FLAME SAFEGUARn CONTRULS phần 6 potx

R4138C,D INDUSTRIAL FLAME SAFEGUARD CONTROLS (FIG. 65) These controls directly replece older R4138A and B models to meet the lates! rElQJirements. They are espe- cially Suitable where Icng petilXi3 01 burner operation with· out s/'lulc:bwn are normal, such as in heat-treating ovens and kilns. The R4138D is (he same as the R4138Cwl!hthe adc:lilion 01 a jXl'I'Ver failure override circuit 10 prevent shut- down during very short;power outages (,oower line switch- Ing of. 1 Second or less). The A4138C is available in 120, 220, and.24O volt rtlOdeIS; the A4138D Is available only in a 120 vol'model. SAFETY FEATURES The A4138C and D provide a Safe Start Check for a flame, or a condition simulating a flame, at startup. If the flame"relay 2K is pulled in before the STAAT button is pressed• .2K.2 is open, preventing the load relay 1K from pulling in. The system cannol be started until the condition Is corrected and 2K drops PUt. They also prOVide safety shutdown on- - failure to Ignite the pilor. (lockout will occur t1the START button is held in IClIlg9f than the 10ckPUt switch liming.) -loss 01 flame during the rUl"l period. -failure in the flame detectiCfl system, If e sell· cheCking system is' used-see Table II. (L.ockoul will occur it lhe START b rIlon is held in longer than the lockout switch timinQ.) On safety shutdown. the pilot and main fuel valve(s) are de-energized. 11 used, the exlernal alarm is energized. The STAAT bulton must be manu8JJy pressed to restart the system. "the lockout switch trips. the load relay 1K drq:>s Oul and the lockout switch must be manually reset to rEt- start the system. OTHER FEATURES " A plu~in $4.27D Purge Timer is available as an ac· cessory (0 provide e timed purge period prior to the manual startup. " An optionei remole reset assembly allows resetting the lockout switch from a remote location. " Irlcandescent indicator lamps (FLAME OFF, PURGE COMPLETE, FLAME ON) prOVide a visual check: 011he system condl1ion. • The R4138C or D plugs into a subbase or cabinet ElQJiA?OO with quick-connect C'-ontacts. • All field wirinQ (except for the optional remote reset assembly) is connected to a terminal strip on the subbase or In the cabinet. The R4138 can be re- moved easily withoul disconnecting any w·lring. " Clear plastic relay covers help prevent conlamina- tion, damage, end lamperinQ. " An ALARM terminal Is available to operate an exler- nalline voltage alarm on salety shutdown. " A zinc-dichromate finish resists the corrosive ef- fects 01 most induslrial atmospheres. KEYED IIECEPTA(L[ FOR PlUG·IN AMPliFIER SPRI",!> CL'P 01'1 CHASSI~ PlUG·I", INCANDESCENT FlAME SIGNAl INDICATOR ~,,"PlIFIEpR lAMPS(J)I\ ••• _~ \ ,_ '\C<'" ~ s'! FLAME 5IGI\IAL \ METER JACK RELAY ZK THREADED fl.ELAY11( ""OU",TI,,,G STUD RELAY JI( RECEP'TACLE: FOR PVRGE TIMER FIG. 55-COMPONENTS OF THE R4138C OR O. 186 - SEOUENCE OF OPERATION FOR THE R4138C OR D (FIG. 66) The cperalion orlhe 120voll models oflhe R4138Cand D win be described. Theseq.Jel1ceofoperalion for a 220 or 240 volt model ot the R4138C is the same; it just has an aci:jitionaltransformer 10 provide 120 volts tor the sMutler : If·~ ,~ ,o~ "I .""n. 1 .MO ~'SC€L""M€OUS 1 IM'U.OC'" , 'u 2 ; ~ r & ,~, , .l I, T 5 , , - - , I & "f ~'''N.e "'".'N '~'u 0 "H'. ,.CO , I D€1r(ftI. I __ '-;'c " , • l~ 1 If€ 'n , "'.>t.t? " ._ _. • "'\IT1"' • • (£, 00 , /:::~~ ~~.& , € D" 1.'Ol , ". '" " , , , " , II ~TO. or"II: , •• u, R- 10"f€1'I) fn'l ,", I , r • I I,U & , ,- , \r, y co ~,., .u., 10\ I , ~ T I _' e llI"Sl I ,., I I' ' "' T ITO, ." l , •• , I , ,., I '"' ". ,. , , , , , , , , , , , , ,., , , , , I , , , , ,. , , , , , ~ '""(') ~ ; I _ •• AI o •••• 'O€ " ,otU CU1. I I I , " '" • ", 00 I " " " - & "'''.'01 O'sc_.C"I.l.O ; , L.CI.O~.O CT'O .'QU'.'C1. & "'L.CIT UN. Ju M; , II:(U_O '0"'" ce OO I" 'IOCIl """T eAT><I LIN. IT I.SO ~U-"'" ".eu o "ou UV1n: & ' n o' ,"". c""11 D.' "" I"II:UO:. ULT IOUT o.n~TO". LlJ. "H'" uTTl" ,.1::1 1 ""LV", C"',,, D •• "''' 1"11: U. , v, <:Ct'ltTO" "IT~ ,(~.C., 'u"'- ""' •• TO 0"'.' "'I ' n " ~""LJ.O TO , "" . .,~ a ,,,,",,UGH. SOUOI1U' '''TC~ t~T~' .>,.>c Ov 'C "LF c Cl<_ IFI.", ~ u.o""".U'" "'.c"' . CO OT.O TO .' """ R TO "'''0 ,"" OI OOS' & tF "'OH .'''.'", IlLOC UUCl. v ,. """c()HT.~T ,., .'" TTl", "'ND _R , u.lO .~.N , 'N 11 • "0 . on a C7012E or F Purple Peeper Ultraviolel Flame Deteclor. The lad:ler diagram (Fig. 66) shows all relay contaclf; In the d&energized position. Refer to the S8QJence of 0p- eration on the following 4 pages. , , , , , ." 