60-2337-3
Flame Safeguard Programming Controls
APPLICATION
The R4140G Flame Safeguard Programmers provide
flameout protection plus automatic sequencing of the burner
motor (blower), firing rate motor, ignition, pilot valve, and main
fuel valve(s) for commercial and industrial burners using gas,
oil, coal, or a combination of fuels.
FEATURES
• Approvals: Underwriters Laboratories Inc. listed or
component recognized, Canadian Standards
Association certified, and Factory Mutual approved for
automatic fired burners.
• The R4140 directly replaces the R4150 for most
applications and mounts on the same Q520A Wiring
Subbase.
• Low-high-low purge programmers.
• Field selectable main burner flame-establishing
period.
• Early spark termination (five-second ignition and fivesecond pilot only) available on some models.
• Plug-in, solid state, flame signal amplifiers are colorcoded and interchangeable to allow the use of any
type of flame detector-flame rod, photocell, infrared
detector, or ultraviolet detector.
• Amplifier capability includes three standard models,
three Dynamic Self-Check models, and one Dynamic
Ampli-Check® model.
R4140G
PRODUCT DATA
• R7247C or R7476A Dynamic Self-Check Amplifier,
when used with an ultraviolet flame detector with a
self-checking shutter (R7247C with a C7012E or F;
R7476A with a C7076), tests all electronic components
in the flame detection system (amplifier and detector)
60 to 240 times a minute during burner operation and
shuts down the burner if the detection system fails.
• R7247B Dynamic Self-Check Amplifier, when used with
a rectifying flame rod (which is considered fail-safe),
or R7248B Dynamic Ampli-Check Amplifier, when used
with a C7015A Infrared (lead sulfide) Flame Detector,
tests the flame signal amplifier at least 150 times a
minute during burner operation and shuts down the
burner if the amplifier fails.
• All models feature capability of proving low fire position
of the firing rate motor before starting ignition trials.
• Provisions for connecting preignition or start
interlocks (depending on model) to prove the proper
conditions for startup, and for a combustion airflow
switch to prove airflow throughout the operating cycle.
• All models have 4-wire firing rate switching circuitry—
firing rate can be modulated while the burner is firing,
and the firing rate motor can be driven to both low and
high fire positions during prepurge.
• Safe start check at startup and during prepurge. If
flame relay 2K is holding in at startup, the programmer
cannot be started. If a flame (or a condition simulating
a flame) is detected during prepurge, ignition trials
cannot be started and the programmer recycles.
• Safety shutdown occurs on failure to ignite the pilot or
main burner, on loss of flame during the Run period,
or if the flame detection system fails (if a self-checking
system is used).
• All relays are visible, labeled, and easily accessible.
• Alarm terminal is available to operate an external, line
voltage alarm on safety shutdown.
Contents
Application .......................................................................... 1
Features .............................................................................. 1
Specifications ...................................................................... 2
Ordering Information ........................................................... 2
Operation ............................................................................ 6
Wiring .................................................................................. 23
Copyright © 1996 Honeywell Inc. • All Rights Reserved
X-XX UL
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
SPECIFICATIONS
Interlock Circuits:
Start Interlocks (R4140G1049, G1056, G1064, G1114,
G1122, G1148 and G1171)—System controls must be
IMPORTANT
The specifications given in this publication do not
include normal manufacturing tolerances. Therefore,
this unit may not match the listed specifications
exactly. Also, this product is tested and calibrated
under closely controlled conditions, and some minor
differences in performance can be expected if those
conditions are changed.
in proper positions or programmer will not start.
Preignition Interlocks (R4140G1007, G1015, and
G1106)—Must be closed to start programmer. Prevent
ignition trials if interlocks open during prepurge; timer
recycles the programmer and system restarts if
condition is self-correcting.
Running Interlocks (all models)—Must be closed (airflow
must be proven, fuel pressure must not be too low or
too high) within 9.5 seconds after startup or ignition
MODELS:
R4140G Flame Safeguard Programming Controls—Flame
Safeguard protection and sequencing controls for use on gas,
oil, coal, or combination burners. See Table 1 for models
available.
trials cannot be started. Running interlocks must remain
closed through the Run period or the automatic fuel
valves de-energize, the burner flame(s) goes out, and
the timer recycles the programmer.
Low Fire Interlock (all models)—Timer stops at 52 seconds
until low fire proving switch closes, indicating damper is
closed prior to ignition.
Table 1. Models Available.
Flame-Establishing
Pilot
Period (sec)
Main Burner
c
(Field Selectable)
Postpurge
c
(sec)
Interlock
Circuits
Airflow
Switch) and
Low Fire
Firing Rate
Switching
Circuit
4-wire
common,
Timer
a
Cycle
(sec)
Prepurge
(sec)
Early Spark
Termination
b
Model
R4140G1007 Yes 120 60 No 10 10 or 30 16 Preignition,
R4140G1015 No Running
R4140G1106 No 120 60 No 10 10 or 15 16 (including
R4140G1049 No 120 60 Yes 10 10 or 30 16 Start, high fire,
R4140G1056 Yes 120 60 Yes 10 10 or intermittent 16 Running low-fire,
R4140G1064 No 120 60 Yes 10 10 or intermittent 16 (including modulate)
R4140G1114 No 180 70 Yes 10 10, 30, or 60 25 Airflow
R4140G1122 No 180 70 Yes 10 10, 30 or 60 25 Switch) and
R4140G1148 No 120 60 Yes 10 10 or 15 16 Low Fire
R4140G1171 No 180 70 Yes 10 10 or 15 25
a
202050C Cover with reset button; heavy duty, metal cover for outside panel mounting.
b
Early spark termination available on terminal 18 (5 second ignition and 5 second pilot only).
c
If used for direct spark ignition (oil or gas), the flame-establishing period is 10 seconds.
With
Cover
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the
TRADELINE® Catalog or price sheets for complete ordering number or specify order number. Order separately:
1. Flame detection system (amplifier and matching flame detector). See Table 4.
2. Q520A1089 or Q520A1121 Wiring Subbase.
3. Accessories, if desired.
If you have additional questions, need further information, or would like to comment on our products or services, please write or
phone:
1. Your local Home and Building Control Sales Office (check white pages of your phone directory).
2. Home and Building Control Customer Logistics
Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9.
International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,
Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
60-2337—3
2
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Safety Features:
Safe Start Check—For the presence of a flame (or a
condition simulating a flame) provided at startup and
during prepurge. If the flame relay 2K is pulled in at
startup, 2K2 is open and the programmer cannot be
started. If the flame relay 2K pulls in during prepurge
(before 57.5 seconds), 2K2 opens, relay 1K drops out,
and ignition trials cannot be started. Instead, the timer
completes its revolution and stops at the standby position
(zero seconds). If the flame relay 2K drops out by the end
of the cycle, the programmer restarts the system.
Safety Shutdown—Ignition transformer and all automatic
fuel valves de-energize. The lockout switch trips and
locks out the programmer. If used, the external alarm is
energized. The timer completes its revolution and locks
up at the stand-by position (zero seconds). The lockout
switch must be manually reset to restart the system.
Safety Shutdown occurs on:
• Failure to ignite the pilot (or first stage burner if using
direct spark ignition).
• Failure to light the main burner (unless monitoring
an intermittent pilot).
• Loss of flame during the Run period.
• Failure in the flame detection system (if a self-
checking system is used, see Table 4).
Flame Failure Response Time—2 to 4 seconds.
Lockout Switch Timing—30 seconds (nominal).
Electrical Ratings:
Voltage and Frequency: 120 Vac (102V minimum to 132V
maximum), 50/60 Hz.
R4140G1114: 240 Vac, 60 Hz.
R4140G1122: 208 Vac, 60 Hz.
NOTE: Use of a 50 Hz power supply lengthens the
sequence timings by a factor of 1.2.
Power Consumption (With No Loads Connected to Output
Terminals): 13W maximum.
Maximum Total Connected Load: 2000 VA.
Terminal Ratings:
See Table 2.
Table 2. Terminal Ratings.
Maximum Rating at
Terminal Typical Load
5 or 6 Ignition
Transformer/Pilot
120 Vac, 60 Hz
4.5A ignition and 50 VA pilot duty or
2.5A ignition and 75 VA pilot duty
Valve/First Stage
Fuel Valve
7 Main Fuel Valve(s)
(solenoid/motorized
/diaphragm) and
Vent Valve if
required
250 VA pilot duty or 65 VA pilot duty
in parallel with motorized valve(s)
using a total of 1150 VA locked
rotor (inrush),460 VA to open, and
250 VA to hold or motorized
valve(s) using a total of 1500 VA
locked rotor (inrush), 600 VA to
open, and 250 VA to hold
8 Burner Motor
(blower)
9.8A full load, 58.8A locked rotor
(inrush)
9 120V Alarm 75 VA pilot duty
10, 11, 12,
and 14
Firing Rate
(damper) Motor
50 VA pilot duty
Contacts
18
(if available)
Ignition
Transformer
4.5A ignition
NOTE: Allowable inrush can be up to ten times the pilot duty
rating.
EXAMPLE: Pilot duty rating = 50 VA.
At 120V, running current is:
50
120
= 0.42A
.
Maximum allowable inrush is ten times
0.42A = 4.2A.
Interlock Ratings:
See Table 3.
Table 3. Interlock Ratings.
Requirements must be abIe to
Interlocks
Limits, Burner Controller,
and Running Interlocks
carry and break current to:
Ignition transformer, pilot valve,
and main fuel valve(s).
(including airflow switch)
Start or Preignition
Programmer relay 1K (5W max).
Interlocks
Ambient Operating Temperature Ratings:
Minimum: Minus 40°F (minus 40°C).
Maximum:
Programmer Mounting Position
Standard Vertical (With Handle Up) Any Other
+150°F (+66°C) +135°F (+57°C)
Storage Temperature Ratings:
Minus 60°F to plus 150°F (minus 51°C to plus 66°C).
Mounting:
3-sided Q520A1089 Wiring Subbase, or 4-sided Q520A1121
Wiring Subbase; both have 20 knife-blade contacts (subbase
ordered separately).
Dimensions:
See Fig. 1 and 2.
Weight (Without Plug-in Flame Signal Amplifier and
202050C Cover):
4 lb, 12 oz (2.15 kg).
Flame Detection System (Ordered Separately):
Plug-in Flame Signal Amplifier and matching Flame Detector;
see Table 4.
Approvals:
Underwriters Laboratories Inc. Listed Section of Primary
Safety Control (120V Models With Covers): File No.
MP268; Guide No. MCCZ.
Underwriters Laboratories Inc. Component Recognized
(120V Models Without Covers): File No. MP268; Guide
No. MCCZ2.
Canadian Standards Association Certified: File No.
LR1620.
Factory Mutual Approved: Report No. 24180.
