The grounding surface in actual
contact with the flame must be at least four times greater than the area of the portion of the flame
rod in contact with the flame. It is essential to adjust the flame rod and ground area ratio to provide a maximum test meter reading.
WRONG POSITION
OF ROD
INADEQUATE FLAME
CORRECT
POSITION
OF ROD
PILOT BURNER
CORRECT POSITION OF PILOT FLAME
Note: Interference from the ignition spark can alter the true test-meter reading by adding to or subtracting from it. This trend sometimes may be reversed by interchanging the primary wires (line voltage) to the ignition transformer, and may be made ineffective by the addition of grounded shielding
between the flame rod and ignition spark.
8.
Proven types of flame grounding adapters as shown below may be used to provide adequate
grounding surface. High temperature stainless steel should be used to minimize the effect of
metal oxidation. This assembly may be welded directly over the pilot or main burner nozzle.
BOMB FIN
GROUNDING ASSEMBLY
10
THREADED ROD
ASSEMBLY
£
DESCRIPTION OF OPERATION
Fireye control D30 with programmer 71D81 (15 second purge), 71D80 (30 second purge), 71D90
(90 second purge) and with amplifier 72D1R1 (Infrared), 72DUV1 (UV), 72DUVS4 and 72DUVSIT
(UV-Self-checking), 72DRT1 (Rectification), provides the following burner operation.
Note: For direct spark ignited oil burners, substitute the words “main oil valve” for “pilot valve.”
Start Up
With power applied, the limit-operating control circuit closed and the main fuel valve interlock
closed, the burner/blower motor (Terminal M) is energized.
2. The running interlock circuit closes (air flow, fuel pressure, etc.) and the Air Flow indicator
(LED) lights.
3. Programmer 71D81 provides a 15 second purge, 71D80 a 30 second purge, 71D90 a 90 second
purge.
4. When the purge is completed, and low fire start position proven, the Ignition is energized (Terminals X, 5, 6) and the TFI Indicator (LED) lights.
5. When flame is detected, the Fireye Indicator lights.
6. Five seconds after being energized, Terminal X is deenergized and shuts off the spark ignition. A
5 second pilot stabilization period follows.
7. Following a 10 second trial-for-ignition (if the flame is detected) the main fuel valve (Terminal
7) is energized and the TFI indicator (LED) goes out.
8. Ten seconds later, Terminal 5 de-energizes the interrupted pilot gas valve.
9. Terminal 6 (intermittent pilot), remains energized for the duration of the firing period.
10. End of start up program.
1.
Normal Shutdown
1.
2.
3.
When the operating control opens its circuit, the main fuel valve and the intermittent pilot (if
used) is deenergized.
Following a 15 second post-purge, the burner/blower motor is deenergized.
All indicators go out.
Note: If the main fuel valve interlock is not closed at the start, the control will not initiate a start up.
If it opens during the prepurge and stays open, the programming will stop and the burner/blower
motor will be de-energized in 15 seconds. If the running interlock circuit does not close at the start,
the programming sequence will not be initiated and the burner/blower motor will continue to be
energized. If it opens during the purge, the purge timing will reset. If it opens during a firing cycle,
all fuel will shut off immediately and the programming cycle will reset. If the low fire start switch is
not closed before ignition, the programming sequence will pause until it closes.
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Safety Shutdown
1.
2.
3.
4.
If pilot flame is not detected during the 10 second pilot trial-for-ignition period, the pilot valve
and ignition transformer will be deenergized and the control will lockout on safety.
If flame is not detected at the end of the 10 second main flame trial-for-ignition period, all fuel
valves will be deenergized and the control will lockout on safety.
If the main flame fails during a firing cycle, all fuel valves will be deenergized within four seconds after loss of flame signal and the control will lockout on safety.
Manual reset is required following any safety lockout.
Description of Functions of Operating Controls
1.
2.
3.
4.
5.
Operating Controls. Generally pressure or temperature activated. Normally, when the operating control closes, the burner start-up programming starts. When the operating control opens, the
burner shuts off. They are connected between Terminals L1 and 13.
Limit switches. Generally pressure, water level or temperature activated. These devices stop the
burner when the limit switch opens and restarts it when the limit switch recloses. They are connected between Terminals L1 and 13.
