flame safeguard control phần 5 pot

through the LS HTA. However, 11 a Ilame is notestablished and 2K OOesr'l't PJII in. 2K2 stays closed and the LS HTA continues 10 heal unlll thelockOLlI switch trips. (If the flame ~ 0Ll1 and 2K drq>s OLlI, the same thing will ~.) When this ~s, Contact LS2 opens and load relay 1K drClp5 out. AlSO. contaci L$1 clos9s. energlzlng an exler· nal line voltage alarm (il connected). When 1K drq>s out, coolacllK3 opens, 60 lhe lQ1itlon lransformer, pilot, and main 1ueI valve(s) cannot be ener- gized and lhe burner cannol: be slarted. Contact 1K1 q:oens and 11<2 closes, starting Ihe timer motor (IhrOl.Jltt M1 and 11<2). The programmer will complete its cycle and Slop. 11 cannot start another cycle untllihe lockout switch 1$ manually rG6EII. (COAO IllCAVI ., ICll;l$fSI\IUR E"""~ ~IIE~uRGfl 120~OlTS " I, ~ Impedance 01 1-KA whiCh i$ aoout ,0.06 ampere 'or a 120 volt progammer. However, current I, Is not enough to heat the LS HTA. The impedance of the 1KA section of the load reray coil is about 100 times the resistance of the LS tiTA, so the cur- rent can bErapproximated by the 8qJatioo FIG. 27 - CURRENT WHEN THE LOCKOUT SWITCH HEATER IS HEATING •. SAFETY INTERLOCKS Start, PreigliUon, Running, LockOLd. H~ Are, or Low Flre Interlocks may be usee! to shut dOwn the burner tt an FIG_ 28- TYPICAL PROGRAMMER OPERATION CURING SAFETY SHUTDOWN. SAFETY OPERATION IF A LIMIT OPENS An exlernal limil swilch is usually usee! to cause a OOmef shuf<bwn in case a dangerous, Pf&(.t3:tennk1ed condition occurs In the conlrolled medh rn. For e1:8JTl)le, If the pressure In a bailer gets too hlQl. or the waler level gets too low. we wanl to stop healing the bailer. Generally. severa! limit switches are used to monitor several condI· lions. l't1e5a limits are conneeted In Mrles with the bJrner eonlroller. If one opens. It causes the system tost'lutOOwn, just as U'IOlJQh the demand for heal has stq:lpEld (which, indeed, It has). When normal conditIons aToll restored. the Iimit(s) closes and the programmer restarts lhe burner. To prevent lhe P'OQrammer from recycling tt a limit keeps ~Ing and ClOSing. it Is deSirable to use manual reset limits. Once one opens, it stays c.pe'l until it Is manually reset. This ensures thaI the condltiCl"l which causes the limll to ~ Is detected and corrected as soon as possible. '1.0 I'IORMAlLY Of'("I. "IL M)IIMAl~ YCl.OS((l. @l " ., " /CLO'$"UHlAIl (\(lAO RELAY) ~NO OF P1UPURGE) " .",., " 1121'1.c:.~ 8U~ ,52 (N.C,) COh'UOLLEII IGNITION. I ~ PllOT.ANO 1131'1.0,) MAINVAllIEISl ,,1(' IN.OJ - lK21'1C.1 TIMFR MOTOR 8UR'IER MOTOR t- ., 18\0_EI'I) (Ol'ENSAT ENO OF eVCl,) LI'IE VOL lAGE- ~ A\AR" LSl IN.O.I ., ., LSHIR (toe_OUT SYlITCl< HEA'H~I lI2IN.C. Fl E IlElA" CONTACT! 2121'1.e.) t A" LS MTR ~tl)5n,'''l'A1l 11 ENl)OFPRE"lJIlGEI (lQAOIl(\AYl + N.C._ oRNALLYCl.OSlO. L52 IN.C,I lS2IN.C, lOC~OUT SWITCH CONTACT! " I" 120\I()lTS d.oa , IM"!:OANU O~ 11." AMP lIURNER CQHlIIOLLER Ill) lions " I~ 1"0:1 Resistance of the LS HTR which is aboul 0.3 amPere. This is enough 10 cause the LS HTR to begin heating. FIG. 26- LOCKOUT SWITCH HEATER CURRENT AT STARTUP AND DURING I'REPURGE. Near the end of prElPJrge, llmer COOlact M7 closes in preparation for Ignition trials. Autotransformer action of the 1K relay coJl eslablishes about a vo,,~ across the other part of 1 K. This voltage is al60 across the LS HTR. prod.Jc· !~ a curranl ,~ gi en by lhe equation 8 volts Normally, as soon as the pilOt name is detected, relay 2K pulls in and 21<2 cpens, stepping the current flow 145 71-97558-1 abnormal or U"tSafe condilion occurs. Each programmer model has differenl circuitry tQ accommodate differWlt typeS 01 interloCks. Generally, a programmer prOVides circuits for either Start 01 Preiglltion Interlodcs. and effher Running or lock- out Inlertocks. Opening 01 these Interlocks may cause eUher recycle or safety shutdown, depending on the pro- grammer model. A progrDrmier also may proviQe for borh High Fire anc::t Low Fire Inter1~ks. only a loW Fire Interlock, or neither. If any 01 these Mng rale interlocks doesn'l close at lhe prq?8r time during prepurge. the programmer stops be- fore 191ition IrilUs can be started. A complete description ot the q?8ralion 01 these Inter- locks may be found In the Detailed Operating sequences for the R4140G1007, torm 60-0443. R4140L1147. lorm 6().