Honeywell R7140G, R7140L, R7140M Installation Instructions Manual

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Page 1

R7140G,L,M Burner Control Modules

FEATURES

• Device status available to ModBus™ through S7810M

• Safety features:

• Access for external electrical voltage checks.

• Application flexibility.

• 0.8 or 3.0 second Flame Failure Response Time

• Dependable, long-term operation provided by

APPLICATION

The Honeywell R7140G,L,M Burner Control Modules are microprocessor-based integrated burner controls for automatically fired gas, oil or combination fuel single burner applications. The Burner Control Module system consists of a Relay Module, Q520A Subbase, Amplifier and Purge Card. Options include S7800 Keyboard Display Modules (KDM).

The R7140 Burner Control Modules directly replace many BC7000 PM720G,L,M, and many R4150G,L,M and R4140G,L,M units using the existing Q520A 20-terminal Wiring Subbase.

The R7140 can be demonstrated or tested on the FSP5004 tester. Note that the R7849 UV Amplifier or the R7851 Optical Flame Amplifier cannot be tested.

The R7140G,L,M is programmed to provide a level of safety, functional capability and features beyond the capacity of conventional controls.

Functions provided by the R7140G,L,M include automatic burner sequencing, flame supervision, system status indication, system or self-diagnostics and troubleshooting.

• Five LEDs for sequence information. See Fig. 1.

• Five function Run/Test Switch.

• Interchangeable plug-in flame amplifiers.

• Nonvolatile memory; R7140 retains history files and

• Report generation (optional).

NOTE: Check Service Notes on page 7 and Static Checkout

• Burner controller data (optional):

• Status of configuration jumpers.

• Status of Run/Test Switch.

INSTALLATION INSTRUCTIONS

card or S7800A1001 Series 5 Keyboard Display.

— Interlock check. — Closed loop logic test. — Dynamic AMPLI-CHECK™. — Dynamic input check. — Dynamic safety relay test. — Dynamic self-check logic. — Expanded safe-start check. — High Fire Purge Switch test (R7140L only). — Internal hardware status monitoring. — Low Fire Start Switch test. — Tamper resistant timing and logic.

(FFRT), depending on amplifier selected.

microcomputer technology.

sequencing status after loss of power and can be viewed using the Keyboard Display Module S7800A1001 (sold separately).

on page 25 prior to installation of R7140.

— Lockout/alarm status. — Total cycles of operation. — Total hours of operation.

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R7140G,L,M BURNER CONTROL MODULES

Maximum Total Connected Load: 2000VA.

RUN/TEST SWITCH

Fusing—Total Connected Load: 15A fast blow, type SC or

equivalent.

Environmental Ratings:

Ambient Temperature:

Operating: -40°F to +140°F (-40°C to +60°C).

Storage: -40°F to +150°F (-40°C to +66°C). Humidity: 85% relative humidity, continuous, noncondensing. Vibration: 0.5G environment.

Weight:

With Dust Cover and Q520A Subbase: 4 lb., 5 oz. (1.96 kg).

Dimensions:

See Fig. 2.

Approvals:

Underwriters Laboratories Inc. UL, CUL Component

SEQUENCE STATUS LEDs

RESET PUSHBUTTON

FLAME SIMULATOR INPUT

AMPLIFIER

FLAME CURRENT TEST JACKS

PLUG-IN

PURGE

CARD

DUST

COVER

RELAY

MODULE

FLAME

M7552B

Recognized.

Fig. 1. Burner Control Module and sequence status LEDs.

Federal Communications Commission: Part 15,

Class B—Emissions.

Mounting:

Q520A 20-terminal Subbase for panel mounting.

SPECIFICATIONS

Required Components:

Plug-in Flame Signal Amplifier. See Table 1.

Electrical Ratings (See Table 1):

Plug-in Purge Timer Cards. See Table 2.

Voltage and Frequency: 120 Vac (+10%/-15%), 50 or 60 Hz

(±10%).

Power Dissipation in the Run Mode: 10W maximum.

Table 1. Flame Detection Systems.

Plug-in Flame Signal Amplifiers Applicable Flame Detectors

Flame

Failure

Response

Type Color Self-Checking Model

Rectification Green No

Dynamic Ampli-Check

Dynamic Ampli-Check®R7847B

R7847A

R7847B

Time (sec)

0.8 or 3 Gas Rectifying Flame

3 Gas, oil,

c,e

0.8 or 3 Gas Rectifying Flame

c,e

3 Gas, oil,

Fuel Type Models

coal

Infrared Red No R7848A 3 Gas, oil,

coal

Dynamic Ampli-Check

R7848B

3 Gas, oil,

coal

Rod Holders

Ultraviolet (Purple

Peeper

)

Rod Holders

Ultraviolet (Purple Peeper®)

Infrared (Lead Sulfide)

C7004, C7007, C7011 Complete Assemblies: C7008, C7009, Q179

C7012A,C.

C7004, C7007, C7011 Complete Assemblies: C7008, C7009, Q179

C7012A,C

C7015

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R7140G,L,M BURNER CONTROL MODULES

Table 1. Flame Detection Systems. (Continued)

Plug-in Flame Signal Amplifiers Applicable Flame Detectors

Flame

Failure

Response

Type Color Self-Checking Model

Time (sec)

Ultraviolet Purple No R7849A 0.8 or 3 Gas, oil Ultraviolet

Dynamic Ampli-Check

Dynamic Self-Check

Blue Dynamic

Self-Check

R7849B

R7861A

R7886A

0.8 or 3 Gas, oil Ultraviolet

0.8 or 3 Gas, oil,

3 Gas, oil,

Fuel Type Models

(Minipeeper)

C7027, C7035, C7044

Ultraviolet C7061

coal

C7076

coal

Ultraviolet (Adjustable Sensitivity)

Optical White Dynamic

Ampli-Check

Dynamic Self-Check

Flame Failure Response Time (FFRT) depends on selection of amplifier.

Circuitry tests all electronic components in flame detection system (amplifier and detector) 12 times a minute during burner

R7851B 0.8 or 3 Gas, oil,

coal

R7851C

3 Gas, oil,

coal

Optical (UV, IR, Visible Light)

C7927, C7935, C7915, C7962

Optical (UV only) C7961

operation and shuts down burner if detection system fails.

Circuitry tests flame signal amplifier 12 times a minute during burner operation and shuts down burner if amplifier fails.

Use C7027, C7035 and C7044 Flame Detectors only on burners that cycle on-off at least once every 24 hours. Use C7961 Flame Detector with R7851C Amplifier, C7061A Ultraviolet Detector with R7861A Amplifier or C7076A Flame Detector with R7886A Amplifier as ultraviolet flame detection system for appliances with burners that remain on continuously for 24 hours or longer.

R7847A,B Amplifiers with 0.8 second FFRT should not be used with C7012A,C Solid State Ultraviolet Detectors.

Order flame rod separately; see flame detector Instructions for holder.

Table 2. Plug-in Purge Timer Cards.

Pre-Purge Timing Product Number

7 ST7800A1013 30 ST7800A1039 40 ST7800A1047 60 ST7800A1054 90 ST7800A1062

Above times cover the Purge timings of the R4140/50 Pro-

grammers and PM720.

Other timings exist—consult the Tradeline catalog for com-

plete list of ST7800 Purge timers.

Accessories:

The following accessories enhance the R7140 Burner Control

Module and are available through local 7800 SERIES distributors.

Keyboard Display Modules (KDM):

S7800A1001 English language. S7800A1035 French language. S7800A1043 German language. S7800A1050 Italian language. S7800A1068 Spanish language. S7800A1118 Katakana (Japanese) language. S7800A1126 Portuguese language. S7800A1142 English language.

Communications:

Q7700A1015 Network Interface Unit, 120 Vac, 50/60 Hz

applications, external modem required.

Q7700B1004 Network Interface Unit with universal 100 to

250 Vac, 50/60 Hz external power supply, external

modem required. QS7800A1001 ControlBus Module, standard. QS7800B1000 ControlBus Module, multidrop. QS7850A1001 ControlBus Module, General Purpose

Interface. ZM7850A1006 Combustion System Manager

software.

S7810A1009 Data ControlBus Module™ (if no KDM is

used). S7810B1007 Data ControlBus Module™, Multi-Drop

Switch Module. S7810M1003 ModBus™ Module.

Miscellaneous:

S7820A1007 Remote Reset Module. S7830A1005 Expanded Annunciator, 120 Vac, 50/60 Hz. 203541 Data ControlBus Connector, 5-wire. 203765 Remote Display Mounting Bracket. 221729 Dust cover, Relay Module. 204718A Keyboard Display Module Cover, NEMA 4, clear. 204718B Keyboard Display Module Cover, NEMA 1, clear. 204718C Keyboard Display Module Cover, NEMA 4, clear

with reset button. 205321 Flush Display mounting kit. 221818A Extension Cable, display, 5 ft. (1524 mm). 221818C Extension Cable, display, 10 ft. (3048 mm). FSP5004 Tester. 123514A Rectification Flame Simulator. 203659 Ultraviolet Flame Simulator.

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R7140G,L,M BURNER CONTROL MODULES

BURNER CONTROL

5-3/4 (146)

1-1/4

(32)

(127)

POWER PILOT FLAME MAIN ALARM

RESET

(127)

(177)

6-5/32

(156)

M22604

Fig. 2. Mounting dimensions of R7140G,L,M Burner Control Module with Q520A Subbase, in in. (mm).

Table 3. Terminal Ratings.

Terminal No. Description Ratings

Earth G

Flame Sensor Earth Ground

Earth Ground

—

L2(N) Line Voltage Common — L1 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50 or 60 Hz (±10%). 3 Lockout/Running Interlock 120 Vac, 8A run, 43A inrush. 4 Pre-Ignition Interlock Input 120 Vac, 1 mA. 5 Pilot Valve/Ignition 120 Vac. See Table 4. 6 Interrupted/Intermittent Pilot Valve/First Stage Oil Valve 120 Vac. See Table 4. 7 Main Fuel Valve 120 Vac. See Table 4. 8 Burner Motor 120 Vac, 9.8 AFL, 58.8 ALR (inrush). 9 Alarm 120 Vac, 1A pilot duty. 10 Firing Rate High Fire 120 Vac, 75 VA pilot duty. 11 Firing Rate Common 120 Vac, 75 VA pilot duty. 12 Firing Rate Modulate 120 Vac, 75 VA pilot duty. 13 Low Fire Switch Input 120 Vac, 1 mA. 14 Firing Rate Low Fire 120 Vac, 75 VA pilot duty. 15 High Fire Switch Input 120 Vac, 1 mA. 16 Burner Controller and Limits 120 Vac, 1 mA. 17 Shutter 120 Vac, 0.5A. 18 Ignition

120 Vac,

4.5A ignition.

F Flame Sensor 60 to 220 Vac, current limited.

The R7140 must have an earth ground providing a connection between the subbase and the control panel or the equipment. The earth ground wire must be capable of conducting the current to blow the 15A fast blow fuse (or breaker) in the event of an internal short circuit. The R7140 needs a low impedance ground connection to the equipment frame, which, in turn, needs a low impedance connection to earth ground.

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R7140G,L,M BURNER CONTROL MODULES

Table 4. Terminal Ratings.

