flame safeguard control phần 6 ppsx

For BKample, a flame red can be used 10 delecl Ihe pilot, and a self-checking C7012E or F Ultraviolet Flame Deleclor can be used for the main burner flame.. 3 210 cloS85, applying power

R4075E DUAL INDUSTRIAL FLAME

SAFEGUARD CONTROL (FIG 63)

The R4075E consIsts 01 2 controls on 1 chassis 10 pro­

vide Independer1t ~rvislon of 2 indusUial burners 11

can al$O be used for redundanl safely conlrol systems or

for l1JaI·fuel applications With 2 controls on' chassis, the

mOUFllinQ space r9QJlred Is only hatf (hal previously

.-

Each control is similar to the R4075C, and thus is

ac:lapled for the 'Same family of plug-in name sIgnal amplifi·

ers developed for the R4140 Any ccrrt>inalion 01 standard

and/or sal1·checking flame detection system can be used

by mi;ling or matching the amplifiers For BKample, a flame

red can be used 10 delecl Ihe pilot, and a self-checking

C7012E or F Ultraviolet Flame Deleclor can be used for

the main burner flame Since all amplifiers are plug-in, Ihe

detection rJ'\C:lClI3'can be changed anytime after Jnstallation

Because terminal designations for lhe R4075E are

unlQJ9, II requires a special Q295A1054 Wiring Subbase

The R4075E is available in 120 and 220 voll models

SEQUENCE OF OPERATION FOR THE R4075E

(FIG 64)

The q:>eration of the 120 volt model o1lhe R4075E will

be described The sequence 01 operalion for the 220 voll

model is the same; it just has 2 addilionallransforrners to

provide 120 volts for the shullers on C7012E or F Purple

Peeper Ullraviolet Flame Detectors The schematic ill

Fig 64 shows all relay conlacls in the de-enerQized posl­lion Refer 10 file 8eq.Jence 01 {)peralion on the following

FIG

63-182

I I .~ l , I r­

® ® C'J (0) (0) "

,

lRe R4075E consists of 2 identical sections A and B This sequence of operation is tor one section The operalion 01 the olher section is identical

NOTE: Italics denote special applications

NORMAL OPERATION

TO START;

1 Reset an limits O:ls:e the master

_ h on' the .~ silencing

swilch (If used)

1TI0>t

Cb ret push in the srART

buttm' _before the rna_

_ itch 18 COITIpletely cbsed

1 a

b

Poo¥9r iI5 applied to terminalS thrtJUgh

the Ifllits, alarm sll&ncing switch, and STOP station; the plug-in amplifier is energized

Power Ie applied to terminal 7 (through

the alarm silencing switCh} Ilnd to tar­

minal 8 ('through 11<2)

, 11

b

Standby to start

The alarm is energized

2 Push in 1t'Ie START button on Itll~

S445A and I1:lld it in

2 a Power is appliell Ie the ignition trans­

former and to termiN.I 3 through thE!

limits, alarm silenCing ~h STOP

6't!ltion, imernal jlmper in trnI S445,A,., and START S'tlltion

2 a Th ignition transformer on' pibt vaJve (or 1st stage oil valYe) afe ener· glzad The pilot valve opens and the pi­

bt is ignited The flame detector de­ (ects the pilot flame

b Relay 1K pUll$ in lIlrough 2K2 (sale 6't!lrt contacl) Contact 1Kl eto$MI by·

passing 2~: 1K2 opens on' 'KJ

clo!l9S

b The alarm i$ dlHlnerglzed

pMer is used, power is applied from ler­

c It a C70f2E rx F Purpfe Peeper Ultra·

viciel Flame Derectrx ('wI~h se/f<;heck·

3 Release 1I1e START button

"'''

TO STOP'

S Push in the STOP button on the

S4'SA ,,' "''' •;, until the

.larm is energized

used)

7 Open the master switCh

, When the pibt flarne is d6t9Ct8d, relay 2K pulls in Contact 2K1 closes, by­

pusing lIlll START station fran ter

mil'\8.l 6, lIlroullh 2Kl and 110, 10 ter·

minal 3 Contset 2K2 opens ContaCl 2K3 closes: power is applied Irem ter·

minal 3111rough 1K1 anO 21<3 to tsrm~

nal S

3 Normal operation including setl-chec:k­

ing or the flarntl detectioo sysiem frf a sell·

checking system is used)

• Normal operation

,~,

S a. _ -I&rminal o

This removes ~ fran terminals 3,

S and 12 The plug-in amplifier is energized and relay 2K drops out

de-b Relay 1K drops out: 11<2 closes

, All relay ronlecle are rasat lor the nelCl

, Tho automatic main fuel vatve(s} ;,

energizeo The valve(s) opens lind lila main bumer;$ ignited Tha system i$ in

th, , " , condition, (If • mMLIally opened valve is used, the maoil burl"lEW"

pleled.)

3 The igntfun 1rlinstormer is de-energized

• The main burner is ignited The system 1$

S a The pilot valVe (or 1st stage ell valVe) and 1t'Ie main fu&t VIltve(S) are de-ener· giZed The valves clo6e and the pilot anI:! main burner flames go Out

b The alarm is energiz80

, N~

0 The alarm is d&-energized

7 The SyStem is de-energizad

SEQUENCE OF OPERATION FOR THE R4075E (Continued)

SAFETY OPERATION

Relay 2K pulls in when the name (or flame­

simutaTing condiOOn) is deteel&d Conlacl:

21<2 opens, preventing relay 1K trom pulling

in when the START button is p~sed

• Contact 1K3 stays open: the STAAT sta·

tial is no! bypassed Power is removed

fn:n1lBrmil"lRl J whOl'\ the START bl./tt:ln

is relaased

• Contact 11<2 remains c'oseO

• Conuel 1K1 flmains open

Relay 2K does rot pUll in

• Contact 2Kl slBys open: ltle SfAHT s\a

tbn is not bypassed When 1M srAAT butIl:ln is released power ~ retJ"lO';'ed fTtm t9nTlinll\ 3 and relay 1K drops out