3
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
2-3/8 (60)
7/8 (22) DIAMETER KNOCKOUT (2)
13/64 (5) DIAMETER (4)
(FOR MOUNTING ON
4 X 4 [102 X 102] JUNCTION BOX)
35
4
31/32
(25) (2)
1-27/32
(47)
9
10
11
6-5/32
(156)
15/16
(24) (2)
3-3/8
(86)
1-3/4
(45)
7-3/16 (183)
2-11/32 (60)
5/8 (16) (4)
L1
L2
12
13
7/8 (22) DIAMETER
KNOCKOUT (2)
18
17
16
15
14F
3-3/8 (86)
7 -1/16 (179)
3/8 (10) (4)
6
7
8
G
1
202050C COVER
202050C COVER
LOCKOUT SWITCH
RESET BUTTON
7-3/16 (183)
47/64
(19)
35/64
(14)
1-51/64
(46)
5-5/8
(143)
2-5/64
5-7/8
(149)
(53)
6-1/2
(165)
6
(152)
2-11/32 (60)
1-3/4
(45)
3/4
(19)
1-13/32 (36) 1-13/32 (36)
7/8 (22) DIAMETER KNOCKOUT (4)
1 OPEN ON 3-SIDED Q520A1089.
Fig. 1. Mounting dimensions of the Q520A
wiring subbase in in. (mm).
31/32
(25)
M6776
(ON Q520A1089 3-SIDED WIRING SUBBASE)
M6777
Fig. 2. Mounting dimensions of the R4140 Programmer
on the Q520A wiring subbase in in. (mm).
60-2337—3
4
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Accessories:
W136A Test Meter (includes 117053 Meter Connector
Plug); has SPL position with damping for testing self-
checking flame detection systems.
117053 Meter Connector Plug (for older W136A models).
123514A Flame Simulator (for use with R7247A
Rectification Amplifiers).
123514B Flame Simulator (for use with R7249A Ultraviolet
Amplifiers).
139695C (Series 1 and 2) Cover with reset button; heavy
duty, metal cover for outside panel mounting.
202050C (Series 3) Cover with reset button; heavy duty,
metal cover for outside panel mounting.
118760B (Series 1 and 2) Remote Reset Cover; heavy
duty, metal cover with remote reset assembly; 120V,
60 Hz solenoid.
202051B (Series 3) Remote Reset Cover; heavy duty,
metal cover with remote reset assembly; 120V, 60 Hz
solenoid.
R1061012 Ignition Cable; for ignition installations in a high
temperature environment; rated at 350°F (177°C) for
R1298020 Cable; for flame detector (F lead-wire)
installations in a high temperature environment; rated
up to 400°F (204°C) for continuous duty; tested for
operation up to 600V and breakdown up to 7500V.
R1239001 High Tension Ignition Cable; for ignition
installations in a contaminating environment; very
resistant to severe conditions of oil, heat, and corona,
and tested to withstand high voltages up to
25,000V rms in a salt bath for one minute without
breakdown; rated at 200°F (93°C) for continuous duty,
and up to 350°F (197°C) for intermittent use.
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. For use only
with gas pilots.
FSP5004 Tester; provides a quick operational check of
most R4140 Flame Safeguard Programming Controls.
Q520E1002 Service Tool; allows any of the programmer
terminals to be monitored while the programmer is
operating.
continuous duty, and up to 500°F (260°C) for
intermittent use; tested to 25,000V.
Table 4. Flame Detection Systems
NOTE: Neither the R414G1114 or the R4140G1122 can be used with the C7012E or F Purple Peeper Ultraviolet Flame
Detector and with the R7247C Dynamic Self-Check Amplifier.
Plug-In Flame Signal Amplifiers Applicable Flame Detectors
Type Color
Checking Model
Rectification Green No R7247A 2 to 4 sec Gas Rectifying
Self-
Flame Failure
Response Time Fuel Type Models
Holdersa: C7004, C7007, C7011.
Flame Rods
Complete assemblies: C7005,
C7008, C7009, Q179.
R7247A,
R7247B
Dynamic
R7147B
Self-
Check
R7247C
Infrared Red No R7248A 2 to 4 sec Gas,
Dynamic
R7248B
Ampli-
Check®
Ultraviolet Purple No R7249A 2 to 4 sec Gas,
Blue Dynamic
R7476A
Self-
Check
a
Order flame rod separately; see Instructions for the holder.
b
Circuitry tests the flame signal amplifier at least 150 times a minute during burner operation and shuts down the burner if the
amplifier fails.
c
Use only Honeywell part no. 38316 Photocell.
d
Circuitry tests all electronic components in the flame detection system (amplifier and detector) 60 to 240 times a minute during
2 to 4 sec Oil Rectifying
b
Gas,
Oil,
Coal
b
2 to 4 sec Gas Rectifying
d
2 to 4 sec Gas,
Oil,
Coal
Oil,
Coal
b
2 to 4 sec Gas,
Oil,
Coal
Oil
d
2 to 4 sec Gas,
Oil,
Coal
Photocells
Ultraviolet
(Purple
Peeper)
Flame Rods
Ultraviolet
(Purple
Peeper)
Infrared
(Lead
Sulfide)
Infrared
(Lead
Sulfide)
Ultraviolet
(Minipeeper)
Ultraviolet
(Adjustable
Sensitivity)
C7003, C7010, C7013, C7014.
c
C7012A or C.
Holdersa: C7004, C7007, C7011.
Complete Assemblies: C7005,
C7008, C7009, Q179.
C7012E or F
C7015.
C7015.
C7027, C7035, C7044.
C7076.
burner operation and shuts down the burner if the detection system fails.
5
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
OPERATION
Models with Preignition Interlocks
Fig. 3 shows all contacts in the standby position (zero
seconds). The opening and closing times are shown adjacent
to each timer contact. Refer to Fig. 4 and the Step-by-Step
Operation section.
R4140G1007/G1015 SCHEMATIC
(WITH/WITHOUT HEAVY DUTY COVER)
INTERNAL
O—OPENING TIME
C—CLOSING TIME
LS DENOTES LOCKOUT SWITCH; HTR DENOTES HEATER
L1
1
EXTERNAL
2
3
G
4
F
3 9 13 5 8 12 10
5
6
7
8
9
10
11
12
13
FLAME
DETECTOR
BURNER
LIMITS
CONTROLLER
1K1 1K2
TIP JACK
M7A
C-57.5 O-111
4
PREIGNITION
INTERLOCKS
17
16 3 5
14
15
16
17
18
19
M1B
C-4
O-120
M3A
O-52 C-66
8
LOW FIRE
SWITCH
LS1
NORM
13
TIMER SWITCH
20
21
22
23
M10B O-4 C-45
24
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
1
AS REQUIRED.
2
TERMINAL 17 IS USED ONLY TO DRIVE THE SHUTTER ON A C7012E OR F
OR A C7076A ULTRAVIOLET FLAME DETECTOR WITH SELF-CHECKING
FEATURE. POWER TO DRIVE THE SHUTTER IS APPLIED TO TERMINAL 17
FROM TERMINAL 8 THROUGH A SOLID STATE SWITCH IN THE R7247C
OR R7476A DYNAMIC SELF-CHECK AMPLIFIER. REFER TO SAMPLE BLOCK
DIAGRAM OF FIELD WIRING.
M10A C-4 O-41
M8A C-100 O-112
Fig. 3. Simplified schematic diagram of R4140G1015 Programmer.
120V, 60 HZ
POWER SUPPLY
L1
(HOT)
PLUG-IN AMPLIFIER
7
17
2K
2
M7B
O-9.5 C-116
RUNNING
INTERLOCKS
(INCLUDING
AIRFLOW SWITCH)
TEST
L2
M11B
C-15 O-70
2K3
1K3
M5B
O-104
C-108
M8B O-100 C-116
3
10 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
4
30 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
5
FOR DIRECT SPARK IGNITION (GAS OR OIL,) A JUMPER IS INSTALLED
BETWEEN TERMINALS 6 AND 7. REFER TO SAMPLE BLOCK DIAGRAM
OF FIELD WIRING FOR HOOKUP.
6
USE A SERIES 90 MODULATING MOTOR IF MODULATION IS REQUIRED.
1
MASTER
SWITCH
TO
TERMINAL
8
UNDERLINED O OR C DENOTES SNAP ACTION OF CONTACT.
A TIMER CONTACTS SNAP CLOSED.
B CONTACTS SNAP OPEN.
FLAME SIGNAL
METER JACK
1611
M2B
O-70
C-113.5
2K1
LS2
M4A
C-60
O-85
M2A
C-70
O-109.5
M9A
C-57.5 O-109.5
2K2
M6B
C-50 O-80
TIMER MOTOR
HIGH FIRE
COMMON
MODULATE
LOW FIRE
LS HTR
6
5
7
9
10
11
12
14
1K
10 SECOND
INTERRUPTED
PILOT/IGNITION
30 SECOND
INTERRUPTED
PILOT/IGNITION
MAIN FUEL
VALVES (S)
BURNER MOTOR
(BLOWER)
120 V ALARM
B
R
W
FIRING
RATE
MOTOR
3
4
SERIES 90
CONTROLLER
6
L2
M10149
NUMBERS BELOW
DESIGNATE LINE
LOCATIONS OF
RELAY CONTACTS.
(UNDERLINE
INDICATES A
NORMALLY CLOSED
CONTACT.)
2K - 13, 9, 8
1K - 14, 14, 11
LS - 19, 9
B
R
W
60-2337—3
6
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
TIMER
0 10 20 30 40 50 60 70 80 90 100 110 120
SECONDS
TIMER DIAL
TIMER
MOTOR
BURNER
MOTOR
(BLOWER)
INTERRUPTED
PILOT/IGNITION
MAIN FUEL
VALVE(S)
(GAS OR OIL)
FIRING RATE
MOTOR
SWITCHING
ACTUAL
DAMPER
OPERATION
START
8
5
6
7
1
PREIGNITION INTERLOCKS
PREPURGE
HIGH FIRE POSITION
10 TO 11
2
MOTOR
DRIVES
DAMPER
OPEN
1
MOTOR
DRIVES
DAMPER
CLOSED
RUNNING INTERLOCKS (PROVEN AIRFLOW)
IGN
PILOT
3
STOP
START
10 SECONDS
30 SECONDS
LOW FIRE POSITION
14 TO 11
2
3
MAIN
6
5
STOP
START
MODULATE
12 TO 11
2
4
MOTOR DRIVES
DAMPER CLOSED
RUN
PERIOD
PURGE
5
STOP
LOWLOW
2
TERMINAL NUMBERS (CIRCLED).
1
SLOPE DEPENDS ON MOTOR TIMING.
2
TIMER STOPS AT 52 SECONDS UNTIL LOW FIRE PROVING SWITCH CLOSES.
3
Fig. 4. Timer sequence for R4140G1015 Programmer.
Step-By-Step Operation (R4140G1015)
Start And Prepurge
0 seconds—On a call for heat, the burner controller
contacts close. If the limits and preignition interlocks
are closed and flame relay 2K is not holding in, relay 1K
pulls in through M7B, LS2, 2K2, and the LS HTR
(lockout switch heater—thus proving its continuity).
— 1K1 closes and 1K2 opens, timer motor starts
(through 1K1, M3A, and M5B), power is applied to
terminal 8, starting the burner motor (blower); 1K3
closes.
— Prepurge begins.
4 seconds—M10A closes, M10B opens; firing rate motor
drives toward high fire position (open).
—M1B closes, bypassing 1K1; the timer can complete
its revolution if shutdown occurs.
