CES-5001

CES-5001

CES-5001
AUGUST 1997
INSTALLATION MANUAL
FIREYE® FOCUS™
COMBUSTION EFFICIENCY
SYSTEM
WIRING BASE WITH CONTROLLER
and ACTUATOR MODULE INSTALLED
SCANNER
ACTUATOR
IMPORTANT NOTICE: THE SUCCESSFUL OPERATION OF THIS PRODUCT DEPENDS ON PROPER
INSTALLATION. OPTIMAL PERFORMANCE REQUIRES UNDERSTANDING THE PROCEDURES IN
THIS DOCUMENT. IT IS HIGHLY RECOMMENDED THAT YOU READ THIS MANUAL BEFORE ANY
HARDWARE INSTALLATION!
TABLE OF CONTENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAIN COMPONENTS OF FOCUS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT PICTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MECHANICAL INSTALLATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SELECTION OF THE FIRING RATE FEEDBACK POTENTIOMETER . . . . . . . . . . . . 6
ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIRST APPLICATION OF POWER - OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OVERVIEW OF CONTROLLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SETTING AND USING PASSWORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LEARNING THE FIRING RATE FEEDBACK POTENTIOMETER POSITION . . . . . . 9
INSTALLATION OF THE CA202 ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SCANNER (CS200) SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LEARNING THE BIN LOCATIONS AND BIN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 13
KEYPAD AND DISPLAY INTERACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SYSTEM VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LEARN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MECHANICS OF COMBUSTION — GASEOUS FUELS . . . . . . . . . . . . . . . . . . . . . . . . 26
GAS COMBUSTION PHASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TROUBLESHOOTING LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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.
1

DESCRIPTION
The function of the Fireye FOCUS™ Combustion Efficiency System (Patent Pending) is to maintain
preset combustion efficiency levels on commercial and industrial gas burners. The system provides
these benefits by optically monitoring combustion at the flame, rather than at the stack. The system
learns the optimal performance parameters and constantly monitors and adjusts the fuel/air ratio to
maintain it for the life of the burner. Long term savings both in fuel and maintenance can be
expected.
The FOCUS system consists of three major components: The Combustion Efficiency Scanner, the
Controller, and the Actuator. The Fireye CS200 scanner monitors the ratio of two constituents (OH
AND CH) in the targeted flame to maintain the efficiency ratio. The Fireye CES1000 controller
receives this information from the CS200 and automatically adjusts the fuel/air mixture by positioning the Fireye CA202 actuator. The CES1000 Controller is housed in the 60-2555 Wiring Rack,
along with the AM300 Actuator Module which powers the CA202 Actuator itself.
The control action, speed of response, and range within the burner firing rate may be configured in
the CES1000 controller to optimize burner performance. When used as both an efficiency controller
and flame supervision system, an output from the 60-2555 wiring rack (S1,S2) may be wired to the
input (S1,S2) of a Fireye Flame-Monitor™ as the flame signal, eliminating the need for a second
sight port and flame scanner. When this option is selected, the Fireye Flame-Monitor must use an
E1R1 flame amplifier to process the input signal.
The 60-2555 wiring rack accepts inputs from various accessories. Inputs available are for an analog
4-20 mA DC signal, a type K thermocouple, and a digital input. Outputs are provided and include an
analog 4-20 mA DC and a RS485 for data transfer to a proprietary Fireye software program. A configurable SPDT relay contact can also function as an alarm or flame relay.
CAUTION: Installation of the Fireye FOCUS combustion efficiency system should only be
performed by a qualified combustion control technician.
2

MAIN COMPONENTS OF FOCUS SYSTEM (See Component Picture Next Page)
PART NUMBER
DESCRIPTION
60-2555
ITEM
USE WITH
Wiring Rack
3
—
CES1000
FOCUS Controller
5
60-2555
AM300
FOCUS Actuator Module
4
60-2555
CS200
FOCUS Scanner
9
CES1000
CA202
FOCUS Actuator
2
AM300
ACCESSORIES FOR FOCUS SYSTEM (See
PART NUMBER
Component Picture Next Page)
DESCRIPTION
ITEM
USE WITH
ACC-59-10FF*
10 ft. metal flex, 1 female straight connector, flying leads
12
Actuator and JB100
ACC-59-10FM*
10 ft. metal flex, 7 pins male straight connector, flying leads
NS
Controller and JB100
ACC-59-10F90*
10 ft. metal flex, 1 female right angle connector, flying leads
10
Actuator and JB100
ACC-59-10D*
10 ft. metal flex., 2 straight connectors male and female
NS
Actuator and Controller
ACC-59-10D90ST*
10 ft. metal flex, 1 right female and 1 straight male connectors
NS
Actuator and Controller
AC-59-10
10 ft. cable with two connectors
11
Actuator and Controller
AC-59-25
25 ft. cable with two connectors
NS
Actuator and Controller
AC-59-50
50 ft. cable with two connectors
NS
Actuator and Controller
AC-59-75
75ft. cable with two connectors
NS
Actuator and Controller
SCC-59-10FF*
10 ft. metal flex, 1 female straight connector, flying leads
12
Scanner and JB100
SCC-59-10FM*
10 ft. metal flex, 6 pins 1 male straight connector, flying leads
NS
Controller and JB100
SCC-59-10F90*
10 ft. metal flex, 1 female right angle connector, flying leads
10
Scanner and JB100
SCC-59-10D*
10 ft. metal flex, 2 straight connectors male and female
NS
Scanner and Controller
SCC-59-10D90ST*
10 ft. metal flex, 1 right female and 1 straight male connectors
NS
Scanner and Controller
SC-59-10
10 ft. cable with two connectors
NS
Scanner and Controller
SC-59-25
25 ft. cable with two connectors
NS
Scanner and Controller
SC-59-50
50 ft. cable with two connectors
NS
Scanner and Controller
SC-59-75
75 ft. cable with two connectors
NS
Scanner and Controller
59-489
FOCUS cable
NS
JB100
JB100
FOCUS cable junction box, 7 conductors terminal
6
STS100-12A
Stack Temperature Sensor (K type)
8
CES1000
FPQ181
135 ohm Feedback Potentiometer
1
CES1000
FP1000
1000 ohm Feedback Potentiometer
NS
CES1000
7
CES1000
FP5000
5000 ohm Feedback Potentiometer
*
Use when UL listing is required.
** UL Listed System
NS = Not Shown in Picture
STANDARD RETROFIT PACKAGE KITS
The FOCUS system can be purchased in the form of an FK1 or FK2 kit. (The difference is the type
of prefabricated cable included).
PART
NUMBER
DESCRIPTION
FK1
Includes 60-2555, CES1000, AM300, CS200, CA202, AC-59-25***, SC-59-25***
FK2 **
Includes 60-2555, CES1000, AM300, CS200, CA202, ACC-59-10F90*, ACC-59-10FM*, SCC-59-10F90*, SCC-59-10FM*,
(2 each JB100)
*
Use when UL listing is required.
** UL Listed System
*** Cables not UL Listed
3

COMPONENT PICTURE
4
2
5
3
1
6
9
7
8
12
10
FIGURE 1.
11
60-2555 WIRING RACK
FB
+
-
INTERNAL
RIBBON CABLE
TMP
Y
R
+
DIN
-
+
AIN
-
COMM
A
B
S1 S2
AOUT
+
-
RLY
NC
RLY
COM
RLY
NO
DRY
CONTACT
L1
L2
EARTH GROUND
MONITORS
FLAME STATUS
OR PROVIDES ALARM
TO COMM
PORT ON
COMPUTER
CONNECT TO 120 VOLT
50/60 HZ OVERLOAD
PROTECTED
SUPPLY WITH DISCONNECT
CA202
4-20MA SIGNAL
FROM CUSTOMER
DEVICE
PREFABRICATED
CABELS
CS200
FIRING RATE
FEEDBACK
POTENTIOMETER
CUSTOMER DEVICE
THAT ACCEPTS
4-20MA MAX. LOAD
750 OHMS
TYPE “K”
THERMOCOUPLE
WIRE
STACK TEMPERATURE
SENSOR STS100-12A
4
FIREYE FLAMEMONITOR WITH
E1R1 AMPLIFIER
FOR MORE SPECIFIC DETAILS:
Refer to the following bulletins:
CES-1001
CONTROLLER
CES-2001
SCANNER
CES-2002
ACTUATOR
CES-3001
ACTUATOR MODULE
CES-2555
MOUNTING RACK
CES-4001
ACCESSORIES