Fuel Valve Proof of Closing Interlocks. Generally an integral switch mounted on the main fuel
valve and activated by the valve stem. It is connected between Terminal 3 and 13. The valve
proof of closure interlock prevents a burner start-up if the valve stem is not in the valve closed
position.
Running Interlocks. Generally air flow switches, high and low fuel pressure switches, oil temperature switches, atomizing medium pressure switches, and excess smoke density controls.
These interlocks prove proper conditions for normal operation of the burner. They are connected
between Terminals 3 and P.
Low Fire Start Interlocks. Usually a firing rate motor linkage position switch, or a damper
position switch, that prove the linkage and dampers are in their proper position for burner light
off. They are connected between terminals M and D.
PROGRAMMING SEQUENCE CHART, SERIES D30
FIGURE 1.
LIMIT AND OPERATING CONTROLS CLOSED (L1-13)
OPERATING
CONTROLS
AND INTERLOCKS
RUNNING INTERLOCKS - CLOSED (AIR FLOW, FUEL PRESSURE, ETC.) (3-P)
FUEL VALVE PROOF OF CLOSURE SWITCH CLOSED (13-3)
LFS
CLOSED
15, 30, OR 90
PROGRAMMING
SEQUENCE
PREPURGE
(M-D)
PILOT
TRIAL FOR
IGNITION
5
10
10
MAIN FLAME
TRIAL FOR
IGNITION
15
FIRING PERIOD
POST PURGE
BURNER/BLOWER MOTOR (M)
SPARK
(X)
IGNITION
BURNER
PILOT VALVE INTERRUPTED (5)
PILOT VALVE INTERMITTENT (6)
MAIN FUEL VALVE (7)
AIR FLOW
INDICATORS
TFI
FIREYE
CONTROL TYPE 70D30 WITH PROGRAMMER 71D81 - 15 SECOND PURGE
12
71D80 - 30 SECOND PURGE
71D90 - 90 SECOND PURGE
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EXTERNAL METER CONNECTIONS
The test jacks are located on the amplifier card. If external access is desired for a panel meter the figure shown below will assist you in locating the position to drill through the front cover. The hole
sizes should be large enough to accommodate the body of the meter probes. The test jacks accept
meter probes up to .080” of 2mm in diameter.
FIGURE 2.
1.625
ADDING HOLES IN COVER TO ACCESS TEST JACKS
.625
+
RECOMMED
5/16” TO 3/8” HOLES
TO ACCOMODATE
METER PROBES
4.3125
+
INSTALLATION TESTING
CAUTION: Before testing the control operation on the boiler, close the manual main fuel
supply. Failure to do this may cause injury or property damage.
1.
2.
3.
4.
5.
Close the manual main shut-off fuel valve.
Recheck all limit circuit wiring for proper operation and correct connection.
Confirm that the automatic main fuel valves are wired to terminal 7.
Power the control and electrically check the proper sequence of operation according to the operation section in this bulletin.
After assuring that all interlocks and valves are properly wired and that the sequence of operation is correct, open the manual main shut-off valve and proceed cautiously through the boiler
light off process. Check all safety interlocks for proper shut down of the boiler.
To measure the Series D30 control’s flame signal strength, use a 1,000 ohm/volt (or greater) DC voltmeter or a Digital meter with input impedance of 500K ohms or greater. Set the meter scale to read
a normal flame signal of 18-25 volts DC.
Note: The Fireye 45UV5-1009 is a repetitive self-check scanner that contains a highly reliable shutter that closes every 4 seconds to initiate a system check. When the shutter closes, the test jack voltage should go down to approximately zero, and then back to the normal reading in about 2 seconds.
To assure sufficient flame signal margin to hold in the flame relay during random momentary downward fluctuations of flame signal, it is recommended that a signal close to normal be obtained.
Note: The leads from the test meter plug into the red and black test jacks on the amplifier (red +
black — ).
Normal Pilot Flame Test
1.
2.
3.
CAUTION: Before making a pilot flame test, manually shut off the fuel supply to the
main burner.
Place the check-run switch on the programmer in the check position. A small tool such as a
screwdriver is required.
Turn power on and initiate a normal start-up.
13
£
Observe the pilot flame signal on the test meter. If the average voltage is below normal, re-adjust
the pilot flame or re-align the detector.
