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R7140G,L,M BURNER CONTROL MODULES

66-1153—2

8

Mounting R7140 Relay Module 

Installing the Programmer (Fig. 3)

WARNING

Electrical Shock Hazard.

Can cause severe injury, death or property 

damage.

Disconnect power before installation to prevent 

electrical shock. More than one disconnect may be 

involved.

1.

Open the master switch.

2.

Make sure no subbase wiring is projecting out beyond 

the terminal blocks. Tuck in wiring against the back of 

the subbase so it does not interfere with the contacts.

3.

Grasp the programmer chassis and engage the chassis 

hinge brackets with the pivot pins at the bottom of the 

subbase.

4.

Swing the chassis inward until the spring connectors 

engage the knifeblade contacts. Push in until the 

contacts are fully engaged.

5.

Tighten the chassis retaining screw securely.

6.

Close the master switch to restore power.

Removing the Programmer

1.

Open the master switch.

2.

Loosen the chassis retaining screw.

3.

Pull outward on the top of the chassis.

4.

Disengage the chassis hinge brackets from the subbase 

pivot pins.

Fig. 3. Mounting the programmer on the subbase.

Fig. 4. Operating sequence, R7140G1000/R7140G2008.

CHASSIS

RETAINING

SCREW

SPRING

CONNECTORS

KNIFE-BLADE

CONTACTS (20)

WIRING

SUBBASE

PIVOT PIN (2)

HINGE

BRACKET (2)

PROGRAMMER

CHASSIS

M22605

R7140G

POWER

OPERATING

CONTROLS

AND

INTERLOCKS

BURNER

FLAME

SIGNAL

FIRING

RATE

MOTOR

INITIATE

(INITIAL

POWERUP 

ONLY)

POWER

STANDBY

PREPURGE

HOLD 

DRIVE TO

LOW FIRE 

POWER

PILOT
FLAME
MAIN

POWER

PFEP

10 SEC.

(4 SEC. IF

JR1 CLIPPED

PILOT
FLAME
MAIN

POWER

MFEP

PILOT
FLAME
MAIN

RUN

POWER

POSTPURGE

POWER

STANDBY

00

00

10

25

00

15

20

MOTOR ACTION

BURNER/BLOWER MOTOR

IGN.

15 SEC. INTERRUPTED PILOT VALVE 

LIMITS AND BURNER CONTROLLER CLOSED

RUNNING INTERLOCKS CLOSED

PII CLOSED 

LOW FIRE SW.

SAFE START CHECK

FLAME PROVING

10 SEC. IGN./PILOT 5

18

8

5 SEC.

6

TO

3

TO

16

TO

8

13

TO

10

11

TO

10

11

TO

M23319

INTERLOCK. CHECK

14

11

TO

14

11

TO

4

16

L1

MAIN VALVE

7

TIMED

PREPURGE 

POWER

FLAME

MAIN

PILOT

ALARM

POWER

FLAME

MAIN

PILOT

ALARM

ALARM

ALARM

ALARM

00

IC

SSC

LED 

DISPLAY

R7140G SWITCHING

1 TERMINAL 6 HAS THE FOLLOWING OPTIONS:

 

AS RECEIVED - INTERMITTENT PILOT

JR2 CLIPPED - 15 SECOND MAIN FLAME ESTABLISHING PERIOD (INTERRUPTED PILOT)

JR2 CLIPPED PLUS TERMINALS 8 - 15 JUMPERED - 30 SECOND MAIN FLAME ESTABLISHING PERIOD (INTERRUPTED PILOT)

1

16

2

2

PII MEANS PRE-IGNITION INTERLOCK.

3

FOR R7140G1000:

 

L1 TO 4

4 TO 3

3

3

Содержание R7140G

Страница 1: ...ubleshooting FEATURES Device status available to ModBus through S7810M card or S7800A1001 Series 5 Keyboard Display Safety features Interlock check Closed loop logic test Dynamic AMPLI CHECK Dynamic input check Dynamic safety relay test Dynamic self check logic Expanded safe start check High Fire Purge Switch test R7140L only Internal hardware status monitoring Low Fire Start Switch test Tamper re...