FIGURE 2.
FOCUS SYSTEM INSTALLED ON A JACK SHAFT OPERATED BURNER
60-2555 MOUNTING RACK
WITH AM300 AND CES1000
INSTALLED
FIREYE
60-2555
COMBUSTION
CHAMBER
CA202
ACTUATOR
CS200
FIRING RATE
ACTUATOR
JACK SHAFT
ON BURNER
FUEL VALVE
FIRING RATE
FEEDBACK
POTENTIOMETER
FIGURE 3.
CONFIGURATIONS FOR FOCUS COMBUSTION EFFICIENCY SYSTEM
CONFIGURATION WITH
KIT FK1
FIREYE
USER ALTERNATIVE
CONFIGURATION
FIREYE
60-2555, CES1000, AM300, CS200
CA202, AC-59-25, SC-59-25
SCC-59-10FM
60-2555
ACC-59-10F90
60-2555
ACC-59-10FM
CA202
CA202
CS200
CS200
JB100
JB100
SCC-59-10FF
USER SUPPLIED
CONDUIT
JB100
JB100
FP5000
FP5000*
USER SUPPLIED CABLE
BELDEN # 9318 OR
EQUIVALENT
* Not included with FK1
USER SUPPLIED CABLE
BELDEN # 9318 OR
EQUIVALENT
FIREYE
FIREYE
USER ALTERNATIVE
CONFIGURATION #2
CONFIGURATION WITH
KIT FK2
60-2555, CES1000, AM300, CS200, CA202, ACC-59-10F90,
ACC-59-10FM, SCC-59-10F90, SCC-59-10FM
(2 each of JB100)
60-2555
60-2555
ACC-59-10D
CA202
CA202
JB100
SCC-59-10D
CS200
CS200
JB100
FP5000
FP5000*
* Not included with FK2
USER SUPPLIED CABLE
BELDEN # 9318 OR
EQUIVALENT
USER SUPPLIED CABLE
BELDEN # 9318 OR
EQUIVALENT
5

MECHANICAL INSTALLATION OF COMPONENTS
After locating a position for the 60-2555 mounting rack, the following sequence should be followed.
Remember, do not locate any component where it will exceed the published ambient temperature limitations.
1.
Perform the mechanical installation of the 60-2555 Mounting Rack, along with the CES1000
Controller and AM300 Actuator Module according to Technical Bulletins # CES-2555, CES1001 and CES-3001 respectively.
Determine which firing rate feedback potentiometer will be used. (FP5000 mounted on the
burner and actuated via a linkage assembly or FPQ181 mounted directly on the firing actuator).
Once the feedback potentiometer has been determined perform the mechanical installation
according to its associated Bulletin CES-4001. (See the following section entitled SELECTION OF THE FIRING RATE FEEDBACK POTENTIOMETER for additional information.)
Mount the CS200 scanner to provide an unobstructed view of the burner flame. (If used for
flame detection and combustion efficiency, this sighting location must also provide an unobstructed view of the pilot burner). Install according to Technical Bulletin # CES-2001.
Install the CA202 trim actuator adapted correctly to the burner air linkage according to Technical Bulletin CES-2002.
Finally, install any accessory equipment to be used with the system according to enclosed bulletins and instructions.
2.
3.
4.
5.
SELECTION OF THE FIRING RATE FEEDBACK POTENTIOMETER
JUMPER
135 OHM
POSITION
J1
Dotted line shows
correct location
for 5,000 ohm
position
5,000 OHM
POSITION
The FOCUS system must use one of two styles of firing rate feedback potentiometers to
provide a signal to the CES1000 controller indicating the firing rate position of the
burner. The CES1000 controller can take an input from a feedback potentiometer having a total resistance range of either 0 to 135 ohms or 0 to 5,000 ohms. Depending on
which potentiometer is used, a range selector jumper on the CES1000 must be properly
positioned. If a change to the jumper setting is required, first remove all power to the
unit. Then remove the CES1000 module from the mounting rack, by removing the
screws located on the front panel and pull it out by the two handles. See the drawing for
jumper location. Reverse procedure to reinstall module.
FPQ181 mounts directly on the end of a manufacturers actuator. (See Figure 4).
JUMPER ON CORNER OF LOWER
BOARD OF CES1000 CONTROLLER
(SHIPPED IN 5,000 OHM POSITION)
The Fireye potentiometer FP5000 mounts on the burner assembly and is driven through
the use of a linkage rod. The FP5000 should be linked so the rotation of the potentiometer provides the maximum resistance change when the burner is stroked from low to
high fire. (See Figure 5).
After the mechanical installation is complete, the potentiometer’s electrical connection
should be made from the wiper and one end of the potentiometer to the terminals
marked “FB+, FB-” (See Figure 1) in the 60-2555 mounting rack. The beginning resistance at low
fire is between 10-20 ohms for the FPQ181, or between 50-150 ohms for the FP5000. The span for
the FPQ181 should be a minimum of 110 ohms while the FP5000 should be a minimum of 1,000
ohms.
The resistance should increase in value as the firing rate feedback potentiometer moves from the low
to the high fire position. Maximize the span to provide the highest resolution to be seen by the
CES1000 controller and to allow better repeatability (a good hand-held Ohmmeter is important for
this process).
6

FIGURE 4.
FIRING RATE FEEDBACK POTENTIOMETER FPQ181
POTENTIOMETER DRAWING APPLIES TO INCREASING CW
TRAVEL AT POWER SHAFT END OF
FIRING RATE ACTUATOR
FEEDBACK
POTENTIOMETER
R
INCREASING CW TRAVEL AT POWER SHAFT
END OF FIRING RATE ACTUATOR.
SLOTS FOR
8.32 SCREWS, AND
WASHERS TO MOUNT
UNIT TO MOTOR
HOUSING BOSSES.
TOP VIEW
THREAD FOR
.50 CONDUIT
CONNECTION
3.25 (82.5)
1.62
(41.1)
CL SHAFT AND
COUPLING
2.43
(61.9)
2.24
(57.1)
W B
(WIPER) (LOW) (HIGH)
SIDE VIEW
3.25
(82.5)
3.38 (85.8)
1.38
(35.0)
1.25
(31.7)
2.50
(63.5)
DRIVE COUPLING
ASSEMBLY
LOAD INDEX
TRANSMITTER
EXISTING FIRING
RATE ACTUATOR
COUPLING ASSEMBLY NOTES —
MOTOR AUX. SHAFT TRAVEL SET AT THE FULL CW
POSITION. (POWER SHAFT END CCW).
SLIDE COUPLING HALF WITH SETSCREWS OVER
MOTOR AUX. SHAFT UNTIL SIDE OF SETSCREWS
ARE LOCATED AS SHOWN. SECURE TO SHAFT IN
THIS POSITION WITH TWO SETSCREWS. SLIP OTHER
HALF OF COUPLING OVER POT DRIVE PIN AND
ROTATE CAM 45° CCW SO THAT TANGS ON COUPLING
FIT INTO SLOTS IN MOTOR COUPLING. ATTACH
UNIT TO MOTOR HOUSING WITH TWO SCREWS.
DRIVE PIN IN
POT SHAFT
DRIVE PIN
HOLE SIZE COUPLING
WILL FIT .50 RD.
AND .375 SQ. MOTOR SHAFT END
DIMENSIONS IN INCHES (MM)
FIGURE 5.
PRELIMINARY ADJUSTMENT —
USING SPAN ADJUSTMENT SCREW, SET
SPAN FOR APPROX. 90° MOTOR SHAFT
TRAVEL AS INDICATED ON THE SPAN
SCREW BRACKET. ADJUST ZERO
ADJUSTMENT SCREW SO THAT
WIPER TRAVEL IS WITHIN OPERATING
SECTION OF POTENTIOMETER.
TERMINAL BOARD
WITH #6 SCREWS
TYPICAL FIRING RATE FEEDBACK POTENTIOMETER TRAVEL (90° MINIMUM)
45°
DRIVING
LEVER
45°
ROD LINKING FIRING RATE MODULATOR
MOTOR TO FIRING RATE FEEDBACK
POTENTIOMETER
45°
FP5000
45°
ELECTRICAL INSTALLATION
Refer to the previously mentioned technical bulletins and Figure 1 to determine which and how components must be connected to the 60-2555 mounting rack. Electrical connections must comply with
all applicable codes. A good earth-ground must be connected to the 60-2555.
Failure to connect a continuous earth-ground could result in erratic operation. Do NOT
connect or disconnect actuator or scanner cables with power applied to the controller.
7