Terminal Typical Load Maximum Rating at 120 Vac, 60 Hz

5 or 6 Ignition

7 Main Fuel Valve(s) (solenoid/

Device Initiate Standby Purge

R7140G 10 sec. * ** 4 or 10

R7140L 10 or 15

R7140M 10 sec. or

30 seconds with JR2 clipped and jumper from terminal 8 to terminal 15.

* STANDBY and RUN can be an infinite time period.

** PURGE will be determined by which ST7800A purge card is selected; 15 timings are available from 2 seconds to 30 minutes.

Transformer/Pilot Valve/First Stage Fuel Valve

motorized/diaphragm) and Vent Valve, if required

4.5A ignition and 50 VA pilot duty, or

2.5A ignition and 75 VA pilot duty.

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.

Table 5. Sequence Timing for Normal Operation.

Flame

Establishing

Period

sec.

10, 15 sec.a or

intermittent.

sec.

intermittent

Post

Purge

Run

Timing Interlock Circuits

* 15 sec. Pre-Ignition,

Running, Low Fire

Pre-Ignition, Lockout High and Low Fire

Pre-Ignition, Running, isolated Low Fire.

Firing

Rate

Circuit

4-wire modulating

2-wire isolated On-Off-On contacts

Energy Saving

Pre-Purge

No UL/CSA

Approval

BodiesPilot Main

Modulating

FM/IRI Modulating

UL/CSA On-Off.

Code

NOTE: Allowable inrush can be up to ten times the pilot duty

rating.

EXAMPLE: Pilot duty rating = 50 VA.

At 120 V, running current is: 50/120 = 0.42A.

Maximum allowable inrush is ten times 0.42A = 4.2A.

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 marked

on the product to make sure the product is suitable for the application.

3. Installer must be a trained, experienced, flame

safeguard service technician.

4. After installation is complete, check out the product

operation as provided in these instructions.

WARNING

Fire or Explosion Hazard. Can cause property damage, severe injury, or death.

To prevent possible hazardous burner operation, verify safety requirements each time a control is installed on a burner.

WARNING

Electrical Shock Hazard. Can cause serious injury or death.

Disconnect the power supply before beginning installation. More than one power supply disconnect may be required.

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R7140G,L,M BURNER CONTROL MODULES

IMPORTANT

1. Wiring connections for the relay modules are unique; therefore, refer to Fig. 4–11 or the correct Specifications for proper subbase wiring, and sequence charts.

2. Wiring must comply with all applicable codes, ordinances and regulations.

3. Wiring must comply with NEC Class 1 (Line Voltage) wiring.

4. Loads connected to the R7140 must not exceed those listed in the Specifications; see Table 3 and 4.

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

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

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

8. Two Flame Detectors can be connected in parallel with the exception of flame detectors C7015, C7927, C7935, C7915, C7961, and C7962.

9. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class B computing device of Part 15 of FCC rules which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area may cause interference; in which case, the users at their own expense may be required to take whatever measures are required to correct this interference.

10.This digital apparatus does not exceed the Class B limits for radio noise for digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications.

Location

Humidity

Install the relay module where the relative humidity never reaches the saturation point. The relay module is designed to operate in a maximum 85 percent relative humidity continuous, noncondensing moisture environment. Condensing moisture may cause a safety shutdown.

Vibration

Do not install the relay module where it could be subjected to vibration in excess of 0.5G continuous maximum vibration.

Weather

The relay module is not designed to be weathertight. When installed outdoors, protect the relay module using an approved weathertight enclosure.

Mounting Wiring Subbase

1. Mount the subbase in any position except horizontally

with the quadfurcated contacts pointing down. The standard vertical position is recommended. Any other position decreases the maximum ambient temperature rating.

2. Select a location on a wall, burner, or electrical panel.

The Q520A can be mounted directly in the control cabinet. Be sure to allow adequate clearance for servicing, installation, access or removal of the R7140, Expanded Annunciator, Keyboard Display Module, flame amplifier, flame amplifier signal voltage probes, Run/Test Switch, electrical signal voltage probes and electrical field connections.

3. For surface mounting, use the back of the subbase as a

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

4. Securely mount the subbase using four no. 6 screws.

Wiring Subbase

WARNING

Electrical Shock Hazard. Can cause serious injury, death or equipment damage.

Disconnect the power supply before beginning installation to prevent electrical shock, equipment and control damage. More than one power supply disconnect may be required.

1. For proper subbase wiring, internal drawings, and

sequence check charts, refer to Fig. 5, 6, 7, 8, 9 and 11.

2. Disconnect the power supply from the main disconnect

before beginning installation to prevent electrical shock and equipment damage. More than one disconnect may be required.

3. All wiring must comply with all applicable electrical

codes, ordinances and regulations. Wiring, where required, must comply with NEC, Class 1 (Line Voltage) wiring. a. Follow recommended wire size and type. b. Follow recommended grounding practices.

4. Recommended wire routing of leadwires:

a. Do not run high voltage ignition transformer wires in

the same conduit with the flame detector.

b. Do not route flame detector leadwires in conduit

with line voltage circuits.

c. Enclose flame detector leadwires without armor

cable in metal cable or conduit.

d. Follow directions in flame detector Instructions.

5. Maximum wire lengths follow:

a. R7140 leadwires—The maximum length of leadwire

is 300 feet to terminal inputs (Control, Pre-Ignition Interlock, Running/Lockout Interlock, High Fire Switch and Low Fire Switch).

b. Flame Detector leadwires—The maximum flame

sensor leadwire length is limited by the flame signal strength.

c. Remote Reset leadwires—The maximum length of

wire is 1000 feet to a Remote Reset push button.

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

Refer to the label on the R7140 or to the ratings in Table 3 and 4.

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R7140G,L,M BURNER CONTROL MODULES

Final Wiring Check

1. Check the power supply circuit. The voltage and

frequency tolerance must match those of the R7140. A separate power supply circuit may be required for the R7140. Add the required disconnect means and overload protection.

2. Check all wiring circuits and complete the Static

Checkout, Table 8, before installing the R7140 on the subbase.

3. Install all electrical connectors.

4. Restore power to the panel.

Service Notes:

Check the Q520 Wiring Subbase terminals against the typical wiring drawings, Figures 7, 8, 12, 13, 17, or 18.

If wires are attached to terminals that are unused in the figures, DO NOT INSTALL THE R7140 until you have identified the connections’ functions. Most likely the old subbase terminals were used as tie points, so removing the wires, capping with a wire nut, and tucking the wire down into the subbase is all that needs to be done.

Make sure the wiring subbase of the old device is a 20-terminal Q520 (four rows of 5 terminals).

Make sure the system Controller is connected to the correct terminal on the Q520 wiring subbase. It may be in a wire nut tucked into the subbase. It needs to be connected to a terminal (like terminal 4 or 16).

Make sure there is an electrical service ground wire connection to the G terminal in the wiring subbase.

Replacing GP201 or GP301 devices:

— High Fire (or Purge Rate) Switch may be connected to

terminal D.

— Identify, remove, and connect to terminal M.

Replacing GP101 devices:

— Check wiring subbase. If D is jumpered to 8, remove

the jumper.

Replacing R4140 programmers on Carlin 1050 and 1150 burners:

— Remove jumper from 6 to 7. — Remove jumper from L2 to 12 and wire nut the wires

together. Note: There will be no wire on terminal 12. R4140M replacements:

Check terminal 13 of the Q520 wiring subbase.

— If nothing is on 13, install the new R7140M1007. — If 13 is jumpered to 8, remove the jumper and install

R7140M1007.

— If 13 goes somewhere (assume a low fire switch

because the system has a damper motor), remove J1

and J2 from the back of the R7140M1007. NOTE: J1 and J2 provide an input for the R7140M when the

system does not have a spring return damper with a low fire switch.

Leaving J1 and J2 in place with either 13 jumpered to 8 or with the low fire switch will cause the blower motor to come on after the R7140M is installed and power is supplied to the system.

Generally, the following table will apply to select the R7140M1007 model and the status of jumpers J1 and J2.

Table 6. J1/J2 Jumper Configuration for R4140M/PM720M.

Model Purge Timer Leave J1 & J2 Remove J1 and J2

R4140M1004/M1012 A1039 X

R4140M1020/M1038 A1047 X

R4140M1046/M1053 A1062 X

R4140M1079 (GP101) A1062 X

R4140M1103/M1111 A1039 X

R4140M1145/M1152 A1047 X

R4140M1160/M1178 A1062 X

R4140M1186 A1047 X

R4140M1194 ST7800A1062

BC7000L1000 w/PM720M2002 ST7800A1062 X

BC7000L1000 w/PM720M2036 * X

* Check terminal 8 and 15.

If jumpered, ST7800A1031 (7 second purge). If not jumpered, ST7800A1039 (30 second purge).

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R7140G,L,M BURNER CONTROL MODULES

Mounting R7140 Relay Module

Installing the Programmer (Fig. 3)

WARNING

Electrical Shock Hazard. Can cause severe injury, death or property damage.

Disconnect power before installation to prevent electrical shock. More than one disconnect may be involved.

1. Open the master switch.

2. Make sure no subbase wiring is projecting out beyond

the terminal blocks. Tuck in wiring against the back of the subbase so it does not interfere with the contacts.

3. Grasp the programmer chassis and engage the chassis

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

4. Swing the chassis inward until the spring connectors

engage the knifeblade contacts. Push in until the contacts are fully engaged.

5. Tighten the chassis retaining screw securely.

6. Close the master switch to restore power.

PREPURGE HOLD DRIVE TO LOW FIRE

BURNER/BLOWER MOTOR

15 SEC. INTERRUPTED PILOT VALVE

RUNNING INTERLOCKS CLOSED

LED DISPLAY

BURNER

OPERATING CONTROLS AND INTERLOCKS

FLAME SIGNAL

FIRING RATE MOTOR

INITIATE (INITIAL POWERUP ONLY)

POWER

INTERLOCK. CHECK

STANDBY

00 00 10 25 00 1520

TIMED PREPURGE

POWER

PILOT

FLAME

MAIN

LIMITS AND BURNER CONTROLLER CLOSED

PII CLOSED

SAFE START CHECK

R7140G SWITCHING

10 11

MOTOR ACTION

POWER

PILOT

FLAME

MAIN

LOW FIRE SW.

14 11

Removing the Programmer

1. Open the master switch.

2. Loosen the chassis retaining screw.

3. Pull outward on the top of the chassis.

4. Disengage the chassis hinge brackets from the subbase

pivot pins.

KNIFE-BLADE

WIRING SUBBASE

Fig. 3. Mounting the programmer on the subbase.

R7140G

PFEP 10 SEC.

(4 SEC. IF JR1

CLIPPED

POWER

PILOT

FLAME

MAIN

IGN.

5 SEC.

10 SEC. IGN./PILOT

CONTACTS (20)

PIVOT PIN (2)

MFEP

POWER

PILOT

FLAME

MAIN

ALARMALARMALARMALARM

MAIN VALVE

FLAME PROVING

RUN

POWER

PILOT

FLAME

MAIN

ALARM

3TO

10 11

POSTPURGE

14 11

SPRING CONNECTORS

HINGE BRACKET (2)

POWER

STANDBY

POWER

SSC

CHASSIS RETAINING SCREW

PROGRAMMER CHASSIS

M22605

TERMINAL 6 HAS THE FOLLOWING OPTIONS:

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

PII MEANS PRE-IGNITION INTERLOCK.