{)444. and R4140M1004. form S0-D445. Each of these programmer models provides circuits tor a different com· bination of interlocks, so all three ptblicafions are neces- sary for an explanation of all six types of Interlocks. R4140 PROGRAMMING CONTROLS DEVELOPMENT OF THE R4140 FLAME SAFEGUARD PROGRAMMING CONTROLS Way back In 1931, HQl"lEllljWeli inlroc1Jced the firm elec- Ironic flame satfo,Jard control-the Protecloglo system. This systEm replaced the mechanical, bimetallic systems. which were Inhetent'Y-slow in responding to flame faiture. Instead of a bimetallic elemeril, it used a flame roo which q?8rated on the flame cord.Jctivlty principle. In 1941, Honevwell develq:l8Cl a circuil that operated on the flame rectificallon principle and eliminated the shortcomings 01 the flame conductivity circuil. The flame recll1icalioo circuli also permitted the use of a photocell or a flame rod as a flame detector. (For an explanation ot the flame conc:UCllvlty and flame rectification circuits, refer to the Flame safeguard Reference Material on Flame Rod .AWlicatlCl'l, form 7C~·8108.) To provide the capability of detecting bcllh a gas pilot and a mail'! oil flame with 'a single delEtctor, the infrared (lead sulfide) flame deteclor was develq:l8Cl in '952. This detector was the first one to use an amplifier to process the flame SllTlilf. To a1irninate the hot refractory hold-In problem SOIT1e' limes encounlered with photocells or infrared flame detec- tors, Hor"lElywe" developed' the • pl)(ple peeper~ ultravlolel flame delector In 1957_ This was the tirst ultra- vlotet flarM deteclor used In flame safeguard syslems. In 1962, Honeywell intrcxiJced lis first Flame safe- ~rd Programming Controls-the R4126 and R4127. "These controls used the same type 01 synChronous. ma- tor-oriven Ilmers which are used on alT"Honey.,veli pro- grammers, excePl lhe BC7000. They also incorporated plug in flame signal amplifiers thai could be raadily Inter- changed to allow Ihe use 01 any type 01 flame detector- flame rods, photocells. Infrared detectors. or ultra lolet delectors. Stlortly after, Ihe R4181 Seff-Checking Programming Control was intrOOuced. This was the first complete pr0- grammer wilh a Dynamic Self Check system. The self- CheCking circuitry was Internal, so only flame rods and C7012E (l( F Purple Peeper Ultra iolet Flame DeteclOls 146 cwld be used with the R41Bl. It was nol adapted for pllJlj" in amplifiers. The R4150 family of programmers was intrcx:l!Ced in 1964. They were much smaller and more compact than the R4126 and R4127. ~i~.Ialuri;ed. solid stale, pll.)Q-in flame signal amplifiers maintained the interchangeability feature. The amplifiers were also Kpol(ed~ for ar.t::titional r~ElSS and moisture resislance. • In 1971. a solidstate Dynamic Self O1ack plug in ampli- fier (the R7253 B) was inlfoduced. The self-checking func- tion could now easily be added fo R4126. R4127. and R4150 programmers. which feature the fleXibility of inter- changeable, plug-in amplifiers. Finally. in 1974. Honeywell Introduced the R4140's. They have all the features of previous programmers, plus several new ones. The plug in amplifiers have been fur" ther miniaturized. and are now available in 6 models, in- Cluding Dynamic Self Check and DynamiC Ampli-Check models. The R4140's have been designed to replace lhe R4126, R4127, R41a" and R4150 Flame safeguard Pro- gramming Controls. APPLICATIONS The R4140 Flame safeguard Programming Controls provide flameout prolec\ion plus aul.omalic sequencing of the burner motor (blowsr). firing rate molar. ig1iUon. pilot valve. and main fuel valve(s) for commercial and lrd rstrlal burners using gas. oil. coal, or a combinali()fl of fuels. They incorporate all the timing changes required by the Octobal 1. 1974. revisions to Underwriters laboratories Inc. Standards for safety-UL 296 for all bUrners and UL 795 for commercial-indJslrial gas-heating eqUipment. Con eniently. the R4140 family haS been developed in models of varying COl1l=llexlty. This allows the user 10 ctxx:tse the ~impl8St programmer fhat will meet his awli- cation reqJlraments (Table I). TABLE I-PROGRAMMER APPLlCA110NS I IHTfl'lLOCK I rlRIII.O RATE I OTHER olPPllCAeU "'~lICATIClN CIRCUITS IWITCHING PllCABLE PItOQRAw,IIERiI~HICH RfOUIIlEMI:HTs" R[QUllilO REQUIIiED 1'14140 AN A~1~0 eu LACE) UI. on·oll . ~ '"' ~~ ~".'" R~15M, B. C !