FIRST APPLICATION OF POWER - OVERVIEW
The LEARN process is how we program the controller to operate and control the combustion process. The CES1000 LEARNS the various parameters associated to the trim actuator, firing rate,
feedback potentiometer, the scanner, and optimal combustion parameters at various loads.
The first function to be performed after applying power to the unit is to LEARN the firing rate feedback potentiometer. Those instructions follow the OVERVIEW OF CONTROLLER OPERATION and USING AND SETTING PASSWORDS. Do not jump to that section until reviewing
these two important sections.
When the FOCUS system is used for flame detection, the system can then be brought to and through
the pilot proving position. It may be necessary to place the FLAME-MONITOR programmer in
CHECK while the pilot flame signal values (OH/CH) are observed under the SYSTEM VALUE
menu. At this point, it may be necessary to adjust the gain of the scanner to display an OH signal
greater than 700 but less than 2500. The gain is adjusted under the SETUP menu. The value of pilot
signal must be balanced against the value of main flame signal. Once a pilot signal is established, the
FLAME-MONITOR programmer can be placed in the RUN mode and allowed to continue its
sequence.
The burner should be recycled and a minimum pilot turndown test must be performed before
proceeding with the configuration for the FOCUS system.
OVERVIEW OF CONTROLLER OPERATION
There are four primary programming groups which can be accessed using the keypad and viewed on
the display. These groups coincide with the four keys on the left side of the keypad. These keys are
marked:
SYSTEM VALUES
SYSTEM TEST
SETUP
LEARN
At any time, when you push one of these keys, you will leave the primary group you are currently
viewing and enter the group corresponding to the key pushed. These groups are separate and distinct.
To view, or change a parameter in that group, requires the pressing of that respective key. As we proceed with installation, we will refer to various functions in these groups.
SETTING AND USING PASSWORDS
OVERVIEW
This system is equipped with password security. It has been added to insure that once the FOCUS
system is set up properly, no one can alter its operation without entering the password combination.
Before proceeding, make sure all electrical connections have been properly performed.
When the SETUP key is pushed, the display will read:
TRIM CONTROL
DISABLED
This is the factory default value and message on the display when first received and powered.
You may proceed to review all the parameters in this group by pressing either the UP/NEXT key or
the DOWN/BACK key. The parameters will be displayed in the order shown later in this bulletin.
These keys will take you forward or backward through that list.
You cannot modify any of the parameters in this group until you enter the password parameters
shown as Password LV 1 and Password LV 2 in this group.
8

SETTING PASSWORD
Go to the display position within the SETUP group which says, Password LV 1. When you have
this on the display, push the MDFY/ENTER key and an “*” will appear on the upper line of the display. This indicates that you can change the value on line 2 to the proper password. THIS IS DONE
ONLY WHILE THE “*” IS ON THE DISPLAY. By pressing the UP/NEXT or DOWN/BACK
keys, the second line on the display will change to allow you to find the proper password numerical
value. The default value for Password LV 1 as received from the factory is the number 2. When it is
present on the display, by pressing the MDFY/ENTER key, you will have selected this number and
the “*” on the upper line will disappear.
Press the UP key. Password LV2 will appear.
With the Password LV 2 display message, again, press the MDFY/ENTER key and the “*” will
appear on the upper line. By pressing the UP/NEXT or DOWN/BACK key, you will be able to find
the proper password numerical value. The default value for Password LV2 as received from the factory is the number 5. When it is present on the display, by pressing the MDFY/ENTER key, you will
have selected this number and the “*” on the upper line will disappear.
You do have the option to program the CES1000 with personalized password codes as described in
the following paragraph. Once you have entered the proper password, you can enter, store and edit
data in the Controller.
After selecting the proper passwords for these two levels, the next display will show, Set LV 1 and
Set LV 2. This will allow you to select new passwords for either, or both of these levels, if you
choose. Follow the procedure described above in order to modify, select and enter the new passwords. Remember to record your new passwords and store them in a secure location.
Please note, when the passwords are enabled, it will automatically disable if no key is pressed within
10 minutes. You will have to re-enter the password if left longer than that period.
LEARNING THE FIRING RATE FEEDBACK POTENTIOMETER POSITION
After the firing rate feedback potentiometer has been mechanically and electrically installed, continue as noted below.
Enter the SETUP group and enter the passwords for LV1 and LV 2
Then press the LEARN key
Lrn Bin Params appears on the display.
Press the UP key. - Lrn ModLow Pos appears on the display. Verify that the firing rate modulator
motor and the feedback potentiometer are in the low fire position before proceeding.
Press MDFY key and the “*” appears on the display in the far right of the upper line.
Press MDFY key again - Mod Motor Low Learned appears on the display for a few seconds and
then, Lrn ModLow Pos 0% appears on the display.
Press the UP key - Lrn ModHigh Pos 0% appears on the display. Verify that the firing rate modulator motor and the feedback potentiometer are in the high fire position before proceeding.
Press the MDFY key and the “*” appears on the display in the far right of the upper line.
Press the MDFY key again - Mod Motor High Learned appears on the display for a few seconds
and then, Lrn ModHigh Pos 100% appears on the display.
The firing rate feedback potentiometer position LEARN is now complete.
NOTE: Learning the firing rate feedback potentiometer will erase all previously learned bin
data.
9

INSTALLATION OF THE CA202 ACTUATOR
An actuator LEARN must be performed before the rod/CA202 assembly is permanently installed.
This process is how the CES1000 LEARNS the outer limits of travel of which the actuator is capable. It also will learn the normal operating, or, NULL position. If you have fixed the new assembly in
place, it must be loosened to perform the following LEARN function.
Before proceeding, you must enter the SETUP group and enter the passwords for LV1 and LV 2.
Having loosened the assembly (LEARN Actuator can be established before installing the CA202
assembly, but is most often performed as described), the trim actuator can be positioned at the
NULL, EXTENDED and RETRACTED positions.
EXTENDED is when the nut slide is at it’s maximum distance from the gear case housing and is displayed as 100%. RETRACTED is when the nut slide is closest to the gear case housing and is displayed at 0% (See Figure 6).
FIGURE 6.
CA202 TRIM ACTUATOR
DUST COVER
INSTALLATION
EXTENDED ACTUATOR
RETRACTED ACTUATOR
D FELT RING
TO LEARN THE ACTUATOR
Enter the SETUP group and enter the passwords for LV1 and LV 2
Press the LEARN key — Lrn Bin Params appears on the display.
Press the UP key three times until Lrn Act Retrac appears.
Press the MDFY key and the “*” will appear on the display in the far right of the upper line.
Press MDFY - Lrn Act Retract appears on the display and then Actuator Ret Learned appears on
the display for a few seconds. You will observe during this procedure that the actuator is moving to
its RETRACT position. If it does not reach this point, an error message will be displayed. Refer to
the section entitled MESSAGES for further instructions if this occurs. Once completed, the display
will read, Lrn Act Retract 0.0%.
Press the UP key and Lrn Act Extend will appear on the display.
Press the MDFY key twice and Lrn Act Extend 100% will appear on the display. Actuator Ext
Learned appears for a few seconds. You will observe during this procedure that the actuator is moving to its EXTEND position. If it does not reach this point, an error message will be displayed. Refer
to the section entitled MESSAGES for further instructions if this occurs. Once completed, the display will read Lrn Act Extend 100%.
Press the SYSTEM VALUES key once. The CA202 actuator will drive to the NULL position.
The CA202 Actuator Assembly is now assumed to be installed according to Technical Bulletin CES2002. As a reminder, make sure the new rod/CA202 assembly is exactly the same length as the original rod. (See Figure 7).
10