0'."" O''' T. e' •• 0<"'''0''10' v CO"T .cn, ( 00. •• , , , "'O'OTO. "'" VOL.CI D CO."(T.) "L.CI'U.Y€ 0. ~ Gil ~ ~ _'TIl ~ =,:.~~,':;'~': ':':'~~~'~;;~Uc'=:"~;;.'Jo~~J ~"u."'''- u f. l'H€ , Tell ,. cL.Dloll.o. &. IF • , ". ST •• ' '." •• """ ,. roar 0. TH, IT""" ""'TC" ,. ca.H'C'l"'D OI •• CTL v TO " & _ ,. ·."'.51.T"", TII ' "N 'U OR •• u,v _0 """ "lMOn: 0l"l T1001. & , ' ,Te" It 100. U"O, ,~ •• ,"" ST" nOOl "'u. O CUD D''''CT.V "' "., """ nR '~ L . CO KTtO TO e, ~ 'H'.OS" • fC~ O .~. C''''''"''O UX><5- A ""n"", • .". F~ ",,"o., v. " u ""'0 0 v '1< TOIUU, ,,, ,. , T V ~u _R ,A "TN ' v ••• ' C,otUIT _ '"~ TN' ,U.' v FIG. 66- SIMPLIFIED SCHEMATIC DIAGRAM OF TME 120 VOLT MODELS OF THE R4138C AND D SHOWING TYPICAL FIELD WIRING FOR A GAS OR OIL CUTOFF SYSTEM. '87 71-97sss 1 SEQUENCE OF OPERATION FOR THE R4138C, D NOTE: Italics denote special 8HJlications. NORMAL OPERATION OPERATOR ACTION R41J8 OPERATION SYSTEM OPERATION TO START- 1. RElsel tI111 Ioc~ut switch on tile 1, a. ap~lied " terminal ,. a. The lan(5) s\lIrts R4138. Reset all limrts. and inter- " " • " Ihrough thE! il1lerlocks and limits, and 'bcks. Close the maste!" SWitch. to terminal 3 Ihrough the jumper Irom larminal L 1: the plug-in amplifier is 8f\o ergized. b. Po- i' applied " terminal b. The alarm 115 energized, bU1 may be ('tHough the alarm silaneing switl:hl, " - turned off by opening the alarm si!enc- and ID I8rmineJ 16 ('through 3K1). ing switch (If u~d) , "'""' • app"ed " terminal 18 , None. (through 3K3): ltle FlAME OFF (RED) lamp fights. 2. Open the damper D high fire posi- 2. a. None. 2. a. The high fil"ll interlock closes Whe!1 the lion (rt mahually operated). damper Is open. (The damper may open eu1on'lalicalty.) b. • appfled " terminal 17 tI. The purge perod belilins: the lan(s) ~gh the high fire irrtBr1ock) and to Pow" clean the combustion chamber of un- lhe mobr ofltle pur~e timer (through bU!l19d fuel and fuel vapor. PT1): 1he purge timer starts. c. At the end 01 lhe preset time. PT1 ,. Relay 1R pulls In: 1R1 closes to bypass opens and ll1e purga timer stops. PT2 the nigh fira jnter10ck end keep power ctJses, IlPPtyinll power Ie terminal 6 applied Ie the purlle timer. (If power is (Trom terminal L 1); the PURGE COM- removed In:m the pur'ile timer, it will PLETE (GREEN) lamp li'ilhts. reset, PT2 will open. anll tile system cannot be started.) 3. When the PURGE COMPLETE 3. Nono. 3. The hl'ilh fire inter10ck opens. and the 'uw ,,, , (GREEN) I8mp II'ilhts. close tile inler10ck "co "'" damper t:J low fire posi1ion damper Is Closed. (The damper may cbse manualo/ operated). (' """" "'" automatically.) 4. Close the alarm silencing switch (II" , None. ,. The alarm is ener'ilized. it WIlS opened in step 1). 5. Push In the START button and 5. e. ~er is applied Ie the i'ilniOOn trans· 5. a. Tha i~nrtion transformer Is 9n9r~lZall t1:Ild it In. former and to terminal 6 tthrou'ilh the NOTE: To avoid nuisance low lire start lnlertock and the sr ART statkJn). shutcbwns when not using b. ~er Is applied to tarmir.al 7ln:m te!'- b. None. a purge liry'let, wait at lea$!' minal 6 (II1rou~h the low lire start InlBr- 10 seconds after the tan in- lock, START statkJn, intemal jl.M"lper, terlock closes before push- STOP staOOn, ,"d alarm silencil\l;l ing in the START bullon. , switch). RBlIlY 1K pulls In throu'ilh LS1, 2K2, aNl HTR ,h LS (\oCkout 1'I9lIter1. thus provin'il lhlt continuity of lhlt heater. (1l 1K1 ebses. applyin'il power to tur· ,. (1) TI"MI pilot vllive (or 1st sta~e oil minai'S tro-n terminal 3. valve) • ener~lled. The valve opens and the pilol: (or 191 sta'ila Oil burner) Is I~n~ed. (2) Jt the pilfJl/lnlc lumper wi/1l I'!~s been clipped fr:T 8 continurxJs (sr~ng) piJfJl app/iC81ion, the tfame derec- rion circUit fO the amp/if/Sf is com pleted. (2l 1K2 closes. (3) lK3 cbses; the LS HTR (lockoul (3) None . be'ilins heatin'il (tty autJtransfonner action of 1K thf'OU'ilh 1K3 and 21<2). ,h hea"" d. If 8 C7012E cr F PurpJe Peeper U/tfit pJiffet"Js used, power is applied from ter- d. If an Rrn7C DpIarric Self ChecJc Am- vir:itJt FlsmtJ DBtacta (NitI'! seIf-eheck· rrifllll 7 t!roUgl'! Itle Jumper to trJm"inaJ Ing feature) is used, the shtmer is ener· 13, t!roU¢ the sr:iid "'are swircfl in the gized. 