9.5 seconds—M7B opens; running interlocks must close
(airflow must be proven) or 1K drops out, 1K3 opens,
FIRING RATE MOTOR MODULATES UNDER CONTROL OF SERIES 90
4
CONTROLLER FROM 100 TO 112 SECONDS (INCLUDING RUN
PERIOD WHILE BURNER IS FIRING).
5
TIMER STOPS AT 104 SECONDS FOR THE RUN PERIOD WITH THE
BURNER FIRING.
6
RUNNING INTERLOCKS (INCLUDING THE AIRFLOW SWITCH)
MUST REMAIN CLOSED THROUGH THE RUN PERIOD.
M10054
and ignition trials cannot be started. Running interlocks
must remain closed through the Run period or the
system shuts down; the timer completes its revolution
and recycles the programmer.
15 seconds—M11B closes; flame relay 2K can pull in if a
flame (or a condition simulating a flame) is detected. If
detected during prepurge (until 57.5 seconds), 2K pulls
in, 2K2 opens, 1K drops out, and the system shuts
down; the timer completes its revolution and recycles
the programmer (if 2K dropped out).
45 seconds—M10B closes; firing rate motor drives toward
low fire position (closed).
52 seconds—M3A opens; timer stops until the low fire
proving switch closes; timer can be stopped by opening
the timer switch (until 66 seconds when M3A closes
again).
57.5 seconds—M9A closes; the LS HTR (lockout switch
heater) begins heating in preparation for ignition trials.
— M7A closes, bypassing the preignition interlocks.
7
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Ignition Trials
60 seconds—M4A closes; power is applied to terminals 5
and 6, energizing the ignition transformer and pilot
valve (or main fuel valve(s) on terminal 7 if using direct
spark ignition).
— When a flame is detected, relay 2K pulls in, 2K2
opens, and the LS HTR stops heating; 2K1 and
2K3 close.
66 seconds—M3A closes, bypassing the low fire switch
and the timer switch.
70 seconds—M2B opens; pilot or ignition trial ends; a
flame must be detected by this time (2K pulled in and
2K1 closed) or safety shutdown occurs and the lockout
switch trips.
— M2A closes; power is applied to terminal 7,
energizing the main fuel valve(s).
— M11B opens; prevents 2K from pulling in after this
time.
80 seconds—M6B opens; 10 second interrupted pilot/
ignition (terminal 5) is de-energized.
100 seconds—M4A opens; 30 second interrupted pilot/
ignition (terminal 6) is de-energized.
— M8A closes, M8B opens; firing rate motor is
released to modulate under control of the Series 90
Controller.
104 seconds—M5B opens; timer stops with the system in
the Run condition.
Run Period (Burner is Firing)
Postpurge And Stop
104 seconds—When the operating setpoint is reached, the
burner controller contacts open; relay 1K and the main
fuel valve(s) (terminal 7) de-energize.
— 1K2 closes; timer motor starts; postpurge begins.
— When the flame goes out, relay 2K drops out.
112 seconds—M8A opens; firing rate motor stops
modulating under control of the Series 90 Controller.
116 seconds—M8B closes; firing rate motor drives toward
low fire position (closed).
120 seconds—M1B opens; timer and burner motor stop;
cycle ends.
Fig. 5 shows all contacts in the standby position (zero
seconds). The opening and closing times are shown adjacent
to each timer contact. Refer to Fig. 6 and the Step-by-Step
Operation section.
60-2337—3
8
R4140G1106 SCHEMATIC
INTERNAL
O—OPENING TIME
C—CLOSING TIME
LS DENOTES LOCKOUT SWITCH; HTR DENOTES HEATER
EXTERNAL
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
120V, 60 HZ
POWER SUPPLY
L2
L1
(HOT)
1
MASTER
SWITCH
UNDERLINED O OR C DENOTES SNAP ACTION OF CONTACT.
A TIMER CONTACTS SNAP CLOSED.
B CONTACTS SNAP OPEN.
1
L1
2
3
G
4
F
3 9 13 5 8 12 10
5
6
7
8
9
10
11
12
13
FLAME
DETECTOR
BURNER
LIMITS
CONTROLLER
1K1 1K2
TIP JACK
M7A
C-57.5 O-111
4
PREIGNITION
INTERLOCKS
17
17
2
M7B
O-9.5 C-116
16 3 5
14
15
16
17
18
19
M1B
C-4
O-120
M3A
O-52 C-66
B
LOW FIRE
SWITCH
LS1
NORM
13
TEST
TIMER SWITCH
20
21
22
23
M10B O-4 C-45
24
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
1
AS REQUIRED
2
TERMINAL 17 IS USED ONLY TO DRIVE THE SHUTTER ON A C7012E OR F
PURPLE PEPPER ULTRAVIOLET FLAME DETECTOR WITH SELF-CHECKING
FEATURE. POWER TO DRIVE THE SHUTTER IS APPLIED TO TERMINAL 17
FROM TERMINAL 8 THROUGH A SOLID STATE SWITCH IN THE R7247C
DYNAMIC SELF-CHECK AMPLIFIER. REFER TO SAMPLE BLOCK DIAGRAM
OF FIELD WIRING.
3
FOR DIRECT SPARK IGNITION OR OIL, REFER TO SAMPLE BLOCK DIAGRAM
OF FIELD WIRING FOR HOOKUP OF IGNITION AND MAIN OIL VALVE SOLENOID.
4
SOME AUTHORITIES HAVING JURISDICTION PROHIBIT THE WIRING OF ANY LIMIT
OR OPERATING CONTACTS IN SERIES WITH THE MAIN FUEL VALVE(S).
M10A C-4 O-41
M8A C-100 O-112
PLUG-IN AMPLIFIER
M11B
7
C-15 O-70
2K
2K3
RUNNING
INTERLOCKS
(INCLUDING
AIRFLOW SWITCH)
M5B
O-104
C-108
5
M8B O-100 C-116
1K3
FLAME SIGNAL
METER JACK
LS2
M4A
C-60
O-85
M2A
C-70
O-109.5
M9A
C-57.5 O-109.5
2K2
M6B
C-50 O-80
TIMER MOTOR
HIGH FIRE
COMMON
MODULATE
LOW FIRE
LS HTR
6
7
9
10
11
12
14
1611
TO 8
M2B
O-70
C-113.5
2K1
TIMER SWITCH IS SHOWN IN "NORM" POSITION; IT IS OPEN IN "TEST"
5
POSITION.
6
USE A SERIES 90 MODULATING MOTOR IF MODULATION IS REQUIRED.
7
FOR DIRECT SPARK IGNITION (OIL OR GAS), A JUMPER IS INSTALLED
BETWEEN TERMINALS 6 AND 7. REFER TO SAMPLE BLOCK
DIAGRAM OF FIELD WIRING FOR HOOKUP.
8
10 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
15 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
9
3
7
1K
10 SECOND
INTERRUPTED
PILOT/IGNITION
15 SECOND
INTERRUPTED
PILOT/IGNITION
MAIN FUEL
VALVES (S)
BURNER
MOTOR
ALARM
B
R
W
FIRING
RATE
MOTOR
8
9
4
SERIES 90
CONTROLLER
6
L2
NUMBERS BELOW
DESIGNATE LINE
LOCATIONS
RELAY CONTACTS.
(UNDERLINE
INDICATES A
NORMALLY CLOSED
CONTACT.)
2K - 16, 10, 8
1K - 17, 17, 12
LS - 22, 8
B
R
W
M10044
Fig. 5. Simplified schematic diagram of R4140G1106 Programmer.
9
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
TIMER
0 10 20 30 40 50 60 70 80 90 100 110 120
SECONDS
TIMER DIAL
TIMER
MOTOR
BURNER
MOTOR
(BLOWER)
INTERRUPTED
PILOT/IGNITION
MAIN FUEL
VALVE(S)
(GAS OR OIL)
FIRING RATE
MOTOR
SWITCHING
ACTUAL
DAMPER
OPERATION
START
8
5
6
7
1
PREIGNITION INTERLOCKS
PREPURGE
HIGH FIRE POSITION
10 TO 11
2
MOTOR
DRIVES
DAMPER
OPEN
1
MOTOR
DRIVES
DAMPER
CLOSED
RUNNING INTERLOCKS (PROVEN AIRFLOW)
IGN
PILOT
3
STOP
START
10 SECONDS
15 SECONDS
LOW FIRE POSITION
14 TO 11
2
3
MAIN
6
5
STOP
START
MODULATE
12 TO 11
2
4
MOTOR DRIVES
DAMPER CLOSED
RUN
PERIOD
PURGE
STOP
LOWLOW
2
TERMINAL NUMBERS (CIRCLED).
1
SLOPE DEPENDS ON MOTOR TIMING.
2
TIMER STOPS AT 52 SECONDS UNTIL LOW FIRE PROVING SWITCH CLOSES.
3
Fig. 6. Timer sequence for R4140G1106 Programmer.
Step-By-Step Operation (R4140G1106)
Start and Prepurge
0 seconds—On a call for heat, the burner controller
contacts close. If the limits and preignition interlocks
are closed and flame relay 2K is not holding in, relay 1K
pulls in through M7B, LS2, 2K2, and the LS HTR
(lockout switch heater—thus proving its continuity).
— 1K1 closes and 1K2 opens; timer motor starts
(through 1K1, M3A, and M5B); power is applied to
terminal 8, starting the burner motor (blower); 1K3
closes.
— Prepurge begins.
4 seconds—M10A closes, M10B opens; firing rate motor
drives toward high fire position (open).
— M1B closes, bypassing 1K1; the timer can
complete its revolution if shutdown occurs.
9.5 seconds—M7B opens; running interlocks must be
closed (airflow must be proven) or 1K drops out, 1K3
opens, and ignition trials cannot be started. Running
interlocks must remain closed through the Run period
FIRING RATE MOTOR MODULATES UNDER CONTROL OF SERIES 90
4
CONTROLLER FROM 100 TO 112 SECONDS (INCLUDING RUN
PERIOD WHILE BURNER IS FIRING).
5
TIMER STOPS AT 164 SECONDS FOR THE RUN PERIOD WITH
THE BURNER FIRING.
RUNNING INTERLOCKS (INCLUDING THE AIRFLOW SWITCH)
6
MUST REMAIN CLOSED THROUGH THE RUN PERIOD.
M10052
or the system shuts down; the timer completes its
revolution and recycles the programmer.
15 seconds—M11B closes; flame relay 2K can pull in if a
flame (or a condition simulating a flame) is detected. If
detected during prepurge (until 57.5 seconds), 2K pulls
in, 2K2 opens, 1K drops out, and the system shuts
down; the timer completes its revolution and recycles
the programmer (if 2K dropped out).
45 seconds—M10B closes; firing rate motor drives toward
low fire position (closed).
52 seconds—M3A opens; timer stops until the low fire
proving switch closes; timer can be stopped by opening
the timer switch (until 66 seconds when M3A closes
again).
57.5 seconds—M9A closes; the LS HTR (lockout switch
heater) begins heating in preparation for ignition trials.
— M7A closes, bypassing the preignition interlocks.