FIGURE 7.
LINKAGE ROD CONFIGURATIONS
CONFIGURATION AFTER INSTALLATION OF CA202
EXISTING CONFIGURATION
5/16" DIA.
NEW ROD
EXISTING
LINKAGE ROD
ACTUATOR IN
NULL POSITION
(FACTORY
DEFAULT)
Y
X
DISTANCE “X” = DISTANCE “Y”
ON BOTH RODS WHEN THE
CA202 ACTUATOR IS IN
THE “NULL” POSITION.
NULL CAN BE SELECTED AS
RETRACTED, EXTENDED, OR
CENTERED POSITIONS
OF THE TRIM ACTUATOR.
NOTE: CA202 SHOWN WITH
DUST COVER REMOVED
Re-install the CA202 actuator and associated linkage on to the burner. The Learn Actuator position is
now complete.
After the Actuator Learn is complete there are two additional features that can be configured for the
CA202 actuator. First is the NULL Position and the second is the CONTROL ACTION.
The choices for the NULL Position are, Retracted, Center or Extended. The factory default for
NULL Position is Center.
The choices for the CONTROL ACTION are Direct or Inverse. The factory default for CONTROL ACTION is DIRECT. Direct means that the actuator will move to the Extended position to
trim the air or close the air damper. It will move to the Retracted position to add air or open the air
damper. Conversely, Inverse means that the actuator will move to the Extended position to add air
or open the air damper and move to the Retracted position to trim air or close the air damper.
THESE ARE FACTORY SET AND NEED NOT BE ADJUSTED UNLESS A SPECIAL
REQUIREMENT IS NECESSARY. THE FOLLOWING PROCEDURE IS FOR INFORMATION
PURPOSES.
SELECTING ACTUATOR NULL POSITION
The factory default value for the NULL Position may be changed as follows.
Note; If the null position is changed, the mechanical installation of the CA202 actuator must be
done again.
Enter the SETUP group and enter the passwords for LV1 and LV2.
After the proper passwords have been entered Press the SETUP key once.
Trim Control is displayed,
xxxxx
Depending in what mode the control is, the “xxx” may display as Disabled or Enabled.
Press the UP key twice.
NULL POSITION
CENTER
11

Press the MDFY key once and the “*” will appear on the display in the far right of the upper line.
Press the UP key until the desired selection is displayed.
Press the MDFY key once and the “*” will disappear on the display in the far right of the upper line
while the actuator drives to the selected position.
SELECTING ACTUATOR CONTROL ACTION
The factory default value for the CONTROL ACTION may be changed as follows.
Enter the SETUP group and enter the passwords for LV1 and LV2.
After the proper passwords have been entered press the SETUP key once. - TRIM CONTROL is
displayed,
xxxxx
Depending on what mode the control is in the “xxx” may display as Disabled or Enabled
Press the UP key three times.
CONTROL ACTION
DIRECT
Press the MDFY key once and the “*” will appear on the display in the far right of the upper line.
Press the UP key until the desired selection is displayed.
Press the MDFY key once and the “*” will disappear on the display in the far right of the upper line,
the CONTROL ACTION has been selected.
CAUTION: When the actuator is at its NULL position and the mod motor is traveling through
its firing range, the actuator must not be forced against any mechanical stops.
TRIM ACTUATOR ADJUSTMENT
When learning bin data, (described later in LEARNING THE BIN LOCATIONS AND BIN
DATA) the CA202 trimming actuator may be used as a fine tuning adjustment. This happens in the
setup menu under the LEARN BIN mode. The screen will display the OH/CH ratio and the actuator
trim position in percentages. The UP/NEXT, DOWN/BACK keys can be used to extend or retract
the trimming actuator. This change in position is represented by an increase or decrease in the actuator position percentage on the display. This feature is NOT intended to be used to tune the burner.
Variances greater than 5 percent result in excessive trim actuator movement as the burner modulates
between bins and may result in unsatisfactory control.
SCANNER (CS200) SETUP
It is assumed the CS200 Scanner has now been installed and wired as per Bulletin CES-2001. The
CS200 must now be optimally “fixed” in position. This is done by rotating the scanner, by 90 degree
increments and logging OH and CH values at both pilot and low fire as displayed on the Controller at
each position. Once you determine which orientation provides the highest value for OH and CH,
lock (or “fix”) the scanner in this position. Note in the space provided in the SCANNER ORIENTATION LOG (Figure 8) which position was used.
To view the OH and CH values:
Press the SYSTEM VALUES key
Press the MDFY key ten times until the following screen is visible.
FLAME ON
OH = xxxx
CH=yyy
Using this screen of information, rotate the scanner inurement, find the optimal position and lock it in
that place.
Once the scanner has been “fixed,” it should not be rotated from that position. Rotating will require
all LEARN sequences associated with BIN DATA (discussed later in this document) to be performed again. The scanner contains a detector assembly consisting of two adjacent detectors. Rotating the scanner changes the field of view and flame signal levels seen by each detector. It also effects
the value of the resultant OH/CH ratio.
12

SCANNER OPERATION
Flame On OH and CH values can be read from the CES1000 controller display in the SYSTEM
VALUES group. (These are described in the KEYPAD DISPLAY INTERACTION section later in
this document). The FOCUS system references the OH value and uses it to determine flame on and
flame off. For the purposes of flame on, the OH value must exceed 500 for a minimum of one second. Should the OH value drop below 200, the FOCUS system will interpret it as a flame off condition. Under the flame off condition, the trimming actuator will return to the NULL position and the
flame signal output from terminal S1 and S2 is terminated. The FOCUS system will function in a
trimming mode once the trim control feature has been enabled, the flame is on, the OH/CH ratio is
below 9.99 and the firing rate feedback potentiometer is within the trim limits. The burner should be
tuned and the scanner oriented to provide an OH/CH ratio with values between 1.2 and 7.5. OH/CH
ratios less than 1.2 and greater than 7.5 should be avoided. If values less than 1.2 or greater than 7.5
are being observed on a continuous basis, the burner should be readjusted and/or the scanner orientation/sighting angle should be reassessed. (See the SETUP OF THE SCANNER section).
Note: Any action taken to change either the burner tuning, or scanner alignment, requires
relearning all bin information.
FIGURE 8.
SCANNER ORIENTATION LOG
®
OH _____________
PILOT:
UL
OH _____________

CES SCANNER
CS200
PILOT:
OH _____________
CH _____________
LOW FIRE: OH _____________
UL

UL
CH _____________
LISTED
SECTION OF
PRIMARY
SAFETY
CONTROL
274R
APPROVED
LISTED
SECTION OF
PRIMARY
SAFETY
CONTROL
274R

LOW FIRE: OH _____________
CH _____________
DERRY, NH
MADE IN USA
CH _____________
®
OH _____________
®
CES SCANNER
CS200
PILOT:
LOW FIRE: OH _____________
®
APPROVED
CH _____________
CES SCANNER
CS200
APPROVED
LOW FIRE: OH _____________
CH _____________
®
APPROVED

DERRY, NH
MADE IN USA
CH _____________
®
CES SCANNER
CS200
LISTED
SECTION OF
PRIMARY
SAFETY
CONTROL
274R
UL
LISTED
SECTION OF
PRIMARY
SAFETY
CONTROL
274R
PILOT:
DERRY, NH
MADE IN USA
CH _____________
®
DERRY, NH
MADE IN USA
®
LEARNING THE BIN LOCATIONS AND BIN DATA
The CES controller allows up to 10 firing rate locations to be learned and the data saved within the
associated bins. For bins not learned, the controller will determine and display the theoretical values
at the mid-point of each bin. This is noted by an asterisk (*) following the bin number. You must
LEARN a minimum of four bins with at least two bins above and two bins below the 50% firing rate
point. It is recommended to LEARN all bins as the control will be more accurate with more bins
learned.
Using a combustion flue gas analyzer (such as the Fireye Firetron® Analyzer), the boiler technician
should first tune the burner (with the CA202 trim actuator in the NULL position) to its optimum performance. After tuning is complete, all pertinent data should be logged for future reference. A sample troubleshooting log is provided in this manual.
The CES1000 controller provides up to 10 bin locations to maintain optimum burner performance
data between low and high fire. After analyzing the data log from the burner tune-up:
Enter the SETUP group and enter the passwords for LV1 and LV2.
Press the LEARN key and continue.
13

