Honeywell R4140G Installation Instructions Manual Download Page 1 | Manualshive

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Honeywell R4140G Installation Instructions Manual Download Page 1

INSTALLATION INSTRUCTIONS

Copyright © 1996 Honeywell Inc. • All Rights Reserved

R4140G,L and M

Flame Safeguard Programming Controls

60-0770-2

IMPORTANT

Applications, Features, Specifications (including
dimension drawings), Operation (including
schematics and bar charts), and Wiring Diagrams
are included in these Specifications for models of
the R4140G, L, and M: R4140G—60-2337;
R4140L—60-2339; R4140M—60-2340.

Contents

Installation ........................................................................... 2
Checkout ............................................................................. 11
Troubleshooting .................................................................. 18
Service Information ............................................................. 27
Testing and Maintenance .................................................... 28

Fig. 2. Components of R4140L Programmers.

RESET BUTTON

RELAY/TIMER
COVER

FLAME SIGNAL
METER JACK

TIMER DIAL

TIMER

RELAY
2K

RELAY
3K

RELAY 1K

RELAY 4K

TIMER
MOTOR

HINGE
BRACKET (2)

CHASSIS

SAFETY SWITCH
BUTTON

CHASSIS RETAINING
SCREW

HANDLE

TIP JACK

PLUG-IN
FLAME SIGNAL
AMPLIFIER

M7959

OPTIONAL HEAVY DUTY
COVER (PART NO.
202050C OR 139695C)

RESET BUTTON

OPTIONAL
202050C
COVER

RELAY/TIMER
COVER

FLAME SIGNAL
METER JACK

TIMER DIAL

TIMER

RELAY
2K

RELAY
1K

TIMER
MOTOR

HINGE
BRACKET (2)

CHASSIS

SAFETY SWITCH
BUTTON

CHASSIS RETAINING
SCREW

HANDLE

TIP JACK

PLUG-IN
FLAME SIGNAL
AMPLIFIER

M10053

Fig. 1. Components of R4140G and R4140M Programmers.

1
2
3
...
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Summary of Contents for R4140G

Page 1: ...tion 27 Testing and Maintenance 28 Fig 2 Components of R4140L Programmers RESET BUTTON RELAY TIMER COVER FLAME SIGNAL METER JACK TIMER DIAL TIMER RELAY 2K RELAY 3K RELAY 1K RELAY 4K TIMER MOTOR HINGE BRACKET 2 CHASSIS SAFETY SWITCH BUTTON CHASSIS RETAINING SCREW HANDLE TIP JACK PLUG IN FLAME SIGNAL AMPLIFIER M7959 OPTIONAL HEAVY DUTY COVER PART NO 202050C OR 139695C RESET BUTTON OPTIONAL 202050C C...

Page 2: ...tarting Vibration Do not install the R4140 where it could be subjected to excessive vibration Vibration shortens the life of the electronic components Weather The R4140 is not designed to be weather tight If it is installed outdoors it must be protected Mounting the Wiring Subbase NOTE For installation dimensions see Fig 1 and 2 in the Specifications for the R4140G L or M The subbase can be mounte...

Page 3: ...40 to a circuit that is subjected to line voltage variations such as would occur with on off switching of heavy loads A separate power supply circuit can be required for the flame safeguard control Add required disconnect means and overload protection Check all wiring circuits and complete the Static Checkout in Table 2 before installing the R4140 Installing the Flame Detector NOTE Table 1 lists t...

Page 4: ...rrectly and that the external controllers limits interlocks actuators valves transformers motors and other devices are operating properly Equipment Required 1 Voltmeter W136A or equivalent set on 0 to 300 Vac scale 2 Jumper wires 2 of No 14 wire insulated 12 in 304 8 mm long with alligator clips at both ends General Instructions Perform all applicable tests in Table 2 in the order listed Make sure...

Page 5: ... opens if connected to terminal 5 NOTE Refer to wiring diagram of the programmer being tested 1 Watch for spark or listen for buzz a Ignition electrodes are clean b ignition transformer is OK 2 Listen for click or feel head of valve for activation a Actuator if used is OK b Pilot valve is OK 7 All models L1 6 Same as test no 6 for connections to terminal 6 If using direct spark ignition check the ...

Page 6: ...osed line voltage at terminal 13 after motor closes 1 Low Fire switch is connected between terminals 8 and 13 If not proceed to test no 14 2 Low Fire switch is closed 3 Firing rate motor and transformer are OK 14 All R4140L models L1 15 and 14 11 13 L2 Firing rate motor drives closed line voltage at terminal 13 after motor closes 1 Low Fire switch is connected between terminals 15 and 13 If not pr...