81tfJIiffet" (between ampli~B>' tfJi"trlnaJs 16 fIftd 17), 10 ttrrTinaJ 12. '" •• SEQUENCE OF OPERATION FOR THE R4138C. 0 (Continued) NORMAL. OPERATION (cOflrinued) OPERATOR ACTION R4138 OPERATION SYSTEM OPERATION None. • The "arne detector detects the ."" nlllT!8 lor llrt stage oiIl1ame). r. When the llama is detected. relay 2K pull, in. (1) 2K1 closes, bypassing the purtle l. (1) None. ~m8f contact PT2, low nre stan interbck. START slam, and inter- nal jumpel". Power will be applied t:I terminal 7 {tmm terminal 3. tt1rcugh 2Kl ID tenninal e, and tI1rough tI1e STOP stillion and alarm sileJ'ICing !Witchl tJ tvJld in relay 1K (unl", Ih8 limb open. the STOP button il pressed. oc safetj shulQaoNn occurs. . (2) 2K2 opens; the LS HTR stJps heat· (2) None. Ing. (3) 210 cloS85, applying power lD tar· (3) The aubnatic main fuel vaMl(a) jljI minal 20 (frt:rn terminal 3 throUgh energized. The valwl(s) Optms and 1 Kl). Relay 3K pulls in and the the main burner is ignited. The sys- FLAME ON (WHITE) IlImp Wghts. lern is in the run conditbn. (If II mat1lJ8Ify opened vahe i, usBa', fhe main l:IUmet will not be igrittKi unrif step 7 is compleuKf.' , When relay 3K pulls in- (1) 3K1 opens. rel'TlOVing power fn:m ,. (1) The alarm is de-energized. terminal 15. (2) R4138D only: 3K2 closes, bypass- (2) None. ing 110. Relay 11< can pull back in after e fT'OTIenlary power failure if 31< is still pulled in. PI 310 opens, rel'TlOVing power fn:m P} Retay 1R drops out and 181 opens. _, 18. Th. FLAME OFF {REO) lamp goes out The purge resets F'T2 ~, 'n" '''"'''. rerroving power fn:m terminal 5. The PUAGE COMPLETE (GREEN) lamp goes out 5. When the FLAME ON (WHITE) 5. Normal operation, including self~l1eck- 5, The ignib't ltanmlTl'lel" is de-energIUld, lamp lights. relaase ltle START ing of the name deteeiion system (rl a self- checking system is used). bullon. 7. Normal operetion. 7. Open manual main Iw/ valve(s) 7. The main burlJ8f is igrrlfKi. Too system is (it used). in 100 fUn condition. TO SIOP' a. Push in the STOP button ;tnd 8. a. Power Is rer'l'W:'Ved lmm terminal 7. 8. a. C7012E, F shtJrtBt' is ~D1d, hold it in until the FLAME OFF b. Relay 11< drops out lKl operul. re- b. The pilol valve (or lsi stage oil valve) (REO) 1=. IiQhls or U!TtII all moving power lmm terminal$ 19 and and the main fuel valwlfsJ ere de-ener- relays drop out 20. Relay 31< drops out and the FLAME gized. The valves Close end a11l1ames ON (WHITE) lamp g.oes oul. go out. c. When relay 31< drops oul- (1) 31<1 close:9. c. (11 The alarTn is en8l:gizlld. (2) 310 ck:ls&6: ltle FlAME OFF (REO) (2) None. , IlIrnp lightll. Vv'tlen the lIames go oul. reilly 2K , None. drops out. e. All relay contacts are resellor the next None, startup. 9. Power ~ retro'tIed from tel'min4l:9 1S end 9. The alarm is 4e-e08f"9iZIJd (ll used). 9. Open the alarm silern:ing svwiIch 15. 10. Power is rllr1'DWd from tel'miMIs L1 and '0 The lan(9) stipe end the systIlm is de- 10. Open Ihe masler swilr::h 3. The plug n amplifier is de-energized. 808I'"glzed. and the FLAME OFF (RED) lamp goes ,," 189 71·97558·1 SEQUENCE OF OPERATION FOR THE R4138C, D (Continued) SAFETY OPERATION ABNORMAL CONDITION R4138 OPERATION SYSTEM OPERATION Safe Stan Dleck-A flame, or a condi· Raley 2K puns In when the name (or flame- The system cannot be started unm the con· tion simulating a name, is present be- simulating condition) is detected. Contact ditiol'l is corrected and 2K drops out. lore !he STAAT button Is pressed. 2K2 opens, prewnlirlg relay 1K fran pul~ng NOTE: r,.s c.heck does not apply if us· in when the START button. is pressed. inrJ a.cootinuous (st8flding) pilat. , K1 stays open; no IlOM'I' can be ap- • The pilot valw (or 1st stage oil valve) and • plied D tlIrminals 19 and 20. the automatic main fuel vatve(s) cannot - be energized. • Relay 3K cannot pull in; 3K1 and 310 re- • The alarm remains energized. main closed. The FLAME OFF (RED) lamp remains on. The PURGE COM· PLETE (GREEN) lamp may also cane , DO. No name is detected. so relay 2K does not The system c~ be started. The ignrtion The pilot (or 1st stage oil buma" is not ignitBd. pull in. transtormer is de-enerllized wheo th. START bbltlDn is released. ,. Contact 2K2 stays Cbsed; the LS HTR " Salety shutdown with lockout occurs. (lockout II'I'o'itc:h heater) heats until !he The lockout switch must be manually re- lockout switch 1I1ps (If the START button set to try to restart !he syslem. is held in longer !han the 'Ockout switch timing). a. lS1 opens and relay 1K drops out. a. The pilot valve (or 