The controller display reads LRN BIN PARAMS,
Press the MDFY key once, again. The display will show the present bin number and modulator position in percentages.
Press MDFY key again. Act Pos and Ratio will appear on the display.
Manually, set the burner to a desired firing rate position at some point above the LOW TRIM
START point. Typically this should be in the 15% - 18% region.
Pressing the UP or DOWN key will force the CA202 actuator to move UP toward the extended end
and DOWN toward the retracted end; as such, the CA202 is being used as a fine tuning adjustment
for the burner. When used with an analyzer (such as the Firetron Analyzer), and when an actuator
position is found yielding the lowest value O2 with no generation of CO and the burner has stabilized, press the MDFY/enter key once and the displayed information will be entered into controller
memory.
Repeat this process to learn additional bins.
Bins may be learned in any order, at any time. Should it be determined that a previously learned bin
is not correct, the technician can proceed to that bin and relearn it. If the next position is within the
same bin range of any previously learned bin, that data will then be overwritten with the new data.
A minimum of four learned bins are required in order to place the control in ENABLED mode; however, it is recommended the maximum number of bins be learned. The more bins learned, the better
the control over the entire firing range. Any bins that are not learned by the technician, will be calculated by the controller.
After the controller is placed in a ENABLED mode, the processor references the learned bins and
calculates a set point for OH/CH ratio along a line connecting the learned bins.
When sufficient bin data has been accumulated, modifying the TRIM CONTROL to ENABLED
will now allow the FOCUS system to control the burner/boiler environment. The system will not
allow you to enable unless at least four (4) bins must be learned (two below 50% and two above
50%).
Enter the SETUP group and enter the passwords for LV1 and LV2.
Press the SETUP key again. TRIM CONTROL, disabled will appear on the screen.
Press the MDFY key once and the “*” will appear on the display in the far right of the upper line.
Press the UP key until the ENABLED is displayed.
1.
2.
3.
In the chart above, log the OH and CH values at both pilot and low fire with the CS200 scanner
oriented at 90° increments. The OH/CH values can be read under the SYSTEM VALUES
GROUP section later in this document.
Determine which orientation provides the highest levels of OH and CH.
Lock the scanner in this position and note in the spaces above which position was used.
Note: A change in the orientation of the CS200 scanner after the system has been enabled will
require recalibrating the system. If not recalibrated, the system will no longer function optimally.
14

KEYPAD AND DISPLAY INTERACTION
FIGURE 9.
FOCUS CES1000 MODULE DISPLAY
DISPLAY CONTRAST ADJUSTMENT
CES1000
Md = 0%
Tg = x.xx
At = 50.0%
Rt = 9.99
SYSTEM
SETUP
VALUES
UP
MDFY
NEXT ENTER
DOWN
SYSTEM
TEST LEARN
BACK
HELP
SYSTEM VALUES
Pressing the SYSTEM VALUES key will allow you to step through the parameters listed in this
group. You will move in sequence through the various parameters by using the UP/NEXT or
DOWN/BACK keys. One will take you through the listing forward, the other in the reverse order.
When in this group, you will not be able to change any setting of the parameters.
(Note that these parameters are not modifiable and information can only be reviewed on the display) (If there are no key
entries within 10 minutes, the display on the Controller will move back into this group automatically)* = Factory Default.
Md=xxx% At=yyy.a%, (.a=0 or 5)
Tg=z.zz Rt=r.rr
“Md” is the Mod Motor position in %.“At” is the firing rate Actuator Position in
%. “Tg” is the “OH/CH” Target Ratio that the control will attempt to maintain.
“Rt” is the “OH/CH” Actual Ratio Value that the CS200 scanner is monitoring.
Bn
#
Learn values, max of 10 bins. Unlearned bins are not displayed if number of
learned bins is less than 2. A minimum of 4 bins must be learned before the control
will become functional. Two of the bins must fall below 50% and two of the bins
must fall above 50% of the firing rate feedback potentiometer value.
Bn =Bin # 0 to 9, An “*” after the # denotes calculated learn values.
Md =Firing Rate Feedback Potentiometer position in %.
At = Trimming Actuator position in %.
Ratio =“OH/CH” Actual Ratio Value that the CS200 scanner is monitoring.
Md
At
Ratio
xx% yyy% z.zz
Scanner Ambient
xxx°F
Displays the Ambient Temperature as read in the CS200. Proper Units, as selected
under “Temp. Units” in Setup Group.
Detector Temp
xx°F
Displays the temperature of the detector as read in the CS200. Proper Units, as
selected under “Temp. Units” in Setup Group.
Scanner Gain
xx
Value displayed will be within 0-100
Scanner F/W Ver
x.x
Displays the version of firmware that is in the CS200 Scanner
15

DelayStartIntlk
xxxxx
Where “xxxx” is as noted below. Unused, Feature is Inactive. Time, Number of
minutes before the system will begin to trim on initial startup.Stack Temp, Measured temperature must equal or exceed the value entered in the SETUP group
before the system will begin to trim on initial startup.(“Enabled” must be selected
in the SETUP group to use this function)
Stack Temp
xxx° F
Proper Units, as selected under “Temp. Units” in Setup Group.
Digital Input
xxxxx xxxx
Where “xxxx” is as noted below. Unused, Feature is Inactive. Trim Enabled,
Trim disabled (as selected under “Digital Input” in Setup Group)
xxxxxxx AuxAO
yyy% zz ma
Where xxxxxxx is the selection made in the SETUP GROUP. “AuxAO,” Analog
Output. “yyy%,” numeric value of selected variable in %. “zz ma,” milliampere
output that equates to the numeric value of selected variable.
xxxxxxx AuxAI
yyy% zz ma
Where xxxxxxx is the selection made in the SETUP GROUP. “AuxAI,” Analog
Input. “yyy%,” numeric value of selected variable in %. “zz ma,” milliampere
input that equates to the numeric value of selected variable.
FLAME OFF
OH=xxxx CH=yyy
(or ON)
3-20-97
12:42 pm
FLAME ON or FLAME OFF displays the present flame status. OH=xxxx, OH
Averaged Raw Counts. CH=yyy, CH Averaged Raw Counts.
Actual Date and Time.
FIREYE
* CES VER X:Y *
Displays the version of firmware that is in the CES1000. Where X denotes major
version and Y denotes minor version.
SYSTEM TEST
SYSTEM TEST GROUP
Before entering this group the password MUST be enabled. (See SETTING PASSWORD).
Pressing the SYSTEM TEST key will allow you to access a number of system parameters found in
the group. Some of these parameters allow you to alter the setting and some are for viewing only.
Select the parameter you want to view by pressing the UP/NEXT or DOWN/BACK key to choose
the number of the SYSTEM TEST you want. A listing is shown later in this bulletin. Holding the
key down will allow you to scroll through the numbers faster. You can chose a number from 0 to 255.
When you wish to change a variable within a parameter, you must go to the MDFY/ENTER key and
when you see the “*”symbol select the value using the UP/NEXT or DOWN/BACK keys. Then
press MDFY/ENTER and the “*” symbol will disappear and the setting is saved.
SET DATE AND TIME
For example, if you want to view and change the date and time of the controller, you would go
through the following steps:
16

Press the SYSTEM TEST key and the following will appear:
SYS TEST #0
The Set Date and Time parameter is System Test #7 from the chart shown on the following pages.
Therefore, you press the UP/NEXT key seven times until the number 7 appears on the screen. Then
press MDFY/ENTER and the following appears on the display:
SYS TEST #7
MONTH = 07
*
Because the “*” symbol is on the upper line of the display, the lower line can be adjusted using the
UP/NEXT or DOWN/BACK keys. Once the proper month is selected, press the MDFY/ENTER
key. If you press the MDFY/ENTER key again will move you to the next step in selecting the date
and time. In this case, it is the “day” and it appears on the display with the “*” symbol which again
allows you to change the value using the UP/NEXT or DOWN/BACK keys.
Pressing the UP/NEXT or DOWN/BACK key when the “*” is not present will advance you to the
SYS TEST # X display position and allow you to chose another System Test parameter number.
All tests except #8 are password protected. See SETTING PASSWORD.
2
Forced Time Out of Password
3
OH and CH Instantaneous Values
OH=YYYY CH=ZZZZ
7
Set the Date and Time
Month = XX, Day = XX, Year = XX, Hrs = XX PM or AM, Min = XX
8
Restore All Factory Settings
Clears all data
9
Forced Actuator
Takes control of actuator, allows manual movement when in trim mode with time out.
12
Clear Comm Errors
Clear scanner’s comm errors.
17
View Lockout History
View last 10 Lockouts, Type, Date/Time, Detected, and Date/Time Resolved
27
Clear All Lockouts
70
Bin Learn Parameters Edit
75
Delete all Learned Bin Data
161
Set Count Averaging Filter in %
NewAvg=(OldAvg * (100-Filter) + (CurReading * Filter)) /100, default is 4%
248
Set Ratio Control Integral Multiplier
Setpoint range from 1 to 1000, higher numbers result in larger corrections, 0=Disabled, default = 80
249
Additional Ratio Control Integral
If Firing Rate <=30% AND this Flag Divider Flag Multiplier of Test248 is halved. default
is “Disabled”
252
Feed Forward Hold Timer
Setpoint range 0 to 300 sec, default = 0
255
View Communication Errors
View scanner’s communications errors. To clear use Test #12.
17

