Honeywell R4140G, R4140M, R4140L Installation Instructions Manual

R4140G,L and M

Flame Safeguard Programming Controls

INSTALLATION INSTRUCTIONS

OPTIONAL
202050C
COVER

TIMER DIAL

HANDLE

TIMER

RELAY
2K

CHASSIS RETAINING
SCREW

RELAY
1K

RESET BUTTON

RELAY/TIMER
COVER

TIP JACK

PLUG-IN
FLAME SIGNAL
AMPLIFIER

FLAME SIGNAL
METER JACK

Fig. 1. Components of R4140G and R4140M Programmers.

RESET BUTTON

TIP JACK

PLUG-IN
FLAME SIGNAL
AMPLIFIER

HANDLE

CHASSIS RETAINING
SCREW

TIMER
MOTOR

RELAY 4K

SAFETY SWITCH
BUTTON

CHASSIS

HINGE
BRACKET (2)

M10053

SAFETY SWITCH
BUTTON

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

RELAY/TIMER
COVER

Fig. 2. Components of R4140L Programmers.

IMPORTANT

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

Copyright © 1996 Honeywell Inc. • All Rights Reserved

FLAME SIGNAL
METER JACK

CHASSIS

HINGE

TIMER

TIMER DIAL

RELAY
2K

RELAY
3K

RELAY 1K

TIMER
MOTOR

BRACKET (2)

M7959

Contents

Installation ........................................................................... 2

Checkout ............................................................................. 11

Troubleshooting .................................................................. 18

Service Information ............................................................. 27

Testing and Maintenance .................................................... 28

60-0770-2

R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS

INSTALLATION

When Installing this Product...

1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous
condition.

2. Check the ratings given in the instructions and on the
product to make sure the product is suitable for your
application.

3. Installer must be a trained, experienced, flame
safeguard control technician.

4. After installation is complete, check out product
operation as provided in these instructions.

CAUTION

1. Disconnect power supply before beginning
installation to prevent electrical shock and
equipment damage.

2. All wiring must be NEC Class 1 (line voltage).

3. Loads connected to the control terminals must
not exceed those listed on the R4140 label or in
the Specifications section of the Specifications for
the R4140G,L or M.

4. Limits and interlocks must be rated to carry and
break current to the ignition transformer, pilot
valve, and main fuel valve(s) simultaneously.

5. All external timers must be listed or component
recognized by authorities having jurisdiction for
the specific purpose for which they are used.

Weather

The R4140 is not designed to be weather tight. If it is installed
outdoors, it must be protected.

Mounting the Wiring Subbase

NOTE: For installation dimensions, see Fig. 1 and 2 in the

Specifications for the R4140G,L or M.

 The subbase can be mounted in any position except

horizontally with the knife-blade contacts pointing down.
The standard vertical position (shown in Fig. 5) is
recommended. Any other position decreases the
maximum ambient temperature rating.

 Select a location on a wall or instrument panel. (The

0520A Subbase can be mounted directly in the
customer’s cabinet.) Be sure to allow clearances for
servicing and for removal of the R4140.

IMPORTANT

Do not mount the wiring subbase horizontally with
the knife-blade contacts pointing down.

 For surface mounting, use the back of the subbase as

a template to mark the four screw locations. Drill the
pilot holes.

 Insert the mounting screws and tighten them securely.

Wiring to Subbase

IMPORTANT

1. For on-off gas-fired systems, some authorities
having jurisdiction prohibit the wiring of any limit or
operating contacts in series between the flame
safeguard control and the main fuel valve(s).

2. Do not connect more than two C7012E,F or C7076A
Ultraviolet Flame Detectors (with self-checking
shutter) in parallel to the same terminals.

Use applicable installation instructions provided by the burner
manufacturer in addition to the corresponding instructions
given here. Before putting the system into service, check out
the installation using the procedures in the Checkout section
and any other procedures stipulated by the burner
manufacturer.

Location

Temperature

Install the R4140 where the surrounding temperatures
remain within the Ambient Operating Temperature Ratings in
the Specifications section of the Specifications for the
R4140G,L or M.