1st stalle oil valve) 1 K1 opens, removinll power from Ier- is de-energized, eo' th. valve minaJ 19. ,"""" b. 210 stays open; power cannot be b. The automa1ic main fuel vslve(s) can- applied to 18nTIinaJ 20. ,. not be energized, Relay 3K cannot pull in; 3K1 and 310 ,. The slerm remains enerllized remain closed. Tho FLAME OFF (RED} lamp remains on. 2. If the START button is released before 2. Safely shutdown occurs. The START the Iockolll swill:h trips- button must be manually pressed to try to restart the system, a. When the START button is released, not bypassed. When the START but- 2K1 stays open: the START station is the ignition transtormer is de-ener· ton is released, power is removed gized. fn:m terminal T. b. Relay 1K drops out end 1 K1 opens, b. The pilot valve (or 1st stage oil valve) removing IlOM'I' fn:m terminal 19. • de-enerllized, ,,' th. ,,"'" , closed, 210 stays open; IlOM'I' cannot be ,. The eutomatic mein fuel valve(s) can- epplied to terminel 20. not be __ glzed. ,. Relay 3K cannot puK in; 3K1 and 310 ,. The elarm remains energized. remain closed. Th, FLAME OFF (RED) lamp remains 011, System shutdown occurs period. NOTE: Safely operation is the same if The flame \lOBS out during the run Relay 2K drops out. • The pilot vlllve (or 1st stall~ oii valve) and the mllin burner is rxrt ig nired in a • 2K1 opens, removinll power fn:m termi- the automlltic mllin luel vsive(s) are de- system w;th an interrupted pilot nsls 8 and 7. Relay 1K drops out and 1K1 energized, and the valves close. (obtained only by the addition 01 opens, removing JXlwer from terminals 19 and 20. The FLAME ON ('NHITE) eJdemal circuitry). lamp goes out. • Thll alarm is energized. The FLAME OFF (RED) lamp lights. • Relay 3K drops out; 3K1 and 310 close. The system shuts down. All valves lire de- A limit or interlock opens. Power is fllITW:M'Id fn:m all terminliis except 15. All indicator lemps go out and all relays energized, and the valves c!osB. The IIlarm drop out. 3K1 closes, applying power 10 ler- is energized. minal16. 190 ~.~ SEQUENCE OF OPERATION FOR THE R4138C, D (Continued) SAFETY OPERATION (continued) ABNORMAL CONDITION R4138 OPERATION SYSTEM OPERATION Momentaty power "fsHure. . . B4138C; Power ~ r9IT'QYed from all tanninals. aN lndl- calor lamps go out. and all r8l6y, drop out. llill& Power is rerooved Irem all terminals. all indio calor lamps go out, and aU relays except 3K drop out The charge on capacitor Cl will hold in 3K tJr about 1 second. • It poWllf' is restored before 3K drops out end before lila plot flame (or 1st stage oil !IamEI) ~ out- -3K2 will stay cbsed. bypassing lK3; 3Kl and 3K3 Will stay open. - rllfey 2K will pUll bacl( in: 2Kl and 2K3 will cbse. and 2K2 will open. -the STAAT staliol1 will be bypassed through 2Kl, the STOP statkm, anl:l the alarm silencing switch. - po er ill be reappliel:l to lerrninal 7. - relay 1K 111 pull back in thrtluOh LS1 ani:! 3K2. - operation Will re!lJm to normal. • If 3K l:lrops OU1 before power is r&- stored- - 3K2 will open, so 110 will nat be by- passed; 3K1 ani:! 310 will cbse. - relay 1K cannot puU back In since both 110 8Il1:l 3K2 are open. ~ 1 K1 stays open. so 3K cannal puJf beck In. -!he FLAME OFF (RED) lamp win liOh1 when poWllf' is rr.mred. • II the pilot flame (or 1 st staOe oU name) ooes CM before power Is reslDred- - relay 2K C8Il1WJ1 pu~ back in. 80 2Kl stays open. - the START sta1bn cannot be by- passel:l. - paMll'" will not be respplied b terml- r.a17. - relay 1K cannot pull be,ck In. - relay 3K willl:lrop out; 3K1 anl:l JIC will close. -lhe FLAME OFF (RED) IM'lp will light when paMll'" is restJrel:l. The system shut:l down. The alarm is aner- llized wherI power Is restored. • If pc:JYIIer is re:Jlored within 1 second llnd the pilot llama (or 1st stage cil name) is still burning (1l1e \/lWe must be sbw cbsino), rormal OPer4OOr1 will be resumed. The aJarm 'l¥ill not be en- ergi2ed. lIthe main burner name hal gone out, it will be reionifed by the pi- lot nama. (Power failure override eir· cuits may ha~e b be al:ll:lel:l b the pilot valve and me,in vaNe(s) b enS\J{e lt1al they 1:10 not close on a mctr\EIntary power interruption) • The systBrn ~huts llown. All valVes are I:IlHIn«gizel:l, anl:l the ~a'- cbse. The alarm is 8I18rO~ed lIltlen PQ't¥er is _. • The system ~huts llown. Ad valves are l:Ie-energizeG, 8111:1 the valves clow. The alann Ie 8l'18fO~ed when poWllf'ilI _. IF USING A SELF-CHECKING FLAME