• Ca1tact 21<3 stays open; power canl'lOl

~ applied tJ terminel 5

• Contact 11<2 closes

Relay 2K drops out

• CorTtact 2K1 opens: poweI" is rerroved

fftm terminal 3 and ra!ay 1K drops out

• Contact 21<3 opens; power is I'8r'l'lOWd

fftm terminal 5

• Contact 1K2 cbses

All felEVJ'8 drop out

Relay 2K cannot pull in When IN syst1Irn Is startBd-ume operation as if N pitrt Is tI:lt ignited

Sale Start Check - A "name, or a oondi­

ticn simutanng.8 name is present be­

101'9 "lt1e START button is pressed

FLAME DETECTION SysrEM'

The name de18Ction system laila While

h syvt8m is IU.med of!,

The name det8Ctloll $Vslern tails dur·

ing tl1e run period Wllh !he burner

~ng

Relay 2K dropa out-same operation all II'

the 1Ieme gee! 0Ul

The vaNe closes and !he pi'ct 1\ame goeo out

• The alarm remaine energized

• The 8ubnatic main fuel valve(sl canrot:

be en6I'giZ8CI

ststem cannot be lllarted

• When 1M srART b~ is relessad tt1e ignition lrans10rmer and ltle pilot valve (or 1M stage oil Valve) are de-energized The pilOt vatve cbsa$

• TIle automatiC main fuel valve(s) cannot

be energized

• The alarm is energized

sa/Qty' sh tdown OC:CUr3

The pilOt valve (or lsi llIage oil valve) ill

• de-energized and I!"e valve closes

• The main fuel valve(s) ia de-enMlJized and the varve(a) closes

The alarm Is energized

• safety Elhutdovm oCCunl but the alarm is not

lJIr18l'"giZed umn power 18 rastonld

safety ElhUldown oCcurs

safety shutdown occurs

R4138C,D INDUSTRIAL FLAME SAFEGUARD

CONTROLS (FIG 65)

These controls directly replece older R4138A and B

models to meet the lates! rElQJirements They are espe­

cially Suitable where Icng petilXi3 01 burner operation with·

out s/'lulc:bwn are normal, such as in heat-treating ovens

and kilns The R4138D is (he same as the R4138Cwl!hthe

adc:lilion 01 a jXl'I'Ver failure override circuit 10 prevent shut­

down during very short;power outages (,oower line switch­

Ing of 1 Second or less) The A4138C is available in 120,

220, and.24O volt rtlOdeIS; the A4138D Is available only in a

120 vol'model

SAFETY FEATURES

The A4138C and D provide a Safe Start Check for a

flame, or a condition simulating a flame, at startup If the

flame"relay 2K is pulled in before the STAAT button is

pressed• 2K.2 is open, preventing the load relay 1K from

pulling in The system cannol be started until the condition

Is corrected and 2K drops PUt

They also prOVide safety shutdown on­

- failure to Ignite the pilor (lockout will occur t1the

START button is held in IClIlg9f than the 10ckPUt

switch liming.)

-loss 01 flame during the rUl"l period

-failure in the flame detectiCfl system, If e sell·

cheCking system is' used-see Table II (L.ockoul

will occur it lhe START b rIlon is held in longer

than the lockout switch timinQ.)

On safety shutdown the pilot and main fuel valve(s) are

de-energized 11 used, the exlernal alarm is energized The STAAT bulton must be manu8JJy pressed to restart the

system "the lockout switch trips the load relay 1K drq:>s Oul and the lockout switch must be manually reset to rEt­start the system

OTHER FEATURES

" A plu~in $4.27D Purge Timer is available as an ac· cessory (0 provide e timed purge period prior to the manual startup

" An optionei remole reset assembly allows resetting the lockout switch from a remote location

" Irlcandescent indicator lamps (FLAME OFF, PURGE COMPLETE, FLAME ON) prOVide a visual check: 011he system condl1ion

• The R4138C or D plugs into a subbase or cabinet ElQJiA?OO with quick-connect C'-ontacts

• All field wirinQ (except for the optional remote reset assembly) is connected to a terminal strip on the subbase or In the cabinet The R4138 can be re­moved easily withoul disconnecting any w·lring

" Clear plastic relay covers help prevent conlamina­tion, damage, end lamperinQ

" An ALARM terminal Is available to operate an exler­nalline voltage alarm on salety shutdown

" A zinc-dichromate finish resists the corrosive ef­fects 01 most induslrial atmospheres

- - - -

SEOUENCE OF OPERATION FOR THE R4138C

OR D (FIG 66)

The cperalion orlhe 120voll models oflhe R4138Cand

D win be described Theseq.Jel1ceofoperalion for a 220 or

240 volt model ot the R4138C is the same; it just has an

aci:jitionaltransformer 10 provide 120 volts tor the sMutler

& "'L.CIT UN Ju M; , II:(U_O '0"'" ce OO

'IOCIl """T eAT><I LIN - IT I.SO ~U-"'"

& ' n o' ,"" c""11 D.' "" I"II:UO: ULT

~=,:.~~,':;'~': ':':'~~~'~;;~Uc'=:"~;;.'Jo~~J ~"u."'''- u f l'H€ - ,

& IF • ., " ST••' ' "••""" , roar 0 TH, IT""" ""'TC" ,

FIG 66- SIMPLIFIED SCHEMATIC DIAGRAM OF TME 120 VOLT MODELS OF THE R4138C AND D

SHOWING TYPICAL FIELD WIRING FOR A GAS OR OIL CUTOFF SYSTEM

SEQUENCE OF OPERATION FOR THE R4138C, D NOTE: Italics denote special 8HJlications

NORMAL OPERATION

TO START­

1 RElsel tI111 Ioc~ut switch on tile 1, a ap~lied

" terminal , a The lan(5) R4138 Reset all limrts and inter­ Ihrough " " • thE! "

'bcks Close to terminal 3 Ihrough the jumper Irom

larminal L 1: the plug-in amplifier is 8f\o ergized

b Po- i' applied

('tHough the alarm silaneing switl:hl, "