Страница 2: ...anel mounting Required Components Plug in Flame Signal Amplifier See Table 1 Plug in Purge Timer Cards See Table 2 SEQUENCE STATUS LEDs RESET PUSHBUTTON FLAME SIMULATOR INPUT FLAME CURRENT TEST JACKS RUN TEST SWITCH PLUG IN PURGE CARD DUST COVER RELAY MODULE FLAME AMPLIFIER M7552B Table 1 Flame Detection Systems Plug in Flame Signal Amplifiers Applicable Flame Detectors Type Color Self Checking Mo...

Страница 3: ...004 Network Interface Unit with universal 100 to 250 Vac 50 60 Hz external power supply external modem required QS7800A1001 ControlBus Module standard QS7800B1000 ControlBus Module multidrop QS7850A1001 ControlBus Module General Purpose Interface ZM7850A1006 Combustion System Manager software S7810A1009 Data ControlBus Module if no KDM is used S7810B1007 Data ControlBus Module Multi Drop Switch Mo...

Страница 4: ...L1 120 Vac 10 15 50 or 60 Hz 10 3 Lockout Running Interlock 120 Vac 8A run 43A inrush 4 Pre Ignition Interlock Input 120 Vac 1 mA 5 Pilot Valve Ignition 120 Vac See Table 4 6 Interrupted Intermittent Pilot Valve First Stage Oil Valve 120 Vac See Table 4 7 Main Fuel Valve 120 Vac See Table 4 8 Burner Motor 120 Vac 9 8 AFL 58 8 ALR inrush 9 Alarm 120 Vac 1A pilot duty 10 Firing Rate High Fire 120 Va...

Страница 5: ... a control is installed on a burner WARNING Electrical Shock Hazard Can cause serious injury or death Disconnect the power supply before beginning installation More than one power supply disconnect may be required Table 4 Terminal Ratings Terminal Typical Load Maximum Rating at 120 Vac 60 Hz 5 or 6 Ignition Transformer Pilot Valve First Stage Fuel Valve 4 5A ignition and 50 VA pilot duty or 2 5A i...

Страница 6: ... installed outdoors protect the relay module using an approved weathertight enclosure Mounting Wiring Subbase 1 Mount the subbase in any position except horizontally with the quadfurcated contacts pointing down The standard vertical position is recommended Any other position decreases the maximum ambient temperature rating 2 Select a location on a wall burner or electrical panel The Q520A can be m...

Страница 7: ...ch may be connected to terminal D Identify remove and connect to terminal M Replacing GP101 devices Check wiring subbase If D is jumpered to 8 remove the jumper Replacing R4140 programmers on Carlin 1050 and 1150 burners Remove jumper from 6 to 7 Remove jumper from L2 to 12 and wire nut the wires together Note There will be no wire on terminal 12 R4140M replacements Check terminal 13 of the Q520 w...

Страница 8: ...4 Operating sequence R7140G1000 R7140G2008 CHASSIS RETAINING SCREW SPRING CONNECTORS KNIFE BLADE CONTACTS 20 WIRING SUBBASE PIVOT PIN 2 HINGE BRACKET 2 PROGRAMMER CHASSIS M22605 R7140G POWER OPERATING CONTROLS AND INTERLOCKS BURNER FLAME SIGNAL FIRING RATE MOTOR INITIATE INITIAL POWERUP ONLY POWER STANDBY PREPURGE HOLD DRIVE TO LOW FIRE POWER PILOT FLAME MAIN POWER PFEP 10 SEC 4 SEC IF JR1 CLIPPED...

Страница 9: ...TEST JACK REMOTE RESET DDL DDL COMMUNICATIONS INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS IGNITION PILOT PILOT V2 MAIN VALVE 1K 9K RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS LIMITS CONTROLLER RUNNING LOCKOUT INTERLOCK PRE IGNITION INTERLOCK 1K1 2K1 5K1 8K1 8K2 9K1 9K2 120 Vac 50 60 Hz FLAME SIGNAL TEST LOW FIRE SWITCH PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION ...