DETECTION SYSTEM' The naome l:Ietec:tion system falle \fIthi1e Relay 2K canrot pull in when the 9)'SI&'n is Safety sl'w.1l'lSoWn occurs. LJx:kout'l¥ill occur the system is turnel:l all or l:Iuri~ the startel:l-sarne OperllOOt'l as it lhe pibt (or it the STAAT bllltCn is hell:l in IongBf than puroe perlol:l. 1~ stage oil burner) is nat ignrtel:l. the b:toJl: switch timing. The name l:Ietection system lails l:Iur- Ino the run periol:l with the bumBf tiring. Aelay 2K l:lrop~ out-same operation as if the name goee out Safety shutdown «CUI'S, 191 71-97558-1 This sectlon provides I;lBneral Information about this section does not cover all possible maintenance ac- troubleshooting and maintaining Flame safeguard sys- livlties tllat are req;ired for every system. Again, its pur· lems. Its PlJrp:lSe is not to allow the service technician to pose Is to help tl'lE! service technician develop ettective perform specifiC troubleshooting q)Elrations, but to help and efficienl preventive mainlenance programs thaI can the technician develop a consistent, analytical approach be applied 10 all installations. to Flame safeguard system troubleshooting. Likewise, TROUBLESHOOTlNG Troubleshooting of control and burner system prob- TABLE I-BC7000 SYSTEM ANNUNCIATION AND Iem6 is made easier Ihrough the BC7000 MicroCorTlJuter DIAGNOSTIC CODES Burner Control Syslam self-dla\1lOSlic and 1irst-out annun- clallon funclions. In addition 10 a line voltal;lB alarm termi- nal (audible armuncialion), the BC7000 Microcomputer Burner Control System prOVides visual annunciation by displaying a 3<:ligit alphanumeric code and one or two se- quence status lig,ts. SELF· DIAGNOSTICS of the BC7000 detect and an- nunciatel:xJlh external and internal BC7000 system prob- lems. Exlernal faults such.as interlock failure, 11ame failure, false flame Sib'f\8l, and damper motor problems, and internal faults associated wllh (he BC7000 chassis, the PM72Q Program Module, or the flame amplifier are all reporfed through tl'lE! Multi-function Annunciator Display. FIRST-OUT ANNUNCIATION is aChieved through the 3<:ligit alphanumeric Multi-function Annunciator Display thaI rep:lrts the cause 01 a safety shutdown, failure to slarl, or a failure to continue in the burner sequence. The cause of a safety shutdOwn is displayed as an "F" (faulll, fol- lowed by a 2-digil nurTt:ler. The cause of failure to ~ontinue with the burner sequence is displayed as an "H" (hold), followed by a 2-digil nurTt:ler. SElquence status lights (LEOs) provide pOsilive visual indication of the program sequence: STANDBY /power on), PREPURGE, HOLD IGN TRIAL. FLAME ON, RUN, POSTPURGE, and safety shutdown (illuminated reset bullon). Momentary power loss erases this annunciation and requires resel. Safety shutdown (lockout) is indicated by the illuminated reset bullon and an "F" (fault) code followed by a 2-digit num- ber. safety shutcbwn (lOCkout) d&-energizes all loads. en- ergizes the alarm terminal (atter a 1Q second delay) and requires a rest. With this information, most problems can be diagnosed without axlansive triat-and-error testing. Table 1 shows the codes used to annunciate and dia~ nose system problems with the BC7000. For the Interpre- lation and possible remedies for each code, as well as SYSTElol MOLD CODES M70 _ FlAME SIGNAL OURING STANDeY M73 - OPEN PRE-IGNITION INTERLOCK H74 _ OPEN RUNNING I~ERLOCK SYSTEM FAULTA-OCKOUT CODES FCQ _ FALSE FLAME SIGNAL DURING PREPURGE FD, _ MIGM FIRE PURGE SWITCH FAULT FlU -_ PRE-IGNITION INTERLOCK OPENEO OURING PREPURGE F()oO - LOCKOUT/RUNNING INTERLOCK OPENED DUR'NG FREPURGE FlO _ FALSE FLAlolE SIONAL DURING LOW FI."E HOLD F11 - LOW FIRE START SWITCH FAULT F'3 - PRE·IGNITION INTERLOCK OPENED DURING LOW FIRE HOLO Fl" _ LOCKOUT/RUNNING INTERLOCK OPENEO DURING LOW FIRE HOLD F30 - PILOT (FIRST STAGE OIL) FLAME FAILURE F31 - LOW FIRE START SWITCH OPENED OURING PILOT TRIAL F34 _ LOCKOUT/RUNNING INTERLOCK OPENEO DURING PJl OT TRIAL FJ,S _ PILOT FLAr.lE FAILURIO IN TEST r.lODE F4(J _ MAIN FLAME FAILEO TO 'GNITE F _ LOCKOUT/RUNNING INTERLOCK OPEN EO DURING MAIN FLAME TRIAL F~ -_ FLAr.lE FAILURE DURING RUN PERIOO F!l4 _ LOCKOUT/RUNNING Ih'TERLOCK OPENED DURING RUN PERIOD F70 - FALSE FLAME SIGNAL OURING STANDBY F73 - P~E·IGNlnON INTERLOCK FAILED TO CLOSE Fe' _ INTE~lolrnENT (eOUNDING) PRE·IGNITION INTERLOCK F82. FB.3. F~} INTERr.lITIENT IBOUNCING) BURNER F8!I, Fe7 CONTROLLEAr Ir.lIT F80 _ INTERr.llrTENT (BOUNDING) LOCKOuT/RUNNING INTERLOCK FIlO - PROGRAM r.lODULE FAULT FIl7 _ eYNCH~DNIZATION ILiNE FREOUENCYI FAULT F99 - INTERNAL CIRCUIT FAULT cOf1l)lete systam troubleshooting and CJ;lElrating Instruc- lions, refer to form 65.