\uM"'iI Ul on,oll 1-w111lb ~ FWlllCQ,012, (IotIh 2·t!ag<o Flunnl~ and Rdl40l.h FWl«Jal0l"Ol ~"" Low ~"- LL Modulll1lnQ .~'"' ' ~'" ~h~c~111l RUMlng " - ","'" repUl9"c Ul Modulll1ll\'i1 SUI1 ~r PNlgnnlon. "'-' A~12l1 fWI1h Low-Migh-l"ow Ell.Innl"ll. and 0' ~"OO A4127A.ll!& n1i7 Pfjopu'll'J Low __ A.!~ ~IFIA ModulallllQ FftlgnltlOn. I ' A412llA1112• al '.!Ill lI88 fWI1n Low-HlgI1-l"ow ,,,''',,. " A41dQ FWl"A'042, ''* Prapurr,: and PrOll9n H~I1l, aro:l "".'- High F re Purg9) ". " a Ul ' _ U~.", UDo!ZO~" iIC. >eqU~; <8t> - 'ao:IOl'/ ~W'lual ~l; F I _ IndullrIaI Aif,k IJIIlftr.I(1a " ,. '.IAI requl_ b Fb1"1l (81" "",lor _ clo by heW ~oprll'llt"llllml when ~ II s. c ClUI;deoecl _ ulKl anynlO'" FEATURES RETAINED FROM THE R4150 Many features that have proved successful in the R41S0 programmern have been included in the R41<W'S. EASY MOUNTING (FIG. 29) The R4140 is small and compact like the A4150. It mounts on the same QS20A wiring Subbase, so it can di· reclIy replace the R4150 for most awlicalions. The pro- grammer simply plUgs Into the sutbase. 20 KNIFE·ILAD£ CONTACTS THIS SIDE IS DPEN ON" :l-5IDED QUO"IOn FIG. 30- FEATURES OF THE STANDARO Q520A WIRING SUBBASE. WELL-DESIGNED CONTACTS (FIG. 31) The R41<W uses the same weli<klslg'lEld contactslhal proved so successful for the R41SO, Each female spring connector on the programmer Is actually cCll'TlXlSEld of 4 separate conlacts. These 4 contacts wipe the knl1e-blade, contact on the SUbbase when the programmer is plL.Jg'JeCl In. After mounting, all 4 separate spring-loaded CClI'Kacts press against the knife-blade. making a flrm connection. A captive relaining screw in the programmer chassis (Ag. 29) screws Into the suttJase to hOld the programmer in place. The contact design and retaining screw graarty rectJce Sf'tY fX)SSibility of an intermittent electrical connection. PLUG-IN AMPLIFIERS (FIG. 32) Ukethe R4150. lhe R4140 incorporates plug-In flame slgnal amplifiers that are InterCl"Iangeable to allow the use of any type of flame detector-flame rod, photocell. InI'ra- RETAINING SCREW SPRING CONNECTORS ,;~r.' ,Ail ~, 1 _ Q520A IIl,ING SUBBASE FIG. 29- THE R4140 MOUNTS ON THE SAME Q520A WIRING SUBBASE AS THE R4150. STANDARD SUBBASE (FIG. 30) The standard Q52QA Wiring Slibase has 20 knife- blade contacls to 'accommodate the most complex R41<W. The 4 sided Q520A1121 shown haS 8 knoCkouts for brino- ing In wires. The 3-Sided Q52OA1089 has an ~ sldefor even more wiring room. 141 71-97558-1 Ill'll f£·BLAO£ CONTACT ON SUBBAS£ • 5EPARATE 5PRING·1.0AOEO CONT ACTS PIIIE55 AGAINST KNlfE·BI.AOE • FEMALE SPRING CONNECTOR ON PROGRAMMER OPTIONAL METAL COVER (FIG. 32) An optional, heavy lirty, melal cover (Part No. 1396958 or C) is available for oulside panel mounting. This cover has a resel l::utlon so 1I ooesn'l have 10 be removed 10 manually reset the lockout switch. METER JACK (FIG. 32) A meter jack on the arrpifier provides a means of plult ging In a mlcroamme!er 10 measure the flame signal with the system In cperatloo. TIP JACK (FIG. 32) A tip jack on the programmer allows the use of a flame simulator during troubleshooling. PUSH·TO·RESET LOCKOUT SWITCH (FIGS. 32 AND 33) The lockoul swilch pcJ;JS out when II trips, and simply pushes Infor reset. An inverted ·V· construction makes it nearly ifTllClSSible 10 grasp it and damage it by pulling II out. II Is Mclased In aeust·resislant case to lessen the possibility of contaminalion. field damage, or jamming /purposely making lhe swllch lnoperallve). 45EPARATE C.ONTAC.T5 .4 SEPARATE SLIDING CONTACT5 WIPE KNI FE-BLADE AS PROGRAMMER IS PLUGGED IN. FIG. 31-CONTACT DESIGN FEATURES. I -;.' PI.UG~N Fl.AME SIGNAl. AMPLlflEIIS ARE INTlEIilCHANG£ABLE \ RE5ET BUTTON fOR LOCKOUT SWITCH OI"TIOfoI"'L,.ME"'VY OUTY • £1 1. COVER "OR unOlinlOE TIP JACK fOR HAW SI"ULATOII , • INVERTED v CONSTRUCTION HELPS PREVENT ANVoNE fROM PULLING OUT "'NO C GING SWITCH • OU5r·R[SrSTAI'H CASE LESSENS POSSIBILITY Clf CONTAI'IIN'" flON. FIELD O"''''''G£. OR J MING (M"'I<,I"G SWITCM INOP(R TIV(1 FIG.33- FEATURES OF THE LOCKOUT SWITCH. FIG.32- R4140 FEATURES LIKE THOSE OF THE R4150. red. or ultraviolet. These amplifiers are color·coded for