~gh the high fire irrtBr1ock) and to

Pow"

clean the combustion chamber of un­

PT1): 1he purge timer starts

c At the end 01 lhe preset time PT1 , Relay 1 R pulls In: 1 R1 closes to bypass opens and ll1e purga timer stops PT2 the nigh fira jnter10ck end keep power ctJses, IlPPtyinll power Ie terminal 6 applied Ie the purlle timer (If power is

(Trom terminal L1); the PURGE COM- removed In:m the pur'ile timer, it will PLETE (GREEN) lamp li'ilhts reset, PT2 will open anll tile system

4 Close the alarm silencing switch (II" , None ,

5 Push In the START button and 5 e ~er is applied Ie the i'ilniOOn trans· 5 a Tha i~nrtion transformer Is 9n9r~lZall

t1:Ild it In former and to

NOTE: To low lire start lnlertock and the srART

statkJn).

shutcbwns when not using

b ~er Is applied to tarmir.al 7ln:m te!'­ b None.

a purge liry'let, wait at lea$!'

minal 6 (II1rou~h the low lire start InlBr­

10 seconds after the tan

in-terlock closes before STOP staOOn, ,"d

(1l 1K1 ebses applyin'il power to tur· , (1) TI"MI pilot vllive (or 1st sta~e oil

minai'S tro-n terminal 3 valve) • ener~lled The valve

opens and the pilol: (or 191 sta'ila Oil burner) Is I~n~ed

(2) Jt the pilfJl/lnlc lumper wi/1l I'!~s been

clipped fr:T 8 continurxJs (sr~ng)

piJfJl app/iC81ion, the tfame derec­

rion circUit fO the amp/if/Sf is com-­ pleted

(2l 1K2 closes

(3) lK3 cbses; the LS HTR (lockoul (3) None

be'ilins heatin'il (tty autJtransfonner action of 1K thf'OU'ilh 1K3 and 21<2)

,h hea""

d If 8 C7012E cr F PurpJe Peeper U/tfit-­ pJiffet"Js used, power is applied from ter­

d If an Rrn7C DpIarric Self ChecJc Am­

vir:itJt FlsmtJ DBtacta (NitI'! seIf-eheck·

13, t!roU¢ the sr:iid "'are swircfl in the gized.

81tfJIiffet" (between ampli~B>' tfJi"trlnaJs

16 fIftd 17), 10 ttrrTinaJ 12

••

SEQUENCE OF OPERATION FOR THE R4138C 0 (Continued)

NORMAL OPERATION (cOflrinued)

None • The "arne detector detects the nlllT!8 lor llrt stage oiIl1ame) .""

r When the llama is detected relay 2K pull, in

(1) 2K1 closes, bypassing the purtle l (1) None

~m8f contact PT2, low nre stan

interbck START slam, and inter­

nal jumpel" Power will be applied t:I terminal 7 {tmm terminal 3 tt1rcugh 2Kl ID tenninal e, and tI1rough tI1e

STOP stillion and alarm sileJ'ICing

!Witchl tJ tvJld in relay 1K (unl", Ih8 limb open the STOP button il pressed oc safetj shulQaoNn

occurs

(2) 2K2 opens; the LS HTR stJps heat· (2) None

Ing

(3) 210 cloS85, applying power lD tar· (3) The aubnatic main fuel vaMl(a) jljI

minal 20 (frt:rn terminal 3 throUgh energized The valwl(s) Optms and

1Kl) Relay 3K pulls in and the the main burner is ignited The

sys-FLAME ON (WHITE) IlImp Wghts lern is in the run conditbn (If II

main l:IUmet will not be igrittKi unrif

step 7 is compleuKf.'

, When relay 3K pulls in­

(1) 3K1 opens rel'TlOVing power fn:m , (1) The alarm is de-energized terminal 15

(2) R4138D only: 3K2 closes, bypass­ (2) None

ing 110 Relay 11< can pull back in after e fT'OTIenlary power failure if

31< is still pulled in

PI 310 opens, rel'TlOVing _, 18 Th FLAME power fn:m OFF P} Retay 1R drops out and 181 opens {REO) lamp goes out The purge

resets ~, F'T2

rerroving power fn:m terminal 5

The PUAGE COMPLETE (GREEN) lamp goes out

5 When the FLAME ON (WHITE) 5 Normal operation, including self~l1eck- 5, The ignib't ltanmlTl'lel" is de-energIUld, lamp lights relaase ltle START ing of the name deteeiion system (rl a self-

checking system is used).

bullon

7 Normal operetion

7 Open manual main Iw/ valve(s) 7 The main burlJ8f is igrrlfKi Too system is

TO SIOP'

a Push in the STOP button ;tnd 8 a Power Is rer'l'W:'Ved lmm terminal 7 8 a C7012E, F shtJrtBt' is ~D1d,

hold it in until the FLAME OFF b Relay 11< drops out lKl operul re- b The pilol valve (or lsi stage oil valve) (REO) 1= IiQhls or U!TtII all moving power lmm terminal$ 19 and and the main fuel valwlfsJ ere de-ener­ relays drop out 20 Relay 31< drops out and the FLAME gized The valves Close end a11l1ames

ON (WHITE) lamp g.oes oul go out

c When relay 31< drops oul­

(1) 31<1 close:9 c (11 The alarTn is en8l:gizlld

(2) 310 ck:ls&6: ltle FlAME OFF (REO) (2) None

, Vv'tlen the lIames go , None

drops out

e All relay contacts are resellor the next None,

startup

9 Power ~ retro'tIed from tel'min4l:9 1S end 9 The alarm is

9 Open the alarm silern:ing svwiIch

15

10 Power is rllr1'DWd from tel'miMIs L 1 and '0 The lan(9) stipe end the systIlm is de­

10 Open Ihe masler swilr::h

3 The plug n amplifier is de-energized 808I'"glzed

and the FLAME OFF (RED) lamp goes,,"

SEQUENCE OF OPERATION FOR THE R4138C, D (Continued)