60-2337—3
10
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Ignition Trials
60 seconds—M4A closes; power is applied to terminals 5
and 6, energizing the ignition transformer and pilot
valve (or main fuel valve(s) on terminal 7 If using direct
spark ignition).
— When a flame is detected, relay 2K pulls in, 2K2
opens, and the LS HTR stops heating; 2K1 and
2K3 close.
66 seconds—M3A closes, bypassing the low fire switch
and the timer switch.
70 seconds—M2B opens; pilot or ignition trial ends; a
flame must be detected by this time (2K pulled in and
2K1 closed) or safety shutdown occurs and the lockout
switch trips.
— M2A closes; power is applied to terminal 7,
energizing the main fuel valves(s).
— M11B opens; prevents 2K from pulling in after this
time.
80 seconds—M6B opens; 10 second interrupted pilot/
ignition (terminal 5) de-energizes.
85 seconds—M4A opens; 15 second interrupted pilot/
ignition (terminal 6) de-energizes.
100 seconds—M8A closes, M8B opens; firing rate motor is
released to modulate under control of the Series 90
Controller.
104 seconds—M5B opens; timer stops with the system in
the run condition.
Run Period (Burner is Firing)
Postpurge and Stop
104 seconds—When the operating setpoint is reached, the
burner controller contacts open; relay 1K and the main
fuel valve(s) (terminal 7) are de-energized.
— 1K2 closes; timer motor starts; postpurge begins.
— When the flame goes out, relay 2K drops out.
112 seconds—M8A opens; firing rate motor stops
modulating under control of the Series 90 Controller.
116 seconds—M8B closes; firing rate motor drives toward
low fire position (closed).
120 seconds—M1B opens; timer and burner motor stop;
cycle ends.
Models with Start Interlocks
Fig. 7 shows all contacts in the standby position (zero
seconds). The opening and closing times are shown adjacent
to each timer contact. Refer to Fig. 8 and the Step-by-Step
Operation section.
11
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
R4140G1049 SCHEMATIC
(WITH/WITHOUT HEAVY DUTY COVER)
INTERNAL
O—OPENING TIME
C—CLOSING TIME
LS DENOTES LOCKOUT SWITCH; HTR DENOTES HEATER
L1
1
EXTERNAL
2
3
G
4
F
3 9 13 5 8 12 10
5
LIMITS
FLAME
DETECTOR
BURNER
CONTROLLER
TIP JACK
START
3 4
INTERLOCK(S)
16 4
17
6
7
8
9
10
11
12
13
RUNNING INTERLOCKS
(INCLUDING AIRFLOW SWITCH)
3
14
15
16
1K1 1K2
17
18
19
20
21
22
M1B
C-4
O-120
M3A
O-52 C-66
8
LOW FIRE
SWITCH
LS1
13
NORM
TIMER SWITCH
23
24
25
26
M10B O-4 C-45
27
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
1
AS REQUIRED.
2
TERMINAL 17 IS USED ONLY TO DRIVE THE SHUTTER ON A C7012E OR F
OR A C7076A ULTRAVIOLET FLAME DETECTOR WITH SELF-CHECKING
FEATURE. POWER TO DRIVE THE SHUTTER IS APPLIED TO TERMINAL 17
FROM TERMINAL 8 THROUGH A SOLID STATE SWITCH IN THE R7247C
OR R7476A DYNAMIC SELF-CHECK AMPLIFIER. REFER TO SAMPLE BLOCK
DIAGRAM OF FIELD WIRING.
TERMINAL 16, ON THE WIRING SUBBASE ONLY, IS USED AS A TIE POINT.
3
M10A C-4 O-41
M8A C-100 O-112
Fig. 7. Simplified schematic diagram of R4140G1049 Programmer.
120V, 60 HZ
POWER SUPPLY
L1
(HOT)
PLUG-IN AMPLIFIER
7
17
2K
2
M7B
O-9.5 C-116
1K3
TEST
L2
1
M11B
C-15 O-70
2K3
M5B
O-104
C-108
M8B O-100 C-116
IF START INTERLOCK(S) IS NOT USED, A JUMPER IS INSTALLED
4
BETWEEN TERMINALS 16 AND 4 ON THE WIRING SUBBASE.
10 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
5
30 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
6
FOR DIRECT SPARK IGNITION (GAS OR OIL), A JUMPER IS INSTALLED
7
BETWEEN TERMINALS 6 AND 7. REFER TO SAMPLE BLOCK DIAGRAM
OF FIELD WIRING FOR HOOKUP.
USE A SERIES 90 MODULATING MOTOR IF MODULATION IS REQUIRED.
8
MASTER
SWITCH
TO
TERMINAL
8
M2B
O-70
C-113.5
2K1
UNDERLINED O OR C DENOTES SNAP ACTION OF CONTACT.
A TIMER CONTACTS SNAP CLOSED.
B CONTACTS SNAP OPEN.
FLAME SIGNAL
METER JACK
1611
M4A
C-60
O-85
M2A
C-70
O-109.5
M9A
C-57.5 O-111
2K2
M9B
C-30
O-65
M6B
C-50 O-80
TIMER MOTOR
HIGH FIRE
COMMON
MODULATE
LOW FIRE
LS HTR
6
7
7
9
10
11
12
14
18
5
1K
5 SECOND
IGNITION
10 SECOND
INTERRUPTED
PILOT/IGNITION
30 SECOND
INTERRUPTED
PILOT/IGNITION
MAIN FUEL
VALVES (S)
BURNER MOTOR
(BLOWER)
120 V ALARM
B
R
W
FIRING
RATE
MOTOR
5
6
8
L2
NUMBERS BELOW
DESIGNATE LINE
LOCATIONS OF
RELAY CONTACTS.
(UNDERLINE
INDICATES A
NORMALLY CLOSED
CONTACT.)
2K - 16, 10, 8
1K - 17, 17, 12
LS - 22, 8
B
R
W
SERIES 90
CONTROLLER
M10155
60-2337—3
12
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
TIMER
0 10 20 30 40 50 60 70 80 90 100 110 120
SECONDS
TIMER DIAL
TIMER
MOTOR
BURNER
MOTOR
(BLOWER)
5 SECOND
IGNITION
INTERRUPTED
PILOT/IGNITION
MAIN FUEL
VALVE(S)
(GAS OR OIL)
FIRING RATE
MOTOR
SWITCHING
ACTUAL
DAMPER
OPERATION
START
8
18
5
6
7
1
HIGH FIRE POSITION
10 TO 11
2
MOTOR
DRIVES
DAMPER
OPEN
PREPURGE
1
MOTOR
DRIVES
DAMPER
CLOSED
RUNNING INTERLOCKS (PROVEN AIRFLOW)
IGN
PILOT
3
STOP
START
10 SECONDS
30 SECONDS
LOW FIRE POSITION
14 TO 11
2
3
MAIN
6
5
STOP
START
MODULATE
12 TO 11
2
4
MOTOR DRIVES
DAMPER CLOSED
RUN
PERIOD
PURGE
5
STOP
LOWLOW
2
TERMINAL NUMBERS (CIRCLED).
1
SLOPE DEPENDS ON MOTOR TIMING.
2
TIMER STOPS AT 52 SECONDS UNTIL LOW FIRE PROVING SWITCH CLOSES.
3
Fig. 8. Timer sequence for R4140G1049 Programmer.
Step-By-Step Operation (R4140G1049)
Start and Prepurge
0 seconds—On a call for heat, the burner controller
contacts close. If the limits and start interlock(s) are
closed and flame relay 2K is not holding in, relay 1K
pulls in through M7B, 2K2, the LS HTR (lockout switch
heater—thus proving its continuity), and LS2.
— 1K1 closes and 1K2 opens; timer motor starts
(through 1K1, M3A, and M5B); power is applied to
terminal 8, starting the burner motor (blower); 1K3
closes.
— Prepurge begins.
4 seconds—M10A closes, M10B opens; firing rate motor
drives toward high fire position (open).
— M1B closes, bypassing 1K1; the timer can
complete its revolution if shutdown occurs.
9.5 seconds—M7B opens; running interlocks must be
closed (airflow must be proven) or 1K drops out, 1K3
opens, and ignition trials cannot be started. Running
FIRING RATE MOTOR MODULATES UNDER CONTROL OF SERIES 90
4
CONTROLLER FROM 100 TO 112 SECONDS (INCLUDING RUN
PERIOD WHILE BURNER IS FIRING).
5
TIMER STOPS AT 104 SECONDS FOR THE RUN PERIOD WITH THE
BURNER FIRING.
6
RUNNING INTERLOCKS (INCLUDING THE AIRFLOW SWITCH)
MUST REMAIN CLOSED THROUGH THE RUN PERIOD.
M10055
interlocks must remain closed through the Run period
or the system shuts down; the timer completes its
revolution and recycles the programmer.
15 seconds—M11B closes; flame relay 2K pulls in if a
flame (or a condition simulating a flame) is detected. If
detected during prepurge (until 57.5 seconds), 2K pulls
in, 2K2 opens, 1K drops out, and the system shuts
down; the timer completes its revolution and recycles
the programmer (if 2K dropped out).
45 seconds—M10B closes; firing rate motor drives toward
low fire position (closed).
52 seconds—M3A opens; timer stops until the low fire
proving switch closes; timer can be stopped by opening
the timer switch (until 66 seconds when M3A closes
again).
57.5 seconds—M7A closes; the LS HTR (lockout switch
heater) begins heating in preparation for ignition trials.
13
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Ignition Trials
60 seconds—M4A closes; power is applied to terminals
18, 5, and 6, energizing the ignition transformer and
pilot valve (or main fuel valve(s) on terminal 7 if using
direct spark ignition).
— When a flame is detected, relay 2K pulls in, 2K2
opens, and the LS HTR stops heating; 2K1 and
2K3 close.
65 seconds—M9B opens; 5 second ignition (terminal 18)
is de-energizes (pilot only until 70 seconds).
66 seconds—M3A closes, bypassing the low fire switch
and the timer switch.
70 seconds—M2B opens; pilot or ignition trial ends; a
flame must be detected by this time (2K pulled in and
2K1 closed) or safety shutdown occurs and the lockout
switch trips.
— M2A closes; power is applied to terminal 7,
energizing the main fuel valve(s).
— M11B opens; prevents 2K from pulling in after this
time.
80 seconds—M6B opens; 10 second interrupted pilot/
ignition (terminal 5) de-energizes.
100 seconds—M4A opens; 30 second interrupted pilot/
ignition (terminal 6) de-energizes.
— M8A closes, M8B opens; firing rate motor is
released to modulate under control of the
Series 90 Controller.
104 seconds—M5B opens; timer stops with the system in
the run condition.
Run Period (Burner is Firing)
Postpurge and Stop
104 seconds—When the operating setpoint is reached, the
burner controller contacts open; relay 1K and the main
fuel valve(s) (terminal 7) de-energize.
— 1K2 closes; timer motor starts; postpurge begins.
— When the flame goes out, relay 2K drops out.
112 seconds—M8A opens; firing rate motor stops
modulating under control of the Series 90 Controller.
116 seconds—M8B closes; firing rate motor drives toward
low fire position (closed).
120 seconds—M1B opens; timer and burner motor stop;
cycle ends.