ld91tificatlon, solid state for ruggedness and reliability, and fully enclosed 10 help prevent conlamlnal1on, tamper- Ing, or etamageln lhe field. (AmplifierImprovements will be discussed In the nelt! 6EIction.) TIMER DIAL IS ROTATABLE AND MARKED IN WORDS (FIG. 34) TIle Iimer dial can be rotated manually in the field, with the relay/llmer cover on or ott. An arrow on the cover indi- cates the proper direction of rotalion. Descriptive words (rather than numbers) on the timer dial Indicate the period 01 the programmer S8QJence. Plastic Shrink film covers the dial to prevent 6EIrvice technI- cians wilh oijy hands from n.t:bing oN Ihe markings. '48 TIMf.R OIAI. CA" Sf. 1l0TATf.O JoIA,.UAI.I.V \ PROPf;R OIRf;CTION OF ROTATION MARKED ON COVER SEQUENCE PERIODS MARKEO IN WOROS- PI.ASTIC COVEREO TO PREVf."T RUBBING OFF ADDITIONAL FEATURES The A4140's include several lf11)rOvemenls 10 make them more flexible and easy-to-use. EXPANDED AMPLIFIER CAPABILITY (FIG. 35) The plug-in flame siglal aJT'4)li1ler capability incrudes 3 standard models, 2 DynamiC Set! Check models, and 1 Dynamic Arll)1I-Qleck mrxieL (Refer 10 Table II tor a c0m- plete listing 01 the flame detecllon systems available.) Each ampllfler has a label with the recoovnended mini- mum flame siglal Qn microamperes). All self-checking amplifiers have a red Indicating lamp (hat blinks when a flame ,Is being detected. ACCESSIBLE RELAYS (FIG. 36) AU relays are visible, labeled, and accessible when the relay/limer cover Is removed. This allows the service tech- nician 10 walch relay cperallon and facilitares checkout and troubleshooting. FIG.34- FEATURES OF THE TIMER DIAL. R7247A GREEN Foa f!lAME RODS, PHOTOCEllS, ANO C7012A,C PURPLE PEEPER OETECTORS (RECTIFICATION TYPE) STANDARD AMPLIFIERS FLAME SIGNAL LABEL R7248A RED FOR INFRARED DETECTORS R7249A PURPLE FOR MINIPEEPER UL TRAV10tET DETECTORS SELF-CHECKING AMPLIFIERS .~ l \ " R7247B OYNAMIC SELF CHECk GREEN FOR FLAME RODS (MAY ALSO BE USEO WITH PHOTOCELLS AND C7012A.C) R7247C OYNAMIC SELF CHECk GREEN FOR C7012E,F PURPLE PEEPER ULTRAVIOLET FLAME DETECTORS R7248B OYNAMIC AMPLI-eHECJ( RED FOR INFRARED OETECTORS 7564 FIG. 3S-PLUG-IN FLAME SIGNAL AMPLIFIERS AVAILABLE FOR R4140 PROGRAMMERS. '49 71-97558·1 TIMER CAMS CAN BE ADDED (FIG. 36) Extra ~ce on lh9 programmer chassis allowS cams to be added 10 lh9 timet wifhout redeslgt ThI6 may be nec- essary If more timer contacts are nq.J1red to mEleI future COdes. ALL IlELAVS A,RE VISIBLE. LA,BELEo. A,NO.ACCESSIBLE '.0 FIG.36-ADDITIONAL FEATURES OF THE R4140. TIMER SWITCH (FIG. 37) A limer switch lets the c:perator stop the Iimer near the end of prepurge or during the PUo! Flame-Establishing P&- ried 10 facilitate checkoUl and troubleshooting. The switch win nol slop the Iimer when the main fuel val~e/S) is energized. S9111NG CLI9 HOLDS A,MPLIFIER '" -~-: . • IlEL",V/TIIOIERCOVER :: _. EASILY SNA,I'S \ : ONOROFF , TIMEII SWITCl-I TO HOI' T"'IE~ FOil CHEC~OUT , OR TROUIILESl-IOOTlNG FIG.37- MORE ADOITfONAL FEATURES OF THE R4140. RELAY(TIMER COVER (FIG. 31) A metal cover helps prOlect the relays and limer cams. The cover easily snaps on or off. There are no screws 10 remove. 150 SPRING CLIP TO HOLD AMPLIFIER (FIG. 37) A spring clip on the relaylllme1 cmer securely hold the plug-In flame slgtal arT\?lIner to ensure good electrical connEilctlons. MODERNIZATION WITH THE R4140 The R4140 Flame 5af9QU8.rd Programming Conffols are Ideal for replacing older pt0g'8JlY'ners thai no longer meetlhe f8CJ,llremenis 01 ~roval agenCies. They incor· porate all the lfming changeS rllqJlred !:PI the OCIet:ler 1, '974, revisions to Underwrltel'$ laboratories Inc. Stan- dards for 5afety-UL 296 for oN burners and UL 795 for comrnerclaHnduslrlaJ gas-heating 8(JJipment. Thus, they are excsllentfor convertlf"Q systems 10 differenl fuels. Th& R4140lls perfect for L pQrading a system 10 meet Factory Mutual and Induslrial Risk Insurers (formerly F.I.A.) re- qJiretTlQ"lts. (Refer to Table I for other applications In meeting awroval to::ly requirements.) With the flexibility provided by the pklQ-ln arT\?lif'iers, the pfq:l8r programmer and flame delecllon system can readily be selected to meet the speclfiCaliOl'l$ and local codes on almost any job. For reliability and long life, all models 1ealure heavy dUty