SAFETY OPERATION

Safe Stan Dleck-A flame, or a condi· Raley 2K puns In when the name (or flame- The system cannot be started unm the con· tion simulating a name, is present be- simulating condition) is detected Contact ditiol'l is

NOTE: r,.s c.heck does not apply if in when the

inrJ a.cootinuous (st8flding)

, K1 stays open; no IlOM'I' can be ap­ • The pilot valw (or 1st stage oil valve) and

• plied D tlIrminals 19 and 20 the automatic main fuel vatve(s) cannot

• Relay 3K cannot pull in; 3K1 and 310 re­ • The alarm remains energized

main closed The FLAME OFF (RED)

lamp remains on The PURGE COM·

PLETE (GREEN) lamp may also cane

No name is detected so relay 2K does not The system c~ be started The ignrtion

The pilot (or 1st stage oil buma" is not

START bbltlDn is released

, Contact 2K2 stays Cbsed; the LS HTR

(lockout II'I'o'itc:h heater) heats until !he The lockout switch must be manually

re-lockout switch 1I1ps (If the START button set to try to restart !he syslem

is held in longer !han the 'Ockout switch timing)

a lS1 opens and relay 1K drops out a The pilot valve (or 1st stalle oil valve) 1K1 opens, removinll power from Ier­ is de-energized, eo' th valve minaJ 19 ,""""

b 210 stays open; power cannot be b The automa1ic main fuel vslve(s) applied to 18nTIinaJ 20

can-, Relay 3K cannot pull in; 3K1 and 310 , The slerm remains enerllized not be energized, remain closed Tho FLAME OFF

(RED} lamp remains on

2 If the START button is released before 2 Safely shutdown occurs The START the Iockolll swill:h trips- button must be manually pressed to try

to restart the system,

a When the START button is released, not bypassed When the START but­

2K1 stays open: the START station is

the ignition transtormer is de-ener·

ton is released, power is removed gized

, Relay 3K cannot puK in; 3K1 and 310 ,

remain closed Th, FLAME

System shutdown occurs period

NOTE: Safely operation is the same if

The flame \lOBS out during the run Relay 2K drops out

• The pilot vlllve (or 1st stall~ oii valve) and the mllin burner is rxrt ig nired in a • 2K1 opens, removinll power fn:m termi­

the automlltic mllin luel vsive(s) are system w;th an interrupted pilot

de-nsls 8 and 7 Relay 1K drops out and 1K1 (obtained only by

opens, removing JXlwer from terminals lamp goes out

• Thll alarm is energized

The FLAME OFF (RED) lamp lights

• Relay 3K drops out; 3K1 and 310 close

The system shuts down All valves lire

de-A limit or interlock opens Power is fllITW:M'Id fn:m all terminliis except

15 All indicator lemps go out and all relays energized, and the valves c!osB The IIlarm drop out 3K1 closes, applying power 10 ler­ is energized

minal16

190

-~.~ -SEQUENCE OF OPERATION FOR THE R4138C, D (Continued)

SAFETY OPERATION (continued)

Momentaty power "fsHure

B4138C;

Power ~ r9IT'QYed from all tanninals aN lndl­

calor lamps go out and all r8l6y, drop out

llill&

Power is rerooved Irem all terminals all indio calor lamps go out, and aU relays except 3K

drop out The charge on capacitor Cl will

hold in 3K tJr about 1 second

• It poWllf' is restored before 3K drops out end before lila plot flame (or 1st

stage oil !IamEI) ~ out­

-3K2 will stay cbsed bypassing lK3;

3Kl and 3K3 Will stay open

- rllfey 2K will pUll bacl( in: 2Kl and

2K3 will cbse and 2K2 will open

-the STAAT staliol1 will be bypassed through 2Kl, the STOP statkm, anl:l the alarm silencing switch

- po er .ill be reappliel:l to lerrninal

7

- relay 1K 111 pull back in thrtluOh LS1 ani:! 3K2

- operation Will re!lJm to normal

• If 3K l:lrops OU1 before power is r&­

stored­

- 3K2 will open, so 110 will nat be by­

passed; 3K1 ani:! 310 will cbse

- relay 1K cannot puU back In since

both 110 8Il1:l 3K2 are open

~ 1K1 stays open so 3K cannal puJf beck In

-!he FLAME OFF (RED) lamp win liOh1 when poWllf' is rr.mred

• II the pilot flame (or 1st staOe oU name) ooes CM before power Is reslDred­

- relay 2K C8Il1WJ1 pu~ back in 80 2Kl stays open

- the START sta1bn cannot be by­

passel:l

- paMll'" will not be respplied b terml­

r.a17

- relay 1K cannot pull be,ck In

- relay 3K willl:lrop out; 3K1 anl:l JIC will close

-lhe FLAME OFF (RED) IM'lp will

light when paMll'" is restJrel:l

The system shut:l down The alarm is aner­

llized wherI power Is restored

• If pc:JYIIer is re:Jlored within 1 second llnd the pilot llama (or 1st stage cil

name) is still burning (1l1e \/lWe must

be sbw cbsino), rormal OPer4OOr1 will

be resumed The aJarm 'l¥ill not be en­

ergi2ed lIthe main burner name hal

gone out, it will be reionifed by the pi­lot nama (Power failure override eir·

cuits may ha~e b be al:ll:lel:l b the pilot valve and me,in vaNe(s) b enS\J{e lt1al they 1:10 not close on a mctr\EIntary power interruption)

• The systBrn ~huts llown All valVes are I:IlHIn«gizel:l, anl:l the ~a'- cbse The alarm is 8I18rO~ed lIltlen PQ't¥er is

FLAME DETECTION SYSTEM'

The naome l:Ietec:tion system falle \fIthi1e Relay 2K canrot pull in when the 9)'SI&'n is Safety sl'w.1l'lSoWn occurs LJx:kout'l¥ill occur the system is turnel:l all or l:Iuri~ the startel:l-sarne OperllOOt'l as it lhe pibt (or it the STAAT bllltCn is hell:l in IongBf than puroe perlol:l 1~ stage oil burner) is nat ignrtel:l the b:toJl: switch timing