Humidity

Install the R4140 where the relative humidity never reaches
the saturation point. Condensation of moisture on the R4140
can cause enough leakage to short the flame signal to ground
and thus prevent the burner from starting.

Vibration

Do not install the R4140 where it could be subjected to
excessive vibration. Vibration shortens the life of the
electronic components.

CAUTION

Make sure the wiring to terminal 7 does not touch any
other terminal, especially terminal 8.

 All wiring must comply with all applicable electrical

codes, ordinances, and regulations. Use NEC Class 1
(line voltage) wiring.

 For normal installations, use moisture-resistant No. 14

wire suitable for at least 194°F (90°C).

 For high temperature installations, use moisture

resistant No. 14 wire, selected for a temperature rating
above the maximum operating temperature, for all but
the ignition and flame detector F leadwires.

a. For the ignition, use Honeywell specification

no. R1061012 Ignition Cable or equivalent. This
wire is rated at 350°F (177°C) for continuous
duty, and up to 500°F (260°C) for intermittent
use. It has been tested to 25,000 volts.

b. For the flame detector F leadwire, use Honeywell

specification no. R1298020 or equivalent. This
wire is rated up to 400°F (204°C) for continuous
duty. It is tested for operation up to 600 volts and
breakdown up to 7500 volts.

IMPORTANT

Do not run high voltage ignition transformer wires in
the same conduit with the flame detector wiring.

 For ignition installations in a contaminating

environment, use Honeywell specification no. R1239001
High Tension Ignition Cable or equivalent. This wire is
very resistant to severe conditions of oil, heat, and
corona, and is tested to withstand high voltages up to

60-0770—2

2

R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS

25,000V rms in a salt bath for one minute without
breakdown. It is rated at 200°F (93°C) for continuous
duty, and up to 350°F (177°C) for intermittent use.

 Refer to the appropriate wiring diagram in the

Specifications for the R4140G,L or M. Follow the burner
manufacturer’s wiring diagram, if provided.

 Make sure the loads do not exceed the terminal ratings.

Refer to the label on the R4140 or to the Terminal
Ratings in the Specifications section of the
Specifications for the R41406,L or M.

 Check the power supply circuit. The voltage and

frequency must match those of the R4140. Do not
connect the R4140 to a circuit that is subjected to line
voltage variations, such as would occur with on-off
switching of heavy loads. A separate power supply
circuit can be required for the flame safeguard control.
Add required disconnect means and overload
protection.

 Check all wiring circuits and complete the Static

Checkout in Table 2 before installing the R4140.

Installing the Flame Detector

NOTE: Table 1 lists the flame detection systems available

for use with R4140 Programmers. Make sure you
are using the correct combination of amplifier and
flame detector(s).

Proper flame detector installation is the basis of a safe and
reliable flame safeguard installation. Refer to the instructions
packed with the flame detector and the burner manufacturer’s
instructions. Follow the instructions carefully for the best
possible flame detector application.

Keep the flame signal lead wires as short as possible from
the flame detector to the wiring subbase. Capacitance
increases with Ieadwire length, reducing the signal strength.
The maximum permissible leadwire length depends on the
type of flame detector, leadwire, and conduit. The ultimate
limiting factor in flame signal leadwire length is the signal
current. Refer to Table 4 in the Checkout section.

Table 1. Flame Detection Systems.

Plug-In Flame Signal Amplifiers Applicable Flame Detectors

Type Color

Checking Model

Rectification Green No R7247A 2 to 4 second Gas Rectifying

Self-

Flame Failure

Response Time Fuel Type Models

Holdersa C7004. C7007,

Flame Rods

C7011. Complete
Assemblies: C7005,
C7008, C7009, Q179.

Dynamic
Self-Check

R7247A,
R7247B

R7247B

b

b

Oil Rectifying

Photocells

Gas, Oil,
Coal

Ultraviolet
(Purple Peeper

Gas Rectifying

Flame Rods

c

C7003, C7010, C7013,
C7014.

C7012A or C.

Holdersa: C7004, C7007,
C7011. Complete
Assemblies: C7005,
C7008, C7009, Q179.