timers, relays, and contacls as waJl as solid slale flame signal arT\?flflers. In adcIlUon, TRADELINE models have been developed thaI make il easy \0 stalX:lardize. Standardization allows dealers to reduce their service and spare parts inventory. Because lhere are 0I11y a few models, it is easier and1aSier to train installers and seNice techniCians. Some of lhese TRADEUNE models can easily replace certain competi- tors' devices by uSing specially deSigned replacemenr packages. FLAME DETECTION SYSTEMS (TABLE II) The flexibility provided by the lnlerchaf'lgeable, plug-in flame signal amplifiers is llvidenlln Table II. Aslandardor a self.Checkin'Ol delection syslem is available 10r burne:s usin'Ol any type of fuel- gas, oil, or coal. NOTE: Table If Is subject 10 change to Include new devel· opments or to reflect requirement modificalions. For lhe lalesl sys:ems available, refer to the table In the in- struction sheel packed with Ihe programmer. TRADELINE MODELS (TABLE III AND FIG. 38) seven TRAOEUNE A4, 40 models can replace sev- enty A4150 models. A cross reference is Included in each TRADruNE JnSlfuCJion Sheel. Twvc ad:::1ilional screw fer- minals on the backs of some of the programmers prOVide a third choice of the Main Burner Flama EslablishJng Pe- riod. (Consult the awropriate Instruction sheet for further information.) SUPER TRADELlNE Y4'40 Modernization Packages, containing one of the 120 voll TRADEUNE R4140 modelS and a Q52QA1'21 Wiring SLtbase, are also avaifable. They also contain cocle requirements, installation instruc· lions, wiring matrices, and preprlnlud wire markers. Com· plele packages also inClude either a plug-in infraracl ampl11ier and matching flame detector, or a plug-in reclifl· caliOf'l amplifier. Par1ial packages. withoUl the deleclor and/ct amplifier, are also available. (For further informa- tion, consult the Y4140 mslrt/cliOn sheet, form 6o-D574.' TABLE II-FLAME DETECTION SYSTEMS PLUG-IN flAME SIGNAL AMPLIFIERS APPLICABLE flAME DETECTORS SELF- FLAME FAILURE FUEL TYPE MODELS COLOR MODEl TYPE CHECKINI RESPONSE TIME HOlderf: C7004, r::r00l, Rectifying C70ll. R7247A 2 to 4 sec Gas Flame Complete asserrolies: C700 5, Rods C7OOS, C7009, 0179. No C;7OO3, r::rOl0. Rectifying Oil - Photocells d r::r013, C7014. R7247A'b 2to4sec RectifIcation Green Ultraviolet Oil, Gas, R7247B {Purple C7012A or C. Coal Peepe~ , Holders c : C7004, r::roo7, Rectifying C70". " R7247Bb 2to4sec Ga. Flame Complete asserrolies; C700S Rods Dynamic C7008, C7OO9, 0179. Self Check Ga Ultraviolet C7012E or F. Oil, (Purple 2t04sec R7247c! Coal Peeper) No R7248A 2104sec Gas, Infrared Infrared Red Dynamic Oil, (Lead C701S. Ampli· A7248Bb 2to4sec Coal Sulfide) ene" . Purple No R7249A 2to4sec Gas, Oil Ultraviolet (Minipeeper) C7027, C7035, C7044. Ultraviolet Blue Dynamic Selt R7476A a 2t04sec Gas, Oir, Ultraviolel (Adjustable C7076. Check Coal sensitivity) a Circuitry tests all electronic corrp:ll'I8nts in the flame detection system (ampliller and detector) 60 to 120 limes a minute during burner ClI')eration and shuts down the burner il the detection system fails. b Circuitry lests the flame siglal amplifier at least 150 times a minute during burner operation and shuts down the burner it the ~lltier.fcl'lIs. c Order flame rod separately; see Instruction sheet lor the holder. d Use Honeywell photocell, Part No. 38316, only. TABLE 111- TRADEUNE MODELS AVAILABLE TRADE LINE MODEL INSTRUCTION SHEET FORM NO. NUMBER OF R4150'S IT CAN REPLACE MAIN BURNER FLAME-ESTABLISHING PERIOD IN SECONDS (FielD SelECTABLE) R4140G1114 a R4140Gll22 b R4140G1163 R4140Gl171 R4140Ll147 R4140Mll86 R4140Mll94 6<Hl466 6<Hl466 6<Hl414 6(}{)466 6Q-0468 6<Hl412 6<Hl412 ,a ,0 • 7 "22 ,. 10,30 OR SOC 10,30 or SOC 10 or Intermittent 10, 30, or SOC 10, 15, or 30 c 10 Of Intermittent 10 or Inlermlttent a 240 vall model. b 208 volt model. c The longest period is ootained by installing a jumper on Ihe back of the progranmer (Fig. 38). 151 71-97558·1 (;) Q -c -c O",,@ '$ $" u@ '0 c" " @ 0& " @ '0 " ;, . 