FOR R7140G1000:

L1 TO 4 4 TO 3

Fig. 4. Operating sequence, R7140G1000/R7140G2008.

66-1153—2 8

M23319

Page 9

RESET PUSHBUTTON

RUN/TEST SWITCH

CONFIGURATION JUMPERS

MICROCOMPUTER

RELAY DRIVE CIRCUIT

L1 (HOT) L2

120 Vac, 50/60 Hz

PLUG-IN PURGE TIMER CARD

FLAME SIGNAL

PLUG-IN FLAME AMPLIFIER

TEST

R7140G,L,M BURNER CONTROL MODULES

TEST JACK

RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS

SAFETY RELAY

6K1

3K1

RS485

CIRCUIT

PRE-IGNITION INTERLOCK

LOW FIRE SWITCH

REMOTE

RESET

STATUS LEDs

LIMITS

CONTROLLER

KEYBOARD DISPLAY MODULE

DDL

DDL COMMUNICATIONS

PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

8K1

8K2

9K2

RUNNING/ LOCKOUT INTERLOCK

HIGH FIRE

COMMON

MODULATE

LOW FIRE

POWER SUPPLY

9K1

1K1 2K1 5K1

CONTROL POWER

IGNITION

4K1

7K1

2K2

INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS

FIELD WIRING INTERNAL WIRING

PILOT

PILOT/V2

MAIN VALVE

BLOWER

ALARM

M23320

Fig. 5. Internal block diagram of the R7140G1000. (See Fig. 8 for detailed wiring.)

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R7140G,L,M BURNER CONTROL MODULES

CONFIGURATION JUMPERS

RUN/TEST SWITCH

CONTROLLER

LIMITS

6K1

3K1

MICROCOMPUTER

PRE-IGNITION INTERLOCK

RUNNING/ LOCKOUT INTERLOCK

LOW FIRE SWITCH

8K1

8K2

9K2

L1 (HOT)

120 Vac, 50/60 Hz

POWER SUPPLY

1K1 2K1 5K1

HIGH FIRE

COMMON

MODULATE

9K1

LOW FIRE

PLUG-IN PURGE TIMER CARD

FLAME SIGNAL

4K1

7K1

2K2

TEST

TEST JACK

PLUG-IN FLAME AMPLIFIER

CONTROL POWER

INDICATES FEEDBACK SENSING

OF RELAY CONTACT STATUS

AND LINE VOLT INPUTS

FIELD WIRING

INTERNAL WIRING

IGNITION

PILOT

PILOT/V2

MAIN VALVE

BLOWER

ALARM

PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

Fig. 6. Internal block diagram of the R7140G2008. (See Fig. 7 for detailed wiring.)

66-1153—2 10

M23321

Page 11

R7140G,L,M BURNER CONTROL MODULES

FOR DIRECT SPARK IGNITION (OIL OR GAS)

WIRING SUBBASE TERMINAL STRIP (4)

SERIES 90 CONTROLLER

120V, 60 HZ POWER SUPPLY

PREIGNITION INTERLOCK(S)

BURNER CONTROLLER

120V ALARM

HIGH FIRE

COMMON

SERIES 90 FIRING RATE MOTOR

L1 (HOT)

MODULATE

LOW FIRE

MASTER SWITCH

LIMITS

RUNNING INTERLOCKS (INCLUDING AIRFLOW SWITCH)

IGNITION TRANSFORMER

1ST STAGE FUEL VALVE

2ND STAGE FUEL VALVE (OPTIONAL)

5 SECOND IGNITION (EARLY SPARK TERMINATION)

10 SECOND INTERRUPTED PILOT/IGNITION

PILOT/IGNITION

BLUE

WHITE

MAIN FUEL VALVE(S)

BURNER MOTOR (BLOWER)

LOW FIRE START SWITCH

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

C7027A, C7035A, OR C7044A ULTRAVIOLET FLAME DETECTOR

C7012A, C, C7061, OR C7076A ULTRAVIOLET FLAME DETECTOR

WHITE

YELLOW

PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION

AS REQUIRED.

USE ALL NEC CLASS 1 WIRING.

START INTERLOCKS IF USED BECOME PREIGNITION INTERLOCKS - (MUST REMAIN CLOSED UNTIL IGNITION TRIALS BEGIN.)

TERMINAL 6 HAS THE FOLLOWING OPTIONS:

AS RECEIVED - INTERMITTENT PILOT JR2 CLIPPED - 15 SECOND MAIN FLAME ESTABLISHING PERIOD JR2 CLIPPED AND JUMPER FROM 8-15 - 30 SECOND MAIN FLAME ESTABLISHING PERIOD.

C7012E.F NEEDS TO BE UPDATED TO C7061.

M22607B

Fig. 7. Wiring diagram for R7140G2008 for application replacing R4140G with start Interlock or BC7000L1000 with

PM720G.

11 66-1153—2

Page 12

R7140G,L,M BURNER CONTROL MODULES

FOR DIRECT SPARK IGNITION (OIL OR GAS)

WIRING SUBBASE TERMINAL STRIP (4)

SERIES 90 CONTROLLER

120V, 60 HZ POWER SUPPLY

HIGH FIRE

COMMON

PREIGNITION INTERLOCK(S)

BURNER CONTROLLER

120V ALARM

SERIES 90 FIRING RATE MOTOR

L1 (HOT)

MODULATE

LOW FIRE

MASTER SWITCH

LIMITS

RUNNING INTERLOCKS (INCLUDING AIRFLOW SWITCH)

IGNITION

MAIN OIL VALVE

SOLENOID

C7027A, C7035A, C7927 OR

BLUE

C7044A ULTRAVIOLET FLAME DETECTOR

BLUE

WHITE

10 SECOND INTERRUPTED PILOT/IGNITION

PILOT/IGNITION

MAIN FUEL VALVE(S)

BURNER MOTOR

LOW FIRE SWITCH

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

C7067A,D OR C7061 ULTRAVIOLET FLAME DETECTOR

JUMPER

WHITE

YELLOW

PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION

AS REQUIRED.

USE ALL NEC CLASS 1 WIRING.

FOR DIRECT SPARK IGNITION OF OIL, CONNECT IGNITION TO

TERMINAL 5 AND MAIN OIL VALVE SOLENOID TO TERMINAL 7; JUMPER TERMINAL 7 T0 TERMINAL 6. SEE INSET.

SOLENOID MUST NOT EXCEED THE ELECTRICAL RATINGS OF TERMINAL 7.

Fig. 8. Field wiring for R7140G1000 used for replacing R4140G Programmers with pre-ignition interlocks.

66-1153—2 12

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.)

C7012 MUST BE UPDATED TO C7061.

TERMINAL 6 HAS THE FOLLOWING OPTIONS:

AS RECEIVED—INTERMITTENT PILOT. JR2 CLIPPED—15 SECOND INTERRUPTED PILOT. JR2 CLIPPED, TERMINALS 8-15 JUMPERED— 30 SECOND INTERRUPTED PILOT.

M22608B

Page 13

R7140G,L,M BURNER CONTROL MODULES

LED DISPLAY

BURNER

OPERATING CONTROLS AND INTERLOCKS

FLAME SIGNAL

FIRING RATE MOTOR

INITIATE (INITIAL POWERUP ONLY)

POWER

STANDBY

POWER

SAFE START CHECK

PREPURGE HOLD

DRIVE TO HIGH FIRE

POWER

PII CLOSED

SWITCHING

R7140L

PREPURGE

00 00 10 25 00 1520

TIMED PREPURGE

POWER

PILOT

FLAME

MAIN

LIMITS AND BURNER CONTROLLER CLOSED

LOCKOUT INTERLOCKS CLOSED

HIGH FIRE SW.

15TO

10 11

MOTOR ACTION

HOLD DRIVE TO LOW FIRE

POWER

PILOT

FLAME

MAIN

BURNER/BLOWER MOTOR

PFEP 10 SEC.

(4 SEC. IF JR1

CLIPPED

POWER

PILOT

FLAME

MAIN

IGN.

10 SEC. IGN./PILOT

15 SEC. PILOT 6

16TO

LOW FIRE SW.

5 SEC.

10 14

MFEP

POWER

PILOT

FLAME

MAIN

ALARMALARMALARMALARM

MAIN VALVE

16 TO

FLAME PROVING

RUN

POWER

PILOT

FLAME

MAIN

ALARM

10 11

POSTPURGE

POWER

10 14

STANDBY

POWER

SSC

FOR R7140L1009:

L1 TO 4.

4 TO 3.

PII MEANS PRE-IGNITION INTERLOCK.

Fig. 9. Operating sequence, R7140L1009 and R7140L2007.

M23322

13 66-1153—2

Page 14

R7140G,L,M BURNER CONTROL MODULES

CONFIGURATION JUMPERS

RUN/TEST SWITCH

RESET PUSHBUTTON

STATUS LEDs

LIMITS CONTROLLER

(D)

6K1

3K1

KEYBOARD

DDL

DDL COMMUNICATIONS

PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

NOTE: ( ) NUMBERS ON GP201, GP301 SUBBASE.

DISPLAY MODULE

RS485

MICROCOMPUTER

RELAY DRIVE CIRCUIT

SAFETY RELAY CIRCUIT

PII

LOW FIRE SWITCH

HIGH FIRE SWITCH

(8)

REMOTE RESET

(3)

8K1

8K2

9K2

L1 (HOT) L2

RUNNING/ LOCKOUT INTERLOCK

HIGH FIRE

COMMON

MODULATE

9K1

LOW FIRE

120 Vac, 50/60 Hz

POWER SUPPLY

PLUG-IN PURGE TIMER CARD

FLAME SIGNAL

TEST

1K1 2K1 5K1

4K1

7K1

2K2

(X)

(10)

(11)

14(

12)

TEST JACK

PLUG-IN FLAME AMPLIFIER

RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS

CONTROL POWER

(M)

(A)

INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS

FIELD WIRING INTERNAL WIRING

IGNITION

PILOT

PILOT/V2

MAIN VALVE

BLOWER

ALARM

M23323

Fig. 10. Internal block diagram of the R7140L1009. (See Fig. 12 for detailed wiring.)

66-1153—2 14

Page 15

L1 (HOT) L2

RELAY DRIVE CIRCUIT

8K1

8K2

9K2

120 Vac, 50/60 Hz

POWER SUPPLY

1K1 2K1 5K1

HIGH FIRE

COMMON

MODULATE

9K1

LOW FIRE

CONFIGURATION JUMPERS

RUN/TEST SWITCH

MICROCOMPUTER

RESET PUSHBUTTON

SAFETY RELAY

6K1

3K1

RS485

CIRCUIT

PRE-IGNITION INTERLOCK

RUNNING/ LOCKOUT INTERLOCK

LOW FIRE SWITCH

HIGH FIRE SWITCH

REMOTE

RESET

STATUS LEDs

LIMITS CONTROLLER

KEYBOARD

DDL

DISPLAY MODULE

DDL COMMUNICATIONS

PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

PLUG-IN PURGE TIMER CARD

FLAME SIGNAL

TEST

4K1

7K1

2K2

R7140G,L,M BURNER CONTROL MODULES

TEST JACK

PLUG-IN FLAME AMPLIFIER

RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS

CONTROL POWER

INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS

FIELD WIRING INTERNAL WIRING

IGNITION

PILOT

PILOT/V2

MAIN VALVE

BLOWER

ALARM

M23329

Fig. 11. Internal block diagram of the R7140L2007. (See Fig. 13 for detailed wiring.)