R7247C

Infrared Red No R7248A 2 to 4 second

Dynamic

R7248B

d

Gas, Oil,
Coal

Ultraviolet
(Purple Peeper

Gas, Oil, Infrared (Lead

b Coal Sulfide)

C7012E or F.

C7015.

Ampli­Check®

Ultraviolet Purple No R7249A 2 to 4 second Gas, Oil Ultraviolet

C7027, C7035, C7044.

(Minipeeper)

Blue Dynamic

Self-Check

R7476A

d

Gas, Oil,
Coal

Ultraviolet
(Adjustable

C7076.

Sensitivity)

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
burner operation and shuts down the burner if the detection system fails.

3

60-0770—2

R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS

Special Considerations for a C7012E or F

The R4140 provides two sources of power for a C7012E or F
Purple Peeper Ultraviolet Flame Detector (with self-checking
shutter). The power to the black leadwires of a C7012E can
be 120V, 208V, 220V, or 240 Vac, depending on the model of
the detector. The C7012F is available only in a 120V model.
This voltage must match the power supply of the R4140.

After checking all wiring circuits, perform this checkout before
installing the programmer on the subbase. These tests
ensure that the Q520A Wiring Subbase is wired correctly, and
that the external controllers, limits, interlocks, actuators,
valves, transformers, motors, and other devices are operating
properly.

Equipment Required

The power to the white leadwires must be 120 Vac; this is the
power supply for the operation of the self-checking shutter.
The 120V for the shutter is applied automatically at terminal
17 of the R4140 through switching action within the plug-in
R7247C Flame Signal Amplifier.

General Instructions

Using Redundant Parallel C7012E or F Detectors

For a flame that is difficult to sight, using two parallel C7012E
or F Flame Detectors reduces nuisance shutdowns. If only
one of the parallel detectors loses the flame signal, the other
continues to indicate the presence of the flame and keeps the
burner running. A flame simulating failure in either detector
causes the burner to shut down. Two C7012E detectors can
be wired in parallel to the same terminals on any R4140 (if
the voltage ratings match). Two C7012F Detectors can be
wired in parallel only on 120V models. To avoid exceeding the
rating of the solid state shutter switch in the R7247C Flame
Signal Amplifier, do not connect more than two C7012E or F
Detectors in parallel.

Static Checkout (See Table 2)

WARNING

1. Use extreme care while performing these tests;
line voltage is present on most subbase terminals
when power is on.

2. Open the master switch before installing or
removing a test jumper.

3. Be sure to remove the test jumper(s) after
completing each test before continuing to the
next test.

4. Replace all external devices not operating
properly. Do not bypass external devices.

5. Close all manual fuel shutoff valves before
starting these tests.

1. Voltmeter (W136A or equivalent) set on 0 to 300 Vac
scale.

2. Jumper wires (2) of No. 14 wire, insulated, 12 in.
(304.8 mm) long, with alligator clips at both ends.

 Perform all applicable tests in Table 2, in the order

listed.

 Make sure all manual fuel shutoff valves are closed.
 Perform only those tests designated for the specific

programmer model being tested.

 Raise the setpoint of the burner controller to simulate a

call for heat.

 For each test, open the master switch and install the

jumper wire(s) between the subbase wiring terminals
listed in the Test Jumpers column.

 Close the master switch before observing operation.
 Read the voltage between the subbase wiring terminals

listed in the Voltmeter column.

 If there is no voltage or if operation is abnormal, check

the circuits and external devices as described in the
last column.

 Check all wiring in the circuits for correct connections,

tight terminal screws, correct wire, and proper wiring
techniques. Replace all worn or incorrectly sized wires.

쐅 Replace faulty controllers, limits, interlocks, actuators,

valves, transformers, motors, and other devices, as
required.

쐈 Normal operation must be obtained for each required

test before continuing the checkout.

쐉 Be sure to remove the test jumper(s) after completing

each test before continuing on to the next test.

Table 2. Static Tests of External Devices.

Test

No.

R4140

Models

Test

Jumpers Voltmeter

Normal

Operation

If Operation is Abnormal,

Check the Items Listed Below

WARNING

Make sure all manual fuel shutoff valves are closed.