SETUP
SETUP GROUP
When the SETUP key is pushed, the display will read:
Trim Control
Disabled
This is the factory default value and message on the display when first received and powered.
You may proceed to review all the parameters in this group by pressing either the UP/NEXT key or
the DOWN/BACK key. The parameters will be displayed in the order shown later in this bulletin.These keys will take you forward or backward through that list.
You cannot modify any of the parameters in this group until you enter the password parameters
shown as Password LV 1 and Password LV 2 in this group.
(Note that these parameters are all modifiable)* = Factory Default
MESSAGE
DESCRIPTION
Trim Control
xxxxx
Disabled*, Enabled (This selection determines if FOCUS will act as a trimming
system).
Actuator Type
xxxxx
Fireye*, configures the controller to work with the Fireye CA202 trim actuator.
Other, This selection has no function in FIRMWARE VERSION 1.2 or 1.3
Null Position
xxxxxx
Retracted, sets the CA202 actuator in (0%) position. Center*, sets the CA202
actuator in (50%) position. Extended, sets the CA202 actuator in (100%) position.
Control Action
xxxxxx
Direct*, the actuator moves toward the Extended (100%) position to reduce excess
air. Inverse, the actuator moves toward the Extended (100%) position to add
excess air.
CA202 Trim Limit
xxxxx%
Range dependent upon Null Position. For Retracted “100%- 0%” default = 100%.
For Center* “+/- 50%,” default = 50%. For Extended “0%-100%,” default = 0%.
Mod Trim Start
xx%
0% - 30% (position of mod motor below which trimming will cease - zero bias
position), default = 10%.
Mod Trim End
xx%
70% - 100% (position of mod motor above which trimming will cease - zero bias
position), Default = 90%.
Delay Start Intlk
xxxx
Unused, Feature is Inactive. Time, Minutes before the system will begin to trim on
initial startup. default = 0. Stack Temp, Temperature at which trim action will
begin. Default = 200°F.
Relay Option
xxxx
Flame Relay*, Flame failure response (FFRT) time is selectable, 1 or 3 sec.
Default = 1 sec. Relay is de-energized during a flame-our condition.
Alarm Relay, Output from “S1” and “S2” is terminated when an alarm condition
occurs. (See LOCKOUT MESSAGES for exact conditions).
18

Digital Input
xxxxx
Disabled.* Enabled, a dry contact closure across terminals (Din +) and (Din -) on
the 60-2555 mounting rack will cause the “Trim Control” to switch from
ENABLED to DISABLED.
Analog Input
xxxx
Unused*, Feature is Inactive. Mod FeedBack, uses a 4 -20 mA DC signal in place
of the firing rate Feedback Potentiometer.
Analog Output
xxxx
Unused*, Feature is Inactive. The output from the 60-2555 Mounting Rack is 4 -20
mA DC. The maximum load that can be connected to the terminals (AOUT +) and
(AOUT -) is 750 Ohms.
Act Feedback, transmits the position of the CA202 actuator as a function of %.
4 mA DC = 0%
20 mA DC = 100%
OH Counts, transmits the numerical value of the actual “OH” in real time.
4 mA DC = 0% or 0 counts
20 mA DC = 100% or 4095 counts
CH Counts, transmits the numerical value of the actual “CH” in real time.
4 mA DC = 0% or 0 counts
20 mA DC = 100% or 4095 counts.
Ratio, transmits the numerical value of the actual “OH/CH” Ratio in real time.
4 mA DC = 0% or 0
20 mA DC = 100% or 9.99
Mod Feedback, transmits firing rate actuator position of as a function of %.
4 mA DC = 0 %
20 mA DC = 100%
Temp. Units
xxxx
Fahrenheit*, Centigrade.
Scanner Gain
xx
1-100, default=40.
Detector Temp
xx° C
-20° C - + 10° C (or proper units), default = -10° C.
Deadband Type
xxxxxxxx
Symmetrical*, The value selected for “Deadband” is applied to both sides of the
“Target Ratio.” Single Sided, The value selected for “Deadband” is applied to the
upper side of the “Target Ratio.”
Deadband
x.x
0.1-3.0, The value is in “OH/CH” ratio units. default = 0.1.
Sample Size
xxx
Scanner Sample Size 62*, 125, 250.
Password LV1
x
If password not enabled, default = 2.
Password LV2
x
If password not enabled, default = 5.
19

Set LV1
If password enabled user can set a new value.
Set LV2
If password enabled user can set a new value.
LEARN
LEARN GROUP
This group will allow you to program the needed values of OH/CH ratio at various firing rates. It also
allows the controller to learn the firing rate potentiometer values at low and high fire positions, to
learn the trim actuator retract and extend positions.
Before you proceed to make changes to the parameters in this group, you must move to the SETUP
group and enter the password LV 1 and LV 2 commands. After successfully entering these passwords, you can press the LEARN key and by pressing the MDFY/ENTER key in any of these
parameters, you will be able to modify the data. Remember that the “*” symbol must be on the upper
line of the display before you will be allowed to change the information in the parameter.
Lrn Bin Params
Learn Bin Parameters: 10 bins available based on Mod Motor Positions.
Bin 0: 0% to 9%, Bin 1: 10% to 19%, Bin 3: 20% to 29%, . . . , Bin 9:90% to
100%. Parameters saved are OH, CH, Mod Motor Position and Actuator Position.
At least four bins must be learned (two below 50% and two above 50%).
Lrn ModLow Pos
User sets mod motor to low position, hit modify, then hit enter to capture current
value. Display ModMotor Low Learned.
xx%
Lrn ModHigh Pos
xx%
User sets mod motor to high position, hit modify, then hit enter to capture current
value. Display Mod Motor High Learned.
Lrn Act. Retract
xx.x%
Hit modify, then hit enter. Actuator travels toward fully retracted position until no
further movement detected. Display Actuator Ret Learned.
Lrn Act. Extend
xx.x%
Hit modify, then hit enter. Actuator travels toward fully extended position until no
further movement detected. Display Actuator Ext Learned.
MESSAGES
MESSAGE RULES
• Timed messages are for the specified time.
• If a timed message occurs while another timed message is currently being displayed, the second
message will be ignored.
• Message priority is Normal (lowest), Solid, Lockout (highest).
If a new message has a higher priority than the current one, then the new message will overwrite
the current message. If a new message has a lower priority than the current message, then the
new message will be ignored.
20

•
•
Lockout messages are date/time stamped and saved within battery backed-up RAM in the Lockout log. Should the lockout condition be resolved, the lockout log can be reviewed within System Test #17.
Pressing any key when the displayed message is Solid or Lockout message will inhibit that display message for 2 minutes.
TYPICAL NORMAL MESSAGE
Pressing ENTER Will Erase Bin
Data
Mod Motor learn selected with Bin data present. If ENTER pressed, Mod Motor
learn will be initiated. This invalidates the learned bin data. Bin data automatically
erased.
TIMED MESSAGES
FIREYE
*CES VER X.Y*
At Power Up. Where X denotes major version and Y denotes minor version.
Control Error
Out of Adjust
While in “Trim” mode, the actuator has been adjusted to the actuator trim limits.
After this occurs, the actuator will be repositioned to the “Feed Forward” position
and “Trim” will restart.
Mod Motor Low
Learned
After a successful Mod Motor Low Learn.
Mod Motor High
Learned
After a successful Mod Motor High Learn
Actuator Ret
Learned
After a successful Actuator Retract Learn.
Actuator Ext
Learned
After a successful Actuator Extend Learn.
Flame is OFF
Learn Denied
Bin learn denied as no flame present.
Mod Range Error
ReLearn Mod
The difference between the Mod Motor High and Low learn values is less than 120
counts. Tested after a Mod Motor learn. Mod Motor learn defaults are reloaded.
Mod Align Error
ReLearn Mod
The Mod Motor High learn value is NOT greater than the Mod Motor low learn
value. Tested after a Mod Motor learn. Mod Motor learn defaults are reloaded.
Act Range Error
ReLearn Mod
The difference between the Actuator High and Low learn values is less than 700
counts. Tested after an Actuator learn. Actuator learn defaults are reloaded.
21