During the pilot flame test and adjustment period, if flame is not detected, the control will lockout. To re-establish the pilot flame trial-for-ignition (TFI) manually reset the lockout switch, and
re-purge the boiler.
6.When UV flame detection is used, a test is required to verify that
UV radiation from the ignition spark is not being detected. To
accomplish this, manually shut off both pilot and main fuels.
Initiate a normal start-up and when the TFI light comes on,
observe the test meter which should read no more than 1 volt.
If more than 1 volt is observed, realign the UV scanner, and/or
shield the spark from the scanner’s view. Programmers 71D80,
71D81, 71D90 provide ignition spark cutoff prior to pilot
flame proving (when the ignition transformer is connected to
Terminal X), to assist with installations where UV radiation
from spark ignition is difficult to eliminate from the view of the
UV scanner.
7. With all methods of flame detection, check pilot flame failure
response by manually shutting off the pilot fuel and then initiate a normal start-up. With no pilot flame present, the control
will de-energize the pilot assembly at the end of the trial-forignition interval, and the control will lockout. The check-run
switch must be in the “run” position for this test.
4.
5.
TYPICAL WIRING ARRANGEMENT FOR PILOT IGNITED BURNER
FIGURE 3.
Lockout
Alarm Circuit
S1
Burner Motor
Control Circuit
Not Used
FIREYE
WIRING BASE
TERMINALS
10
11
L1
L2
3
M
D
P
X
12
13
5
6
7
8
A
S1
Flame
Rod*
S2
*
FLAME
SCANNER
IR or UV
LOW FIRE
START
INT.
H
S2
Plug In
Flame Amplifier
Not Used
NOT USED
IMPORTANT; A Good
Earth Ground is
Essential
Disconnect
Means And
Overload
Protection
Required
Ignition And Fuel Valve Control Circuit
Note: When A Flame Rod Is
Used, Jumper S2 To The Terminal Board Screw directly
above green grounding screw
on the wiring base
120 VOLT
50/60 Hz
RUNNING
INTERLOCK
N
L1
Burner
Switch
L2
S1
S2
FUEL VALVE
PROOF OF
CLOSURE
S2
RED
LIMIT OPERATING
SWITCHES
BURNER/
BLOWER
MOTOR
IGNITION
TRANSFORMER
INTERRUPTED
PILOT
VALVE(S)
S1
MAIN
FUEL
VALVE(S)
INTERMITTENT
PILOT
VALVE(S) †
L2
LOCKOUT
ALARM
BLACK
L1
45UV5-1009
WIRING ARRANGEMENT FOR SPARK IGNITED OIL BURNER
X
IGNITION
TRANSFORMER
14
6
PRIMARY
MAIN OIL VALVE
† Intermittent pilot not permitted on oil burners
7
SECONDARY
MAIL OIL VALVE
Caution: All safety limit switches should be approved as
limit controls and should be wired directly in the circuit of
the Flame Safeguard control. The use of electronic switches to close interlock circuits may cause erratic operation.
£
SIMPLIFIED SCHEMATIC DIAGRAM 70D30 CONTROL
FIGURE 4.
OPERATING CONTROLS
HOT
FUEL VALVE PROOF
OF CLOSURE
3
13
L1
AIR FLOW
SWITCH
RL
P
RA
RP
RB
LS1-2
A
ALARM
NEUTRAL
LOW FIRE
POSITION SWITCH
M
RF
RV
D
X
5
6
SPARK
IGN 10
PILOT
BLOWER
7
MAIN
L2
Main Flame Test
Proceed through a normal startup. After the pilot flame is shut off, observe the reading on the
test voltmeter. If the voltmeter reading is low, readjust main flame or realign detector.
2. Check main flame failure protection by manually shutting off the main fuel supply. Within 4
seconds after main flame goes out, the fuel valve will be deenergized. The alarm circuit will be
energized following safety lockout.
Note: This test requires an interrupted pilot.
1.
Minimum Pilot Test
This test assures that the flame detector will not detect a pilot flame too small to reliably light off the
main flame. This test should be made on every new installation, as well as after the following:
1.
2.
3.
A change-out of the control and/or flame detector
Any repositioning of the flame detector.