1 All models None L1-L2 Line voltage at terminal L1. 1. Master switch is closed.

2. Power is connected to the master switch.

3. OverIoad protection (fuse, circuit breaker
etc.) has not opened the power line.

2 Models with

Preignition
Interlocks

Models with
Start
Interlocks

60-0770—2

None 4-L2 Line voltage at terminal 4. IMPORTANT

Low fuel pressure limits, if used, could be
open. Bypass them with jumpers for the
remaining Static Tests (if required).

None 16-L2 Line voltage at terminal 16. 1. Limits are closed. If open, determine

cause(s) and correct the condition(s).

2. Burner controller contacts are closed (call for
heat).

4

(Continued)

R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS

Table 2. Static Tests of External Devices

Test

No.

3 Models with

4 All models L1-8 3-L2 1. Burner motor (fan or blower)

R4140

Models

Preignition
Interlocks

Models with
Start
Interlocks

Test

Jumpers Voltmeter

None 16-L2 Line voltage at terminal 16. 1. Preignition interlocks are closed. If open,

None 4-L2 Line voltage at terminal 4. 1. Start interlock(s), if used, is closed. If open,

starts.

2. Line voltage at terminal 3
within 12 seconds.

Normal

Operation

(Continued).

If Operation is Abnormal,

Check the Items Listed Below

determine cause(s) and correct the
condition(s).

determine cause(s) and correct the
condition(s).

2. If start interlock(s) is not used, jumper is
installed between terminals 4 and 16.

1. Burner motor circuit:

a. Manual switch of burner motor is closed.
b. Burner motor power supply, overload

protection, and starter are OK.

c. Burner motor is OK.

2. Running or Iockout interlocks (including the
Airflow switch) are closed.

WARNING

Make sure all manual fuel shutoff valves are closed.

5 Models with

5 second
ignition

6 All models L1-5 — 1. Ignition spark (if ignition

7 All models L1-6 — Same as test no. 6 for

L1-18 — Ignition spark (if ignition

transformer is connected to
terminal 18).

transformer is connected to
terminal 5).

2. Automatic pilot valve opens
(if connected to terminal 5).

NOTE: Refer to wiring diagram

of the programmer being
tested.

connections to terminal 6. (If
using direct spark ignition,
check the first stage fuel
valve(s) instead of the pilot
valve.)

1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is OK.

1. Watch for spark or listen for buzz:
a. Ignition electrodes are clean.
b. ignition transformer is OK.

2. Listen for click or feel head of valve for

activation.

a. Actuator (if used) is OK.
b. Pilot valve is OK.

Same as test no. 6. (If using direct spark
ignition, check the first stage fuel valve(s)
instead of the pilot valve.)

WARNING

Make sure all manual shutoff valves are closed.

8 All models L1-7 — Automatic main fuel valve(s)

9 All models L1-9 — Alarm (if used) turns on. 1. Alarm is OK.
10 All R4140L

modeIs

11 All R4140G

modeIs

12 All R4140L

models

L1-8 and
10-11

L18 and
14-11

L1-8 and
14-11

13-L2 Firing rate motor drives open;

13-L2 Firing rate motor drives closed;

15-L2 Firing rate motor drives open;

opens. (If using direct spark
ignition on a model with
intermittent pilot/ignition on
terminal 6, check the optional
second stage fuel valve, if
used.)

zero volts at terminal 13 after
motor starts driving open.

line voltage at terminal 13 after
motor closes.

line voltage at terminal 15 after
motor opens.

1. Listen for and observe operation of the main

fuel valve(s) and actuator(s).

2. Valve(s) and actuator(s) are OK.

1. Low Fire switch is open.

2. Firing rate motor and transformer are OK.

1. Low Fire switch is closed.

2. Firing rate motor and transformer are OK.

1. High Fire switch is closed.

2. Firing rate motor and transformer are OK.

(Continued)

5

60-0770—2

R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS

Test

No.