Page 7: ...s with the two scribe marks alongside the receptacle on the programmer Push in the amplifier until the circuit board is fully inserted into the receptacle Make sure the amplifier is firmly in place then replace the relay timer cover Make sure the spring clip on the cover fits over the amplifier NOTE For further information about a self checking amplifier refer to the Instructions packed with the a...

Page 8: ...ons a Firing rate motor must close by itself spring return when power is removed FM Factory Mutual requirements IRl Industrial Risk Insurers formerly FlA requirements UL Underwriters Laboratories Inc requirements IMPORTANT Before replacing an R4140 make sure the replacement model has the required prepurge time pilot ignition timing on terminal 6 5 second ignition on terminal 18 if required interlo...

Page 9: ...R C7027A C7035A OR C7044A ULTRAVIOLET FLAME DETECTOR C7012A C E F OR C7076A ULTRAVIOLET FLAME DETECTOR RECTIFYING FLAME ROD RECTIFYING PHOTOCELL OR INFRA RED LEAD SULFIDE FLAME DETECTOR LOW FIRE SWITCH 1 LIMITS C8347 1 2 3 4 7 8 9 5 6 LEAVE INTERLOCKS CONNECTED BETWEEN TERMINALS 4 AND 16 IF INTERLOCKS ARE NOT USED INSTALL A JUMPER WIRE BETWEEN TERMINALS 4 AND 16 IF THE R4140G REPLACEMENT MODEL HAS...

Page 10: ... FLAME ROD RECTIFYING PHOTOCELL OR INFRA RED LEAD SULFIDE FLAME DETECTOR LOW FIRE SWITCH 10 HIGH FIRE SWITCH 2 LIMITS C8349 1 BURNER MOTOR BLOWER ALTERNATE LOW FIRE SWITCH 9 C7012A C E F OR C7076A ULTRAVIOLET FLAME DETECTOR 1 2 3 4 7 8 9 5 6 LEAVE INTERLOCKS CONNECTED BETWEEN TERMINALS 3 AND 16 LEAVE INTERLOCKS CONNECTED BETWEEN TERMINALS 4 AND 16 IF THERE IS A JUMPER WIRE BETWEEN TERMINALS 14 AND...

Page 11: ...couple to measure temperature at the flame detector s 8 Orifice plates aperture disks or filters as necessary to adjust sensitivity of flame detector s Checkout Summary The following list summarizes the checkout tests required for each type of installation Instructions for each test are included in this section also consult the burner installation instructions Preliminary Inspection all installati...

Page 12: ...master switch is closed connections are correct and the power supply is of the correct voltage and frequency Check the detector wiring for defects including incorrect connections wrong type or size of wire deteriorated wire open circuits short circuits leakage paths caused by moisture soot or accumulated dirt For a flame rod make sure there is enough ground area the flame rod is properly located i...

Page 13: ...blished in ten seconds safety shutdown occurs in about one half minute Let the timer complete its revolution and stop Wait about one minute reset the lockout switch and let the system recycle once If the pilot still does not ignite make the following ignition pilot adjustments a Open the master switch and remove the programmer from the subbase a This minimum or stronger signal is easily obtained w...

Page 14: ...equired to purge the lines and bring sufficient fuel to the burner NOTE This step requires two people one to open the manual valve s and one to watch for ignition 씈 If the main burner flame is not established within five sec onds or within the normal lightoff time specified by the burner manufacturer close the manual main fuel shutoff valve s and open the master switch Check all burner adjustments...

Page 15: ...ame is established during IGN within the normal lightoff time specified by the burner manufacturer 씏 Measure the flame signal Continue to check for the proper signal Table 4 through the MAIN part of the timer dial and into the Run period after the timer stops Check the signal at both the high and the low firing rate positions and while modulating if applicable Any pulsating or unsteady readings re...

Page 16: ...adiation from hot refractory does not mask the flickering radiation of the flame itself Start the burner and monitor the flame signal during the warmup period A decrease in signal strength as the refractory heats up indicates hot refractory saturation If saturation is extreme the flame relay 2K drops out and the system shuts down as though a flame failure occurred If hot refractory saturation occu...

Page 17: ...ponse of an ultraviolet detector To check for proper detector operation conduct flame failure response tests Safety Shutdown Tests 1 2 and 3 under all operating conditions Flame Signal with Hot Combustion Chamber All Installations With all initial startup tests and burner adjustments completed operate the burner until the combustion chamber is at maximum expected temperature Observe the burner man...

Page 18: ...erlocks are closed b Reset the Lockout switch c Start the system d After about 30 seconds open a preignition interlock e Relay 3K should drop out and there should be no ignition f Safety shutdown should occur about one half minute after 3K drops out Opening of a Lockout Interlock R4140L Only a Make sure all manual fuel shutoff valves are open this includes the manual pilot shutoff valve if using a...