0" ,@ i & ,1lO\i "00£1.5 HAVE NO l[R"'NAI.5 "AND 16 FIG. 38-REAR VIEW OF MODELS WITH 3 CHOICES OF THE MAIN BURNER FLAME·ESTABLISHING PERIOD. Y593 REPLACEMENT PACKAGES (FIG. 39) EiQht Y593 Replacement Packages are designed to re- place 64 different models of a compelilor's flame sale- guard controls. EaCh package includes a prewired adapter base to make replacement as easy and conven- ient as possible. No eXlernal wiring changes are neces- sary for most fl"ICX:iels. After the removal altha compelilo(s conlrol, the adapter base is mounted directly on the exist- ing &.tbase or in the existing Cabinet. The TRADELINE R4140 included in the replacement package is simply plugged into the adapter base. (Cons\.l'lt lhe Y593 instruc- tion sheel, form 60-0407, for further information.) INSTALLATION OF AN R4140 The bask sleps in the installation of an R4140 are (1) mounting the wiring Sl.t:lPase. (.2) wiring \0 sutbase, (3) installing the flame detector, (4) performing a static checkout, and (5) mounling the programmer. These steps will be desCribed in general in this sectiOl1. During an ac· lual installation, follow the applIcable instructions pte> vided by the burner manufacturer in addition 10 those in the instruction sheet particular model being 'or Ihe Installed. MOUNTING THE WIRING SUBBASE First, ChOOSe a location where the temperature will stay wilhin specification limits for the R4140, and where the re/antle humidity never reaches the saturalion lX>inL C0n- densation 01 moisture on the R4140 could cause enough leakage to short the flame signal to ground and thus pre venl the burner from starting. Locate the sutbase close to the name detector(sj in order 10 keep Ihe flame signal lead- wires as short as possible. 00 not Inslall it where II could ~(T"'NING SCR(W KNIF(-BlADE CONTACTS (NGAGE FLAM( SAFEGUARD QS~OC PF!(W'F!(O ADAPT(F! BASE ,",OUNTING SCR(WS 121 CONTROl " FIG.39- TYPICAL INSTALLATION OF A Y593 REPLACEMENT PACKAGE IN AN EXISTING CABINET. be subject [0 extreme vibration. Vibration shortens the 1I1e 01 the eJaclronic comp::lnents. Finally, the R4140 is not weathartighl, so prolection wilt be required If it is installed O!.JtdOOrs. 152 The sut::oase can be mounted in any position except on a horizontal surface with the knifErblade contacts pointing down; the relays on Ihe programmer cb not operate prop- erly if il Is mol,.Jnted in this position. The standard moonling position for the programmer Is on a lr&I1ical surface with its handle up. as shown in Fig. 41. Ani other posilion de- creases the maximum awt:lienl terJl)Elrature raling. Whan yOu selec! the Iqcatlon on a wall or instrument panel. be sure to allow clearances for servicing and tor re- moval of th~ progrartlmer- it swings out. Use the back of the sutoase as a template to marl< the 4 screw locatiQf1s. and drilllh~ pilot holes. (If mounting the sutoase in an ex- isting C3binet, new holes may not be necessary.) Start the mOLintlng screws and scr~ them most of IMe way In. [fhe sutOase has keyhOle type mounting ho.'es. so the mount- In'il screw,s can be statted alone.) Fil the subbase over the screws and ,tighten them securely. WIRING TO THE SUBBASE (FIG. 40) The external devices anc:l wiring required will be differ· ent 10r every Installation. A typical wiring diagram for an R4140L is shown in Fig. 40. If one is furnished. follow the burner manufacturer's wiring diagram. Remember that all wiring must comply with all applicable local electrical codes. ordinances. and regulations, and it must be NEC Class 1 (line voltage). An Important thing 10 remember is - Do not run high vol/age ignirion transformer wires in the same conduit with the flame detector wiring. Check all wirin'il circuitsa(kj perform a Static Checkout before mountin'ilthe programmer. Make sure the wiring to any terminal does not touch any other terminal. Especially make sure the wiring 10 termjr.aJ 7 does nor touch terminal 8. INSTALLING THE FLAME DETE.CTOR Proper flame detector installatlon is the basis of a safe and reliable fla,mo sal9l;)Jafd InstaJlati::ln. Refer to the in- structions packed with the flame delec.tor and amplifier, and to the burner manufacturer's instructions. Follow the Instructions carefully to'maka the best possible applica- tion of the flame detector. Keep the name Signal leadwires Irom the flame detector to tfJe terminal strip or win'ng subbase as short as possible. capaCitance Increases with leadwire length. redUcing the si'ilnal stren'ilth. The I'TIaXlmum permissible leadwire len'ilth depends on the type oflaadwlre, conduit, a(kjtlame detector. The