15 66-1153—2

Page 16

R7140G,L,M BURNER CONTROL MODULES

FOR DIRECT SPARK IGNITION (OIL OR GAS)

WIRING SUBBASE TERMINAL STRIP (4)

SERIES 90 CONTROLLER

120V, 60 HZ POWER SUPPLY

COMMON

PREIGNITION INTERLOCKS

BURNER CONTROLLER

120V ALARM

HIGH FIRE

SERIES 90 FIRING RATE MOTOR

L1 (HOT)

MODULATE

LOW FIRE

MASTER SWITCH

LIMITS

LOCKOUT INTERLOCKS (INCLUDING AIRFLOW SWITCH)

IGNITION TRANSFORMER

MAIN FUEL VALVE

5 SECOND IGNITION (EARLY SPARK TERMINATION)

10 SECOND INTERRUPTED PILOT/IGNITION

BLUE

WHITE

BLUE

WHITE

15 SECOND INTERRUPTED PILOT/IGNITION

MAIN FUEL VALVE(S)

BURNER MOTOR (BLOWER)

LOW FIRE SWITCH

HIGH FIRE SWITCH

RECTIFYING FLAME ROD,OR INFRARED

(LEAD SULFIDE) FLAME DETECTOR

C7027A, C7035A, OR C7044A ULTRAVIOLET FLAME DETECTOR

C7061, C7927 OR C7076A, D ULTRAVIOLET FLAME DETECTOR

JUMPER

WHITE

YELLOW

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

USE ALL NEC CLASS 1 WIRING.

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

TRANSFORMER AND MAIN FUEL VALVE(S) AS SHOWN IN INSET.

FOR THE C7015A INFRARED (LEAD SULFIDE) FLAME DETECTOR, EITHER LEADWIRE CAN BE CONNECTED TO THE F TERMINAL. RUN THE C7015A LEADWIRES ALONE IN CONDUIT ALL THE WAY TO THE WIRING SUBBASE AND GROUND THE CONDUIT AT THE SUBBASE. (REFER TO PUBLICATION 60-2306 FOR DETAILED INSTRUCTIONS.)

Fig. 12. Sample block diagram of field wiring for the R7140L1009, used for

replacing R4140L Programmers with pre-ignition interlocks.

66-1153—2 16

C7061 OR C7076 MUST BE RATED FOR 120 V, 60Hz. TWO DETECTORS

WITH THE SAME MODEL NUMBER CAN BE WIRED IN PARALLEL TO THE SAME TERMINALS. C7076A, D DOES NOT HAVE LEADWIRES. (FOR INSTRUCTIONS, SEE FORM NUMBERS: 60-2046 FOR C7012A, C MODELS WITH ELECTRON TUBES; 60-2044 FOR C7012A,C,E,F SOLID STATE MODELS; 95-8269 FOR THE C7076A.)

WHITE SHUTTER LEADWIRES ARE ONLY ON THE C7061A, E

ULTRAVIOLET FLAME DETECTORS; C7076A, D ADJUSTABLE SENSITIVITY ULTRAVIOLET FLAME DETECTORS DO NOT HAVE LEADWIRES.

TERMINAL 17 IS USED ONLY FOR THE SHUTTER ON SELF-CHECKING

C7061A, E, F OR C7076A, D FLAME DETECTORS.

M22610

Page 17

R7140G,L,M BURNER CONTROL MODULES

FOR DIRECT SPARK IGNITION (OIL OR GAS)

WIRING SUBBASE TERMINAL STRIP (4)

SERIES 90 CONTROLLER

120V, 60 HZ POWER SUPPLY

PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

USE ALL NEC CLASS 1 WIRING.

IN SOME INSTALLATIONS THE LOW FIRE INTERLOCK IS BETWEEN

TERMINALS L1 AND 13.

C7076 COMES WITHOUT LEADWIRES; C7061 DOES NOT HAVE BLACK LEADWIRES.

PREIGNITION INTERLOCKS

BURNER CONTROLLER

120V ALARM

HIGH FIRE

COMMON

SERIES 90 FIRING RATE MOTOR

L1 (HOT)

MODULATE

LOW FIRE

MASTER SWITCH

LIMITS

LOCKOUT INTERLOCKS (INCLUDING AIRFLOW SWITCH)

IGNITION TRANSFORMER

MAIN FUEL VALVE (S)

5 SECOND IGNITION (EARLY SPARK TERMINATION)

10 SECOND INTERRUPTED PILOT/IGNITION

BLUE

WHITE

15 SECOND INTERRUPTED PILOT

MAIN FUEL VALVE(S)

BURNER MOTOR (BLOWER)

LOW FIRE START SWITCH

HIGH FIRE PURGE SWITCH

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

C7027A, C7035A, OR C7044A ULTRAVIOLET FLAME DETECTOR

C7012A, C, C7076A, OR C7061 ULTRAVIOLET FLAME DETECTOR

BLACK

JUMPER

WHITE

YELLOW

M22611B

Fig. 13. Block diagram of field wiring for the R7140L2007, used for replacing

BC7000L1000 with PM720L.

17 66-1153—2

Page 18

R7140G,L,M BURNER CONTROL MODULES

LED DISPLAY

BURNER

OPERATING CONTROLS AND INTERLOCKS

FLAME SIGNAL

DAMPER MOTOR

INITIATE (INITIAL POWERUP ONLY)

POWER

PREPURGE

00 00 10 25 00 1520

TIMED

STANDBY

POWER

PREPURGE

POWER

PILOT

FLAME

MAIN

LIMITS AND BURNER CONTROLLER CLOSED

PII CLOSED

SAFE START CHECK FLAME PROVING

R7140M SWITCHING

10 L2

MOTOR ACTION

HOLD DRIVE TO LOW FIRE

BURNER/BLOWER MOTOR

RUNNING INTERLOCKS CLOSED

PFEP 10 SEC.

(4 SEC. IF JR1

CLIPPED

POWER

PILOT

FLAME

MAIN

LOW FIRE SW.

POWER

PILOT

FLAME

MAIN

IGN.

10 SEC. IGN./PILOT

INTERMITTENT PILOT VALVE

5 SEC.

16TO

R7140M

MFEP

POWER

PILOT

FLAME

MAIN

ALARMALARMALARMALARM

MAIN VALVE

RUN

POWER

PILOT

FLAME

MAIN

ALARM

3TO

10 L2

POSTPURGE

POWER

STANDBY

POWER

SSC

WHEN USING A SPRING RETURN ACTUATOR MOTOR, REMOVE J1 AND J2 JUMPERS LOCATED ON R7140M SUBBASE.

PII MEANS PRE-IGNITION INTERLOCK.

R7140M WHEN USED AS BC7000 REPLACEMENT ON R4140 WITH START INTERLOCKS L1 TO 16.

Fig. 14. Operating sequence, R7140M.

M23331

66-1153—2 18

Page 19

R7140G,L,M BURNER CONTROL MODULES

LIMITS

CONTROLLER

1R1

START

INTERLOCKS

AIRFLOW

8K2

9K2

FLAME AMPLIFIER

9K1

CONFIGURATION JUMPERS

ALARM

BLOWER

1R1

IGN XFMR

INTERMITTENT PILOT

15 SECOND INTERMITTENT PILOT VALVE

MAIN VALVE

PURGE TIMER

INTERNAL ELECTRONICS

3K1

6K1

2K1

1K1

5K1

4K1

7K1

2K2

M23335

Fig. 15. Internal block diagram of the R7140M1007 with start interlocks. (See Fig. 17 for detailed wiring.)

LIMITS

CONTROLLER

1R1

PRE-

IGNITION

AIRFLOW

8K2

9K2

FLAME AMPLIFIER

9K1

1K1

CONFIGURATION JUMPERS

ALARM

BLOWER

1R1

IGN XFMR

INTERMITTENT PILOT

15 SECOND INTERMITTENT PILOT VALVE

MAIN VALVE

PURGE TIMER

INTERNAL ELECTRONICS

3K1

6K1

2K1

5K1

4K1

7K1

2K2

M23336

Fig. 16. Internal block diagram of the R7140M1007 with pre-ignition interlocks. (See Fig. 18 for detailed wiring.)

19 66-1153—2

Page 20

R7140G,L,M BURNER CONTROL MODULES

FOR DIRECT SPARK IGNITION OF OIL OR GAS

WIRING SUBBASE TERMINAL STRIP (4)

120V, 60 HZ POWER SUPPLY

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND

OVERLOAD PROTECTION AS REQUIRED.

USE ALL NEC CLASS 1 WIRING.

START INTERLOCKS IF USED BECOME PRE-IGNITION INTERLOCKS (MUST REMAIN CLOSED UNTIL IGNITION TRIALS BEGIN.)

PM720M 16 TO 4 IS A PRE-IGNITION INTERLOCK.

USE 2 POSITION SPRING RETURN MOTOR.

WHITE LEADWIRES ON C7012 U.V. FLAME DETECTORS. REPLACE C7012

WITH C7061 UV DETECTOR AND R7861A1026 AMPLIFIER.

MAKE SURE CONNECTOR IS ON TERMINAL 16.

REMOVE J1 AND J2 JUMPERS ON R7140M IF LOW FIRE SWITCH OR A JUMPER

IS CONNECTED BETWEEN 8 AND 13.

BURNER CONTROLLER

120V ALARM

DAMPER CONTROL

L1 (HOT)

MASTER SWITCH

LIMITS

RUNNING INTERLOCKS (INCLUDING AIRFLOW SWITCH)

IGNITION

BLUE

WHITE

1ST STAGE FUEL VALVE

2ND STAGE FUEL VALVE (OPTIONAL)

5 SECOND IGNITION (EARLY SPARK TERMINATION)

10 SECOND INTERRUPTED PILOT/IGNITION

INTERMITTENT PILOT

MAIN FUEL VALVE(S)

BURNER MOTOR

LOW FIRE START SWITCH

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

C7027A, C7035A, OR C7044A ULTRAVIOLET FLAME DETECTOR

C7012A, C, E, OR F ULTRAVIOLET FLAME DETECTOR

BLACK

WHITE

YELLOW

Fig. 17. R7140M1007 used on applications replacing R4140M Programmers with Start Interlocks or BC7000 with

PM720M.

66-1153—2 20

Page 21

R7140G,L,M BURNER CONTROL MODULES

FOR DIRECT SPARK IGNITION (OIL OR GAS)

WIRING SUBBASE TERMINAL STRIP (4)

(P)

(13)

(A)

PREIGNITION INTERLOCKS

BURNER CONTROLLER

ALARM

LIMITS

RUNNING INTERLOCKS (INCLUDING AIRFLOW SWITCH)

IGNITION TRANSFORMER

1ST STAGE FUEL VALVE

2ND STAGE FUEL VALVE (OPTIONAL)

5 SECOND IGNITION (EARLY SPARK TERMINATION)

10 SECOND INTERRUPTED PILOT/IGNITION

INTERMITTENT PILOT/IGNITION

MAIN FUEL VALVE(S)

(X)

(10)

120V, 60 HZ POWER SUPPLY

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

USE ALL NEC CLASS 1 WIRING.