Страница 10: ...ER CONTROL POWER TEST JACK INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS FIELD WIRING INTERNAL WIRING IGNITION PILOT PILOT V2 MAIN VALVE LIMITS CONTROLLER RUNNING LOCKOUT INTERLOCK PRE IGNITION INTERLOCK 1K1 2K1 5K1 8K1 8K2 9K1 9K2 120 Vac 50 60 Hz FLAME SIGNAL TEST LOW FIRE SWITCH PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED L1 HOT L2 L1 16 4 3 4K1 7K1 2K...

Страница 11: ... 10 11 W R B W R B LIMITS PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE ALL NEC CLASS 1 WIRING START INTERLOCKS IF USED BECOME PREIGNITION INTERLOCKS MUST REMAIN CLOSED UNTIL IGNITION TRIALS BEGIN TERMINAL 6 HAS THE FOLLOWING OPTIONS AS RECEIVED INTERMITTENT PILOT JR2 CLIPPED 15 SECOND MAIN FLAME ESTABLISHING PERIOD JR2 CLIPPED AND JUMPER FROM 8 15 30 SECOND MAIN FLAME ESTABLISH...

Страница 12: ...SPARK IGNITION OF OIL CONNECT IGNITION TO TERMINAL 5 AND MAIN OIL VALVE SOLENOID TO TERMINAL 7 JUMPER TERMINAL 7 T0 TERMINAL 6 SEE INSET SOLENOID MUST NOT EXCEED THE ELECTRICAL RATINGS OF TERMINAL 7 1 1 2 2 3 4 4 5 L2 FOR THE C7015A INFRARED LEAD SULFIDE FLAME DETECTOR EITHER LEADWIRE CAN BE CONNECTED TO THE F TERMINAL RUN THE C7015A LEADWIRES ALONE IN CONDUIT ALL THE WAY TO THE WIRING SUBBASE AND...

Страница 13: ...OWER MFEP PILOT FLAME MAIN RUN POWER POSTPURGE POWER STANDBY 00 00 10 25 00 15 20 SWITCHING MOTOR ACTION BURNER BLOWER MOTOR IGN LIMITS AND BURNER CONTROLLER CLOSED LOCKOUT INTERLOCKS CLOSED PII CLOSED LOW FIRE SW SAFE START CHECK FLAME PROVING 10 SEC IGN PILOT 5 18 8 5 SEC 16 TO 16 TO 16 TO 8 13 TO 10 11 TO 10 11 TO M23322 HIGH FIRE SW 15 TO 10 14 TO 10 14 TO 8 4 3 L1 MAIN VALVE 7 TIMED PREPURGE ...

Страница 14: ... REMOTE RESET DDL DDL COMMUNICATIONS INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS FIELD WIRING INTERNAL WIRING IGNITION PILOT PILOT V2 MAIN VALVE 1K 9K RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS 1K1 2K1 5K1 8K1 8K2 9K1 9K2 120 Vac 50 60 Hz FLAME SIGNAL TEST LOW FIRE SWITCH PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED RS485 1 2 3 L1 HOT L2 L1 4K1 7K1 2K...

Страница 15: ...NTROL POWER TEST JACK REMOTE RESET DDL DDL COMMUNICATIONS INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS FIELD WIRING INTERNAL WIRING IGNITION PILOT PILOT V2 MAIN VALVE 1K 9K RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS LIMITS CONTROLLER RUNNING LOCKOUT INTERLOCK PRE IGNITION INTERLOCK 1K1 2K1 5K1 8K1 8K2 9K1 9K2 120 Vac 50 60 Hz FLAME SIGNAL TEST LOW FIRE SWITCH PROVIDE ...