ultimate limiting factor In Dame signal lead- wire length is the Signal current. Refer 10 Table V. For detailed diSCussions on flame defector installation, refar to the Flame Safeguard Reference Materials on Flame ADd Application, form 7Q 8108, and Optical Detec- tor Application. form 7()'8109. PERFORMING A STATIC CHECKOUT (TABLE IV) After checking all wiring circuits. per10nn a checkout of aU eXlernal devices before mounting Ihe programmer on the subbase. These teslS ensure that the wiring subbase is wired correctly a(kj lhat lhe external controllers, limits, inlerlocks, valves. transformers, and molors are qJElrating properly. TneV Can be made ri't1't at the sutoase by Install· ing jumpers and reading the voltage between the proper terminals. Remember that line oItage is present on most terminals when power is on, so be extremely careful when performing these tests. Follow the instruclions In the in· struction sheet for the R4140 e!}' carefully. The tests shown in Table IV are typical lor an R4140L. Tests for other models are similar, but all of them may not beappli· cable, and some ot the terminals may be different. MOUNTING THE PROGRAMMER (FIG. 41) Be sure to open the master switch to remo e power from the subbase terminals before mounting the program- mer. Also make sure that- - there are no bare (unlnSUlaled) wires in lhe suttlase. -the Wiring to any terminal does not touch any other terminal. - no sut:Oase wiring is protruding out beyond the lerm1· nat blocks. - the wlrin'il does not interfere with the connectors. Tuck all wiring In againstlhe back 011he subbase. After you have checked all the wiring, grasp lhe handle of the programmar chassis anc:l engage lhe Chassis hinge braCkets with lhe pivot pins at the ooltom of the S<.tbase. Swing the chassis inward until lhe spring conneclors en- gage lha knifErblade contacts on the sutoase. Push in un- til the contacls are fuJly enga!J8d. Tighten the chassis relaining screw securely. REMOVING AND REPLACING THE RELAYIT\MER COVER (FIG. 42) The operator may wanl to remO\'e the relay/time cover 10- - install or change a ptug-in 11ame Signal amplifier. - observe relay anc:l timer qJElralion. - Inspect ralay or timer cootacts. If the programmer is mounted on the subbase. make sure the master sWilch is qJEln before removing or replac- Ing the cover. REMOVING THE COVER 1. Grasp lha relay/timar cover and 5ql.JBeZe until the V- notch on the cover slides tree of the stud on the handle. 2. Rotate the cover dlwn a(kj oot to disengage the 2 tabs 1rom the slol in the ooUom of lhe programmer chassis. 3. Pull the cover oul. REPLACJNG THE COVER 1. Insert the 2 tabs on IheooUom of the covarbalween the timer and the programmar chassis and engage them with the slot In the bOtiom oflhe chassIs. Make sure the labs are nol jammed in the slot. 2, Rolale the cover up anc:l in, so the V-nolch slides along Ihe stud on the handle. If the cover does not rotate easily, the tabs are jammed. 3. Maka sure the spring clip on the cover fits O\'er the plug-in ampli1ler. 4. Push in on the caver until the V-nOlch snaps into place on the stUd. 153 I r '01'1 FJI'l!CT 5PAIIK IGNITION lOlL 01'1 0 511 I I I I I I : "I I I " I ,e I I J I ) " B;;. """VIP'[ o'K"""[CT [~ ~~o ""U\.O"O """"Cn"" """~£< & "'. ~u. NH'~""" I .'RI~,,_ &. FOR 0'''''' •• ~A ' "'0" (Ol~ OR ,. "'''''"In " " 'o~ ~o TU"'''''L' .~" ,.IN '~'l V.~V!('1 HI ,,_ '. 'u ~ n~"'''''L' to T,RMINAL •. ",'HJU .& FOII'~ uco.a ""T£"~UI'TED.'~OTI'D"'lION, ""T~LLJU" " (IN_ 'Wa'o IN '"''.v.''''' "'U~.CYI "" B.CO< Of "OG~.""'R .,. T ~ """." "'N.li >fL.D 'V •0 U'TIJOl) '" «ON 'RIA~ ':C I H I~ >£'01'0 '~TERRuI'TLo H ~,~ 'VI, , v"c~.", '-l 8U"N'" l- "0'-0'" ~ L"" ,,~( f ."'''c~ FIG. 40-SAMPLE BLOCK DIAGRAM OF FIELO WIRING FOR AN R4140L PROGRAMMER. 154 [...]... During troubleshooting, It is often advantageous to simulate a flame rather than to ignite the pilot or burner Two devices are available for this purpose: 12 351 4A Flame Simulator-for checking out a stan· dard R7247A Rectification Amplifier 12 351 48 Flame Simulator-for cheCking oul a stan· dard R7249A Ultraviolet Amplifier 159 71-9 755 8-1 TABLE V -FLAME SiGNAL C7012A C Ultravi:llet (Purple Peeper) C7012E F... signal This liny signal is fed back through leadwires to the flame signal amplifier on the flame safeguard control, where it is made much larger so it can be read on a meter The mag­ nitude or the flame signal Is proportional to the size and quality of the flame (providing the detector is sensing the flame properly), so the condition or a flame can be deter· mined.by making a Ilame signal measurement... It sIlould be per­ formed at the beQ:inning of lhe checkout before any otller lestS (see Fig 451 0r lXlSitions of the Umerswilct", and dial at startup.) 