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600U ULTRA FLAME ROD SIGNAL PROCESSOR
OUTPUTS
Flame Relay: DPDT contacts, rated 5 A at 125 VAC,
277 VAC, and 30 VDC.
Ignition Transformer Relay: DPST contacts, rated 5 A at
125 VAC and 250 VAC.
Ignition Coil Drive: A capacitance of 4.4 μF is discharged
from 230 VDC through the ignition coil tap at the AC line
rate by a 4 A, 400 V SCR.
ENVIRONMENTAL
Ambient Temperature: Controller 0 to 60 °C (32 to 140 °F).
SAFETY
Flame rod voltage: 175 VAC at 115/230 VAC input.
Flame rod current (not firing):
Maximum current to ground <0.5 ma.
INSTALLATION
The 600U mounts on a 35 mm DIN rail. See Figure 1. The DIN
rail release is at the top of the unit.
See Figure 2. Five Phoenix plugs are provided with the
controller, P1 through P5. AC power is connected to pins
AC L1 and AC L2 of P5. Set P4 for 115 VAC or 230 VAC
depending on the line voltage. The voltage does not have to
be extremely close to 115 VAC or 230 VAC; the controller is
quite tolerant accepting 85 VAC to 132 VAC or 170 VAC to
264 VAC. However, the flame signal strength will be affected
somewhat with AC voltage changes. This should not be a
problem because flame rods have excellent discrimination
between flame on and flame off.
The controller will operate equally well on 50 Hz or 60 Hz
power.
It is very important to connect the GND input on the controller
to the ground of the burner. It is assumed that the third wire
AC ground is at roughly the same potential as the burner
ground, so connection of GND to the AC line ground should
be satisfactory. If the GND input is left open, flame will not be
detected.
The ignition command is applied at pins IGN AC, IGN COM,
and IGN DC. A DC ignition command from 12 VDC to 50 VDC
is applied between IGN DC and IGN COM; it can be either
positive or negative in polarity. An AC ignition command from
85 VAC to 264 VAC (50 or 60 Hz) is applied between pins IGN
AC and IGN COM.
The 600U will operate equally well in several configurations:
flame rod only, flame rod with ignition coil, and flame rod with
ignition transformer. (It will also operate with both an ignition
coil and an ignition transformer.)
66-2070—01
The connection for the flame rod only is shown in Figure 2; it
connects to the ROD/COIL pin on the controller. If the ignition
command is applied without the ignition coil present, the
voltage to the flame rod is not affected. The pulsing of the
ignition coil is done from the COIL TAP pin of the controller.
The connection of the ignition coil is shown in Figure 2. Pin C
for the coil is usually connected to ground in the ignitor
assembly; this ground connection is not necessary for coil
operation. The flame rod operates through the ignition coil
when the ignition coil is not being pulsed. When an ignition
command is present, with every pulse to the coil a strong
spark is emitted from the coil tip through the flame rod to
ground. The pulse rate will be the same as the line frequency,
50 or 60 pulses per second. The air gap between the flame
rod and ground should be 2 to 3 mm. The nominal arc voltage
is 7,000V. If the gap is very large, there will be no arc when the
coil is pulsed. Such pulsing will not be damaging to the coil.
The peak voltage at the coil tip when no arc results will not
exceed 11,000V.
When the ignition command is applied the AC power to an
ignition transformer is turned on by a DPST relay. See
Figure 2. The controller is shipped with two 5 A fuses
installed.
Front Panel Functions and Setup
Six numeric LED digits arranged vertically provide a graphic
visual display of the flame signal. If the Flame Rod is
connected and the AC power is on (green POWER LED will
be on) and there is no flame signal, none of the numeric digits
will be on. With a weak flame signal, either the "1" or "2" digits
will be on but the Flame Relay will be off. A stronger signal will
be indicated by "3" or a higher digit turning on; with this
stronger signal the Flame Relay will be turned on.
In normal operation when the flame is present the "5" or "6"
digits should be on with, perhaps, digit "4" turning on
occasionally. If the "3" or "4" digits are on most of the time, the
gain should be increased by moving P2 to a higher gain
position.
If the "6" digit is on steadily, the gain is probably set too high;
move the P2 plug to a lower gain position. If the LED for ROD
FOULED is on, the 600U controller will continue to operate,
but this is a warning that a small amount of AC current is
flowing from the flame rod to ground. This means that the
flame rod or its mount probably needs cleaning.
If the fouling gets to be significant, approach-ing the point
where the flame signal could be affected, the LED for ROD
FAULT will turn on, causing the flame relay to open. This fault
condition will be removed as soon as the fouling is sufficiently
reduced.
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