The name l:Ietection system lails

l:Iur-Ino the run periol:l with the bumBf

tiring

Aelay 2K l:lrop~ out-same operation as if

the name goee out

Safety shutdown «CUI'S,

This sectlon provides I;lBneral Information about this section does not cover all possible maintenance ac­troubleshooting and maintaining Flame safeguard sys­ livlties tllat are req;ired for every system Again, its pur· lems Its PlJrp:lSe is not to allow the service technician to pose Is to help tl'lE! service technician develop ettective perform specifiC troubleshooting q)Elrations, but to help and efficienl preventive mainlenance programs thaI can the technician develop a consistent, analytical approach be applied 10 all installations

to Flame safeguard system troubleshooting Likewise,

T R O U B L E S H O O T l N G - - - ­

Troubleshooting of control and burner system prob­ TABLE I-BC7000 SYSTEM ANNUNCIATION AND

Burner Control Syslam self-dla\1lOSlic and 1irst-out annun­

clallon funclions In addition 10 a line voltal;lB alarm termi­

nal (audible armuncialion), the BC7000 Microcomputer

Burner Control System prOVides visual annunciation by

displaying a 3<:ligit alphanumeric code and one or two se­

quence status lig,ts

SELF· DIAGNOSTICS of the BC7000 detect and an­

nunciatel:xJlh external and internal BC7000 system prob­

lems Exlernal faults such.as interlock failure, 11ame

failure, false flame Sib'f\8l, and damper motor problems,

and internal faults associated wllh (he BC7000 chassis,

the PM72Q Program Module, or the flame amplifier are all

reporfed through tl'lE! Multi-function Annunciator Display

FIRST-OUT ANNUNCIATION is aChieved through the

3<:ligit alphanumeric Multi-function Annunciator Display

thaI rep:lrts the cause 01 a safety shutdown, failure to slarl,

or a failure to continue in the burner sequence The cause

of a safety shutdOwn is displayed as an "F" (faulll, fol­

lowed by a 2-digil nurTt:ler The cause of failure to ~ontinue

with the burner sequence is displayed as an "H" (hold),

followed by a 2-digil nurTt:ler SElquence status lights

(LEOs) provide pOsilive visual indication of the program

sequence: STANDBY /power on), PREPURGE, HOLD

IGN TRIAL FLAME ON, RUN, POSTPURGE, and safety

shutdown (illuminated reset bullon) Momentary power

loss erases this annunciation and requires resel Safety

shutdown (lockout) is indicated by the illuminated reset

bullon and an "F" (fault) code followed by a 2-digit num­

ber safety shutcbwn (lOCkout) d&-energizes all loads en­

ergizes the alarm terminal (atter a 1Q second delay) and

requires a rest With this information, most problems can

be diagnosed without axlansive triat-and-error testing

Table 1 shows the codes used to annunciate and dia~

nose system problems with the BC7000 For the Interpre­

lation and possible remedies for each code, as well as

SYSTElol MOLD CODES

M70 _ FlAME SIGNAL OURING STANDeY M73 - OPEN PRE-IGNITION INTERLOCK H74 _ OPEN RUNNING I~ERLOCK

SYSTEM FAULTA-OCKOUT CODES FCQ _ FALSE FLAME SIGNAL DURING PREPURGE

FD, _ MIGM FIRE PURGE SWITCH FAULT FlU -_ PRE-IGNITION INTERLOCK OPENEO OURING PREPURGE

F()oO - LOCKOUT/RUNNING INTERLOCK OPENED DUR'NG FREPURGE

FlO _ FALSE FLAlolE SIONAL DURING LOW FI."E HOLD F11 - LOW FIRE START SWITCH FAULT

F'3 - PRE·IGNITION INTERLOCK OPENED DURING LOW FIRE HOLO

Fl" _ LOCKOUT/RUNNING INTERLOCK OPENEO DURING LOW FIRE HOLD

F30 - PILOT (FIRST STAGE OIL) FLAME FAILURE F31 - LOW FIRE START SWITCH OPENED OURING PILOT TRIAL

F34 _ LOCKOUT/RUNNING INTERLOCK OPENEO DURING PJl OT TRIAL

FJ,S _ PILOT FLAr.lE FAILURIO IN TEST r.lODE F4(J _ MAIN FLAME FAILEO TO 'GNITE

F _ LOCKOUT/RUNNING INTERLOCK OPEN EO DURING MAIN FLAME TRIAL

F~ -_ FLAr.lE FAILURE DURING RUN PERIOO F!l4 _ LOCKOUT/RUNNING Ih'TERLOCK OPENED DURING RUN PERIOD

F70 - FALSE FLAME SIGNAL OURING STANDBY F73 - P~E·IGNlnON INTERLOCK FAILED TO CLOSE Fe' _ INTE~lolrnENT (eOUNDING) PRE·IGNITION INTERLOCK

F82 FB.3 F~} INTERr.lITIENT IBOUNCING) BURNER F8!I, Fe7 CONTROLLEAr Ir.lIT

F80 _ INTERr.llrTENT (BOUNDING) LOCKOuT/RUNNING INTERLOCK

FIlO - PROGRAM r.lODULE FAULT FIl7 _ eYNCH~DNIZATION ILiNE FREOUENCYI FAULT F99 - INTERNAL CIRCUIT FAULT

cOf1l)lete systam troubleshooting and CJ;lElrating Instruc­

lions, refer to form 65.()()14 trotbleshooling approach presented below is deslgn&d 10 For syslems without self-dia\1lOStic and annunciation; emphasize the similarities involved in troubleshooting dif· (or for problems tllat are not annunciatedl Ihe I;lBneral lerent types 01 systems