Fig. 9 shows all contacts in the standby position (zero
seconds). The opening and closing times are shown adjacent
to each timer contact. Refer to Fig. 10 and the Step-by-Step
Operation section.
60-2337—3
14
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
R4140G1056/G1064 SCHEMATIC
(WITH/WITHOUT HEAVY DUTY COVER)
INTERNAL
O—OPENING TIME
C—CLOSING TIME
LS DENOTES LOCKOUT SWITCH; HTR DENOTES HEATER
L1
1
EXTERNAL
2
3
G
4
F
3 9 13 5 8 12 10
5
LIMITS
FLAME
DETECTOR
BURNER
CONTROLLER
TIP JACK
START
3 4
INTERLOCK(S)
16 4
17
6
7
8
9
10
11
12
13
RUNNING INTERLOCKS
(INCLUDING AIRFLOW SWITCH)
3
14
15
16
1K1 1K2
17
18
19
20
21
22
M1B
C-4
O-120
M3A
O-52 C-66
8
LOW FIRE
SWITCH
LS1
13
NORM
TIMER SWITCH
23
24
25
26
M10B O-4 C-45
27
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
1
AS REQUIRED.
2
TERMINAL 17 IS USED ONLY TO DRIVE THE SHUTTER ON A C7012E OR F
OR A C7076A ULTRAVIOLET FLAME DETECTOR WITH SELF-CHECKING
FEATURE. POWER TO DRIVE THE SHUTTER IS APPLIED TO TERMINAL 17
FROM TERMINAL 8 THROUGH A SOLID STATE SWITCH IN THE R7247C
OR R7476A DYNAMIC SELF-CHECK AMPLIFIER. REFER TO SAMPLE BLOCK
DIAGRAM OF FIELD WIRING.
TERMINAL 16, ON THE WIRING SUBBASE ONLY, IS USED AS A TIE POINT.
3
M10A C-4 O-41
M8A C-100 O-112
Fig. 9. Simplified schematic diagram of the R4140G1056 and R4140G1064 Programmers.
120V, 60 HZ
POWER SUPPLY
L1
(HOT)
PLUG-IN AMPLIFIER
7
17
2K
2
M7B
O-9.5 C-116
1K3
TEST
L2
1
M11B
C-15 O-70
2K3
M5B
O-104
C-108
M8B O-100 C-116
4
5
6
7
UNDERLINED O OR C DENOTES SNAP ACTION OF CONTACT.
A TIMER CONTACTS SNAP CLOSED.
MASTER
SWITCH
IF START INTERLOCK(S) IS NOT USED, A JUMPER IS INSTALLED
BETWEEN TERMINALS 16 AND 4 ON THE WIRING SUBBASE.
10 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
FOR DIRECT SPARK IGNITION (GAS OR OIL), REFER TO SAMPLE
BLOCK DIAGRAM OF FIELD WIRING FOR HOOKUP.
USE A SERIES 90 MODULATING MOTOR IF MODULATION IS REQUIRED.
B CONTACTS SNAP OPEN.
1611
TO
TERMINAL
8
M2B
O-70
C-113.5
M4A
C-60
2K1
O-110
FLAME SIGNAL
METER JACK
M7A
C-57.5 O-111
2K2
M6B
C-50 O-80
M2A
C-70
O-109.5
TIMER MOTOR
HIGH FIRE
COMMON
MODULATE
LOW FIRE
M9B
C-30
O-65
LS HTR
6
7
9
10
11
12
14
18
5
6
1K
LS2
5 SECOND
IGNITION
B
R
W
FIRING
RATE
MOTOR
5
10 SECOND
INTERRUPTED
PILOT/IGNITION
INTERMITTENT
PILOT/IGNITION
MAIN FUEL
VALVES (S)
BURNER MOTOR
(BLOWER)
120V ALARM
L2
SERIES 90
CONTROLLER
7
NUMBERS BELOW
DESIGNATE LINE
LOCATIONS OF
RELAY CONTACTS.
(UNDERLINE
INDICATES A
NORMALLY CLOSED
CONTACT.)
2K - 16, 10, 8
1K - 17, 17, 12
LS - 22, 8
B
R
W
M10156
15
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
TIMER
SECONDS
0 10 20 30 40 50 60 70 80 90 100 110 120
TIMER DIAL
TIMER
MOTOR
BURNER
MOTOR
(BLOWER)
5 SECOND
IGNITION
10 SECOND
INTERRUPTED
PILOT/IGNITION
INTERMITTENT PILOT
OR 1ST STAGE
FUEL VALVE
MAIN FUEL
VALVE(S)
(GAS OR OIL)
FIRING RATE
MOTOR
SWITCHING
ACTUAL
DAMPER
OPERATION
START
8
18
5
6
7
1
HIGH FIRE POSITION
10 TO 11
2
MOTOR
DRIVES
DAMPER
OPEN
PREPURGE
1
MOTOR
DRIVES
DAMPER
CLOSED
RUNNING INTERLOCKS (PROVEN AIRFLOW)
IGN
PILOT
3
STOP
START
LOW FIRE POSITION
14 TO 11
2
3
MAIN
6
5
STOP
START
MODULATE
12 TO 11
2
4
MOTOR DRIVES
DAMPER CLOSED
RUN
PERIOD
PURGE
5
STOP
LOWLOW
2
TERMINAL NUMBERS (CIRCLED).
1
SLOPE DEPENDS ON MOTOR TIMING.
2
TIMER STOPS AT 52 SECONDS UNTIL LOW FIRE PROVING SWITCH CLOSES.
3
Fig. 10. Timer sequence for R4140G1056 and R4140G1064 Programmers.
Step-By-Step Operation
(R4140G1056 and R4140G1064)
Start and Prepurge
0 seconds—On a call for heat, the burner controller
contacts close. If the limits and start interlock(s) are
closed and flame relay 2K is not holding in, relay 1K
pulls in through M7B, 2K2, the LS HTR (lockout switch
heater—thus proving its continuity), and LS2.
— 1K1 closes and 1K2 opens; timer motor starts
(through 1K1, M3A, and M5B); power is applied to
terminal 8, starting the burner motor (blower); 1K3
closes.
— Prepurge begins.
4 seconds—M10A closes, M10B opens; firing rate motor
drives toward high fire position (open).
— M1B closes, bypassing 1K1; the timer can
9.5 seconds—M7B opens; running interlocks must be
complete its revolution if shutdown occurs.
closed (airflow must be proven) or 1K drops out, 1K3
FIRING RATE MOTOR MODULATES UNDER CONTROL OF SERIES 90
4
CONTROLLER FROM 100 TO 112 SECONDS (INCLUDING RUN
PERIOD WHILE BURNER IS FIRING).
5
TIMER STOPS AT 104 SECONDS FOR THE RUN PERIOD WITH THE
BURNER FIRING.
6
RUNNING INTERLOCKS (INCLUDING THE AIRFLOW SWITCH)
MUST REMAIN CLOSED THROUGH THE RUN PERIOD.
M10056
opens, and ignition trials cannot be started. Running
interlocks must remain closed through the Run period
or the system shuts down; the timer completes its
revolution and recycles the programmer.
15 seconds—M11B closes; flame relay 2K can pull in if a
flame (or a condition simulating a flame) is detected If
detected during prepurge (until 57.5 seconds), 2K pulls
in, 2K2 opens, 1K drops out, and the system shuts
down; the timer completes its revolution and recycles
the programmer (if 2K dropped out).
45 seconds—M10B closes; firing rate motor drives toward
low fire position (closed).
52 seconds—M3A opens; timer stops until the low fire
proving switch closes; timer can be stopped by opening
the timer switch (until 66 seconds when M3A closes
again).
57.5 seconds—M7A closes; the LS HTR (lockout switch
heater) begins heating in preparation for ignition trials.
60-2337—3
16
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Ignition Trials
60 seconds—M4A closes; power is applied to terminals
18, 5, and 6, energizing the ignition transformer and
pilot valve (or first stage fuel valve when using direct
spark ignition).
— When a flame is detected, relay 2K pulls in, 2K2
opens, and the LS HTR stops heating; 2K1 and
2K3 close.
65 seconds—M9B opens; 5 second ignition (terminal 18)
de-energizes (pilot only until 70 seconds).
66 seconds—M3A closes, bypassing the low fire switch
and the timer switch.
70 seconds—M2B opens; pilot or ignition trial ends; a
flame must be detected by this time (2K pulled in and
2K1 closed) or safety shutdown occurs and the lockout
switch trips.
— M2A closes; power is applied to terminal 7,
energizing the main fuel valve(s).
— M11B opens; prevents 2K from pulling in after this
time.
80 seconds—M6B opens; 10 second interrupted pilot/
ignition (terminal 5) de-energizes.
100 seconds—M8A closes, M8B opens; firing rate motor is
released to modulate under control of the Series 90
Controller.
104 seconds—M5B opens; timer stops with the system in
the run condition.
Run Period (Burner is Firing)
Postpurge and Stop
104 seconds—When the operating setpoint is reached, the
burner controller contacts open; relay 1K, intermittent
pilot or first stage fuel valve (terminal 6), and the main
fuel valve(s) (terminal 7) de-energize.
— 1K2 closes; timer motor starts; postpurge begins.
— When the flame goes out, relay 2K drops out.
112 seconds—M8A opens; firing rate motor stops
modulating under control of the Series 90 Controller.
116 seconds—M8B closes; firing rate motor drives toward
low fire position (closed).
120 seconds—M1B opens; timer and burner motor stop;
cycle ends.
Fig. 11 shows all contacts in the standby position (zero
seconds). The opening and closing times are shown adjacent
to each timer contact. Refer to Fig. 12 and the Step-by-Step
Operation section.
17
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
120V, 60 HZ
POWER SUPPLY
L2
L1
INTERNAL
O—OPENING TIME
C—CLOSING TIME
LS DENOTES LOCKOUT SWITCH; HTR DENOTES HEATER
EXTERNAL
(HOT)
1
MASTER
SWITCH
UNDERLINED O OR C DENOTES SNAP ACTION OF CONTACT.
A TIMER CONTACTS SNAP CLOSED.
B CONTACTS SNAP OPEN.
L1
1
2
3
G
4
F
3 9 13 5 8 12 10
5
LIMITS
FLAME
DETECTOR
BURNER
CONTROLLER
TIP JACK
START
3 4
INTERLOCK(S)
16 4
17
6
7
8
9
10
11
12
13
RUNNING INTERLOCKS
(INCLUDING AIRFLOW SWITCH)
3
14
15
16
1K1 1K2
17
18
19
20
21
22
M1B
C-6
O-180
M3A
O-60 C-76
8
LOW FIRE
SWITCH
LS1
NORM
13
TIMER SWITCH
23
24
25
26
M10B O-5 C-40
27
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
1
AS REQUIRED.
2
TERMINAL 17 IS USED ONLY TO DRIVE THE SHUTTER ON A C7012E OR
F OR A C7076A ULTRAVIOLET FLAME DETECTOR WITH SELF-CHECKING
FEATURE. POWER TO DRIVE THE SHUTTER IS APPLIED TO TERMINAL 17
FROM TERMINAL 8 THROUGH A SOLID STATE SWITCH IN THE R7247C
OR R7476A DYNAMIC SELF-CHECK AMPLIFIER. REFER TO SAMPLE
BLOCK DIAGRAM OF FIELD WIRING.