Any air/fuel ratio adjustment or other change that may interfere with reliable light-off of the
main fuel.
This procedure should not be used on a direct spark ignited burner.
CAUTION: The minimum pilot test must be accomplished by a trained and qualified
burner technician.
1.
2.
3.
4.
5.
6.
7.
8.
Manually turn off the main fuel supply.
Place the check-run switch in the check position.
Turn power on and initiate a normal start-up.
Reduce the fuel supply to the pilot until the “Fireye” light goes out. (If a test meter is used, the
DC test jack voltage will be below 5 volts).
Slowly increase the fuel to the pilot until the DC test jack voltage reads about 16-20 volts. This
is the minimum pilot flame that the flame detector will reliably detect.
Place the Check-Run switch in the Run position. When the main fuel safety shut-off valve is
energized, slowly open the manual main fuel valve.
Observe the light-off of the main flame. It must be smooth and normal.
CAUTION: If the main flame does not ignite immediately, shut off the main fuel.
Realign the detector to require a larger minimum pilot flame.
9. Repeat the test until reliable, smooth light-off occurs with the minimum pilot.
10. After this test is completed, increase the fuel to the pilot to its normal setting.
15
£
Operational Test
When the installation and all burner adjustments are completed, the entire burner control system
should be tested in accordance with the burner manufacturer’s instructions. The procedure should
verify the correct operation of:
1.
2.
3.
4.
5.
6.
7.
Each operating control (temperature, pressure, etc.).
Each limit switch (temperature, pressure, low water cutoff, etc.).
Each interlock switch (air flow switch, high and low fuel pressure or temperature switches, low
fire start switches, fuel valve proof of closure interlock, etc.).
Pilot flame failure response and lockout.
Main flame failure response and lockout.
Tight shutoff of all fuel valves.
Note: Before attempting to reset the lockout switch, wait approximately 2 minutes for the lockout
switch heater to cool.
REFRACTORY
REFRACTORY
PILOT
FLAME
MAIN
FLAME
MAIN
FLAME
PILOT
FLAME
MAIN
BURNER
PILOT
BURNER
SCANNER
INSUFFICIENT PILOT
16
REFRACTORY
PILOT
FLAME
MAIN
BURNER
PILOT
BURNER
SCANNER
MINIMUM PILOT
MAIN
FLAME
MAIN
BURNER
PILOT
BURNER
SCANNER
NORMAL PILOT
£
SERVICING
CAUTION: Only trained and qualified Safety Control Technicians should attempt to
service Flame Safeguard control installations.
Special care must be exercised in troubleshooting a burner control
system. Electrically live parts are exposed when covers of devices
are removed. Additionally, safety interlocks and limit switches (air
flow, fuel pressure, LWCO, etc.) should not be jumpered out during
troubleshooting, nor should any attempt be made to eliminate or
alter any portion of the programming sequence beyond use of the
Run-check switch during the pilot trial-for-ignition period of pilot
ignited burners.
Servicing Fireye D-Series units is facilitated by the use of plug-in
programmer and amplifier modules.
Trouble with installations equipped with Fireye D30 controls can
be readily isolated by following the procedure in the sequence
listed below. An AC-DC test meter is required. Test points are
located on the chassis board to assist with measuring line and load
voltages. Test jacks are located on the amplifier for measuring
flame signal strength. The LED indicators are a useful service tool.
Voltage at terminals S1, S2 should read approximately 560 volts AC for 72DUV1, 72DUVS4, and
72DUVSIT amplifiers, 7 volts DC for 72DIRI amplifier, and 280 volts AC for 72DRT1 amplifier,
with power on and burner off.
Before troubleshooting check the following:
1.
2.
3.
4.
5.
6.
7.
Installation and wiring have been made in accordance with the installation instructions.
Contact tabs on bottom of chassis are not bent out of position.
Chassis is properly secured to the wiring base.
The programmer is securely plugged in and the run-check switch is in the run position.
The correct amplifier for the method of flame detection desired is securely plugged in.
The flame detector is clean.
The lockout switch is reset.
TROUBLESHOOTING
In the following tabulation, trouble symptoms appear in bold type and possible causes for that symptom are listed below the bold type.
Note: For direct spark ignited oil burners, substitute the words main oil valve for pilot valve.