()()14 trotbleshooling approach presented below is deslgn&d 10 For syslems without self-dia\1lOStic and annunciation; emphasize the similarities involved in troubleshooting dif· (or for problems tllat are not annunciatedl Ihe I;lBneral lerent types 01 systems. '92 In any troubleshooting situation, il is necessary to con- sider the entire system-Including not only the burner, controls, wiring, etc., but also air sUWly, /\Jel sUW1y, and the condition and characterisllcs 01 the flame Itsel1. In or- der to cover all areas 01' bUrner operallon, lha troubleshoOting proceoJre is broken down into a series of specific sleps. The first general step in approaching a system failure is to doitermine whaiher Ihe shutdown occurs repeatedly or at random. 'RecUrring shutdowns are the result of permanent con- difl'Ons in the system that can usually be identified by CJb. servation or by a few simple tests. Random shU1downs are more difficult to identify, Since they are caused by marginal or intermittent condiUons (oc- cur one time but not the next), they do not always occur at atime when they can be observed. Frequer1tly, the only methOO of Identifying them is to be present when they oc- cur and be fortunate enOUQh to see what has h~. Often, a shutdown occurs buttha evidence needed cannot be obtained. TIlis results in the need for repeated attempts before the correct solution can be found. TIlese two types 01 shutdOwn-recurring and ran- dom-will be discussed separately, since the procedure lor identifying the causes of each are somewhat different. Recurring Shutdowns are obviously much better suiled to solution using a step-by·step procedure. RECURRING SHUTDOWNS After determining the generall'1?9 at failure, determine the point In the operating cycle al which trouble occurs, , and the specific symplom. To get this informaUoo and to determine the proper corrective action, aiways complete the following seven steps; STEP 1 - KNOW THE SYSTEM AND EQUIPME~T Effective troubleshooling requires a knowledge 01 the complete SyStem and its normal sequence, as well as the Indi idual devices and equipment that make l4' the sys- tem. TIle availability of a schemallc diagram of the syslem is a necessity. A written sequence 01' the normal operation of the SyStem is also desjr~le. STEP 2-ASK OUESTIONS Usually, Ihe information available on arrival at the in- stallation consists of a sirrple stalemenl that a burner shuts down. Start by asking all the questions possible of anyone lhat mi~t have some knowle6;)e of what hap- pened. When cbeS the shutdown occur? What part of the CYCle? How lonQ after the startup? Does a shutdown occur following every start? How Is the lightoff? These are only sarrple questions-the lnformation needed will depend on the Individual situation. Be sure the operator 01' the SyStem is contacted and questioned. Re- tTlQrrOer, they were present and involved when the shut- down occurred. STEP 3-EVALUATE YOUR INFORMATION Usa Table II, together With your personal experience, to herp evaluate any information you have concernillQ the shutdown. The conclusions drawn at this stage only pro- vide an idea of where 10 look tor the exaCI solullon 10 the prOOlem. STEP 4-MAKE A TRIAL RUN Observe the operation of the burner system through a corrprete cyCle. Was each slep of the startup in accor- dance with the design sequence? Did any deviations occur? Did the shutdown occur exactly as described? Did anything else happen? Have any new facts been established? AlSO. refer 10 information on measuring the flatTlQ signal during lest runs below. STEP 5-RE-EVALUATE The re-evaluation of availabie facts can often be made during the trial run. Mentaily check the possible causes and eliminate all except those that could b6 resoonsible for lhe shutdown. Remember ,that in some instances, more than one factor may be contributing to the prOblem and must be considered in the solution. STEP 6-VERIFY THE ASSUMED CAUSE BY A TEST RUN After determining the a,warent causa(s) at eqJipmenl matltnction, perform a second test run to see if the evalu- ation is cOfree!. lithe answer has not been found, a new evaluation must be made that Includes any new In1Drma- tion thaI has been obtained cllrlng the second