R4140

Models

13 All R4140L

modeIs

14 All R4140L

models

15 All R4140G

and R4140L
models

16 R4140M

models with
open damper
contacts

17 R4140M

models with
open damper
contacts

Final All models

Table 2. Static Tests of External Devices

Test

Jumpers Voltmeter

L18 and

13-L2 Firing rate motor drives closed;

14-11

line voltage at terminal 13 after

Normal

Operation

motor closes.

L1-15
and
14-11

13-L2 Firing rate motor drives closed;

line voltage at terminal 13 after
motor closes.

12-11 — 1. Raise setpoint of Series 90

Controller—firing rate motor
should drive toward open.

2. Lower setpoint of Series 90
Controller—firing rate motor
should drive toward closed.

L1-10 — If damper control is used,

actuator drives damper open.

L1-8 13-L2 If damper control is used,

spring return drives actuator
and damper closed; line
voltage at terminal 13 after
actuator closes.

CAUTION

After completing these tests, open the master switch and remove all test jumpers from the
subbase terminals. Also remove bypass jumpers from the low fuel pressure limits (if used).

(Continued).

If Operation is Abnormal,

Check the Items Listed Below

1. Low Fire switch is connected between
terminals 8 and 13. If not, proceed to test
no. 14.

2. Low Fire switch is closed.

3. Firing rate motor and transformer are OK.

1. Low Fire switch is connected between
terminals 15 and 13. If not, proceed to test
no. 15.

2. Low Fire switch is closed.

3. Firing rate motor and transformer are OK.

1. Series 90 Controller is OK.

2. Firing rate motor and transformer are OK.

1. Jumper wire is installed between
terminals 11 and 12.

2. Damper actuator is OK.

1. Low Fire switch is closed.

2. Damper actuator is OK.

Installing the Programmer (Fig. 3)

 Open the master switch.
 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.

 Grasp the handle of the programmer chassis and

engage the chassis hinge brackets with the pivot pins
at the bottom of the subbase.

 Swing the chassis inward until the spring connectors

engage the knife-blade contacts. Push in until the
contacts are fully engaged.

 Tighten the chassis retaining screw securely.

Removing the Programmer

 Open the master switch.
 Loosen the chassis retaining screw.
 Pull outward on the handle.
 Disengage the chassis hinge brackets from the

subbase pivot pins.

WIRING
SUBBASE

KNIFE-BLADE
CONTACTS (20)

PIVOT PIN (2)

SPRING
CONNECTORS

HINGE
BRACKET (2)

CHASSIS
RETAINING
SCREW

PROGRAMMER
CHASSIS

M7965

HANDLE

Fig. 3. Mounting the programmer on the subbase.

60-0770—2

6

R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS

Removing and Replacing the Relay/Timer
Cover (Fig. 4)

CAUTION

If the programmer is mounted on the subbase, open
the master switch before removing or replacing the
relay/timer cover.

The relay/timer cover must be removed to install a plug-in
flame signal amplifier, to observe relay and timer operation, or
to inspect the contacts.

Removing the Cover

 Grasp the relay/timer cover and squeeze until the V-notch

on the cover slides free of the stud on the handle.

 Rotate the cover down and out to disengage the two tabs

from the slot in the bottom of the programmer chassis.

 Pull out the cover.

Replacing the Cover

 Insert the two tabs on the bottom of the cover between

the timer and the programmer chassis and engage
them with the slot in the bottom of the chassis. Make
sure the tabs are not jammed in the slot.

 Rotate the cover up and in so the V-notch slides along

the stud on the handle. If the cover does not rotate
easily, the tabs are jammed.

 Make sure the spring clip on the cover fits over the

plug-in amplifier.

 Push in on the cover until the V-notch snaps into place

on the stud.

V-NOTCH
ON COVER

STUD ON
HANDLE

SPRING CLIP
ON COVER

HANDLE

NOTE: If installing a small amplifier, align its ends with

the two scribe marks alongside the receptacle
on the programmer.

 Push in the amplifier until the circuit board is fully

inserted into the receptacle.

 Make sure the amplifier is firmly in place, then replace

the relay/timer cover. Make sure the spring clip on the
cover fits over the amplifier.