WHEN USING A 2-POSITION SPRING DAMPER MOTOR, CLIP AND REMOVE J1 AND J2, LOCATED ON R7140 SUBBASE.

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

FOR THE C7015A INFRARED (LEAD SULFIDE) FLAME DETECTOR, EITHER LEADWIRE MAY BE 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.)

WHITE SHUTTER LEADWIRES ARE ONLY ON THE C7061A OR F OR C7961 E, OR F ULTRAVIOLET FLAME DETECTORS WITH SELF-CHECKING FEATURE; TERMINAL 17 IS NOT USED FOR OTHER DETECTORS. (REFER TO PUBLICATION 60-2358 FOR DETAILED INSTRUCTIONS.)

REPLACEMENT R7140M. START INTERLOCK BECOMES PRE-IGNITION INTERLOCK.

DAMPER CONTROL

L1 (HOT)

MASTER SWITCH

(11)

(D)

(S1)

(3)

(8)

(12)

BLUE

WHITE

NOTE: ( ) NUMBERS ON GP101 SUBBASE.

BURNER MOTOR

LOW FIRE SWITCH

RECTIFYING FLAME ROD OR INFRARED (LEAD SULFIDE) FLAME DETECTOR

C7027A, C7035A, OR C7044A ULTRAVIOLET FLAME DETECTOR

C7061, C7012A, C, ULTRAVIOLET FLAME DETECTOR

(M)

(S2)

WHITE

YELLOW

M23338

Fig. 18. Block diagram of field wiring for the R7140M1007, used for replacing R4140M Programmers with Pre-Ignition

Interlocks.

21 66-1153—2

Page 22

R7140G,L,M BURNER CONTROL MODULES

SAFETY SHUTDOWN

Safety Shutdown (Lockout) occurs if any of the following occur during the indicated period:

1. INITIATE Period:

a. Purge card is not installed or is removed. b. Purge card is bad. c. Configuration jumpers are changed (after 200 hours

of operation). d. AC line power errors occur; see Operation section. e. Four minute INITIATE period has been exceeded.

2. STANDBY Period:

a. Flame signal is present after 240 seconds. b. Pre-Ignition Interlock is open an accumulative time

of 30 seconds. c. Interlock check feature is enabled and the

Interlock String (including airflow switch) is closed

for 120 seconds with controller closed. d. Ignition/pilot valve/intermittent pilot valve terminal is

energized. e. Main valve terminal is energized. f. Internal system fault occurs. g. Purge card is not installed or is removed. h. Purge card is bad.

3. PREPURGE Period:

a. Pre-Ignition Interlock opens anytime during

PREPURGE period (R7140L). b. Flame signal is detected after first ten seconds

during PREPURGE (R7140L). c. High Fire Switch fails to close within 4 minutes and

15 seconds after the firing rate motor is commanded

to drive to the high fire position at the start of

PREPURGE (R7140L). d. Low Fire Switch fails to close within 4 minutes and

15 seconds after the firing rate motor is commanded

to drive to the low fire position at the end of

PREPURGE. e. Running Interlock does not close within 30 seconds

(R7140G,M). f. Lockout Interlock does not close within 10 seconds

(R7140L). g. Lockout Interlock opens during PREPURGE (R7140L). h. Ignition/pilot valve/intermittent pilot valve terminal is

energized. i. Main valve terminal is energized. j. Internal system fault occurs. k. Purge card is removed. l. Purge card is bad.

4. PILOT FLAME ESTABLISHING Period (PFEP):

a. Low Fire Switch opens. b. Lockout Interlock opens (RM7140L). c. Ignition/pilot valve/intermittent pilot valve terminal is

not energized. d. Early spark termination terminal is energized after

five seconds. e. No flame is present at the end of PFEP. f. Main valve terminal is energized (R7140G,M). g. Internal system fault occurs. h. Purge card is removed. i. Purge card is bad.

5. MAIN FLAME ESTABLISHING Period (MFEP):

a. Low Fire Switch Opens. b. Lockout Interlock opens (R7140L).

c. Ignition/pilot valve/intermittent pilot valve terminal is

not energized. d. Main valve terminal is not energized. e. No flame is present at the end of MFEP. f. Internal system fault occurs. g. Purge card is removed. h. Purge card is bad.

6. RUN Period:

a. No flame is present. b. Lockout Interlock opens (R7140L). c. Interrupted pilot valve terminal is energized

(R7140G,M). d. Main valve terminal is not energized. e. Internal system fault occurs. f. Purge card is removed. g. Purge card is bad.

7. POSTPURGE Period:

a. Pre-Ignition Interlock does not close in five seconds

and opens after five-second time period. b. Ignition/pilot valve/intermittent pilot valve terminal is

energized. c. Main valve terminal is energized. d. Internal system fault occurs. e. Purge card is removed. f. Purge card is bad.

OPERATION

Sequence of Operation

The R7140 has the following operating sequences; see Fig. 4, 9, and 14. The R7140 LED provides positive visual indication of the program sequence: POWER, PILOT, FLAME, MAIN and ALARM.

Initiate

The R7140 enters the INITIATE sequence when the Relay Module is powered. The R7140 can also enter the INITIATE sequence if the Relay Module verifies voltage fluctuations of +10/-15 percent or frequency fluctuations of ±10 percent during any part of the operating sequence. The INITIATE sequence lasts for ten seconds unless the voltage or frequency tolerances are not met. When the tolerances are not met, a hold condition is initiated for at least five seconds. When the tolerances are met, the INITIATE sequence restarts. If the condition is not corrected and the hold condition exists for four minutes, the R7140 locks out. Causes for hold conditions in the INITIATE sequence:

a. AC line dropout is detected. b. AC line noise prevents a sufficient reading of the

line voltage inputs. c. Low line voltage brownouts occur.

The INITIATE sequence also delays the burner motor starter from being energized and de-energized from an intermittent AC line input or control input.

Standby

The R7140 is ready to start an operating sequence when the operating control determines a call for heat is present. The burner switch, limits, operating control and all microcomputer monitored circuits must be in the correct state for the R7140 to continue into the PREPURGE sequence.

66-1153—2 22

Page 23

R7140G,L,M BURNER CONTROL MODULES

Normal Start-Up Pre-Purge

The R7140 provides a pre-purge timing selectable from two seconds to 30 minutes with power applied and the R7140 operating control indicating a call for heat:

a. Running Interlocks, Pre-Ignition Interlocks, Burner

Switch, Run/Test Switch, Lockout Interlocks and all microcomputer monitored circuits must be in the correct operating state.

b. The blower motor output, terminal 8, is powered to

start the PREPURGE sequence. The PREPURGE timing for the R7140L does not begin until the High Fire Switch is closed.

NOTE: A jumpered High Fire Switch adds a 30-second hold

before the purge time starts.

c. The Pre-Ignition Interlock input must remain closed

throughout PREPURGE; otherwise, control returns to the STANDBY state and holds (30 seconds) for the R7140G,M or safety shutdown for the R7140L occurs.

d. The Lockout Interlock or Running Interlock inputs

(interlock circuit including Airflow Switch) must close by ten seconds into PREPURGE; otherwise, a recycle to the beginning of PREPURGE for the R7140G,M will happen or a safety shutdown for the R7140L occurs.

e. When PREPURGE timing is complete, the firing rate

motor drives to the low fire position. If a damper motor is used (R7140M), jumpers J1 and J2 should be removed from R7140 subbase.

f. When the firing rate motor reaches low fire position,

the Low Fire Switch, terminal 13, is energized to enter the Ignition Trial state.

NOTE: A 30-second hold occurs for a jumpered Low Fire

Switch before the ignition trial period begins.

Ignition Trials

1. Pilot Flame Establishing Period (PFEP):

a. With the firing rate motor at the low fire position:

(1) The pilot valve and ignition transformer,

terminals 5, 6, and 18, are energized. (a) The R7140G has an interrupted or

intermittent pilot valve, terminal 6, depending on the selection of configuration jumper 2.

(b) The R7140L has a 15-second interrupted

pilot valve, terminal 6.

terminal 6.

NOTE: All of the R7140s have a ten-second interrupted pilot

valve/ignition, terminal 5.

(2) During PFEP, the Low Fire Switch must remain

closed. If it opens, a safety shutdown occurs.

(3) The Pre-Ignition Interlock input is ignored

throughout the Ignition Trial state.

b. Flame must be proven by the end of the 10-second

PFEP (four if JR1 is clipped) to allow the sequence to continue. If flame is not proven by the end of PFEP, a safety shutdown occurs.

c. After five seconds, the ignition, terminal 18, is

de-energized for early spark termination.

2. Main Flame Establishing Period (MFEP):

a. Terminal 7 is energized when the presence of flame is

verified at the end of a 10-second Pilot Flame Establishing Period (PFEP) (four seconds if JR1 is clipped).

b. Terminal 5 is turned off 10 seconds after terminal 7

is energized.

c. Terminal 6 action:

(1) R7140L: De-energized 15 seconds after terminal

7 is energized.

(2) R7140G:

(a) Not turned off, or (b) 15 seconds after terminal 7 is energized and

JR2 is clipped, or

terminals 8 and 15 are jumpered and jumper JR2 is clipped.

(3) R7140M: Remain energized as long as call for

heat is present.

Run

Fifteen seconds after the main valve terminal 7 is energized and flame is maintained, the R7140 goes to Run.

The firing rate motor releases to modulation (R7140G,L). Damper motor is energized (R7140M).

The R7140 is now in RUN and remains in RUN until the controller input, terminal 16 or 4 (model dependent), opens, indicating that the demand is satisfied or a limit opened.

Postpurge

The R7140 provides a 15-second POSTPURGE following the completion of the RUN period (call for heat ends). The blower motor output remains powered to drive all products of combustion and any unburned fuel from the combustion chamber. It also supplies combustion air to burn fuel being purged from the fuel line downstream of the fuel shutoff valve.

1. The main fuel valve and intermittent pilot valve,

terminals 7 and 6, are de-energized and the firing rate motor is commanded to the low fire position to begin the POSTPURGE period.

2. After the 15-second POSTPURGE period is completed,

the blower motor (terminal 8) is de-energized and the R7140 reenters Standby.

Run/Test Switch

WARNING

Explosion Hazard. Can cause serious injury or death.

Do not use the Run/Test switch during the Pilot Flame Establishing Period for the R7140 when using Direct Spark Function, because it turns on the main gas valve, causing an accumulation of fuel in the burner.

The Run/Test Switch is located on the top side of the R7140, see Fig. 1. The Run/Test Switch allows the burner sequence to be altered as follows:

23 66-1153—2

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R7140G,L,M BURNER CONTROL MODULES

1. In Pre-Purge Drive To High Fire Position (R7140L), the

Run/Test Switch, when placed in the TEST position, holds in PREPURGE with the firing rate motor in the High Fire position.