Mod Out of Range
Act Learn Denied
Actuator learn denied, as the Mod Motor is NOT between the Mod Trim Start and
End settings.
Mod Out of Range
Test 9 Denied
System Test 9 (manual actuator control) denied, as the Mod Motor is NOT
between the Mod Trim Start and End settings.
Flame is ON
Act Learn Denied
Actuator Learn denied, as the Flame is ON. Flame must be OFF for actuator learn.
Mod Out of Range
Test 9 Aborted
System Test 9 (manual actuator control) aborted, as the Mod Motor is NOT
between the Mod Trim Start and End settings.
Mod Out of Range
Learn Denied
Bin learn denied, as the Mod Motor is NOT between the Mod Trim start and end
settings.
Mod Motor Active
Learn Aborted
During the final stages of a Bin Learn the Bin # being learned has changed causing
an abort of the bin learn.
Flame is OFF
Learned Aborted
Flame OFF detected during a Bin learn causing an abort of the Bin learn.
Mod Out of Range
Learn Aborted
Bin learn aborted, as the Mod Motor is NOT between the Mod Trim Start and End
settings.
Flame is ON
Act Learn Aborted
Actuator Learn aborted, as the Flame is ON. Flame must be OFF for Actuator
learn.
Actuator Unsafe
Mod Learn Denied
Mod Motor learn denied as the actuator is “Unsafe.” Unsafe is defined as greater
than 2.5% of Full Scale from Null.
Actuator Unsafe
Mod Learn Aborted
Mod Motor learn denied as the actuator is “Unsafe.” Unsafe is defined as greater
than 2.5% of Full Scale from Null.
No Bin Data
to Edit
Attempting to edit nonexisting Bin data within System Test 70.
Refer to Bltn:
CES-5001
Help message that is displayed whenever the HELP key is pressed.
Mod Not Learned
Relearn Mod
Bin learn denied, as the actuator has NOT been learned. Relearn the Mod Motor.
22

Mod Not Learned
Relearn Act
Cannot Change Null
Relearn Act
Bin learn denied, as the actuator has NOT been learned. Relearn the actuator.
Changing Actuator Null position denied, as the Actuator has NOT been learned.
Relearn the Actuator.
SOLID MESSAGES
Cannot Trim
LearnProperBins
Attempted to start Trim (Trim Control set to Enabled) but the proper bins have
NOT been learned. Need minimum of four bins, two below 50% and two above
50% firing rate.
Cannot Trim
ReLearn Act
Attempted to start Trim (Trim Control set to Enabled) but the Actuator has NOT
been learned. Relearn the Actuator.
Cannot Trim
ReLearn Mod
Attempted to start Trim Control. (Trim Control set to Enabled) but the Mod Motor
has NOT been learned. Relearn the Mod Motor.
LOCKOUT MESSAGES
Actuator Error
Stalled
Five consecutive attempts to move the actuator have all failed.
Scanner Error
Communications
Continual consecutive scanner communication errors have persisted for 10 sec.
Actuator Error
Open
Actuator feedback is less than 50% of Actuator Low learn value. Causes all actuator signals to be disabled.
Programmer Error
External RAM test failed.
Interlock
Internal software handshake failure.
23

THEORY OF OPERATION
The Fireye FOCUS system optically monitor’s the burner’s combustion performance. The CS200
scanner contains two independent detectors that continuously monitor the ratio between the OH
(water vapor) and CH (carbon hydrogen bonded molecule) in the flame. Because combustion is a
chemical reaction taking place over time, a snapshot of the reaction at any particular firing rate can
be viewed. This snapshot will show that the OH/CH ratio being monitored varies with a change in the
burner fuel/air ratio.
To explain this phenomena in greater depth, refer to Figure 10. In Figure 10, a dashed horizontal line
signifies the combustion reaction. Extending from the scanner in this figure is a dotted line that represents the scanner line of sight. The Target (TG) OH/CH ratio depicted in the following figures is a set
point value that is stored in one of the ten (10) BINS of the CES1000 controller. The Target (TG)
OH/CH ratio is read at the intersection of these two lines. As long as the combustion reaction remains
in a steady-state condition and the scanner Line of sight remains constant, the Target Ratio will
remain the same. If a change is made to the fuel/air ratio, the combustion reaction will move along
the horizontal line. The Combustion Reaction moves to the left or to the right depending on the
change in fuel/air ratio. The most common cause for a change in fuel/air ratio is an increase or
decrease in the combustion air supplied to the burner.
FIGURE 10.
EXAMPLE OF LEARNED TARGET RATIO
TARGET
(TG) RATIO
1.5
OH/CH RATIO (ACTUAL) 1.0
9.99
SC
AN
NE
R
LI
NE
OF
SI
GH
T
COMBUSTION
REACTION
In Figure 11, Target Ratio (TG) of the combustion reaction has moved to the right causing the scanner to view a lower ratio. This shift was caused by the fuel/air ratio becoming richer. To correct for
this change in fuel/air ratio, the trimming actuator needs to open the air damper, increasing the air
supply. This increase in air causes the combustion reaction to move left, repositioning the original
OH/CH TARGET RATIO (TG) in front of the scanner.
Note: The scanner line of sight remains fixed.
FIGURE 11.
COMBUSTION REACTION MOVED TO RIGHT DUE TO RICH FUEL-AIR RATIO
OH/CH RATIO (ACTUAL)
TARGET
(TG) RATIO
1.25 1.5
1.0
SC
AN
NE
R
LI
NE
OF
SI
GH
T
COMBUSTION
REACTION
24
9.99

In Figure 12, the Target Ratio (TG) of the combustion reaction has moved to the left causing the
scanner to view a higher ratio. This shift was caused by the fuel/air ratio becoming leaner. To correct
for this change in fuel/air ratio, the trimming actuator needs to close the air damper, decreasing the
air supply. This decrease in air causes the combustion reaction to move right, repositioning the original OH/CH TARGET RATIO (TG) in front of the scanner.
Note: The scanner line of sight remains fixed.
COMBUSTION REACTION MOVED TO LEFT DUE TO LEAN FUEL-AIR RATIO
TARGET
(TG) RATIO
OH/CH RATIO (ACTUAL)
1.0
1.5
1.75
LI
NE
OF
SI
GH
T
COMBUSTION
REACTION
9.99
SC
AN
NE
R
FIGURE 12.
The changes in the OH/CH ratio is sensed by the scanner and transmitted to the controller. The controller compares the actual OH/CH ratio to the TARGET RATIO (TG) for that specific firing rate.
(Refer to the LEARN OPERATION under the LEARN GROUP section of this bulletin.). When
the controller sees a difference between the TG and the actual OH/CH ratio, it generates an output to
the CA202 trimming actuator to reposition the burner air damper.
Since the Scanner Line of Sight can be drawn to intersect at any point along the horizontal line in
this snapshot of the combustion reaction no direct correlation can be drawn between the OH/CH
ratio and the traditional excess oxygen in the flue gas. Therefore, the qualified burner technician
must first tune the burner to its optimum combustion efficiency with the use of a combustion analyzer (such as the FIRETRON® analyzer). The data obtained when tuning the burner should be
logged by the burner technician. This data can then be used for future reference if the burner needs
readjusting. Refer to the MECHANICS OF COMBUSTION section later in this document for more
details on the combustion process.
25

MECHANICS OF COMBUSTION — GASEOUS FUELS*
Gas molecules are constantly in motion in straight line paths. Their rate of motion is determined by temperature. The higher the temperature, the faster a molecule moves; and conversely, the lower the temperature, the
slower it moves.
There are very large numbers of molecules in any gas stream and during their random movements may collide
with each other, bounce off and change direction. With increased temperature and energy levels of the gas,
these collisions become more frequent and violent.
In a complete mixture of oxygen and methane (natural gas) one molecule of methane would be colliding with
two molecules of oxygen even at room temperature. The momentum of the collision would not be sufficient to
break the bonds of the hydrogen and carbon or oxygen molecules, and allow the oxygen to be added to the
carbon or hydrogen. As the temperature of the molecules is raised, the velocity of the molecules increase and
more energy is liberated upon impact.
The Chemical Reaction of Methane and Oxygen
O
H
H
C
H
O
+
C
O
H
O
O
+
O
H
H
O
O
H
H
+
HEAT
At about 1200°F enough velocity and energy has been imparted to molecules so that the collision occurs with
enough force to break the double oxygen bond and hydrogen linking to the carbon center of the methane molecule. At this time, the situation is very unstable. The carbon has a high affinity for oxygen and so does hydrogen. Combustion begins.
As soon as this reaction takes place, heat is released in the immediate vicinity of the collision and the molecule
is at a temperature approaching 5200°F. This heat is radiated to the next adjoining molecules and a chain reaction begins. The initial 1200°F can be provided by a match, pilot flame, or spark from an ignition transformer.
If air is substituted for oxygen, the chain reaction will continue but nitrogen absorbs part of energy and impedes
the progress. If the ratio of air to methane is increased, a point will be reached where the energy required to
bring the mixture of 1200°F exceeds the heat released by the molecules ignited by the ignition source. At this
point the flame will go out.
This point is known as the LEL or low explosive limit. At room temperature the lower explosive limit is approximately 4 percent methane in the air. There is also an upper limit of 15 percent methane that is too rich to support combustion.
GAS COMBUSTION PHASES
Referring back to the natural gas combustion reaction, that is the mechanical and chemical reaction of methane and oxygen, further investigation shows that the reaction passes through several intermediate stages
before the reaction is completed. The initial and final reactants and products are:
O
H
H
C
H
H
O
+
O
C
O
O
O
+
H
H
O
O
H
H
+
HEAT
* The information contained in this section (pages 26-28) is from Combustion Technology Manual (5th edition, 1994)
published by IHEA (Industrial Heating Equipment Association). Reprinted with permission of the publisher.
26