TERMINAL 16, ON THE WIRING SUBBASE ONLY, IS USED AS A TIE POINT.
3
IF START INTERLOCK(S) IS NOT USED, A JUMPER IS INSTALLED
4
BETWEEN TERMINALS 16 AND 4 ON THE WIRING SUBBASE.
M10A C-5 O-34
M8A C-148 O-168
PLUG-IN AMPLIFIER
7
17
2K
2
M7B
O-13.5 C-174
1K3
TEST
8
FLAME SIGNAL
METER JACK
M11B
C-15 O-70
2K3
M5B
O-155
C-164
M8B O-148 C-174
A JUMPER IS INSTALLED ON THE BACK OF THE PROGRAMMER TO OBTAIN 60
5
SECOND INTERRUPTED PILOT/IGNITION AT TERMINAL 6; WITHOUT JUMPER,
IT IS 30 SECONDS.
FOR DIRECT SPARK IGNITION OF OIL, A JUMPER IS INSTALLED BETWEEN
6
TERMINALS 6 AND 7. REFER TO SAMPLE BLOCK DIAGRAM OF FIELD WIRING FOR
HOOKUP OF IGNITION AND MAIN OIL VALVE SOLENOID.
7
SOME AUTHORITIES HAVING JURISDICTION PROHIBIT THE WIRING OF ANY LIMIT OR
OPERATING CONTACTS IN SERIES WITH THE MAIN FUEL VALVE(S).
8
TIMER SWITCH IS SHOWN IN NORM POSITION; IT IS OPEN IN TEST POSITION.
9
USE A SERIES 90 MODULATING MOTOR.
1611
TO
TERMINAL
8
M2B
O-80
C-169
2K1
M2A C-80
O-163
M4A
C-70
O-110
M7A
C-67 O-168
2K2
M6B
C-60 O-90
5
TIMER MOTOR
HIGH FIRE
COMMON
MODULATE
LOW FIRE
LS HTR
M9B
C-40 O-75
M12B
C-90
O-140
9
10
11
12
14
18
10 SECOND
INTERRUPTED
5
PILOT/IGNITION
30 OR 60 SECOND
INTERRUPTED
6
PILOT/IGNITION
6
MAIN FUEL
7
VALVES (S)
BURNER MOTOR
(BLOWER)
120V ALARM
1K
LS2
5 SECOND
IGNITION
B
R
W
FIRING
RATE
MOTOR
L2
5
7
SERIES 90
CONTROLLER
9
NUMBERS BELOW
DESIGNATE LINE
LOCATIONS OF
RELAY CONTACTS.
(UNDERLINE
INDICATES A
NORMALLY CLOSED
CONTACT.)
2K - 8, 10, 16
1K - 12, 17, 17
LS - 8, 22,
B
R
W
M10158
60-2337—3
Fig. 11. Simplified schematic diagram of R4140G1171, R4140G122 and R4140G1114 Programmers.
18
TIMER
SECONDS
TIMER DIAL
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
6
RUNNING INTERLOCKS (PROVEN AIRFLOW)
IGN
PILOT
MAIN
PURGEPREPURGE
TIMER MOTOR
BURNER
MOTOR
(BLOWER)
5 SECOND
INGITION
INTERRUPTED
PILOT/INGITION
MAIN FUEL
VALVE(S)
(GAS OR OIL)
ACTUAL
DAMPER
OPERATION
3
3
START
8
1
18
5
6
6
7
HIGH FIRE POSITION
10 TO 11
LOW
MOTOR
DRIVES
DAMPER
OPEN
TERMINAL NUMBERS (CIRCLED).
1
SLOPE DEPENDS ON MOTOR TIMING.
2
TIMER STOPS AT 60 SECONDS UNTIL LOW FIRE PROVING
3
SWITCH CLOSES.
1
2
2
MOTOR
DRIVES
DAMPER
CLOSED
30 SECONDS (WITHOUT JUMPER)
3
STOP
START
10 SECONDS
60 SECONDS (WITH JUMPER)
LOW FIRE POSITION
14 TO 11
FIRING RATE MOTOR MODULATES UNDER CONTROL OF SERIES 90
4
CONTROLLER FROM 148 TO 168 SECONDS (INCLUDING RUN
PERIOD WHILE BURNER IS FIRING).
5
TIMER STOPS FOR THE RUN PERIOD WITH THE BURNER FIRING.
RUNNING INTERLOCKS (INCLUDING THE AIRFLOW SWITCH)
6
MUST REMAIN CLOSED THROUGH THE RUN PERIOD.
Fig. 12. Timer sequence for R4140G1171, R4140G1122 and R4140G1114 Programmers.
5
STOP
START
MODULATE
12 TO 11
2
4
MOTOR DRIVES
DAMPER CLOSED
STOP
LOW
2
M10057
Step-By-Step Operation
(R4140G1171, R4140G1122 and R4140G1114)
Start and Prepurge
0 seconds—On a call for heat, the burner controller contacts
close. If the limits and start interlock(s) are closed, relay
1K pulls in through M7B, 2K2, the LS HTR (lockout
switch heater—thus proving its continuity), and LS2.
— 1K1 closes and 1K2 opens; timer starts (through
M3A and M5B); power is applied to terminal 8,
starting the burner motor (blower); 1K3 closes.
— Prepurge begins.
5 seconds—M10A closes, M10B opens; firing rate motor
drives toward high fire position (open).
6 seconds—M1B closes, bypassing 1K1; the timer
completes its revolution if shutdown occurs.
10 seconds—M11B closes; flame relay 2K can pull in if a
flame (or a condition simulating a flame) is detected. If
detected during prepurge (until 67 seconds), 2K pulls
in, 2K2 opens, 1K drops out, and the system shuts
down; the timer completes its revolution and recycles
the programmer.
13.5 seconds—M7B opens; running interlocks must be
closed (airflow must be proven) or 1K drops out, 1K3
opens, and ignition trials cannot be started. Running
interlocks must remain closed through the Run period
or the system shuts down; the timer completes its
revolution and recycles the programmer.
40 seconds—M10B closes; firing rate motor drives toward
low fire position (closed).
60 seconds—M3A opens; timer stops until the low fire
proving switch closes; timer can be stopped by opening
the timer switch (until 76 seconds when M3A closes
again).
67 seconds—M7A closes; the LS HTR (lockout switch
heater) begins heating in preparation for ignition trials.
19
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Ignition Trials
70 seconds—M4A closes; power is applied to terminals
18, 5 and 6, energizing the ignition transformer and
pilot valve (and terminal 7, main oil valve solenoid, if
using direct spark ignition of oil).
— When flame is detected, relay 2K pulls in, 2K2
opens, and the LS HTR stops heating; 2K1 and
2K3 close.
75 seconds—M9B opens; 5 second ignition (terminals 18)
de-energizes (pilot only until 80 seconds).
76 seconds—M3A closes, bypassing the low fire switch
and the timer switch.
80 seconds—M2B opens; pilot or ignition trial ends; flame
must be detected by this time (2K pulled in and 2K1
closed) or safety shutdown occurs and the lockout
switch trips.
— M2A closes; power is applied to terminal 7,
energizing the main fuel valve(s).
— M11B opens; prevents 2K from pulling in after this
time.
90 seconds—M6B opens; 10 second interrupted pilot/
ignition (terminal 5) de-energizes.
110 seconds—M4A opens; 30 second interrupted pilot/
ignition (terminal 6) de-energizes if jumper was
installed on back of programmer.
140 seconds—M12B opens; 60 second interrupted pilot/
ignition (terminal 6) de-energizes if jumper was installed
on back of programmer.
not
148 seconds—M8A closes, M8B opens; firing rate motor is
released to modulate under control of the Series 90
Controller.
155 seconds—M5B opens; timer stops with the system in
the Run condition.
Run Period (Burner is Firing)
Postpurge and Stop
155 seconds—When the operating setpoint is reached, the
burner controller contacts open; relay 1K and the main
fuel valve(s) (terminal 7) de-energizes.
— 1K2 closes; timer motor starts; postpurge begins.
— When flame goes out, relay 2K drops out.
168 seconds—M8A opens; firing rate motor stops
modulating under control of the Series 90 Controller.
174 seconds—M8B closes; firing rate motor drives toward
low fire position (closed).
180 seconds—M1B opens; timer and burner motor stop;
cycle ends.
Fig. 13 shows all contacts in the standby position (zero
seconds). The opening and closing times are shown adjacent
to each timer contact. Refer to Fig. 14 and the Step-by-Step
Operation section.
60-2337—3
20
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
R4140G1148 SCHEMATIC
(WITH/WITHOUT HEAVY DUTY COVER)
INTERNAL
O—OPENING TIME
C—CLOSING TIME
LS DENOTES LOCKOUT SWITCH; HTR DENOTES HEATER
L1
1
EXTERNAL
2
3
G
4
F
3 9 13 5 8 12 10
5
LIMITS
FLAME
DETECTOR
BURNER
CONTROLLER
TIP JACK
START
3 4
INTERLOCK(S)
16 4
17
6
7
8
9
10
11
12
13
RUNNING INTERLOCKS
(INCLUDING AIRFLOW SWITCH)
3
14
15
16
1K1 1K2
17
18
19
20
21
22
M1B
C-4
O-120
M3A
O-52 C-66
8
LOW FIRE
SWITCH
LS1
13
NORM
TIMER SWITCH
23
24
25
26
M10B O-4 C-45
27
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
1
AS REQUIRED.
2
TERMINAL 17 IS USED ONLY TO DRIVE THE SHUTTER ON A C7012E OR F
OR A C7076A ULTRAVIOLET FLAME DETECTOR WITH SELF-CHECKING
FEATURE. POWER TO DRIVE THE SHUTTER IS APPLIED TO TERMINAL 17
FROM TERMINAL 8 THROUGH A SOLID STATE SWITCH IN THE R7247C
OR R7476A DYNAMIC SELF-CHECK AMPLIFIER. REFER TO SAMPLE BLOCK
DIAGRAM OF FIELD WIRING.
TERMINAL 16, ON THE WIRING SUBBASE ONLY, IS USED AS A TIE POINT.
3
M10A C-4 O-41
M8A C-100 O-112
120V, 60 HZ
POWER SUPPLY
L1
(HOT)
PLUG-IN AMPLIFIER
7
17
2K
2
M7B
O-9.5 C-116
1K3
TEST
L2
1
M11B
C-15 O-70
2K3
M5B
O-104
C-108
M8B O-100 C-116
4
5
6
7
8
UNDERLINED O OR C DENOTES SNAP ACTION OF CONTACT.
A TIMER CONTACTS SNAP CLOSED.
MASTER
SWITCH
IF START INTERLOCK(S) IS NOT USED, A JUMPER IS INSTALLED
BETWEEN TERMINALS 16 AND 4 ON THE WIRING SUBBASE.