2. In the measured PREPURGE sequence, the Run/Test

Switch, when placed in the TEST position, causes the PREPURGE timing to stop. The firing rate motor is in the High Fire position.

3. In Pre-Purge Drive to Low Fire position, the Run/Test

Switch, when placed in the TEST position, holds the burner sequence in PREPURGE with the firing rate motor in the Low Fire position.

In PFEP, the Run/Test Switch, when placed in the TEST position, stops the timer during the first 8 seconds when a 10-second PFEP is selected or during the first 3 seconds when a 4-second PFEP is selected, allowing pilot-turndown test and other burner adjustments to be made. This activates a 15-second flameout timer that permits pilot flame adjustment without nuisance safety shutdowns. The Run/Test Switch is ignored during PFEP for the R7140L if terminals 5 and 7 or 7 and 6 are jumpered.

5. During Run, the Run/Test Switch, when placed in the

TEST position, drives the firing rate motor to the Low Fire position.

NOTE: When R7140 is switched to the Test mode, it stops and

holds at the next Run/Test Switch point in the operating sequence. Make sure that the Run/Test Switch is in the RUN position before leaving the installation.

SETTINGS AND ADJUSTMENTS

Selectable Site-Configurable Jumpers

The R7140 has three site-configurable jumper options; see Fig. 19 and Table 7. If necessary, clip the site-configurable jumpers with side cutters and remove the resistors from the Relay Module.

The R7140M has two additional jumpers located on the back of the chassis. These must be cut if a spring return damper motor is used.

SELECTABLE CONFIGURATION JUMPERS

RUN/TEST SWITCH

NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.

M12301

Fig. 19. Selectable site-configurable jumpers.

Table 7. Site Configurable Jumper Options.

Jumper Number Description Intact Clipped RM7800/RM7840 Type

JR1 Pilot Flame Establishing

10 seconds 4 seconds All

Period (PFEP)

JR2

Pilot Valve

/Main Flame

Establishing Period (MFEP)

10 seconds Intermittent

15 or 30 seconds Interrupted

R7140G

JR3 Start-up Interlock Check Disabled Enabled All

Pilot Valve/First Stage Oil Valve (Valve/Start) terminal 6.

A 30 second MFEP can be accomplished by adding a jumper wire between terminals 15 and 8.

SERVICE NOTE: Clipping and removing these site-configurable jumpers enhances the level of safety. Removal after 200 hours of main valve operation will result in a hard lockout, Code 110.

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R7140G,L,M BURNER CONTROL MODULES

STATIC CHECKOUT

After checking all wiring, perform this checkout before installing the R7140 on the subbase. These tests verify the Q520A Wiring Subbase is wired correctly, and the external controllers, limits, interlocks, actuators, valves, transformers, motors and other devices are operating properly.

WARNING

Explosion and Electrical Shock Hazard. Can cause serious injury, death, or equipment damage.

1. Close all manual fuel shutoff valve(s) before starting

these tests.

2. Use extreme care while testing the system. Line

voltage is present on most terminal connections when power is on.

3. Open the master switch before installing or

removing a jumper on the subbase.

4. Before continuing to the next test, be sure to

remove test jumper(s) used in the previous test.

Replace all limits and interlocks that are not operating properly. Do not bypass limits and interlocks.

CAUTION

Equipment Damage Hazard. Improper testing can damage equipment.

Internal surge protectors can break down and conduct a current, causing the R7140 to fail the dielectric test or possibly destroy the internal lightning and high current protection. Do not perform a dielectric test with the R7140 installed.

Equipment Recommended

1. Voltmeter (1M ohm/volt minimum sensitivity) set on the

0-300 Vac scale.

Two jumper wires; no. 14 wire, insulated, 12 inches (304.8 mm) long with insulated alligator clips at both ends.

3. When jumpered to Ignition, Pilot and Main Valves, use

ammeter in series and verify proper current draw.

General Instructions

1. Perform all applicable tests listed in Static Checkout,

Table 8, in the order listed.

2. Make sure all manual fuel shutoff valve(s) are closed.

3. Perform only those tests designated for the specific

R7140 model being tested.

4. Raise the setpoint of the operating controller to simulate

a call for heat.

5. For each test, open the master switch and install the

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

6. Close the master switch before observing operation.

7. Read the voltage between the subbase wiring terminals

listed in the Voltmeter column.

8. If there is no voltage or the operation is abnormal, check

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

9. Check all wiring for correct connections, tight terminal

screws, correct wire, and proper wiring techniques. Replace all damaged or incorrectly sized wires.

10. Replace faulty controllers, limits, interlocks, actuators,

valves, transformers, motors and other devices as required.

11. Make sure normal operation is obtained for each

required test before continuing the checkout.

12. After completing each test, be sure to remove the test

jumper(s).

WARNING

Explosion Hazard. Can cause serious injury or death.

Make sure all manual fuel shutoff valves are closed before performing static checkout.

Table 8. Static Checkout.

Test

No. R7140 Models

1 All None L1-L2 Line voltage at terminal L1. 1. Master Switch.

2 16-L2 Line voltage at terminal 16 (4 on

3 4-L2 Line voltage at terminal 16. 1. Pre-Ignition interlocks. 4 L1-8 3-L2 1. Burner motor (fan or

5 L1-18 — Ignition spark (if ignition

Test

Jumpers Voltmeter Normal Operation

Pre-Ignition Interlock devices).

blower) starts.

2. Line voltage at terminal 3 within 10 seconds.

transformer is connected to terminal 18).

25 66-1153—2

If Operation is Abnormal,

Check the Items Listed Below

2. Power connected to the Master Switch.

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

1. Limits.

2. Burner Controller.

1. Burner motor circuit. a. Manual switch of burner motor. b. Burner motor power supply, overload

protection, and starter.

c. Burner motor.

2. Running or Lockout Interlocks (including Airflow Switch).

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

Page 26

R7140G,L,M BURNER CONTROL MODULES

Table 8. Static Checkout. (Continued)

Test

No. R7140 Models

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

7 L1-6 — Same as test no. 6 for

8 L1-7 — Automatic main fuel valve(s)

9 L1-9 — Alarm (if used) turns on. 1. Alarm. 10 R7140G,L L1-8

11 R7140G,L L1-8

12 R7140G,L L1-8

13 R7140L L1-8

14 R7140G,L 11-12 — 1. Raise setpoint of Series 90

15 R7140M with

open damper contacts.

16 R7140M with

open damper contacts.

17 R7140M with

open damper contacts.

Final All

Test

Jumpers Voltmeter Normal Operation

transformer is connected to terminal 5).

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

NOTE: Refer to wiring diagram

connections to terminal 5. If using direct spark ignition, check the first stage fuel valve(s) instead of the pilot valve.

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

and 10-11

and 14-11

and 10-11

and 14-11

14-11 — If damper motor is used, motor

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

L1-8 and L1-11

13-L2 Firing rate motor drives open;

zero volts at terminal 13 after motor starts driving open.

13-L2 Firing rate motor drives closed;

line voltage at terminal 13 after motor is in Low Fire position.

15-L2 Firing rate motor drives open;

line voltage at terminal 15 after motor is in High Fire position.

15-L2 Firing rate motor drives closed;

zero volts at terminal 15 after motor starts driving closed.

controller—firing rate motor should drive toward open.

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

drives damper open.

drives open; line voltage at terminal 13 after motor is in Low Fire position.

13-L2 If damper motor is used, motor

drives open; zero volts at terminal 13.

of system being tested.

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

2. Listen for click or feel head of valve for activation. a. Actuator, if used. b. Pilot valve.

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

1. Listen for and observe operation of the main fuel valve(s) and actuator(s).

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

1. Low Fire Start Switch.

2. Firing rate motor and transformer.

1. Low Fire Start Switch.

2. Firing rate motor and transformer.

1. High Fire Purge Switch.

2. Firing rate motor and transformer.

1. Low Fire Start Switch.

2. Firing rate motor and transformer.

1. Series 90 Controller.

2. Firing rate motor and transformer.

Damper motor.

1. Low Fire Start Switch.

2. Damper motor.

1. Low Fire Start Switch.

2. Damper motor.

CAUTION

Equipment Damage Hazard. Improper wiring can damage equipment.

On completing these tests, open the master switch and remove all test jumpers from the subbase terminal. Also remove bypass jumpers from the low fuel pressure limits (if used) to prevent equipment damage.

If Operation is Abnormal,

Check the Items Listed Below

66-1153—2 26

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R7140G,L,M BURNER CONTROL MODULES

SYSTEM CHECKOUT

IMPORTANT

Perform all Static Checkout Procedures in the applicable relay module installation instructions before starting these procedures.

WARNING

Explosion Hazard. Can cause serious injury or death.

Do not allow fuel to accumulate in the combustion chamber for longer than a few seconds without igniting to prevent danger of forming explosive mixture. Close manual fuel shutoff valve(s) if flame is not burning at end of specified time.

WARNING

Electric Shock Hazard. Can cause serious injury or death.

1. Use extreme care while testing system. Line voltage is present on most terminal connections when power is on.

2. Open master switch before removing or installing R7140 Relay Module.

Make sure all manual fuel shutoff valve(s) are closed before starting initial lightoff check and Pilot Turndown tests.

Do not put the system in service until you have satisfactorily completed all applicable tests in this section and any others recommended by the original equipment manufacturer.

Limit trial for pilot to ten seconds. Limit the attempt to light main burner to two seconds after fuel reaches burner nozzle. Do not exceed manufacturer nominal lightoff time.

CAUTION

Equipment Malfunction or Damage Hazard. Incorrect wiring can cause equipment damage.

Each relay module type is unique. Using existing wiring on a relay module change can cause equipment damage.

IMPORTANT

1. If the system fails to perform properly, refer to the Troubleshooting section.

2. Repeat all required Checkout tests after all adjustments are made. All tests must be satisfied with the flame detector(s) in their final position.

Equipment Recommended

S7800A Keyboard Display Module Volt-ohmmeter (1M ohm/volt minimum sensitivity) with:

• 0-300 Vac capability.

• 0-6000 ohm capability.

• 0-10 Vdc capability.

Checkout Summary

Table 9 provides an overview of checkout steps performed for each applicable system.

See Installation Instructions for location of component parts and terminal locations.

Table 9. Checkout Steps and Applicable Detection Systems.

Piloted

Checkout Step

Preliminary Inspection X X X X X Flame Signal Measurement X X X X X Initial Lightoff Check for Proved Pilot X Initial Lightoff Check for Direct Spark Ignition X Pilot Turndown Test X Ignition Interference Test X Hot Refractory Saturation Test X Hot Refractory Hold-in Test X X X X X Ignition Spark Pickup X Response to Other Ultraviolet Sources X Flame Signal with Hot Combustion Chamber X X X X X Safety Shutdown Tests X X X X X

Preliminary Inspection

Perform the following inspections to avoid common problems. Make certain that:

1. Wiring connections are correct and all terminal screws

are tight.

2. Flame detector(s) is clean, installed and positioned

properly. Consult the applicable Instructions.

Systems DSI Systems

3. Combination of amplifier and flame detector(s) is

4. Plug-in amplifier and purge card (if required) are

5. Burner is completely installed and ready to fire; consult

6. Combustion chamber and flues are clear of fuel and fuel

Infrared Flame

Detectors

correctly used. See the amplifier specifications.

securely in place.

equipment manufacturer instructions. Fuel lines are purged of air.

vapor.