Страница 16: ...RING FOR DIRECT SPARK IGNITION OIL OR GAS CONNECT THE IGNITION TRANSFORMER AND MAIN FUEL VALVE S AS SHOWN IN INSET FOR THE C7015A INFRARED LEAD SULFIDE FLAME DETECTOR EITHER LEADWIRE CAN BE CONNECTED TO THE F TERMINAL RUN THE C7015A LEADWIRES ALONE IN CONDUIT ALL THE WAY TO THE WIRING SUBBASE AND GROUND THE CONDUIT AT THE SUBBASE REFER TO PUBLICATION 60 2306 FOR DETAILED INSTRUCTIONS 1 1 2 2 3 4 5...

Страница 17: ...IRFLOW SWITCH PREIGNITION INTERLOCKS BURNER CONTROLLER 120V ALARM MASTER SWITCH 120V 60 HZ POWER SUPPLY L1 HOT L2 TO MAIN FUEL VALVE S L2 5 6 7 FOR DIRECT SPARK IGNITION OIL OR GAS 5 6 7 8 G L1 L2 12 13 F 3 4 9 10 11 W R B W R B 5 SECOND IGNITION EARLY SPARK TERMINATION LIMITS PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE ALL NEC CLASS 1 WIRING IN SOME INSTALLATIONS THE LOW FIRE...

Страница 18: ...BURNER BLOWER MOTOR IGN INTERMITTENT PILOT VALVE LIMITS AND BURNER CONTROLLER CLOSED RUNNING INTERLOCKS CLOSED PII CLOSED LOW FIRE SW SAFE START CHECK FLAME PROVING 10 SEC IGN PILOT 5 18 8 5 SEC 6 4 TO 3 TO 16 TO 8 13 TO 10 L2 TO 10 L2 TO M23331 4 16 L1 MAIN VALVE 7 TIMED PREPURGE POWER FLAME MAIN PILOT ALARM POWER FLAME MAIN PILOT ALARM ALARM ALARM ALARM 00 SSC LED DISPLAY R7140M SWITCHING 1 1 WH...

Страница 19: ...GN XFMR INTERMITTENT PILOT 1R1 3K1 6K1 9 8 6 MAIN VALVE 7 LF 13 F G 17 L1 L1 L2 L2 15 SECOND INTERMITTENT PILOT VALVE 18 5 5K1 4K1 2K1 7K1 2K2 1K1 3 AIRFLOW 4 16 LIMITS CONTROLLER 1R1 10 11 START INTERLOCKS 12 J1 8K2 9K1 14 J2 9K2 INTERNAL ELECTRONICS M23336 CONFIGURATION JUMPERS PURGE TIMER FLAME AMPLIFIER ALARM BLOWER IGN XFMR INTERMITTENT PILOT 1R1 3K1 6K1 9 8 6 MAIN VALVE 7 LF 13 F G 17 L1 L1 ...

Страница 20: ...E DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE ALL NEC CLASS 1 WIRING START INTERLOCKS IF USED BECOME PRE IGNITION INTERLOCKS MUST REMAIN CLOSED UNTIL IGNITION TRIALS BEGIN PM720M 16 TO 4 IS A PRE IGNITION INTERLOCK USE 2 POSITION SPRING RETURN MOTOR WHITE LEADWIRES ON C7012 U V FLAME DETECTORS REPLACE C7012 WITH C7061 UV DETECTOR AND R7861A1026 AMPLIFIER MAKE SURE CONNECTOR IS ON TERM...

Страница 21: ...MINAL STRIP 4 LIMITS POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE ALL NEC CLASS 1 WIRING WHEN USING A 2 POSITION SPRING DAMPER MOTOR CLIP AND REMOVE J1 AND J2 LOCATED ON R7140 SUBBASE FOR DIRECT SPARK IGNITION OIL OR GAS CONNECT THE IGNITION AND MAIN FUEL VALVE S AS SHOWN IN THE INSET FOR THE C7015A INFRARED LEAD SULFIDE FLAME DETECTOR EITHER LEADWIRE MAY BE CONNEC...

Страница 22: ...MAIN FLAME ESTABLISHING Period MFEP a Low Fire Switch Opens b Lockout Interlock opens R7140L c Ignition pilot valve intermittent pilot valve terminal is not energized d Main valve terminal is not energized e No flame is present at the end of MFEP f Internal system fault occurs g Purge card is removed h Purge card is bad 6 RUN Period a No flame is present b Lockout Interlock opens R7140L c Interrup...