'92

In any troubleshooting situation, il is necessary to con­

sider the entire system-Including not only the burner,

controls, wiring, etc., but also air sUWly, /\Jel sUW1y, and

the condition and characterisllcs 01 the flame Itsel1 In or­

der to cover all areas 01' bUrner operallon, lha

troubleshoOting proceoJre is broken down into a series of

specific sleps

The first general step in approaching a system failure is

to doitermine whaiher Ihe shutdown occurs repeatedly or

at random

'RecUrring shutdowns are the result of permanent con­

difl'Ons in the system that can usually be identified by CJb

servation or by a few simple tests

Random shU1downs are more difficult to identify, Since

they are caused by marginal or intermittent condiUons (oc­

cur one time but not the next), they do not always occur at

atime when they can be observed Frequer1tly, the only

methOO of Identifying them is to be present when they oc­

cur and be fortunate enOUQh to see what has h~

Often, a shutdown occurs buttha evidence needed cannot

be obtained TIlis results in the need for repeated attempts

before the correct solution can be found

TIlese two types 01 shutdOwn-recurring and ran­

dom-will be discussed separately, since the procedure

lor identifying the causes of each are somewhat different

Recurring Shutdowns are obviously much better suiled to

solution using a step-by·step procedure

RECURRING SHUTDOWNS

After determining the generall'1?9 at failure, determine

the point In the operating cycle al which trouble occurs,

, and the specific symplom To get this informaUoo and to

determine the proper corrective action, aiways complete

the following seven steps;

STEP 1 - KNOW THE SYSTEM AND

EQUIPME~T

Effective troubleshooling requires a knowledge 01 the

complete SyStem and its normal sequence, as well as the

Indi idual devices and equipment that make l4' the sys­

tem TIle availability of a schemallc diagram of the syslem

is a necessity A written sequence 01' the normal operation

of the SyStem is also desjr~le

STEP 2-ASK OUESTIONS

Usually, Ihe information available on arrival at the in­

stallation consists of a sirrple stalemenl that a burner

shuts down Start by asking all the questions possible of anyone lhat mi~t have some knowle6;)e of what hap­

pened When cbeS the shutdown occur? What part of the CYCle? How lonQ after the startup? Does a shutdown occur following every start? How Is the lightoff?

These are only sarrple questions-the lnformation needed will depend on the Individual situation Be sure the operator 01' the SyStem is contacted and questioned Re­tTlQrrOer, they were present and involved when the shut­down occurred

STEP 3-EVALUATE YOUR INFORMATION Usa Table II, together With your personal experience, to herp evaluate any information you have concernillQ the shutdown The conclusions drawn at this stage only pro­vide an idea of where 10 look tor the exaCI solullon 10 the

prOOlem

STEP 4-MAKE A TRIAL RUN Observe the operation of the burner system through a corrprete cyCle Was each slep of the startup in accor­dance with the design sequence? Did any deviations occur? Did the shutdown occur exactly as described? Did anything else happen? Have any new facts been established?

AlSO refer 10 information on measuring the flatTlQ signal during lest runs below

STEP 5-RE-EVALUATE The re-evaluation of availabie facts can often be made during the trial run Mentaily check the possible causes

and eliminate all except those that could b6 resoonsible for lhe shutdown Remember ,that in some instances, more than one factor may be contributing to the prOblem

and must be considered in the solution

STEP 6-VERIFY THE ASSUMED CAUSE BY A TEST RUN

After determining the a,warent causa(s) at eqJipmenl matltnction, perform a second test run to see if the evalu­ation is cOfree! lithe answer has not been found, a new evaluation must be made that Includes any new In1Drma­tion thaI has been obtained cllrlng the second lest run More than one ra-evaluation lest may be necessary to get all 01' the information needed to positively Identify the

cause(s) 01 lhe Shutdown

STEP 7-CORRECT THE CONOITION(S)

TABLE II-TROUBLESHOOTING RECURRING SHUTDOWNS

To assist In delermining lhe cause of a system shutdown, Ihis tabte lists possible causes and corrective actions for each symptom: For-convenience, lhe lable Is divided inlo sections rapresanling lime perlcxE The problems that could occur during a specific peric:d of the operating cycle are listed in each section If specific information on service of a particular control or piece of equipment is required, refer 10 lhe instructional literature for the particular control

, - - - _ - - - ' - - - I M P O R T A N T - - - ,

Repair or replace all defective comp::lrIents, as necessary

INITIAL STARTUP

A ~nce cbes not

start

1 No JXlMlr

Z L.ockwt (safety) switch tri~

3 Limit switch open (in main JXlwer line or in series with the C(){ltroller)

4 Start or preignition interlock open

5 Process interlock open

6 Wiring open

la O1eck master switch and overload protection (fuse, circuit breaker, etc.) Reset or replace, as necessary

20 Reset- find cause and make necessary repairs

3a Slack damper end switch not made

30 Airflow switch open

3c low-waler-cutoff open

3d Fresh·air dal'11P9r (to boiler room) not open

3e Fuel pressure switch open

31 Other interlocks opErI in JXlwer line

4a Check start or prlHgnition interlocks

sa Check all process controls thaI are interconnected wilh the burner system

6a CheCk wiring for breaks or open splices

FIRST 15 SECONDS AFTER START

B System cbes nol go

10 high fire during

1 Wiring-opens, shorts grounds

2 No JXlMlr at firing rale molor

3 Limit switches in firing rale motor nol made

1 High fire switch open

1, O1eck voltages at the wiring sutbase terminals for firing rate switching

20 Check for JXlwer at T·T terminals on firing rate motor

3a Clean conlacls

1a Check switch

1b AdJlISt linkage

1c Check firing rale motor and its transformer

starfS

2b No airflow Check burner motor (blower) and associated corr-ponenls and circults

2c Plugged air line or filling

194

DURING PREPURGE-AFTER 15 SECONDS-BEFORE IGNITION TRIALS

D Flame relay pulis in

(2) Unwanted flame on flame rod

lb Visible light photocell:

(1 ) Light striking cell

(2) Detecting hot felractory

1c Infrared (lead SUlfide) detector:

(1) Electromagnetic piCkl4) on leads Anchor solidly Install coaxial cable if necessary

(2) Unwanted flame being detected

(3) Detecting hal refractory

(3) Defective sensor (replaCe)

le Flame safeguard control:

(1) Defec/ive amplifier (replace)

la 8l.Irner motor (blower) st~

lb Restricted air passage from air d Jct 10 airflow switch

10 Plugged air line or titling

2a Check interlock

LAST FEW SECONDS OF PREPURGE BEFORE IGNITION TRIALS

F 5eq Jence stq:lS 1 Timer switch on flame sat9lJ lard

control set al TEST

la Set switch 10 NORM lXlSilion

2 low fire switch open 2a Check switch

2b Adjust linkage

2c Qleck tiling rate controller (broken polentlometer)

2d Check firing rate motor and its transformer

G No ignition spark 1 No power 10 19lilion transformer

2 HiQh voltage Insulator(sj faulty

3 Ignition elecnode spaf1( gap selling

ta Leadwires cpen, grounded, or not prcperly connected; insulation damagecl

lb Flame saf9lJ lard control not providing power

lc Flame safeguard control recycling

28 Cracked

2b Covered with soot, dir1, or mOisture-causing a shor1to ground

Ja Clean the electrodes

3b SpaCing incorrect-too wide or shorted

3c E!&ctrodeS not prcperly mounted

(cOI1t1nued on IMxt parle)

PROBLEM POSSIBLE CAUSE CHECK

G.(conli~ 4 Ignition transformer failure 4<1 High voltage grOi,lnded

4b Transformer defective

H No pilot flame

-1 No fuel sLWly

.2 Pilol valve inoperative

1a Manual pilot shutoff alva should be wide open 1b Fuel line plugged

1c Low or high gas pressure switch open-adjusl pilot gas pressure regulator

23 No power at flame safeguard control terminals 2b Incorrect or broken wiring

2c Din in valve, or orifice plugged

2d Faulty actuator or valve

I Flame flOl detected

(llame relay does

no! pUll in)

1 Flame detector (general) 1a Dirty lens, filter, or viewing window

1b Dirt in sight pipe

1c Dirty cells

10 Loose cell

1e, Detector moved to poor location

11 Sighting of detector shifled

19 Delector overheated

1h Low or unstable flame signal

1i Defective detector

2 Fire condition 2a smoky fire

2b Fire pallern changed (Ufled or deflectad')

2c Flame adjustment too lean

3 Wiring 3a Poor connection between burner Qround and flame

safeguard control (Run separate ground wire.) 3b Loose connections

3c Excessively long flame detector laadwires

3d Water in condutt with flame detector leadwifes

Sb Ig'lition interference (SLblraCtive)

St Inadequate grOUnd area

5d Irrprcperly tocaled in flame

59 Broken flame ro::l

6 Infrared (lead sulfide) detector Ga Magnetic piCkup ()(l leads (Should be shielded and

anchored to prevent free vibration or swinging.) fib Defectlve cell

I 7 Ultraviolet detector 7a Excessive vibration (can loosen components in

C7012 types.) 7b C7012-faully electron lube(s)

8 Faulty flame signal amplifier Ga Replace (if a plug-in type)

196

DURING THE MAIN BURNER FLAME·ESTABLISHING PERIOD PROBLEM POSSIBLE CAUSE CHECK

J Main burner does

not light-detective

pilot

1 Pilot flame too small ("soft pilot") la Pilot air vents Clogged

lb Blower inlet clogged

lc Brower housing dirty

ld Blower fan dirty

le Pilot air line dirty

H Blower not running

19 Excessive pilot fuel (ori11ce enlarged)

2 Pilot outage 23 loose connection to pilot valve

2b Main burner air SlWIy blowing out pilot

2c Pilot gas vatve partially closed

3 Pilot not adjusted prcperly 3a Adjust air-fuel ratio

3b Adiust pilot position so 11ame will ignite main burner

K Main burner does

not light - improper

4 Pilot size shrinks 4a Pilot line tap on main fuel line is downstream of

main pressure rSQulator (ShoUld be upstream with separate regulator if one is needecl.)

1 Manual main fuel shutoff valve closed

la Open it

fuel supply

2 Safety shutoff valves not opening 2a No power at actuator or at valve terminal on llama

2b Valve stuck in closed p::lSition

2c Defective valve or actuator

2d Check gas pressure switch (see causes 4 and 5)

3 vent valve cpen 3a Power at valve actuator

3b Valve stuck open

3c Check for proper operation of valve and actuator

4 Low gas pressure switch open 4a Check location of low gas pressure switch in gas

line May open when main gas valve closes

4b Adjust gas pressure regulator

5 High gas pressure switch open sa A pressure regulating valve that does not close off

tight will allow line pressure to build up ahead of the main valve Opening the valve allows excess

pressure in line

Sb Adjust gas pressure regUlator

6 Improper air·fuel ratio Ga Adjust as necessary

6b Check burner motor (blower) cperation

7 Low fueltemperalure (oil) 7a O1eck temperature of oil from oil heater (heavy

oils)

7b Defective oil temperature control

7c Defective wiring

8 Faulty fuel system Ba Fuel line downstream from main fuel valve is too

long-requires eltCessive lime to get fuel to the burner

Bb Plugged or dirty fuel line

8c Out of fuel (Oil)

Sd Low atomizing steam or air prSSSlJre (Oil)

(continued on next page)

PROBLEM POSSIBLE CAUSE CHECK

L Main burner lights,

but QOel5 out

1 Main burner flame nol detected 1a Deleclor has pool' view 01 main burner 11ame

(sightil'lQ plIol but not main flame)

1b Detector shifted

1e Smoke in r:ombustlon eharrber

1d Oil ~apors screening deteclor from flame

2 Imprcper air-fuel ratio 2a Flame unstable-poor shape, quallly or position

Adjust air-fuel ratio

.2b Cheek burner motor (blower) operalion

';­

3 Faulty fuel system 3a Low fuel pressure

3b Fuel spray patlem distone:1

Je Oil lank nearly amply Pump is pullin~ air atter a small inilialflow

3d Cold oil in line belween healef and burner Try a reslan

36 AtomiZing sleam or air SlWly pressure 100 low (oil)

DURING A CHANGE IN THE FIRING RATE

M Flame goes oot

du(lng firing rate

charge

1 P~r sUl+Ily voltage drq:l

2 Conditions in combus:ion charrber

1a AcXjed electriea\ load on jXJWer sU~Iy when lirirg rate changes-check circuilry and cO"Inections_ 2a Smoke screen between delector and ftame