Zero volts at terminals L1-L2. All indicators off.
—
—
—
—
Electrical disconnect switch off.
Blown fuse or tripped circuit breaker.
Bent tab on bottom of control.
Broken wire, loose connection or wiring error.
Low volts at terminals L1-L2. All indicators off.
— Minimum operating voltage 102 volts.
Zero volts at terminals 13-L2. All indicators off.
—
—
—
—
Burner on-off switch off.
Open limit switch or operating control.
Bent tab on bottom of control.
Broken wire, loose connection or wiring error.
17
£
Zero volts at terminals 3-L2. All indicators off.
—
—
—
—
Fuel valve proof of closure switch open (or jumper wire not installed at terminals 13-3).
Bent tab on bottom of control.
Broken wire, loose connection or wiring error.
Replace 70D30 control.
Burner, Blower motor does not start. All indicators off.
—
—
—
—
—
—
—
Motor electrical power off.
Blown fuse or tripped circuit breaker.
Broken wire, loose connection or wiring error.
Defective motor or motor contactor.
Bent tab on bottom of control.
Replace 70D30 control if no voltage at terminals M-L2., (and control is not in “lockout”).
Control is in “LOCKOUT,” depress reset button.
Burner, Blower motor starts. Air flow indicator off.
—
—
—
—
Running interlock circuit open (terminals 3-P).
Broken wire, loose connection or wiring error.
Bent tab on bottom of control.
Replace 70D30 control.
Burner, Blower motor runs. Air flow and Fireye indicators on (controls locks out).
—
—
—
—
Flame scanner is detecting actual flame.
Replace flame scanner or correct scanner wiring.
Replace 72D series amplifier module.
Replace 70D30 control.
Pilot not energized at the end of purge. Air Flow indicator on, TFI and FIREYE indicators off.
—
—
—
—
Low fire start switch open (or jumper wire not installed at terminals M-D).
Broken wire, loose connection or wiring error.
Bent tab on bottom of control.
Replace 70D30 control.
Pilot flame not established. Air Flow, TFI indicators on. Fireye indicator off.
—
—
—
—
—
Defective pilot valve, ignition transformer, electrode or adjustment.
Improper gas pressure or burner adjustment.
Broken wire, loose connection or wiring error.
Bent tab on bottom of control.
Replace 70D30 control.
Pilot flame lights, but is not detected. Air Flow, TFI indicators on. Fireye indicator off. (No test
jack voltage).
—
—
—
—
—
—
—
18
Scanner does not see adequate pilot flame.
Broken scanner wire, loose connection or wiring error.
Bent tab on bottom of control.
Replace 72D series amplifier module.
Replace flame scanner.
Replace 70D30 control.
With UV units, remove factory installed grounding wire (if present) from terminal S2 on the
wiring base.
£
Main flame not established following 10 second pilot flame TFI. Air Flow, Fireye indicators on.
—
—
—
—
—
—
—
Run check switch in check position.
Inadequate main fuel supply.
Defective main fuel valve.
Main burner improperly adjusted.
Broken wire, loose connection or wiring error.
Bent tab on bottom of control.
Replace 70D30 control.
Main flame lights and then goes out. Air Flow indicator on.
— Main flame and pilot blown out.
— Limit-operating control circuit (terminal L1-3) or running interlock circuit (terminals 3-P)
opens momentarily.
Main flame lights normally, but goes out when pilot flame is shut off. Air flow indicator on.
Control locks out.
— Flame scanner does not see main flame.
— Main burner improperly adjusted.
Pilot flame does not shut off following main flame TFI. Pilot connected to terminal 5. Air flow,
Fireye indicators on.
— Pilot valve stuck open.
— Wiring error.
— Replace 70D30 control.
Flame signal drops off while main burner fires. Air Flow indicator on Fireye indicator goes off.
— Main burner improperly adjusted.
— Flame scanner loses sight of flame.
— Control or scanner subjected to excessive temperature.
Main fuel valve does not shut off when operating control opens. Fireye indicator on.
— Main fuel valve stuck open.
— Wiring error.
Burner, Blower motor does not stop following post purge. All indicators off.
— Defective motor contactor.
— Wiring error.