Page 19: ...fer to Table 5 and follow the troubleshooting procedure s outlined Refer to Fig 15 16 and 17 for location of relay and timer contacts Access to the contacts can be gained by removing the relay timer cover Fig 4 Fig 11 Adjusting spring connectors IMPORTANT a Blackened M4A M6B M8B M9B or M11B timer contacts are due to normal deposits of impurities caused by breaking an inductive load ignition transf...

Page 20: ...ll in replace programmer B Relay 1K pulls in but 1 Check manual switch for burner motor 1 Make sure switch is closed burner motor does not start 2 Check external burner motor circuits 2 Make sure circuits are wired correctly replace deteriorated leadwires 3 Check motor power supply motor overload protection and motor starter 3 Replace devices if not operating properly 4 Check burner motor 4 Replac...

Page 21: ... ignition transformer 5 Check operation of automatic pilot valve or first stage valve open master switch and jumper terminals L1 5 or L1 6 on subbase Refer to appropriate wiring diagram to determine proper terminals Close master switch and listen for click or feel head of valve for activation 5 If valve or actuator is not operating properly replace it 6 Open master switch remove test jumpers from ...

Page 22: ...t end of main burner flame establishing period 1 Close all manual fuel shutoff valves open master switch and remove programmer from subbase 1 Make sure that external circuits are wired correctly replace deteriorated leadwires Applicable only if using an interrupted pilot 2 If programmer has provisions for extending the main burner flame establishing period MBFEP at terminal 6 check back of program...

Page 23: ...s b If a running interlock is open determine cause s and correct condition s Make sure that there is airflow If not check burner motor replace if necessary check Airflow switch replace if necessary 3 If the Lockout switch has tripped if the reset button has popped out a For an R4140L only check that all lockout interlocks including the Airflow switch are closed b If using an infrared lead sulfide ...

Page 24: ...t or first stage burner ignites measure the flame signal as described in Flame Signal Measurement in the Checkout section If the signal is unstable or weak check the flame detector installation and circuitry as instructed Recycle the programmer and measure the flame signal again to obtain a good reading If the flame signal is unstable or less than the minimum acceptable value listed in Table 4 pro...

Page 25: ...Remove the flame detector leadwire from terminal F on the subbase Be sure the leadwire does not touch anything after removal 5 Reinstall the programmer on the subbase and reset the Lockout switch if popped out 6 Set the Timer switch to the TEST position 7 Proceed to the following instructions for the appropriate amplifier c R7247A Rectification Amplifier green used with rectifying flame rods recti...

Page 26: ... except substitute a 123514B Flame Simulator in step 3 Restore the programmer to operating condition as follows a Let the timer complete its revolution and set the timer switch to the NORM position b Open the master switch and remove the programmer from the subbase c Reconnect the flame detector Ieadwire to terminal F on the subbase d Reinstall the programmer on the subbase and reset the Lockout s...

Page 27: ...hese tubes with commercial substitutes Contact Cleaning Field cleaning of relay or timer contacts is not recommended IMPORTANT 1 Do not clean contacts 2 Use extreme care to avoid bending the contacts or changing the specifications or configuration in any way 3 Do not use an abrasive or a burnishing tool to clean contacts 4 Do not use hard paper such as a business card to clean contacts Do not use ...

Page 28: ...1 M9 M7 M5 M3 M1 MOTOR B B A INSIDE CONTACTS B OUTSIDE CONTACTS A A B A B A DIAL MANY PROGRAMMERS HAVE ONLY 8 OR 10 SETS OF CONTACTS 1 1 C8348 Fig 17 Location of timer contacts front view TESTING AND MAINTENANCE Periodic tests of all boiler controls and safety devices are required to determine that they are operating as designed to provide a measure of safety Because the operation of all control a...

Page 29: ...Refractory Hold In As required Annual Service Technician See Pilot Turn Down Test Low Water Fuel Cutoff and Alarm Daily Weekly Operator Refer to manufacturer s instruction High Limit Safety Control Annual Service Technician Refer to manufacturer s instructions Operating Control Annual Service Technician Refer to manufacturer s instructions Low Draft Fan and Air Pressure Interlocks Monthly Operator...

Page 30: ...R4140G L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS 60 0770 2 30 ...

Page 31: ...R4140G L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS 60 0770 2 31 ...

Page 32: ...n Hung Kai Centre No 30 Harbour Road Wanchai Hong Kong Honeywell Limited Honeywell Limitée 35 Dynamic Drive Scarborough Ontario M1V 4Z9 Honeywell Latin American Division Miami Lakes Headquarters 14505 Commerce Way Suite 500 Miami Lakes FL 33016 60 0770 2 E C Rev 7 96 Automation and Control Solutions Honeywell International Inc 1985 Douglas Drive North Golden Valley MN 55422 ...

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