lest run. More than one ra-evaluation lest may be necessary to get all 01' the information needed to positively Identify the cause(s) 01 lhe Shutdown. STEP 7-CORRECT THE CONOITION(S) 193 71-97558-1 TABLE II-TROUBLESHOOTING RECURRING SHUTDOWNS To assist In delermining lhe cause of a system shutdown, Ihis tabte lists possible causes and corrective actions for each symptom: For- convenience, lhe lable Is divided inlo sections rapresanling lime perlcxE. The problems that could occur during a specific peric:d of the operating cycle are listed in each section. If specific information on service of a particular control or piece of equipment is required, refer 10 lhe instructional literature for the particular control. , _ ' IMPORTANT , Repair or replace all defective comp::lrIents, as necessary. INITIAL STARTUP PROBLEM POSSIBLE CAUSE CHECK A. ~nce cbes not start. 1. No JXlMlr. Z L.ockwt (safety) switch tri~. 3. Limit switch open (in main JXlwer line or in series with the C(){ltroller). 4. Start or preignition interlock open. 5. Process interlock open. 6. Wiring open. la. O1eck master switch and overload protection (fuse, circuit breaker, etc.). Reset or replace, as necessary. 20. Reset- find cause and make necessary repairs. 3a. Slack damper end switch not made. 30. Airflow switch open. 3c. low-waler-cutoff open. 3d. Fresh·air dal'11P9r (to boiler room) not open. 3e. Fuel pressure switch open. 31. Other interlocks opErI in JXlwer line. 4a. Check start or prlHgnition interlocks. sa. Check all process controls thaI are interconnected wilh the burner system. 6a. CheCk wiring for breaks or open splices. FIRST 15 SECONDS AFTER START PROBLEM POSSIBLE CAUSE CHECK ~ B. System cbes nol go 10 high fire during prepurge (Lo-Hi·Lo system). C. SElQU9nce stops about 4-15 seconds after prepurge 1. Wiring-opens, shorts. grounds. 2. No JXlMlr at firing rale molor. 3 Limit switches in firing rale motor nol made. 1. High fire switch open. 1,. O1eck voltages at the wiring sutbase terminals for firing rate switching. 20. Check for JXlwer at T·T terminals on firing rate motor. 3a. Clean conlacls. 1a. Check switch. 1b. AdJlISt linkage. 1c. Check firing rale motor and its transformer. starfS. 2. Airflow switch open. la. Check switCh. 2b. No airflow. Check burner motor (blower) and associated corr-ponenls and circults. 2c. Plugged air line or filling. 194 DURING PREPURGE-AFTER 15 SECONDS-BEFORE IGNITION TRIALS PROBLEM POSSIBLE CAUSE CHECK D. Flame relay pulis in during repurge. - . , 1. False flame detection. la. Flame rod: (1) Intermittent ground. (2) Unwanted flame on flame rod. lb. Visible light photocell: (1 ) Light striking cell. (2) Detecting hot felractory. 1c. Infrared (lead SUlfide) detector: (1) Electromagnetic piCkl4) on leads. Anchor solidly. Install coaxial cable if necessary. (2) Unwanted flame being detected. (3) Detecting hal refractory. ld. Ultraviolet detector: I 1. Airflow switch open. E. Sequence stq:ls. 2. Preignilion, ruming, or lockout imerlock cpen. (1) Unwanted fire being detected. (2) X-rays. (3) Defective sensor (replaCe). le. Flame safeguard control: (1) Defec/ive amplifier (replace). la. 8l.Irner motor (blower) st~. lb. Restricted air passage from air d Jct 10 airflow switch. 10. Plugged air line or titling. 2a. Check interlock. LAST FEW SECONDS OF PREPURGE BEFORE IGNITION TRIALS PROBLEM POSSIBLE CAUSE CHECK F. 5eq Jence stq:lS. 1. Timer switch on flame sat9lJ lard control set al TEST. la. Set switch 10 NORM lXlSilion. 2. low fire switch open. 2a. Check switch. 2b. Adjust linkage. 2c. Qleck tiling rate controller (broken polentlometer). 2d. Check firing rate motor and its transformer. G. No ignition spark. 1. No power 10 19lilion transformer. 2. HiQh voltage Insulator(sj faulty. 3. Ignition elecnode spaf1( gap selling ta. Leadwires cpen, grounded, or not prcperly connected; insulation damagecl. lb. Flame saf9lJ lard control not providing power. lc. Flame safeguard control recycling. 28. Cracked. 2b. Covered with soot, dir1, or mOisture-causing a shor1to ground. Ja. Clean the electrodes. 3b. SpaCing incorrect-too wide or shorted. 3c. E!&ctrodeS not prcperly mounted. (cOI1t1nued on IMxt parle) 195 71-97558-1 [...]