Note: If operating control recloses during the post purge period, a complete restart is initiated. Do
not momentarily depress the lockout reset button to recycle the unit because it will cause some units
to lockout. Open and reclose the burner control switch instead.
19
£
Special Note
1.
When changing the
24CJ5, Model 3000 to the 70D30-71D80-72DRT1
24CU6 Model 1050 to the 70D30-71D80-72DUV1
26CF6, Model 1000 to the 70D30-71D80-72DIR1
do the following:
— Replace the wiring base with P/N 60-1386-2 or P/N 60-1466-2.
— Replace wires on corresponding terminals except as noted below.
— The existing STARTING INTERLOCK circuit (3 to D) must be changed to M to D.
— The existing RUNNING INTERLOCKS remain between 3 and P.
IMPORTANT: The STARTING INTERLOCKS and RUNNING INTERLOCKS must be
isolated from one another.
FIGURE 5.
COMPLETED CONVERSION
P
RUNNING
INTERLOCK
STARTING
INTERLOCK
D
M
3
2.
TO MOTOR
FROM LIMITS
When changing the
24CJ5, Model 3010 or 3011 to the 70D30-71D80, 71D90-72DRTI
25CU6, model 1062 or 1063 to the 70D30-71D80, 71D90-72DIR1
do the following:
— Replace the wiring base with P/N 60-1386-2 or P/N 60-1466-2.
— Replace wires on corresponding terminals.
MAINTENANCE
Type 48PT2 Infrared and Type UV1, UV8A, UV2, and 45UV5-1009 UltraViolet Scanners
The viewing area of the scanner must be kept clean. Even a small amount of contamination will
reduce the flame signal reaching the detector by a measurable amount. Wipe the viewing area routinely using a soft cloth dampened with concentrated detergent.
Type 48PT2 scanners include a replaceable #4-263-1 Firetron cell.
Type 45UV5-1009 scanners include a replaceable #4-314-1 UV tube.
Type 69ND1 Flame Rod. The flame rod and its insulator should be kept clean by washing routinely
with soap and water. Rods should be routinely replaced as they oxidize.
Flame Signal Strength. Routine observation of the flame signal strength on a DC test meter plugged
into the test jack of the Amplifier will forewarn of any deterioration in the capability of the flame
detector or its application.
Contacts. There are no accessible contacts in the Fireye D30 Series control. Where contacts are
used, their design assures long trouble-free life when the load circuits are maintained within the published load ratings.
Humidity. In areas of high humidity, the control chassis should be removed and placed in a dry
atmosphere when the system is expected to be out of service for an extended period.
Periodic Safety Check. A procedure should be established to test, at least once a month, the complete flame safeguard system. This test should verify the proper operation of all limit switches and
safety interlocks as well as flame failure protection and fuel safety shutoff valve tightness.
Rotation. It is recommended that control and scanner units purchased as spares be installed periodically.
20
£
Suggested Specifications for a Programming Flame Safeguard for Automatically Ignited Oil or Gas
or Combination Fuel Burners.
1.
2.
3.
4.
5.
6.
7.
Each burner shall be equipped with an electronic programing flame safeguard control that is
approved by UL, FM, CSA.
The programming sequence shall be completely controlled by solid state timing logic. The programmer shall be a plug-in module.
The control shall provide direct connection of limit and operating controls. Fuel valve interlock,
low fire start interlock, running interlocks such as air flow, fuel pressure and temperature and
Burner Motor, Ignition, Main fuel valves and lockout alarm.
Operational test facilities shall be provided for measuring flame signal strength and line and load
voltages.
The control shall be a plug-in design.
Plug-in solid state flame amplifiers shall be provided for the rectification, Infrared
(AUTOCHECK), Ultraviolet or ultraviolet repetitive self-check flame detection.
The burner management controls shall be Fireye series D-30.
21
£
5 11/16
(144.5)
WIRING BASE
MOUNTING HOLES
CONTROL WITH COVER
AND WIRING BASE
2 7/16
(61.9)
KNOCKOUTS FOR
1/2” CONDUIT (7)
5 1/4
(133)
7 9/32
(185)
5 3/4
(146)
7
(177.8)
13/64
(5.1)
1 3/4
(44.4) 25/32
(19.8)
KNOCKOUTS FOR
1/2" CONDUIT (7)
6
(152)
1 3/16
(30.2)
1 1/16
(27)
13/16” HEX
(20.6)
2 3/8”
(60.3)
25/64
TYP
(9.9)
13/16” DIA.