Flame Rod

Systems

Ultraviolet

Flame Detectors

27 66-1153—2

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R7140G,L,M BURNER CONTROL MODULES

7. Power is connected to the system disconnect switch

(master switch).

8. Lockout is reset (reset button) only if the Relay Module

is powered.

9. Run/Test Switch (if present) is in RUN position.

10. System is in STANDBY condition. STANDBY message

is displayed in the S7800 Keyboard Display Module.

11. All limits and interlocks are reset.

Flame Signal Measurement

See instructions provided with the amplifier.

INITIAL LIGHTOFF CHECKS

Proved Pilot Systems

Perform this check on all installations that use a pilot. It should immediately follow the preliminary inspection.

NOTE: Low fuel pressure limits, if used, could be open. If so,

bypass them with jumpers during this check.

1. Open the master switch.

2. Make sure that the manual main fuel shutoff valve(s) is

closed. Open the manual pilot shutoff valve. If the pilot takeoff is downstream from the manual main fuel shutoff valve(s), slightly open the manual main valve to supply pilot gas flow. Make sure the main fuel is shut off just upstream from the burner inlet, or disconnect power from the automatic main fuel valve(s).

3. Close the master switch and start the system with a call

for heat by raising the setpoint of the operating controller; see the relay module sequence. The R7140 Relay Module should start a ten-second INITIATE sequence.

4. Let the sequence advance to PILOT IGN (status is

displayed on the Keyboard Display Module, if used), PILOT LED turns on, ignition spark should occur and the pilot should light. If the pilot ignites, the FLAME LED is energized. Go to step 7.

5. If the pilot flame is not established in ten seconds (four

seconds if configuration jumper JR1 is clipped), safety shutdown occurs. Let the sequence complete its cycle.

6. Push the reset push button, and let the system recycle

once. If the pilot still does not ignite, make the following ignition/pilot adjustments: a. Open the master switch and remove the R7140

Relay Module from the subbase.

b. On the subbase, jumper L1 to the ignition terminal;

refer to the appropriate wiring diagram to determine the proper terminal. Disconnect the leadwire to the pilot valve if it is connected to the same terminal.

c. Close the master switch to energize only the ignition

transformer.

d. If the ignition spark is not strong and continuous,

open the master switch and adjust the ignition electrode spark gap setting to the manufacturer

recommendation. e. Make sure the ignition electrodes are clean. f. Close the master switch and observe the spark. g. After a continuous spark is obtained, open the

master switch and add a jumper on the subbase

from terminal L1 power to the pilot terminal 5 or 6.

Reconnect the leadwire from the pilot valve if it was

disconnected in step b.

h. Close the master switch to energize both the ignition

transformer and the pilot valve.

i. If the pilot does not ignite and if the ignition spark is

still continuous, adjust the pressure regulator until a pilot is established.

j. When the pilot ignites properly and stays ignited,

open the master switch and remove the jumper(s)

from the terminals of the subbase. k. Check for adequate bleeding of the fuel line. l. Reinstall the R7140 Relay Module on the subbase,

close the master switch, and then return to step 4.

7. When pilot ignites, measure the flame signal. If the pilot

flame signal is unsteady or approaching the 1.25 Vdc minimum value, adjust the pilot flame size or detector sighting to provide a maximum and steady flame signal.

8. Recycle the system to recheck lightoff and pilot flame

signal.

9. When the MAIN LED turns on, make sure the automatic

main fuel valve is open; then smoothly open the manual main fuel shutoff valve(s) and watch for main burner flame ignition. When the main burner flame is established, go to step 16.

10. If the main burner flame is not established within five

seconds or the normal lightoff time as specified by the equipment manufacturer, close the manual main fuel shutoff valve(s).

11. Recycle the system to recheck the lightoff and pilot

flame signal.

12. Smoothly open the manual fuel shutoff valve(s) and try

lightoff again. (The first re-attempt may have been required to purge the lines and bring sufficient fuel to the burner.)

13. If the main burner flame is not established within five

seconds or the normal lightoff time specified by the equipment manufacturer, close the manual main fuel shutoff valves(s). Check all burner adjustments.

14. If the main burner flame is not established after two

attempts: a. Check for improper pilot size. b. Check for excess combustion air at Low Fire. c. Check for adequate Low Fire fuel flow. d. Check for proper gas supply pressure. e. Check for proper valve operation. f. Check for proper pilot flame positioning.

15. Repeat steps 8 and 9 to establish the main burner

flame; then go to step 16.

16. With the sequence in RUN, make burner adjustments

for flame stability and Btu input rating.

17. Shut down the system by opening the burner switch or

by lowering the setpoint of the operating controller. Make sure the main flame goes out. There may be a delay due to gas trapped between the valve(s) and burner. Make sure all automatic fuel valve(s) close.

18. Restart the system by closing the burner switch and/or

raising the setpoint of the operating controller. Observe that the pilot is established during PILOT IGN and the main burner flame is established during MAIN IGN within the normal lightoff time.

19. Measure the flame signal. Continue to check for the

proper signal through the RUN period. Check the signal at both High and Low Firing Rate positions and while modulating, if applicable.

20. Run the burner through another sequence, observing

the flame signal for: a. Pilot flame alone. b. Pilot and main flame together.

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R7140G,L,M BURNER CONTROL MODULES

c. Main flame alone (unless monitoring an intermittent

pilot). Also observe the time it takes to light the main flame. Ignition of main flame should be smooth.

21. Make sure all readings are in the required ranges before

proceeding.

22. Return the system to normal operation.

NOTE: After completing these tests, open the master switch

and remove all test jumpers from the subbase terminals, limits/controls or switches.

Direct Spark Ignition Systems

This check applies to gas and oil burners not using a pilot. It should immediately follow the preliminary inspection. Refer to the appropriate sample block diagram of field wiring for the ignition transformer and fuel valve(s) hookup.

NOTE:Low fuel pressure limits, if used, could be open. If so, bypass them with jumpers during this check.

1. Open the master switch.

2. Complete the normal ready-to-fire checkout of the fuel

supply and equipment as recommended by the equipment manufacturer.

3. Close all manual main fuel shutoff valve(s). Check that

the automatic fuel valve(s) is closed. Make sure fuel is not entering the combustion chamber.

4. Close the master switch and start the system with a call

for heat by raising the setpoint of the operating controller; see the relay module sequencing. The program sequence should start the INITIATE sequence.

5. Let the sequence advance through PREPURGE (if

applicable). Ignition spark should occur when the PILOT LED turns on. Listen for the click of the first stage fuel solenoid valve(s). The relay module locks out and the ALARM LED turns on.

6. Let the R7140 Relay Module complete its cycle.

7. Open the manual fuel shutoff valve(s).

8. Push the reset button and the relay module recycles the

program sequence through PREPURGE (if applicable).

9. When the PILOT LED turns on, make sure that the first

stage burner flame is established. If it is, go to step 15.

10. If the first stage burner flame is not established within

four seconds, or within the normal lightoff time specified by the equipment manufacturer, close the manual fuel shutoff valve(s), and open the master switch.

11. Check all burner adjustments.

12. Wait about three minutes. Close the master switch,

open the manual fuel shutoff valve(s), and try to light off the burner again. The first attempt may be required to purge the lines and bring sufficient fuel to the burner.

13. If the first stage burner flame is not established within

four seconds, or within the normal lightoff time specified by the equipment manufacturer, close the manual fuel shutoff valve(s), and open the master switch.

14. If necessary, repeat steps 11 through 13 to establish the

first stage burner flame. Then go to step 15.

15. When the first stage burner flame is established, the

sequence advances to RUN. Make burner adjustments for flame stability and input rating. If a second stage is used, go to step 18.

16. Shut down the system by opening the burner switch or

by lowering the setpoint of the operating controller. Make sure the burner flame goes out and all automatic fuel valves close.

17. If used, remove the bypass jumpers from the low fuel

pressure limit and subbase.

18. If a second stage is used, make sure the automatic

second stage fuel valve(s) opened. Check the lightoff as follows (or go to step 19): a. Open the manual second stage fuel valve(s). b. Restart the system by raising the setpoint of the

operating controller.

c. When the first stage burner flame is established, watch

for the automatic second stage fuel valve(s) to open. Observe that the second stage lights off properly.

d. Make burner adjustments for flame stability and

input rating.

e. Shut down the system by lowering the setpoint of

the operating controller. Make sure the burner flame goes out and all automatic fuel valves close.

f. Go to step 19.

19. Restart the system by closing the burner switch and/or

raising the setpoint of the operating controller. Observe that the burner flame is established during PILOT IGN, within the normal lightoff time specified by the equipment manufacturer.

20.

Measure the flame signal. Continue to check for the proper signal through the RUN period. Check the signal at both high and low firing rate positions and while modulating. Any pulsating or unsteady readings require further attention.

21. Make sure all readings are in the required ranges before

proceeding.

NOTE: On completing these tests, open the master switch

22. Return the system to normal operation.

and remove all test jumpers from the subbase terminals, limits/controls or switches.

PILOT TURNDOWN TEST (ALL INSTALLATIONS USING A PILOT)

Perform this check on all installations that use a pilot. The purpose of this test is to verify that the main burner can be lit by the smallest pilot flame that can hold in the flame amplifier and energize the FLAME LED. Clean the flame detector(s) to make sure that it detects the smallest acceptable pilot flame. If using AMPLI-CHECK™ or self-checking amplifier and 1M ohm/volt meter, the flame signal fluctuates every time the amplifier does a self-check or a shutter check.

NOTE: Low fuel pressure limits, if used, could be open. If so,

bypass them with jumpers during this test.

1. Open the master switch.

2. Close the manual main fuel shutoff valve(s).

3. Connect a manometer (or pressure gauge) to measure

pilot gas pressure during the turndown test.

4. Open the manual pilot shutoff valve(s).

5. Close the master switch and start the system with a call

for heat. Raise the setpoint of the operating controller. The 7800 Series sequence should start, and PREPURGE (if applicable) should begin.

6. After the PILOT LED turns on in interrupted pilot

applications, set the Run/Test Switch to the TEST position to stop the sequence. The FLAME LED comes on when the pilot ignites.

NOTE: If the sequence does not stop, reset the system and

make sure you set the Run/Test Switch to TEST within the first eight seconds of the PILOT IGN sequence.

29 66-1153—2

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R7140G,L,M BURNER CONTROL MODULES

IMPORTANT

You have 0.8 second or three seconds, depending on PFEP selected, to position the Run/Test Switch to the TEST position to stop the sequence after the start of the PILOT IGN period.

Turn down the pilot pressure very slowly, reading the

manometer (or pressure gauge) as it drops. Stop instantly when the FLAME LED goes out. Note the pressure. The pilot is at the minimum turndown position. Immediately turn up the pilot pressure until the FLAME LED comes on again or the flame signal increases to 1.25 Vdc.

NOTE: If there is no flame for 15 seconds with the

RUN/TEST switch in the TEST position, the relay module locks out.

8. Repeat step 7 to verify the pilot gas pressure reading at

the exact point the FLAME LED light goes out.