10 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
15 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
FOR DIRECT SPARK IGNITION (GAS OR OIL), A JUMPER IS INSTALLED
BETWEEN TERMINALS 6 AND 7. REFER TO SAMPLE BLOCK DIAGRAM
OF FIELD WIRING FOR HOOKUP.
USE A SERIES 90 MODULATING MOTOR IF MODULATION IS REQUIRED.
B CONTACTS SNAP OPEN.
1611
TO
TERMINAL
8
M2B
O-70
C-113.5
M4A
C-60
2K1
O-85
FLAME SIGNAL
METER JACK
M9A
C-57.5 O-111
2K2
M6B
C-50 O-80
M2A
C-70
O-109.5
TIMER MOTOR
HIGH FIRE
COMMON
MODULATE
LOW FIRE
LS HTR
M9B
C-30 O-65
6
7
7
9
10
11
12
14
18
5
1K
LS2
5 SECOND
IGNITION
B
R
W
FIRING
RATE
MOTOR
5
10 SECOND
INTERRUPTED
PILOT/IGNITION
15 SECOND
INTERRUPTED
PILOT/IGNITION
MAIN FUEL
VALVES (S)
BURNER MOTOR
(BLOWER)
120V ALARM
L2
6
SERIES 90
CONTROLLER
8
NUMBERS BELOW
DESIGNATE LINE
LOCATIONS OF
RELAY CONTACTS.
(UNDERLINE
INDICATES A
NORMALLY CLOSED
CONTACT.)
2K - 16, 10, 8
1K - 17, 17, 12
LS - 22, 8
B
R
W
M10157
Fig. 13. Simplified schematic diagram of R4140G1148 Programmer.
21
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
TIMER
0 10 20 30 40 50 60 70 80 90 100 110 120
SECONDS
TIMER DIAL
TIMER
MOTOR
BURNER
MOTOR
(BLOWER)
5 SECOND
IGNITION
INTERRUPTED
PILOT/IGNITION
MAIN FUEL
VALVE(S)
(GAS OR OIL)
FIRING RATE
MOTOR
SWITCHING
ACTUAL
DAMPER
OPERATION
START
8
18
5
6
7
1
HIGH FIRE POSITION
10 TO 11
2
MOTOR
DRIVES
DAMPER
OPEN
PREPURGE
1
MOTOR
DRIVES
DAMPER
CLOSED
RUNNING INTERLOCKS (PROVEN AIRFLOW)
IGN
PILOT
3
STOP
START
10 SECONDS
15 SECONDS
LOW FIRE POSITION
14 TO 11
2
3
MAIN
6
5
STOP
START
MODULATE
12 TO 11
2
4
MOTOR DRIVES
DAMPER CLOSED
RUN
PERIOD
PURGE
5
STOP
LOWLOW
2
TERMINAL NUMBERS (CIRCLED).
1
SLOPE DEPENDS ON MOTOR TIMING.
2
TIMER STOPS AT 52 SECONDS UNTIL LOW FIRE PROVING
3
SWITCH CLOSES.
Fig. 14. Timer sequence for R4140G1148 Programmer.
Step-By-Step Operation (R4140G1148)
Start and Prepurge
0 seconds—On a call for heat, the burner controller
contacts close. If the limits and start interlock(s) are
closed and flame relay 2K is not holding in, relay 1K
pulls in through M7B, 2K2, the LS HTR (lockout switch
heater—thus proving its continuity), and LS2.
— 1K1 closes and 1K2 opens; timer motor starts
(through 1K1, M3A, and M5B); power is applied to
terminal 8, starting the burner motor (blower); 1K3
closes.
— Prepurge begins.
4 seconds—M10A closes, M10B opens; firing rate motor
drives toward high fire position (open).
— M1B closes, bypassing 1K1; the timer can
complete its revolution if shutdown occurs.
9.5 seconds—M7B opens; running interlocks must be
closed (airflow must be proven) or 1K drops out, 1K3
opens, and ignition trials cannot be started. Running
FIRING RATE MOTOR MODULATES UNDER CONTROL OF SERIES 90
4
CONTROLLER FROM 100 TO 112 SECONDS (INCLUDING RUN
PERIOD WHILE BURNER IS FIRING).
5
TIMER STOPS AT 104 SECONDS FOR THE RUN PERIOD WITH THE
BURNER FIRING.
6
RUNNING INTERLOCKS (INCLUDING THE AIRFLOW SWITCH)
MUST REMAIN CLOSED THROUGH THE RUN PERIOD.
M10058
interlocks must remain closed through the Run period
or the system shuts down; the timer completes its
revolution and recycles the programmer.
15 seconds—M11B closes; flame relay 2K can pull in if a
flame (or a condition simulating a flame) is detected. If
detected during prepurge (until 57.5 seconds), 2K pulls
in, 2K2 opens, 1K drops out, and the system shuts
down; the timer completes its revolution and recycles
the programmer (if 2K drops out).
45 seconds—M10B closes; firing rate motor drives toward
low fire position (closed).
52 seconds—M3A opens; timer stops until the low fire
proving switch closes; timer can be stopped by opening
the timer switch (until 66 seconds when M3A closes
again).
57.5 seconds—M7A closes; the LS HTR (lockout switch
heater) begins heating in preparation for ignition trials.
60-2337—3
22
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Ignition Trials
60 seconds—M4A closes; power is applied to terminals
18, 5 and 6, energizing the ignition transformer and
pilot valve (or main fuel valve(s) on terminal 7 if using
direct spark ignition).
— When a flame is detected, relay 2K pulls in, 2K2
opens, and the LS HTR stops heating; 2K1 and
2K3 close.
65 seconds—M9B opens; 5 second ignition (terminal 18)
de-energizes (pilot only until 70 seconds).
66 seconds—M3A closes, bypassing the low fire switch
and the timer switch.
70 seconds—M2B opens; pilot or ignition trial ends; a
flame must be detected by this time (2K pulled in and
2K1 closed) or safety shutdown occurs and the lockout
switch trips.
— M2A closes; power is applied to terminal 7,
energizing the main fuel valve(s).
— M11B opens; prevents 2K from pulling in after this
time.
80 seconds—M6B opens; 10 second interrupted pilot/
ignition (terminal 5) de-energizes.
85 seconds—M4A opens; 15 second interrupted pilot/
ignition (terminal 6) de-energizes.
100 seconds—M8A closes, M8B opens; firing rate motor is
released to modulate under control of the Series 90
Controller.
104 seconds—M5B opens; timer stops with the system in
the run condition.
Run Period (Burner is Firing)
Postpurge and Stop
104 seconds—When the operating setpoint is reached, the
burner controller contacts open; relay 1K and the main
fuel valve(s) (terminal 7) de-energizes.
— 1K2 closes; timer motor starts; postpurge begins.
— When the flame goes out, relay 2K drops out.
112 seconds—M8A opens; firing rate motor stops
modulating under control of the Series 90 Controller.
116 seconds—M8B closes; firing rate motor drives toward
low fire position (closed).
120 seconds—M1B opens; timer and burner motor stop;
cycle ends.
WIRING (FIG. 15 AND 16)
CAUTION
1. Disconnect power supply before beginning wiring
to prevent electrical shock and equipment
damage.
2. Wiring must comply with all applicable local
electrical codes, ordinances, and regulations.
3. All wiring must be NEC Class 1 (line voltage).
23
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
FOR DIRECT SPARK IGNITION (OIL OR GAS)
WIRING
SUBBASE
TERMINAL
STRIP (4)
SERIES 90
CONTROLLER
120V, 60 HZ
POWER
SUPPLY
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
1
PROTECTION AS REQUIRED.
2
USE ALL NEC CLASS 1 WIRING.
10 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD.
3
30 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD (MBFEP) ON
4
THE R4140G1007 and R4140G1015 MODELS; 15 SECOND MBFEP ON
THE R4140G1106 MODEL.
FOR DIRECT SPARK IGNITION (OIL OR GAS) CONNECT THE IGNITION
5
TRANSFROMER AND FUEL VALVE(S) AS SHOWN IN THE INSET.
6
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.)
2
RUNNING
INTERLOCKS
(INCLUDING
AIRFLOW SWITCH)
3
4
9
10
11
B
R
W
1
PREIGNITION
INTERLOCK(S)
BURNER
CONTROLLER
120V ALARM
HIGH FIRE
COMMON
B
R
W
SERIES 90
FIRING RATE
MOTOR
L1 (HOT)
L2
MODULATE
LOW FIRE
MASTER
SWITCH
LIMITS
IGNITION
TRANSFORMER
TO
L2
MAIN FUEL
VALVE (S)
10 SECOND
INTERRUPTED
PILOT/IGNITION
18
L1
17
L2
12
13
F
C7012 OR C7076 MUST BE RATED FOR 120 V, 60Hz. TWO DETECTORS
7
WITH THE SAME MODEL NUMBER CAN BE WIRED IN PARALLEL TO
THE SAME TERMINALS. C7076A DOES NOT HAVE LEADWIRES. (FOR
INSTRUCTIONS, SEE FORM NUMBERS: 60-2046 FOR C7012A,C MODELS
WITH ELECTRON TUBES; 60-2044 FOR C7012E,F MODELS WITH ELECTRON
TUBES; 60-2398 FOR C7012A,C,E,F SOLID STATE MODELS; 95-8269 FOR
THE C7076A.)
8
WHITE SHUTTER LEADWIRES ARE ONLY ON THE C7012E OR F PURPLE PEEPER
ULTRAVIOLET FLAME DETECTORS WITH SELF-CHECKING FEATURE; C7076A
ADJUSTABLE SENSITIVITY ULTRAVIOLET FLAME DETECTORS DO NOT
HAVE LEADWIRES.
TERMINAL 17 IS USED ONLY FOR THE SHUTTER ON SELF-CHECKING
9
C7012E,F OR C7076A FLAME DETECTORS.
9
16
15
14
BLUE
BLUE
WHITE
WHITE
L2
L1
7
L2
30 (OR 15) SECOND
INTERRUPTED
PILOT/IGNITION
MAIN FUEL
VALVE(S)
BURNER MOTOR
(BLOWER)
LOW FIRE
SWITCH
RECTIFYING FLAME
ROD, RECTIFYING
PHOTOCELL, OR
INFRARED
6
(LEAD SULFIDE)
FLAME DETECTOR
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
C7012A,C,E,F
OR C7076A
ULTRAVIOLET
FLAME DETECTOR
10
BLACK
BLACK
OR
OR
5
JUMPER
6
7
3
4
7
5
5
6
7
8
G
WHITE
YELLOW
M10131
Fig. 15. Sample block diagram of field wiring for R4140G1007, R4140G1015 and R4140G1106 Programmers.
60-2337—3
24
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
FOR DIRECT SPARK IGNITION (OIL OR GAS)
ON MODELS WITH INTERRUPTED
PILOT/IGNITION ON TERMINAL 6
IGNITION
TRANSFORMER
TO
L2
MAIN FUEL
VALVE (S)
WIRING
SUBBASE
TERMINAL
STRIP (4)
SERIES 90
CONTROLLER
120V, 60 HZ
POWER
SUPPLY
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
1
PROTECTION AS REQUIRED.
2
USE ALL NEC CLASS 1 WIRING.