(206)
3/8” PIPE THREAD
UV2 UV SCANNER
1/2”-14 NPT
”L” LENGTH AS SPECIFIED: 12”, 18”, 24” (304.8, 457.2, 609.6)
2”
(50.8)
69ND1 FLAME ROD
1” DIA
(25.4)
UV90 MOUNTING BLOCK
(Included with Scanner)
36” FLEXIBLE CABLE (UV-1A-3)
72” FLEXIBLE CABLE (UV-1A-6)
1.48"
(37.6MM)
1.90
(48.2MM)
2 7/8”
(73)
3.75"
(95.7MM)
0.880"
(22.3MM)
3 3/16:(81)
0.5"
(12.7MM)
9/16” DIA.
(143)
1/2-14
STRAIGHT PIPE THD
3 1/4”
(82)
2 1/2”
(63.5)
1 1/4”
DIA.
7/16 FLEXIBLE
(11) CONDUIT
SCREW,
1/4-20 THD
HOLE FOR
3/4”
SIGHTING
PIPE
WHEN ASSEMBLED
1” DIA.
(25.4)
2 1/4”
(57)
HEAT INSULATOR
1/2-14
TAPERED
PIPE THD
UV SCANNER
Type: 45UV3
Model: 1050
2”
(50.8)
1 5/8”
(41)
2” (51) CLEARANCE REQUIRED TO REMOVE
UV SELF-CHECK
SCANNER
TYPE 45UV5
MODEL 1009
48PT2-1000 SERIES INFRARED SCANNER
4” (102)
1 1/2”
(38)
3 1/8”
(79.4)
WHEN ASSEMBLED
1” DIA.
(25.4)
2 1/2”
(63.5)
45O
13/32” (10)
1 1/4”
DIA.
2 5/16”
(58.7)
9/16” DIA.
(143)
1/2-1
STRAIGHT PIPE THD
1/2-14 STRAIGHT
FEMALE PIPE THREAD
UV1A UV SCANNER
0.875"
(37.6MM)
UV90 SCANNER
2”
(51)
8 1/4”
(210)
72” LEAD
4” (102)
1 11/16”
HEX
(43)
HEAT INSULATOR
1/2-14
TAPERED
PIPE THD
7/16” DIA. (11) FLEXIBLE CONDUIT
48PT2-9000 SERIES INFRARED SCANNER
22
11/16
(17.4)
1/2”
(12.7)
36” (1m APPROX.)
FLEXIBLE CABLE
1.406"
(35.7MM)
4 7/8
(123.8)
2”
(50.8)
”L”
2 3/8”
(60.3)
15/16” HEX
(23.8)
1/4
TYP
(6.35)
3/8-18 NPT FOR
PURGE AIR CONNECTION
1-11 1/2 NPT
FOR SIGHT
TUBE
£
23
£
NOTICE
When Fireye products are combined with equipment manufactured by others and/or integrated into
systems designed or manufactured by others, the Fireye warranty, as stated in its General Terms and
Conditions of Sale, pertains only to the Fireye products and not to any other equipment or to the
combined system or its overall performance.
WARRANTIES
FIREYE guarantees for one year from the date of installation or 18 months from date of manufacture
of its products to replace, or, at its option, to repair any product or part thereof (except lamps, electronic tubes and photocells) which is found defective in material or workmanship or which otherwise
fails to conform to the description of the product on the face of its sales order. THE FOREGOING
IS IN LIEU OF ALL OTHER WARRANTIES AND FIREYE MAKES NO WARRANTY OF
MERCHANTABILITY OR ANY OTHER WARRANTY, EXPRESS OR IMPLIED. Except as
specifically stated in these general terms and conditions of sale, remedies with respect to any product
or part number manufactured or sold by Fireye shall be limited exclusively to the right to replacement or repair as above provided. In no event shall Fireye be liable for consequential or special damages of any nature that may arise in connection with such product or part.
£
24
FIREYE
3 Manchester Road
Derry, New Hampshire 03038 USA
http:www.fireye.com
D-30
AUGUST 22, 2005
Supersedes April 2001
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