NOTE: For further information about a self-checking

amplifier, refer to the Instructions packed
with the amplifier (form 60-2358 for an
R7247B or C, form 60-2357 for an R7248B, or
form 95-8270 for an R7476A).

ALIGNMENT
SCRIBE MARKS
FOR SMALL
AMPLIFIER

KEYED
RECEPTACLE

HONEYWELL
MONOGRAM

HONEYWELL
MONOGRAM

PROGRAMMER
CHASSIS

CIRCUIT
BOARD

AMPLIFIER

AMPLIFIER

TIMER

TIMER DIAL

PLUG IN
AMPLIFIER

TIMER
DIAL

TIMER

RELAY/
TIMER COVER

SLOT IN
CHASSIS

TABS (2)
ON COVER

BOTTOM OF
PROGRAMMER
CHASSIS

M7967

Fig. 4. Removing and replacing the relay/timer cover.

Installing a Plug-in Flame Signal Amplifier
(Fig. 5)

 Remove the relay/timer cover.
 Make sure the Honeywell monogram is on the outside,

then align the circuit board with the keyed receptacle on
the programmer.

KEYED
RECEPTACLE

CIRCUIT
BOARD

PROGRAMMER
CHASSIS

M7961

Fig. 5. Installing a plug-in flame signal amplifier.

Installation Instructions for Special Features

Some TRADELINE® models and international models (rated
for other than 120V, 60 Hz) can have one (or both) of the
following special features.

7

60-0770—2

R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS

Installing Jumper on Back of Programmer (Fig. 6)

Some R4140G, L, and M models have provisions for
extending the main burner flame-establishing period
(MBFEP) at terminal 6 by installing a jumper on the back of
the programmer. If you are installing one of these models,

A system can be upgraded from on-off to modulating by
replacing an R4140M with an R4140G (Fig. 7). A system can
be upgraded to meet Factory Mutual and Industrial Risk
Insurers (formerly FlA) requirements by replacing an R4140M
or an R4140G with an R4140L (Fig. 8).

determine the required MBFEP. If you need the longer period
provided at terminal 6, install the jumper (included in a bag
assembly with the R4140) between the terminals labeled
JUMPER TO EXTEND MAIN IGN. TRIAL on the back of the
programmer. If you do not need the longer period, leave the
jumper off.

NOTE: Some R4140 models for use in Australia have

jumper terminals on the back of the programmer for
safety shutdown alarm options; these jumpers
cannot be used to extend the MBFEP. These R4140
models are shipped with a jumper link between the
N.O. screw terminals on the back of the
programmer. This results in alarm operation on

Requirements

UL On-Off Start and

UL On-Off (with
2-stage firing)

UL modulating
(with low high­low prepurge)

safety shutdown. N.C. screw terminals are provided
for an external auxiliary safety shutdown circuit.
Refer to the R4140 Specifications for these models.

FM/IRl
modulating (with
low-high-low

JUMPER TO

EXTEND MAIN

5

L1

6

7

8

18

L2

17

16

12

IGN. TRIAL

JUMPER

2

3

4

9

10

prepurge and
proven high fire
purge)

FM Factory Mutual requirements.

IRl Industrial Risk Insurers (formerly FlA) requirements.
UL Underwriters Laboratories Inc. requirements.

Table 3. R4140 Applications.

Application

Interlock

Circuits

Firing Rate

Switching

None R4140M

running
Start,

running, and
low fire

Start or

1-wirea (open
damper
contacts)

4-wire R4140G
pre-ignition,
running, and
low fire

Preignition,

4-wire R4140L
lockout, high
fire, and low
fire

a

Firing rate motor must close by itself (spring-return)
when power is removed.

Applicable

R4140

Several
R4140Ms

G

1

AN R4140L IS SHOWN; R4140G AND R4140M PROGRAMMERS HAVE
FEWER SPRING CONNECTORS. TERMINAL NUMBERS ARE NOT ON
THE PROGRAMMER, BUT ARE SHOWN FOR REFERENCE.

2

INSTALL JUMPER (INCLUDED IN BAG ASSEMBLY) TO OBTAIN THE
LONGER MAIN BURNER FLAME-ESTABLISHING PERIOD AVAILABLE
AT TERMINAL 6.