... (blower) 5 Pilot flame not delected-faulty flame detection system sa < Ga Too smoky Check ail·tuel ralio 6b Flame patlern changed 6c Change in c~ition of fuel ', , B Failure to light the main burner or 10 detect 1119 main flame Pilot flame not detected - corroustlon chamber conditions ! Dose, worn, or damaged leadwires to the flame detector - may be te"'lXlrarily open or grounded Sb Loose flame deteclor-shifted... only the flame slgnel empll­ fler duril"lQ burner operatiQrl and snuls down Ihe burner ilthe amplifier fails, dShulter operation of the C7012E or F causes flucluatiQrls in the current readil"lQ, Read the average stable current, disregarding the peaks 9'f11e lead sulfide cells are available in 4 ranges of senSitivity: 10 466 2A (red), lowest; 10 466 28 (yellow) medium; 10 466 2C (green), high; 10 466 20 (White),... Honeywell Flame Simulators, 10rm 95 -64 38 209 11-91558-1 ~lJG5 I~ AI'ID l;;) 1217D8 IU5''''''',B FIG 6- HONEYWELL FLAME SIMULATORS '.' 210 7041 TABLE III-SUMMARY OF HONEY"N'ELL FLAME SIMULATORS TYPE OF fLAME DETECTION SYSTEM USING THE FLAME SIMULATOR {~laCk) FLAME SAFEGUARD CONTROl(S) AH7, AlSO, A187, A1Sl0 A485A, ABa7, A890, A7023A, AAl90, and AA890E wilt'out a tBst acK - 1;]1708 PLUG-IN AMPLIFIER MODEL - fLAME. .. HONEYWELL TESTERS FOR FLAME SAFEGUARD CONTROLS INSTRUCTION FIG TESTER FSP153S SHEET OR SUBBASE NO BOOKLET (FSP'97S ONLY) , - 95 -69 10 FLAME SAFEGUARD CONTROLS TESTED RA890, R4795 FSP 19 76 FSP5004 3 60 -0045 (booklet) R41 26, R4127 R4138, R4181 FSP1992 2 FSP19n FSP1978 FSP1975 Some R4140M models; R4150A,B,C,H and some G models R4140G.L, and soma M models; R4150l,M, and some G moclels - 60 {)219 2 06 R4140E,G,L.M;... 4-1/4 Inches wide x 2·3/8 inches deep [ 160 x 110 x 6OmmJ, with lhe cover closed The W136A Test Meter can be used to measure lhe flame signal (Fig.S) for systems using R7247,R7248, or R7249 Plug-in Flame Sig'la! Amplifiers (R4075C,D,E; R4138C,D; or R4140 Flame safeguard Controls) by 101­ FLAME SIMULATORS Flame simulators are devices which simulate a flame by reproducing the resistance and rectification... fying flame rods, rectifyil"lQ photocells, or C70 76 and C701ZA,C or C7020A Ultraviolet Flame Detectors The 1235148 model is an ultraviolet type l1ame simulator, for systems using C7027, C1035, or C7044 Minipeeper Ultra­ violet Flame Detecrors There is no infrared type flame simulator, but a leadwire with insulation removed from the ends can be used for a system using a C7015A In1rared Flame Detector Flame. .. testers, meIers, and flame simula­ tors The flame safeguard reference on TroLbleshooting Flame Saf~Ja.td Sysl.ems, form 70- 862 6, gives a general approach 10 troubleshooting any flame safeguard system TrOl.bIeshcx>ting procedJres tor the RA890 and R4795 Pri­ mary Controls are given In the service HancbX:lk., torm 70-0010 SpecifiC trOl.bleshooUng procedures for any flame safe\1Jard control may be found in... in flame 59 Broken flame ro::l 6 Infrared (lead sulfide) detector Ga Magnetic piCkup ()(l leads (Should be shielded and anchored to prevent free vibration or swinging.) fib Defectlve cell 7a Excessive vibration (can loosen components in C7012 types.) 7b C7012-faully electron lube(s) I 7 Ultraviolet detector Ga Replace (if a plug-in type) 8 Faulty flame signal amplifier 1 96 DURING THE MAIN BURNER FLAME ESTABLISHING... to avert a 6hulOOwn Ideally, the flame Si "al should be checked for all of lhe following conditions: a During prepurge (A flame siQnal during prepurge indicates a Slray current Induced in the leadwires, a component failure simulating a flame, response 10 hoi refractory, or an unwanted flame present In the combustion chamber This signal must be eliminated.) 202 TABLE IV-INTERPRETATION OF FLAME SIGNAL... only the pilot is on 1 Iglilion interference (flame reds) 1a Make sure there is enough grOlind area lb Be sure the ignition electrode and flame roo are on q:;p::lSile sides of the ground area lc Check for correct spacing on the ignition electrode: , 6, 000 voll systems~ 1/ 16 10 3132 inch [1.5 to 2.5 mm] 10,000 volt systems-liB inch [3 mm) ld Make sure the flame rod and i",ilion teadwlres are not too . POSSIBLE CAUSE CHECK D. Flame relay pulis in during repurge. - . , 1. False flame detection. la. Flame rod: (1) Intermittent ground. (2) Unwanted flame on flame rod. lb. Visible. F [ 260 Cl). 5. Flame rod. sa Grounded. Sb. Ig'lition interference (SLblraCtive). St. Inadequate grOUnd area. 5d. Irrprcperly tocaled in flame. 59. Broken flame ro::l. 6. Infrared. it is a plug-in type). 5h. Loose component(s) in the flame detector. Ga. Too smoky. Check ail·tuel ralio. 6b. Flame patlern changed. 6c. Change in c~ition of fuel. 1a. lcx:ls9, worn,