2b Change in alr·fuel rallo

2c Change in flame paHern

2d Change in oil spray pattern

2e Reclrculalion ol atornlzedoil

N Flame QOes oul , _ Power sUWly ~ariation " Line ~oltage drop due to on-off switching 01 a heavy

electrical load,

1b Power failure

2 Failure In lhe flame deLeclion 2a Check flame signal amplifier Replace amplifier 'f it

2b Clreck 11ame deleclOr

2c If using a 'lame 100, make sure it is nol louching hot re1ractory AlSO check the tempera lure at its

Insulator - if more lhan SOO F [2f>O C], move 11ane rod to a cooler location

2d 11 using an infrared deteclor, chack for hot refractory saluration-make sure that radiation from hot refraclory does not mask the 11ickering radiation of the flame UseN'

38 Delermine cause(s) and correct the condition(s) 3b It airilow switch Is cpen, check burner motor tb!ov'ler) and i!s associaled componenls and circuitry

3 Limil or interlock op8'ls

~

" Check tor improper wiring or deteriorated lead -ires

4b Check: operalion of the val~e and aclualor

4 safety shutoft val~e closes

5• Clean fuel line

5 Plugged 1I.Je1 line

RANDOM SHUTDOWNS

The same general step-by-step procedure is followed

"when troubleshooting random shutdowns as outlined lor

S',ep 1 - Know the system and

Step 2-Ask

Step

S Slep"6- Verify the assumed cause by a test

When troubleshooting random shuldoVoTlS, slep

2-asking questions-becomes an especlallv important

step since the troubleshooter may nof be able to actually

witness a burner shutdOwn Important questions that

might be asked are:

- Has the startup period been complelely

normal-including pilot ignition and main burner Iightoff?

- Have both pilot and main buHlsr flames been burning

properly? At all firing rates? Does the air-fuel ratio

seem satisfactory?

- How has the flame Signal been? Stable or oscillating,

and at what level? (Be sure to verify during trial runs:

check detector sighting)

- How iong since the burner has been serviced and

what was done? Was the detector lens, f\\ter, viewing

window, and sighting pipe cleaned? Flama signal

checked?

- How 10nQ had the burner been running continuously

when the last shutdown occurred, and what was the

firing rate?

- Was there anything different tram normal when the

shutdown occurred?

- Has any eqUipment been 1~IaCed recently? If so,

what an.:::l why?

- Has anything in the system been changed, r~laced,

or worked-on, no mailer hOw unrelated it may seem?

EXAMPLES: A new bOiler installed in the next build­

ing; another healer or boiler connected to the

same stack or breaching

If the cause Of the problem has not been positively iden­

Ilfied after completing the step-by-st~ trOUbleshOOting

procedures, perform routine maintenance on \he burner

Be sure to clean the flame delector, detector mounl, and

not shifted in its mount Clean blowers, air dampers, etc

Check the condmon of the pilot and main burner flame,

and adjust as necessary Perform other routine mainte­

nance checks on the oorner eqUipment as req.Jired Make

a trial (un to be certain that the burner is cperating

correctly

If the problem recurs after the service call, it is best to

connect a memory type tester to the system to monitor

burner operation and plSilively pinpoint the cause of shut·

dovm

LOCKOUT (SAFETY) SWITCH INDICATION The type of failure Indicated by whether the namesafe­guard conlrol is locked out or not dependS on the control design and on the particular awllcation

Some name safeguard primary controls-such as lhe R485-do not have a lockout switch Others-suc:' as the A4138-have a lockout switch that will lock out only on fail­ure 10 ignite Masl automatic primary controls, progam­mars and microcOl'T"Puter systems- RA890, R4795 R4140, A41SO A4126, R4127, R41al BC7QOO-w\U lock out on either failure to ignite or flame failure during the run period

In addition they may be designed to lock out in other circumstances, or they may permil the installer to deter­mine whether a lockout will occur in a given situation The RAB90G primary conlrol, for exal1l'le, will lock out

it a flame-Simulating failure occurs during stancby II is also typically connected to lock out on limit action Olher controls such as some models of the R4140 Programmer, have a special lockout interlock circuH; they wUllock out on the action of critical interlocks but will recycle on \he action

ot other limits Even If a special circuit is not prOVided, criti­callimils may be wired to cut off oorner flame on limit ac­tion, causing a flameout that resulls in tripping the lockout switch

In QBneral, safety lockout will indicate a Shutcbwn that has been caused by marginal or in/f:rmirtent operating conditions Exal1l'les or such conditions are:

- Poor f\ame characteristics poor pilot, unreliable igni tion source

- FaUlty flame delection system; dirty lens or sighting pipe, burned off or drCllXling flame rod shifted detec­

lor mount, overheated detector, loose comJXlflents

- Flame signal al1l'lifier failure

- Operation of critical inlerlocks (dependS upon the application)

Shutdowns which do not result in safely lockout are

generally caused by conditions resulting in momentalf power failure:

- Loss of line VOltage

- Bad ~ces or loose connections,

- Worn or damaged wiring

- Opening of noncritical limits (dependS upon lhe

awlication)

On automatIc systems, the flame sa1eguard control will recycle and make a restart allerJ1)t semiautomatic sys­tems will stqJ and rEqJire a manual reslart

Random shutdowns for the most part may be catego­rized under 3 main headings:

1 Failure to ignite 01' detect the pilot

Z Failure to light or delect the main bUrner flame

3 Flameout after igniling the pliot or maIn nama Shutdowns of types 1 and 2 occur during iQ'lition trials; type 3 Shutdowns occur during the run period Hcpetully, the cperator will be able to say at what point in the cycle the 1ailure occurred 11 not, all possibilities must be checked In Table m, PJSSibl8 causes are grouped under

these 3 main headings