Страница 23: ...ed throughout the Ignition Trial state b Flame must be proven by the end of the 10 second PFEP four if JR1 is clipped to allow the sequence to continue If flame is not proven by the end of PFEP a safety shutdown occurs c After five seconds the ignition terminal 18 is de energized for early spark termination 2 Main Flame Establishing Period MFEP a Terminal 7 is energized when the presence of flame ...

Страница 24: ...R7140 is switched to the Test mode it stops and holds at the next Run Test Switch point in the operating sequence Make sure that the Run Test Switch is in the RUN position before leaving the installation SETTINGS AND ADJUSTMENTS Selectable Site Configurable Jumpers The R7140 has three site configurable jumper options see Fig 19 and Table 7 If necessary clip the site configurable jumpers with side ...

Страница 25: ... of the operating controller to simulate a call for heat 5 For each test open the master switch and install the jumper wire s between the subbase wiring terminals listed in the Test Jumpers column 6 Close the master switch before observing operation 7 Read the voltage between the subbase wiring terminals listed in the Voltmeter column 8 If there is no voltage or the operation is abnormal check the...

Страница 26: ...g rate motor and transformer 12 R7140G L L1 8 and 10 11 15 L2 Firing rate motor drives open line voltage at terminal 15 after motor is in High Fire position 1 High Fire Purge Switch 2 Firing rate motor and transformer 13 R7140L L1 8 and 14 11 15 L2 Firing rate motor drives closed zero volts at terminal 15 after motor starts driving closed 1 Low Fire Start Switch 2 Firing rate motor and transformer...

Страница 27: ... required Checkout tests after all adjustments are made All tests must be satisfied with the flame detector s in their final position Equipment Recommended S7800A Keyboard Display Module Volt ohmmeter 1M ohm volt minimum sensitivity with 0 300 Vac capability 0 6000 ohm capability 0 10 Vdc capability Checkout Summary Table 9 provides an overview of checkout steps performed for each applicable syste...

Страница 28: ...nergize both the ignition transformer and the pilot valve i If the pilot does not ignite and if the ignition spark is still continuous adjust the pressure regulator until a pilot is established j When the pilot ignites properly and stays ignited open the master switch and remove the jumper s from the terminals of the subbase k Check for adequate bleeding of the fuel line l Reinstall the R7140 Rela...

Страница 29: ...s used go to step 18 16 Shut down the system by opening the burner switch or by lowering the setpoint of the operating controller Make sure the burner flame goes out and all automatic fuel valves close 17 If used remove the bypass jumpers from the low fuel pressure limit and subbase 18 If a second stage is used make sure the automatic second stage fuel valve s opened Check the lightoff as follows ...

Страница 30: ... or pressure gauge and turn up the pilot gas flow to that recom mended by the equipment manufacturer 16 If used remove the bypass jumpers from the subbase terminals limits controls or switches 17 Run the system through another cycle to check for normal operation 18 Return the system to normal operation IGNITION INTERFERENCE TEST ALL FLAME RODS Ignition interference can subtract from decrease or ad...

Страница 31: ...NITION SPARK RESPONSE TEST ALL ULTRAVIOLET DETECTORS Test to make certain that the ignition spark is not actuating the FLAME LED 1 Close the pilot and main burner manual fuel shut off valve s 2 Start the burner and use the Run Test Switch if available to stop the sequence in the PILOT IGN period Ignition spark should occur but the flame signal should not be more than 0 5 Vdc 3 If the flame signal ...

Страница 32: ...lve s leave the main fuel manual shutoff valve s closed b Depress the reset button c Start the system d The pilot should ignite and the flame signal should be at least 1 25 Vdc but the main burner cannot light e The flame signal should drop below 1 25 Vdc within the FFRT of the amplifier and the relay module after the interrupted pilot goes out f Safety shutdown occurs 6 Loss of flame during RUN a...

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