IF START INTERLOCK(S) IS NOT USED, INSTALL A JUMPER
3
BETWEEN TERMINALS 4 AND 16.
4
5 SECOND IGNITION IS AVAILABLE ONLY ON THE R4140G1049,
G1056, G1064, G1114, G1122, G1148, AND G1171 MODELS.
10 SECOND MAIN BURNER FLAME-ESTABLISHING PERIOD. ON R4140G114,
5
G1122, G1171 FOR 60 SECOND INTERRUPTED PILOT IGNITION, INSTALL
JUMPER (IN 4074B2V BAG ASSEMBLY) ON BACK OF PROGRAMMER
BETWEEN SCREW TERMINALS LABELED "JUMPER TO EXTEND MAIN
IGNITION TRIAL."
30 SECOND INTERRUPTED PILOT/IGNITION (30 SECOND MAIN BURNER
6
FLAME-ESTABLISHING PERIOD, MBFEP) ON THE R4140 AND
R4140G1049, G1114, G1122, G1171, 15 SECOND INTERRUPTED PILOT/
IGNITION (15 SECOND MBFEP) ON THE R4140G1148. INTERMITTENT
PILOT/IGNITION ON THE R4140G1056, AND R4140G1064.
FOR DIRECT SPARK IGNITION (OIL OR GAS) CONNECT THE IGNITION
7
TRANSFROMER AND FUEL VALVE(S) AS SHOWN IN THE APPROPRIATE INSET.
2
3
4
9
10
11
B
R
W
1
START
INTERLOCK(S)
BURNER
CONTROLLER
ALARM
HIGH FIRE
COMMON
B
R
W
SERIES 90
FIRING RATE
MOTOR
L1 (HOT)
L2
MODULATE
LOW FIRE
MASTER
SWITCH
3
LIMITS
5
JUMPER
6
7
RUNNING
INTERLOCKS
(INCLUDING
AIRFLOW SWITCH)
FOR DIRECT SPARK IGNITION (OIL OR GAS)
ON MODELS WITH INTERMITTENT
PILOT/IGNITION ON TERMINAL 6.
IGNITION
TRANSFORMER
TO
L2
18
L1
17
L2
12
13
F
8
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.)
9
C7012 OR C7076 MUST BE RATED FOR 120V, 60Hz. TWO DETECTORS
WITH THE SAME MODEL NUMBER CAN BE WIRED IN PARALLEL TO
THE SAME TERMINALS. C7076A DOES NOT HAVE LEADWIRES. (FOR
INSTRUCTIONS SEE FORM NUMBERS; 60-2046 FOR C7012A, C MODELS
WITH ELECTRON TUBES; 60-2044 FOR C7012E,F MODELS WITH ELECTRON
TUBES; 60-2398 FOR C7012A,C,E,F SOLID STATE MODELS; 95-8269 FOR THE
C7076A.) C7012E,F UV FLAME DETECTORS WITH SELF CHECKING FEATURE
CANNOT BE USED WITH THE R4140G1122 OR R4140G1114.
10
WHITE SHUTTER LEADWIRES ARE ONLY ON THE C7012E OR F PURPLE PEEPER
ULTRAVIOLET FLAME DETECTORS WITH SELF-CHECKING FEATURE; C7076A
ADJUSTABLE SENSITIVITY ULTRAVILOET FLAME DETECTOR DO NOT
HAVE LEADWIRES.
11
TERMINAL 17 IS USED ONLY FOR THE SHUTTER ON SELF-CHECKING
C7012E,F OR C7076A FLAME DETECTORS.
12
TERMINAL 16 IS USED ONLY AS A TIE POINT.
11
16
12
15
14
BLUE
BLUE
WHITE
WHITE
L2
L1
9
L2
1ST STAGE
FUEL VALVE
2ND STAGE FUEL
VALVE (OPTIONAL)
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
10 SECOND
INTERRUPTED
PILOT/IGNITION
PILOT/IGNITION
MAIN FUEL
VALVE(S)
BURNER MOTOR
(BLOWER)
LOW FIRE
SWITCH
RECTIFYING FLAME
ROD, RECTIFYING
PHOTOCELL, OR
INFRARED
8
(LEAD SULFIDE)
FLAME DETECTOR
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
C7012A,C,E,F
OR C7076A
ULTRAVIOLET
FLAME DETECTOR
10
BLACK
BLACK
OR
OR
5
6
7
4
5
6
4
9
5
7
6
7
8
G
WHITE
YELLOW
M10059
Fig. 16. Sample block diagram of field wiring for R4140G1049, R4140G1056, R4140G1064,
R4140G1114, R4140G1122, R4140G1148 and R4140G1171 Programmers.
25
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Optional Hookups for Two-Stage Switching or
Intermittent Pilot/Ignition
(Nonmodulating Oil Burners)
If modulation of the firing rate is not required, an R4140G can
be used to provide two-stage switching for an oil burner; also,
an R4140G with interrupted pilot/ignition on terminal 6 can be
wired to provide an intermittent pilot/ignition. Refer to Fig. 17
for the necessary wiring changes and make these changes in
the field wiring to the Q520A Wiring Subbase.
쐃 Remove all wiring from terminals 5,6,7,10,11, 12, and 14.
쐇 Install a jumper wire between terminals 6 and 7.
(If using an R4140G1056 or R4140G1064, this jumper
is not necessary.)
쐋 Install a jumper wire between terminals 7 and 11.
쐏 Connect the ignition transformer between terminals 5
and L2 (for 20 second interrupted ignition), or between
terminals 6 and L2 (for intermittent ignition).
쐄 For two-stage switching:
a. Connect the first stage oil valve solenoid between
terminals 6 and L2.
b. Connect the second stage controller (if used) and
second stage oil valve solenoid in series between
terminals 12 and L2.
쐂 For an intermittent pilot:
a. Connect the intermittent pilot between terminals 6
and L2.
b. Connect the main fuel valve between terminals
12 and L2.
IMPORTANT
The fuel valve or solenoid connected to terminal 12
must not exceed the electrical rating of terminal 7.
R4140G PARTIAL SCHEMATIC
TO M2B, 2K1, AND L1
1
20 SECOND
5
M4A
C-60
O-100
M10B
O-4
C-45
REFER TO SCHEMATIC DIAGRAMS FOR COMPLETE INTERNAL WIRING
1
AND CONTACT SWITCHING.
M4A O-85 ON THE R4140G1106, AND R4140G1148; O-110 ON THE
2
R4140G1056, R4140G1064, R4140G1114, R4140G1122, AND R4140G1171.
JUMPER IS NOT NECESSARY TO OBTAIN INTERMITTENT PILOT/IGNITION
3
ON THE R4140G1056, OR R4140G1064; THESE MODELS PROVIDE
INTERMITTENT PILOT/IGNITION ON TERMINAL 6.
IF A 2ND STAGE CONTROLLER IS USED, THE 2ND STAGE OIL VALVE
4
SOLENOID IS NOT ENERGIZED UNTIL THE 2ND STAGE CONTROLLER
CONTACTS CLOSE.
M6B
C-50
O-80
2
M2A C-70 O-109.5
M8A C-100 O-112
6
7
10
11
12
14
JUMPER
3
JUMPER
2ND STAGE
CONTROLLER
(IF USED)
INTERRUPTED
PILOT/IGNITION
INTERMITTENT
PILOT/IGNITION
OR 1ST STAGE OIL
VALVE SOLENOID
MAIN FUEL VALVE
OR 2ND STAGE OIL
VALVE SOLENOID
(ENERGIZED AT
100 SECONDS)
L2
4
M10060
NOTE: The maximum Pilot or First Stage Flame-
Establishing Period is ten seconds.
For a description of the Ignition Trials for this hookup, refer to
Fig. 18 and the Step-by-Step Operation section.
Fig. 17. Field wiring changes (dashed) to provide
two-stage switching or intermittent pilot/ignition
for a nonmodulating oil burner.
60-2337—3
26
TIMER
0 10 20 30 40 50 60 70 80 90 100 110 120
SECONDS
20 SECOND
INTERRUPTED
PILOT/IGNITION
INTERRUPTED
PILOT/IGNITION
OR 1ST STAGE
OIL VALVE
MAIN FUEL VALVE
OR 2ND STAGE
OIL VALVE
TERMINAL NUMBERS (CIRCLED).
1
TIMER STOPS AT 104 SECONDS FOR THE RUN PERIOD WITH THE
2
BURNER FIRING.
5
1
6
12
Fig. 18. Partial timer sequence for optional hookups of R4140G Programmers.
Step-By-Step Operation
(for Two-Stage Switching or Intermittent Pilot/
Ignition of a Nonmodulating Oil Burner)
Ignition Trials
60 seconds—M4A closes; power is applied to terminals 5
and 6, energizing the ignition transformer and pilot
valve (or first stage oil valve solenoid when using twostage switching).
— When a flame is detected, 2K pulls in, 2K2 opens,
and the LS HTR stops heating; 2K1 and 2K3 close.
70 second—M2B opens; pilot or ignition trial ends; a flame
must be detected by this time (2K pulled in and 2K1
closed) or safety shutdown occurs and the lockout
switch trips.
— M2A closes; power is applied to terminal 7,
maintaining power at terminals 6 and 11 (through
80 seconds—M6B opens: 20 second interrupted pilot/
100 seconds—M8A closes; power is applied to terminal
the jumpers) until the Run period is completed.
ignition (terminal 5) de-energizes.
12, energizing the main fuel valve (or second stage oil
valve solenoid when using two-stage switching).
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
2
RUN
PERIOD
3
3
IF A 2ND STAGE CONTROLLER IS USED, THE 2ND STAGE OIL VALVE
IS ENERGIZED ONLY WHEN THERE IS A DEMAND FOR MORE HEAT
AND THE 2ND STAGE CONTROLLER CONTACTS CLOSE.
M10061
NOTE: If using two-stage switching with a second stage
controller, the second stage oil valve solenoid
energizes only when there is a demand for more
heat and the second stage controller contacts close.
104 seconds—M5B opens; timer stops with the system in
the run condition.
NOTE: Intermittent pilot/ignition and all fuel valves and
solenoids (terminals 6 and 12) de-energize when the
Run period is complete and the main burner
controller contacts open.
For complete installation, checkout, troubleshooting, and
service information, refer to form 60-0770.
27
60-2337—3
R4140G FLAME SAFEGUARD PROGRAMMING CONTROLS
Home and Building Control
Honeywell Internationsl, Inc.
1985 Douglas Drive North
Golden Valley, MN 55422
Home and Building Control
Honeywell Limited-Honeywell Limitée
35 Dynamic Drive
Scarborough, Ontario
M1V 4Z9
Honeywell Asia Pacific Inc.
Room 3213-3225
Sun Hung Kai Centre
No. 30 Harbour Road
Wanchai
Hong Kong
Honeywell Latin American Division
Miami Lakes Headquarters
14505 Commerce Way Suite 500
Honeywell Europe S.A.
3 Avenue du Bourget
B-1140 Brussels Belgium
Miami Lakes FL 33016
Printed in U.S.A. on recycled
paper containing at least 10%
60-2337—3 E.C. Rev. 8-96 www.honeywell.com
60-2337—3
post-consumer paper fibers.
28
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