'a­ ro 157 71-9 755 8·1 FlAME SIGNAL MEASUREMENT is required for all In­ stallatIons to ensure that the flame detector is sighting the flame and lhat the proper flame sig"lal is provided to the pr.QQrammer It should be performed thrOlJl'ttlout the checkout... slated In Note 5 the clan"Per will modJlate In between lis opEln and closed p:lSllions during the Run Period In response to an exle0'\31 controller FIG 50 - TYPICAL LOCATION OF RELAY CON· TACTS (FRONT VIEW) I 8~-'" 'M'O' AL _J '" • '" • EJ 8 8 B • • " ,p < I r , l':t.: ~ I~ EI EJ El: "OTOA A U' 15' O( CONTACT5 8 oUT5'DE CONTACTS FIG 51 - TYPICAL LOCATION OF TIMER C~NTACTS (FRONT VIEW) AS5EMIlLY ROD ~OMMO"... 110 FDA '''''oLlOI .'u FIG 59 -OPERATION OF THE BC7000l WITH THE PM720Ll030 PROGRAM MODULE 173 71-9 755 8-1 , 7 ~ soon es the presence 01 flame Is det8cled, the FLAME ON status light comes on 8 5 secorx:ls Into the iQrlilion trial period the iQrlition transformer (Iermlnal 18) Is energized 9 10 seconds into -the ignition lrial period and will, presence 01 flame detected (FLAME ON status lighl on) the... interlocks R407SC,D INDUSTRIAL FLAME SAFEGUARD CONTROLS (FIG 60) These controls directly replace older R4075A and B mOClels to meet the lalest requirements The R4075D is the same as the R4075C witn lhl;! addilion of a power fail· ure O\Ierride circuit to prevent Shutdown during very shJrt power outages (power line switching of 1 seCOnd or less) SP~t"G CLIP OTHER FEATURES • The R4075C or D plugs into a sutbase... check is expanded to in' cll.lde a flame signal check dur.ing si'anctJv (Off-CyCle) ar\d a preignition output circuit check - Off-Cycle (Standby) Flame Signal Check is apro­ vision Ihat monitors the sfatus of lhe flame detection sub­ system (flame detector and amplifier) If a flame simUlating condition as a result of marginal or faulty flame detection components (or actual flame) exists, a hold code will... visual indication ot the program sequence: STANDBY !power on), PREPURGE, HOLD, IGN TRIAL, FLAME ON, RUN, POSTPURGE, and, through the illuminated reset switch, safety $hutoown (lOCkout) WIRING TO SUBBASE (FIG 55 ) Wiring connections for the BC7QOO diHer from those or other controls that mount on the Q520A Subbase Fig 55 shows the pr~r subbase wiring for the BC7000L with the PM720L1030 program module Disconnect... control Adcl Ihe rElQUired disconnect means and overload protection INSTALLATION OF A BC7000 INSTALLING THE FLAME DETECTOR NOTE: Table IIlisls the flame detection systems available for use with the BC70Q0 Mic·rocomput9l' Burner Control System Maka sure you are using the correct corrblna· lion of ampli1ier and flame detector(s) Proper flame detector inslallation is Ihe basis of a safe and reliable flame. .. INSTAUATlON FIG 57 -INSTALLING THE PM720 PROGRAM MODULE IN mE BC7000 INSTALLING THE PLUG-IN FLAME SIGNAL AMPLIFIER (FIG 58 1 1 Remove the amplifier compartment cover 2 Grasp the flame signal amplifier with the monogram toward the ootside face of the amplifier companlTlEll"ll Align the circuit board with the keyecl receptacle in the 171 71-9 755 8-1 E11U BC7000 CHASSIS -­ SMALL AMPLIFIER LARGE AMPLIFIER FIG 58 -INSTALLING . been designed to replace lhe R4126, R4127, R41a" and R4 150 Flame safeguard Pro- gramming Controls. APPLICATIONS The R4140 Flame safeguard Programming Controls provide flameout prolecion plus aul.omalic sequencing of the. the shortcomings 01 the flame conductivity circuil. The flame recll1icalioo circuli also permitted the use of a photocell or a flame rod as a flame detector. (For an explanation ot the flame conc:UCllvlty and flame. six types of Interlocks. R4140 PROGRAMMING CONTROLS DEVELOPMENT OF THE R4140 FLAME SAFEGUARD PROGRAMMING CONTROLS Way back In 1931, HQl"lEllljWeli inlroc1Jced the firm elec- Ironic flame satfo,Jard control- the Protecloglo system. This