15

13

14

F

1

11

C8346

Fig. 6. Installing jumper to extend main burner flame-

establishing period.

Upgrading Systems

Conveniently, the R4140 family was developed in models of
varying complexity to allow the user to choose the simplest
programmer that meets their application requirements (Table 3).

IMPORTANT

Before replacing an R4140, make sure the
replacement model has the required:
— prepurge time.
— pilot/ignition timing on terminal 6.
— 5-second ignition on terminal 18 (if required).
— interlock circuits.
— safety features.
— electrical ratings.
— temperature ratings.
— approvals.

60-0770—2

8

R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS

REPLACING AN R4140M WITH AN R4140G

TO
L2

WIRING SUBBASE
TERMINAL STRIP (4)

3

2

4

9

10

HIGH FIRE

COMMON

11

FOR DIRECT SPARK IGNITION (OIL OR GAS)

ON MODELS WITH INTERRUPTED

PILOT/IGNITION ON TERMINAL 6

START OR
PREIGNITION
INTERLOCKS

BURNER
CONTROLLER

120V ALARM

DAMPER
CONTROL

IGNITION
TRANSFORMER

MAIN FUEL
VALVE(S)

1

LIMITS

4

4

L1

L2

12

13

5

JUMPER

6

7

RUNNING
INTERLOCKS
(INCL. AIRFLOW
SWITCH)

2

FOR DIRECT SPARK IGNITION (OIL OR GAS)

ON MODELS WITH INTERMITTENT

PILOT/IGNITION ON TERMINAL 6

IGNITION
TRANSFORMER

TO
L2

18

17

16

2

15

1ST STAGE
FUEL VALVE

2ND STAGE
FUEL VALVE
(OPTIONAL)

5 SECOND IGNITION
(EARLY SPARK
TERMINATION)

10 SECOND
INTERRUPTED
PILOT/IGNITION

PILOT/IGNITION

MAIN FUEL
VALVES(S)

BURNER MOTOR
(BLOWER)

LOW FIRE
SWITCH

7

9

6

5

6

7

5

8

6

7

8

G

5

B

R

W

SERIES 90
CONTROLLER

1

120V, 60 HZ
POWER
SUPPLY

1

LEAVE INTERLOCKS CONNECTED BETWEEN TERMINALS 4 AND 16. (IF
INTERLOCKS ARE NOT USED, INSTALL A JUMPER WIRE BETWEEN
TERMINALS 4 AND 16.)

2

IF THE R4140G REPLACEMENT MODEL HAS "START" INTERLOCKS,
CONNECT THE BURNER CONTROLLER TO TERMINAL 16.

3

IF THE R4140G REPLACEMENT MODEL HAS "PREIGNITION" INTERLOCKS,
CONNECT THE BURNER CONTROLLER TO TERMINAL 4.

4

IF REPLACING AN R4140M WITH OPEN DAMPER CONTACTS, REMOVE
DAMPER CONTROL FROM TERMINALS 10 AND L2, AND REMOVE JUMPER
WIRE FROM TERMINALS 11 AND 12.

B

R

W

L1 (HOT)

L2

MODULATE

LOW FIRE

SERIES 90
FIRING RATE
MOTOR

MASTER
SWITCH

F

Fig. 7. Sample block diagram of field wiring for replacing an R4140M with an R4140G.

14

BLUE

BLUE

WHITE

WHITE

L2

L1

L2

5

ADD SERIES 90 CONTROLLER AND SERIES 90 FIRING RATE MOTOR.

5 SECOND IGNITION IS NOT AVAILABLE ON SOME MODELS.

6

REFER TO SPECIFICATIONS OF THE SPECIFIC R4140G MODEL TO

7

DETERMINE THE PILOT/IGNITION TIMING AVAILABLE ON TERMINAL 6.

FOR DIRECT SPARK IGNITION (OIL OR GAS), CONNECT THE

8

IGNITION TRANSFORMER AND FUEL VALVE(S) AS SHOWN IN THE
APPROPRIATE INSET.

9

ADD LOW FIRE SWTICH (IF NOT ALREADY CONNECTED).