But actually, the first action taking place is:
H
H
H
+
H
C
O
H
C
OH
H
H
METHANE
OXYGEN
ALCOHOL
Or, methane plus oxygen equals an alcohol. The collision force actually drives the oxygen atom into a methane
molecule. The opening of the chemical linkages holding the atoms releases the energy of these linkages, raising the temperature of the molecule. The second phase is:
H
H
H
+
H
C
O
OH
C
OH
H
H
METHANE
OXYGEN
ALCOHOL
The alcohol unites with another oxygen to form a secondary alcohol. This alcohol is very unstable and beaks
down almost immediately to formaldehyde and water vapor:
OH
H
H
H
C
OH
C
O
O
H
H
H
METHANE
FORMALDEHYDE
WATER
The formaldehyde has a high affinity for oxygen and when another oxygen is added an acid is formed:
H
OH
C
+
O
O
C
H
O
H
FORMALDEHYDE
OXYGEN
FORMIC ACID
The step-by-step reaction is proceeding with increasing releases of energy and a constantly rising temperature
level. In this high-energy state, formic acid is unstable and breaks down with the oxygen to form carbon monoxide and the second water molecule is released.
H
OH
C
O
C
O
+
O
H
H
FORMIC ACID
CARBON MONOXIDE
WATER
The carbon monoxide then combines with the last oxygen atom available to form carbon dioxide, and complete
the reaction
C
O
+
CARBON MONOXIDE
O
OXYGEN
O
C
O
CARBON DIOXIDE
These reactions all take place at extremely high-energy levels, progress almost instantaneously and at very
high temperatures, approaching 5000°F internal molecular temperature.
The combustion phases indicated occur with a characteristic blue flame, when oxygen is intimately mixed with
the gas, and readily available to add to the methane molecule.
27

LUMINOUS GAS FLAMES
If insufficient oxygen is present at the beginning of the combustion reaction some of the gas molecules will
combust and raise the temperature of the remaining gas stream above the 1200° F linkage-bond fracture point.
The high-velocity movement of the methane molecules colliding with each other causes the shearing off of the
hydrogen atoms, leaving the carbon as free atoms or linked molecules.
H
H
C
H
H
+
+
HEAT
H
H
METHANE
H
WATER
+
C
H
WATER
At these temperatures the carbon atoms are incandescent and they impart a yellow glow to the flame. Some
luminous flame nozzle mixing burners deliberately control the rate of air addition to moving gas stream to produce maximum flame color.
The combustion phases for thermally disassociated molecules then becomes a simple two-step process with
the addition of oxygen:
C+O→C
=O
C=O+O→O=C=O
2 H —H + O
= O → 2 H —O —H
CARBON MONOXIDE
CARBON DIOXIDE
WATER VAPOR
FLAME QUENCHING
If during the multiphase reaction the temperature of the molecules dropped drastically from some external
causes, the reaction would cease and the reactants would be isolated in their various stages of formation.
When this occurs the flame is quenched. A burning gas flame contains all of the partially reacted compounds
at the time in their various states of transformation. Should a refrigerating medium be brought in contact with
any part of the flame and reduce the temperature of that part below 1200°F, the flame will be arrested or
quenched and combustion will be halted in any stage of completion. When this occurs, there are alcohols,
aldehydes, formic acid, higher order acids, and carbon monoxide present as well as carbon dioxide and water
vapor.
FLAME QUENCHENING OF AN UNPROTECTED FLAME
In actual practice, flame quenching is a possibility on lower temperature industrial processes, especially air
heaters. In a case where recirculated air is being heated by mixing with hot flue gases, the air itself might
become the refrigerating medium if it impinged into the flame. Long, unprotected flames from a burner firing
into a high velocity air stream may permit the air to quench the edge of the flame and produce the aldehydes
and the other undesirable flue products. Arrested or quenched combustion conditions can be detected, even in
small quantities, by the acrid odor of the products.
In this particular process, the arrested aldehyde formation can be prevented by protecting the flame from the
cooling effects of the air with an air shield, and thereby controlling the rate of introduction of secondary air into
the flame.
28

FIGURE 13.
TYPICAL COMBUSTION CURVES
16
ANTHRACITE
COAL
O2 AND CO2 IN FLUE GAS (% BY VOLUME)
O2 AND CO2 IN FLUE GAS (% BY VOLUME)
18
16
BITUMINOUS
COAL
14
% O2 ALL FUELS
12
FUEL
OIL
10
NATURAL
GAS
8
6
PROPANEBUTANE
4
14
12
% O2
% CO2
10
% CO2
8
6
4
% CO
2
2
0
20
40
60
80
100
120
140
160
180 200
% THEORETICAL AIR
0
20
40
60
80
100
120
140
160
EXCESS AIR SIDE
FUEL RICH SIDE
STOICHIOMETRIC MIX
EXCESS AIR ( % )
CONVERTING BETWEEN WET % O2, DRY % Ox, AND % EXCESS AIR
% Oxygen Dry
0
1.00
1.10
1.22
2.00
2.09
2.41
2.98
3.00
3.57
3.80
4.00
4.54
4.71
5.00
5.22
5.83
5.85
6.00
6.43
6.92
7.46
8.00
8.38
9.04
9.83
10.00
11.00
11.10
% Oxygen Wet
0
0.82
0.90
1.00
1.66
1.73
2.00
2.49
2.51
3.00
3.20
3.38
3.85
4.00
4.26
5.02
5.00
5.02
5.16
5.55
6.00
6.50
7.01
7.35
8.00
8.77
8.93
9.92
10.00
% Excess Air
0
4.53
5.00
5.57
9.54
10.00
11.70
15.00
15.10
18.60
20.00
21.40
25.00
26.20
28.40
30.00
34.80
35.00
36.30
40.00
44.60
50.00
55.90
60.00
68.70
80.00
82.60
100.00
102.00
29

TROUBLESHOOTING LOG
The information below is required for effective troubleshooting. Fill in all the values to find the best
solution to your problem.
Boiler Manufacturer
Burner Type
Hot Water
MAX Input
Minimum Input
Feedback Jumper (J1) position,
Feedback Potentiometer span
Scanner Amb.
Detector Temp.
Scanner Gain
Scanner F/W Ver
OH/CH Burner off OH
OH/CH Pilot
OH/CH Low Fire
Style of Air Damper
CA202 null position
CA202 operation Direct
Lo trim start
Hi trim end
Controller F/W Version
LEARNED BINS (Indicate bins
that display an (*) after the BIN
number. Example, 3*
FEEDBACK POSITION
ALLOWABLE RANGE (%)
Feedback Potentiometer
Position % (md)
CA202 Position, % (At)
OH/CH Ratio (Tg)
OH/CH Ratio (Rt)
OH VALUE
CH VALUE
% Excess Oxygen
NET Stack Temperature
% Combustion Efficiency
PPM Carbon Monoxide
30
_____________________________________
_____________________________________
___________
Steam _______________
Millions of BTU/HR _____________________
Millions of BTU/HR _____________________
135 _____________ 5000 _______________
span ____________________________ ohms
________________________________ ° F
________________________________ ° F
______________________________________
______________________________________
OH_______________ CH _________________
OH_______________ CH _________________
OH_______________ CH _________________
Single Blade Butterfly ____________________
Extend ________________________________
Direct _________________________________
0-30__________________________________
70-100 ________________________________
______________________________________
hp ______________________________
psi ______________________________
Inlet Vane ________ Other ___________
Center ___________ Retract _________
Inverse __________________________
0
1
2
3
4
5
6
7
8
9
0-9
0-19
20-29
30-39
40-49
50-59
60-69
70-79
80-89
90-99

31

WARRANTIES
FIREYE guarantees for one year from the 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 which may arise
in connection with such product or part.
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 it 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.

32
FIREYE
3 Manchester Road
Derry, New Hampshire 03038 USA
http://www.fireye.com
CES-5001
AUGUST 1997
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement