R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS
60-0770—2
17
(Burn a solid instead of a liquid, or a liquid instead of a gas.)
When the maximum refractory temperature is reached, close
all manual fuel shutoff valves, or open the electrical circuits of
all automatic fuel valves. Visually observe when the burner
flame goes out. After the flame goes out, measure the time it
takes for the flame relay 2K to drop out. (Watch or listen to the
flame relay to determine when it drops out.) If the flame relay
fails to drop out within four seconds, the infrared detector is
sensing hot refractory. Immediately terminate the firing cycle.
(Lower the setpoint of the burner controller, or set the fuel
selector switch to OFF. Do not open the master switch.)
NOTE:
Some burners continue to purge their oil lines
between the valve(s) and nozzle(s) even though the
fuel valve(s) is closed. Terminating the firing cycle
(instead of opening the master switch) allows
purging the combustion chamber, if available. This
reduces a buildup of fuel vapors in the combustion
chamber caused by oil line purging.
If the detector is sensing hot refractory, the condition must be
corrected. Add an orifice plate ahead of the cell to restrict the
viewing area of the detector. If this does not work, resight the
detector at a cooler, more distant part of the combustion
chamber. While resighting the detector, remember that it must
also properly sight the flame. For an infrared detector, you
can also try lengthening the sight pipe or decreasing the pipe
size (diameter). For details, refer to the C7015A Instructions,
form 60-2306. Continue adjustments until hot refractory hold-
in is eliminated.
Ultraviolet Response Tests (All Ultraviolet
Detectors) Ignition Spark Response Test
Test to be sure that ignition spark is not actuating flame
relay 2K.
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Close the pilot and main burner manual fuel shut-off
valves.
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Start the burner and run through the ignition period.
Ignition spark should occur, but relay 2K must not pull in.
The flame signal should not be more than 1/4 microamp.
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If relay 2K does pull in, resight the detector farther out
from the spark, or away from possible reflection. It may
be necessary to construct a barrier to block the ignition
spark from the detector’s view. Continue adjustments
until the flame signal due to ignition spark is less than
1/4 microamp.
NOTE:
Honeywell Q624A Solid State Spark Generator
prevents detection of ignition spark when properly
applied with flame detection systems using C7027,
C7035, or C7044 Minipeeper Ultraviolet Flame
Detectors. The Q624A is for use only with gas pilots.
Response to Other Ultraviolet Sources
Some sources of artificial light produce small amounts of
ultraviolet radiation. Under certain conditions, an ultraviolet
detector responds to them as if sensing a flame. Do not use
an artificial light source to check the response 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
manufacturer warmup instructions.) Recycle the burner under
these hot conditions and measure the flame signal. Check the
pilot alone, the main burner flame alone, and both together
(unless monitoring only the pilot flame when using an
intermittent pilot, or only the main burner flame when using
direct spark ignition). Check the signal at both the high and the
low firing rate positions and while modulating, if applicable.
Also check the flame failure response time. Lower the
setpoint of the burner controller and observe the time it takes
flame relay 2K to drop out after the burner flame goes out (2K
should drop out within four seconds).
If the flame signal is too low or unsteady, check the flame
detector temperature. Relocate the detector if the
temperature is too high. If necessary, realign the sighting to
obtain the proper signal and response time. If the response
time continues to be too slow, replace the plug-in flame signal
amplifier. If the detector is relocated or resighted, or the
amplifier is replaced, repeat all required checkout tests.
IMPORTANT
Repeat all required Checkout tests after all
adjustments are complete. All tests must be satisfied
with the flame detector(s) in its FINAL position.
Safety Shutdown Tests (All Installations)
Perform these tests at the end of Checkout after all other
tests are complete.
For all R4140 Programmers, safety shutdown should occur
on: (1) failure to ignite the pilot (or first stage burner when
using direct spark ignition), (2) failure to light the main burner
(unless monitoring an intermittent pilot), and (3) loss of flame
during the Run period. (If a self-checking flame detection
system is used, safety shutdown should also occur on a
failure in the detection system. However, because the
programmer acts the same if a flame failure has occurred, no
separate test is necessary.)
For an R4140L, safety shutdown should also occur upon (1)
detection of a flame (or a condition simulating a flame) before
or during prepurge, (2) opening of a preignition interlock
during prepurge, and (3) opening of a lockout interlock after
14 seconds.
On safety shutdown, the lockout switch should trip (pop out)
and lock out the programmer. The ignition and fuel valve
terminals should be de-energized. If used, the external alarm
should turn on. The timer should complete its revolution and
lock up at the start position. The lockout switch must be
manually reset to restart the system.
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Failure to Ignite Pilot (or First Stage Burner if Using
Direct Spark Ignition).
a.
Close all manual fuel shutoff valves; this includes
the manual pilot shutoff valve and all manual
main burner shutoff valves.
b.
Make sure all interlocks are closed.