RECTIFYING FLAME
ROD, RECTIFYING
PHOTOCELL, OR INFRA­RED (LEAD SULFIDE)
FLAME DETECTOR

C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR

C7012A,C,E,F OR
C7076A ULTRAVIOLET
FLAME DETECTOR

BLACK

BLACK

WHITE

YELLOW

C8347

9

60-0770—2

R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS

REPLACING AN R4140M OR G WITH AN R4140L

FOR DIRECT SPARK IGNITION (OIL OR GAS)

ON MODELS WITH INTERRUPTED

PILOT/IGNITION ON TERMINAL 6

IGNITION
TRANSFORMER

TO

L2

WIRING SUBBASE
TERMINAL STRIP (4)

HIGH FIRE

COMMON

B

R

W

PREIGNITION
INTERLOCKS

BURNER
CONTROLLER

120V ALARM

DAMPER
CONTROL

MODULATE

LOW FIRE

SERIES 90
FIRING RATE
MOTOR

3

4

9

10

11

5

B

R

W

SERIES 90
CONTROLLER

1

120V, 60 HZ
POWER
SUPPLY

1

LEAVE INTERLOCKS CONNECTED BETWEEN TERMINALS 3 AND 16.

LEAVE INTERLOCKS CONNECTED BETWEEN TERMINALS 4 AND 16.

2

IF THERE IS A JUMPER WIRE BETWEEN TERMINALS 14 AND 16, REMOVE
IT AND INSTALL INTERLOCKS.

IF REPLACING MODEL WITH "START" INTERLOCKS, DISCONNECT THE

3

BURNER CONTROLLER FROM TERMINAL 16 AND CONNECT IT TO
TERMINAL 4.

4

IF REPLACING AN R4140M WITH OPEN DAMPER CONTACTS, REMOVE
DAMPER CONTROL FROM TERMINALS 10 AND L2, AND REMOVE
JUMPER WIRE FROM TERMINALS 11 AND 12.

5

IF REPLACING AN R4140M, ADD SERIES 90 CONTROLLER AND SERIES 90
FIRING RATE MOTOR.

L1 (HOT)

L2

4

4

MASTER
SWITCH

MAIN FUEL
VALVE(S)

2

LIMITS

L1

L2

12

13

F

5

JUMPER

6

7

LOCKOUT
INTERLOCKS
(INCL. AIRFLOW
SWITCH)

3

ALTERNATE
LOW FIRE
SWITCH

FOR DIRECT SPARK IGNITION (OIL OR GAS)

ON MODELS WITH INTERMITTENT

PILOT/IGNITION ON TERMINAL 6

IGNITION
TRANSFORMER

TO

L2

1

18

17

16

15

9

14

BLUE

BLUE

WHITE

WHITE

L2

6

5 SECOND IGNITION IS NOT AVAILABLE ON SOME MODELS.

7

REFER TO SPECIFICATIONS OF THE SPECIFIC R4140L MODEL TO
DETERMINE THE PILOT/IGNITION TIMING AVAILABLE ON TERMINAL 6.

8

FOR DIRECT SPARK IGNITION (OIL OR GAS), CONNECT THE
IGNITION TRANSFORMER AND FUEL VALVE(S) AS SHOWN IN THE
APPROPRIATE INSET.

9

ADD LOW FIRE SWITCH (IF NOT ALREADY CONNECTED).

ADD HIGH FIRE SWITCH.

10

BLACK

L1

BLACK

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
VALVES(S)

BURNER MOTOR
(BLOWER)

LOW FIRE
SWITCH

HIGH FIRE
SWITCH

RECTIFYING FLAME
ROD, RECTIFYING
PHOTOCELL, OR INFRA­RED (LEAD SULFIDE)
FLAME DETECTOR

C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR

C7012A,C,E,F OR
C7076A ULTRAVIOLET
FLAME DETECTOR

7

9

10

6

WHITE

YELLOW

5

6

7

5

8

6

7

8

G

C8349

60-0770—2

Fig. 8. Sample block diagram of field wiring for replacing an R4140M or G with an R4140L.

10