9. Increase the pilot pressure immediately until the FLAME

LED comes on, and then turn it down slowly to obtain a pressure reading just above the dropout point or until the flame signal increases to 1.25 Vdc.

10. Set the Run/Test Switch in the RUN position (if used)

and let the sequence proceed. When the MAIN LED turns on, make sure the automatic main fuel valve(s) opens; then smoothly open the manual main fuel shutoff valve(s) (or any other manually-opened safety shutoff valve(s), if used) and watch for main burner ignition. If the main burner flame is established, go to step 18.

NOTE: This step requires two people, one to open the

manual valve(s) and one to watch for ignition.

11. If the main burner flame is not established within five

seconds, or within the normal lightoff time specified by the equipment manufacturer, close the manual main fuel shutoff valve(s) and open the master switch. If the lightoff is rough, the pilot flame size is too small.

12.

Close the master switch to recycle the burner and stop the sequence in the PILOT period by using the Run/Test Switch.

13. Increase the pilot flame size by increasing its fuel flow

until a smooth main flame is accomplished.

14. Reposition the flame scanner sight tube or use orifices

until the pilot flame signal voltage is in the range of 1.25 to 1.50 Vdc.

15. When the main burner lights reliably with the pilot at

turndown, disconnect the manometer (or pressure gauge) and turn up the pilot gas flow to that recommended by the equipment manufacturer.

16. If used, remove the bypass jumpers from the subbase

terminals, limits/controls, or switches.

17. Run the system through another cycle to check for

normal operation.

18. Return the system to normal operation.

IGNITION INTERFERENCE TEST (ALL FLAME RODS)

Ignition interference can subtract from (decrease) or add to (increase) the flame signal. If it decreases the flame signal enough, it causes a safety shutdown. If it increases the flame signal, it could cause the FLAME LED to come on when the true flame signal is below the minimum acceptable value.

Start the burner and measure the flame signal with both ignition and pilot (or main burner) on, and then with only the pilot (or main burner) on. Any significant difference (greater than 0.5 Vdc) indicates ignition interference.

To Eliminate Ignition Interference

1. Make sure there is enough ground area.

2. Be sure the ignition electrode and the flame rod are on

opposite sides of the ground area.

3. Check for correct spacing on the ignition electrode:

a. 6000V systems—1/16 to 3/32 in. (1.6 to 2.4 mm). b. 10,000V systems—1/8 in. (3.2 mm).

4. Make sure the leadwires from the flame rod and ignition

electrode are not too close together.

5. Replace any deteriorated leadwires.

6. Try wrapping the ignition wire with an insulated wire

(No. 18 stranded, for example). See Fig. 13.

7. Strip the insulation nearest the ignitor and ground it;

also, strip the insulation nearest the ignition transformer and ground it.

8. If the problem cannot be eliminated, consider changing

the system to an ultraviolet flame detection system.

IGNITION

TRANSFORMER

BURNER MODULE

IGNITION

LEAD

FLAME ROD

LEAD

BURNER ASSEMBLY

M19423B

Fig. 20. Eliminating ignition interference.

Hot Refractory Saturation Test (All Infrared Detectors)

Start the burner and monitor the flame signal during the warm-up period. A decrease in signal strength as the refractory heats up indicates hot refractory saturation. If saturation is extreme, the flame signal drops below 1.25 Vdc and the system shuts down as though a flame failure occurred.

If hot refractory saturation occurs, the condition must be corrected. Add an orifice plate in front of the cell to restrict the viewing area, lengthen the sight pipe or decrease the pipe size (diameter). Continue adjustments until hot refractory saturation is eliminated.

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R7140G,L,M BURNER CONTROL MODULES

Hot Refractory Hold-in Test (Rectifying Photocell, Infrared Detectors, Ultraviolet Detectors)

This condition can delay response to flame failure and also can prevent a system restart if hot refractory is detected.

Infrared (lead sulfide) detectors can respond to infrared rays emitted by a hot refractory, even when the refractory has visibly ceased to glow. Infrared radiation from a hot refractory is steady, but radiation from a flame has a flickering characteristic. The infrared detection system responds only to flickering infrared radiation; it can reject a steady signal from hot refractory. The refractory steady signal can be made to fluctuate if it is reflected, bent or blocked by smoke or fuel mist within the combustion chamber. Be careful when applying an infrared system to verify its response to flame only.

The ultraviolet detector can respond to hot refractory above 2300°F (1371°C).

1. Operate the burner until the refractory reaches its

maximum temperature (Infrared Only). If the installation has a multi-fuel burner, burn the heavier fuel that is most likely to reflect, bend or obscure the hot refractory steady infrared radiation.

2. When the maximum refractory temperature is reached,

close all manual fuel shutoff valves, or open the electrical circuits of all automatic fuel valves.

3. Visually observe when the burner flame or FLAME LED

goes out. If this takes more than three seconds, the infrared detector is sensing hot refractory.

4. Immediately terminate the firing cycle. Lower the

setpoint to the operating controller, or set the Fuel Selector Switch to OFF. Do not open the master switch.

NOTE: Some burners continue to purge oil lines between

the valves and nozzles even though the fuel valves are closed. Terminating the firing cycle (instead of opening the master switch) allows purging the combustion chamber. This reduces a buildup of fuel vapors in the combustion chamber caused by oil line purging.

5. If the detector is sensing hot refractory, correct the

condition by one or more of the following procedures: a. Add an orifice plate in front of the cell to restrict the

viewing area of the detector.

b. Resight the detector at a cooler, more distant part of

the combustion chamber. Make sure the detector properly sights the flame.

c. Try lengthening the sight pipe or decreasing the

pipe size (diameter).

For details, refer to the detector Instructions and the equipment Operating Manual. Continue adjustments until hot refractory hold-in is eliminated.

IGNITION SPARK RESPONSE TEST (ALL ULTRAVIOLET DETECTORS)

Test to make certain that the ignition spark is not actuating the FLAME LED:

1. Close the pilot and main burner manual fuel shut-off

valve(s).

2. Start the burner and use the Run/Test Switch (if

available) to stop the sequence in the PILOT IGN period. Ignition spark should occur, but the flame signal should not be more than 0.5 Vdc.

If the flame signal is higher than 0.5 Vdc and the FLAME LED does come on, consult the equipment operating manual and resight the detector farther out from the spark, or away from possible reflection. It may be necessary to construct a barrier to block the ignition spark from the detector view. Continue adjustments until the flame signal due to ignition spark is less than 0.5 Vdc.

NOTE: The Honeywell Q624A and Q652B Solid State Spark

Generators prevent detection of ignition spark when properly applied with C7027, C7035, C7044 or C7061 Ultraviolet Flame Detectors. The Q624A and Q652B are only for use with gas pilots.

Response To Other Ultraviolet Sources

Some sources of artificial light (such as incandescent or fluorescent bulbs, mercury sodium vapor lamps and daylight) produce small amounts of ultraviolet radiation. Under certain conditions, an ultraviolet detector responds to these sources as if it is sensing a flame. To check for proper detector operation, check the Flame Failure Response Time (FFRT) and conduct Safety Shutdown Tests under all operating conditions.

Flame Signal With Hot Combustion Chamber (All Installations)

With all initial start-up tests and burner adjustments completed, operate the burner until the combustion chamber is at the maximum expected temperature.

Observe the equipment manufacturer warm-up instructions.

Recycle the burner under these hot conditions and measure the flame signal. Check the pilot alone, the main burner flame alone, and both together (unless monitoring only the pilot flame when using an intermittent pilot, or only the main burner flame when using DSI). Check the signal at both High and Low Firing Rate positions and while modulating, if applicable.

Check the FFRT of the flame amplifier and relay module.

Lower the setpoint of the operating controller and observe the time it takes for the burner flame to go out. This should be within the maximum FFRT.

If the flame signal is too low or unsteady, check the flame detector temperature. Relocate the detector if the temperature is too high.

If necessary, realign the sighting to obtain the proper signal and response time.

If the response time is still too slow, replace the Plug-in Flame Signal Amplifier.

If the detector is relocated or resighted, or the amplifier is replaced, repeat all required Checkout tests.

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SAFETY SHUTDOWN TESTS (ALL INSTALLATIONS)

Perform these tests at the end of Checkout, after all other tests are completed. If used, the external alarm should turn on. Press the RESET pushbutton on the relay module to restart the system.

Opening a Preignition Interlock during the STANDBY or PREPURGE period (R7140L - Lockout; R7140G and M Standby Hold 40 seconds, then Lockout). a. Safety shutdown occurs.

Opening a Lockout Interlock during PREPURGE, PILOT IGN, MAIN IGN or RUN period (R7140L Only). a. R7140G and R7140M go to Standby. b. Safety shutdown occurs.

Detection of flame 40 seconds after entry to STANDBY from RUN. Detection of flame from ten seconds up to 30 seconds into PREPURGE time. a. Simulate a flame to cause the flame signal voltage

level to be at least 1.25 Vdc for 40 seconds after entry to STANDBY from RUN and also simulate a flame

signal for 10 seconds to 30 seconds for PREPURGE. b. Flame LED is on. c. Safety shutdown occurs after 40 seconds.

Failure to ignite pilot. a. Close pilot and main fuel manual shutoff valve(s). b. Cycle burner on. c. Automatic pilot valve(s) should be energized but the

pilot cannot ignite. d. Safety shutdown occurs.

Failure to ignite main (only interrupted pilot application). a. Open the manual pilot valve(s); leave the main fuel

manual shutoff valve(s) closed. b. Depress the reset button. c. Start the system. d. The pilot should ignite and the flame signal should be

at least 1.25 Vdc but the main burner cannot light.

e. The flame signal should drop below 1.25 Vdc within

the FFRT of the amplifier and the relay module after the interrupted pilot goes out.

f. Safety shutdown occurs.

Loss of flame during RUN. a. Open the main fuel manual shutoff valve(s) and open

manual pilot shutoff valve(s). b. Depress the reset button. c. Start the system. Start-up should be normal and the

main burner should light normally. d. After the sequence is in the normal RUN period for at

least ten seconds with the main burner firing, close

the manual main fuel shutoff valve(s) to extinguish the

main burner flame. (On intermittent pilot applications,

also, close the pilot manual shutoff valve.) e. The flame signal should drop below 1.25 Vdc within

the FFRT of the amplifier and the relay module after

the main flame and/or pilot goes out. f. R7140L goes to Safety Shutdown; R7140G, M recycle

after 15-second postpurge. g. Safety shutdown occurs. (R7140L only.)

Opening a Preignition Interlock after the first five seconds of POSTPURGE. a. Open the main fuel manual shutoff valve(s) and open

manual pilot shutoff valve(s). b. Depress the reset button. c. *Preignition ILK* fault is displayed on the Keyboard

Display Module. Fault code 33 is displayed to denote

the fault. d. Safety shutdown occurs.

IMPORTANT

1. If the relay module fails to shut down on any of these

tests, take corrective action; refer to Troubleshooting and the relay module diagnostics and return to the beginning of all Checkout tests.

2. When all Checkout tests are completed, reset all

switches to the original status.

Automation and Control Solutions

Honeywell International Inc. Honeywell Limited-Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley, MN 55422 Scarborough, Ontario M1V 4Z9 customer.honeywell.com