Honeywell R4795A User manual

160-2285—7

R4795A

Flame Safeguard

Primary Controls

The R4795A Protectorelay™ Primary Control

provides solid state electronic flame safeguard

protection for commercial and industrial gas or oil

burners. It provides a prepurge period before each

start, and intermittent pilot.

■120V models meet the requirements of Underwrit-

ers Laboratories Inc. Standard 795 for mechanical

draft and atmospheric burner inputs from 400,000 to

2,500,000 Btu.

■Meets Underwriters Laboratories Inc. requirements

for oil burner group 8 when 30, 60, or 90 second pre-

purge timer is used.

■Selection of solid state, plug-in prepurge timers pro-

vides 7, 10, 30, 60, or 90 second prepurge time.

■Includes terminals for connection of air flow switch

to prove airflow before prepurge period starts, dur-

ing purge, and during the entire Run period.

■Choice of interchangeable, color-coded, solid state,

plug-in flame signal amplifiers allows use with rec-

tification or ultraviolet type flame detectors.

■Safe-start feature prevents start when flame or flame

simulating condition is present.

■Recycles through prepurge if the flame goes out

while burner is running. If pilot flame is not re-

established, safety switch trips and locks out system.

■A tripped safety switch must be manually reset to

restore operation.

■Push-to-resetsafetyswitchisdust-resistantenclosed.

■Optional spdt alarm contacts operate external alarm

on safety switch lockout.

■Ignition interference circuit (rectification amplifier

only) protects electronic network from high voltage

ignition crossover and provides visual indication

when interference occurs.

■Solid state circuitry eliminates vacuum tube replace-

ment and increases resistance to vibration. Applica-

tion of power not required during Off cycle; no tube

warmup before starting.

■Easy-to-replace plug-in components result in faster

service and reduced inventory.

■Flame current jack, located on the amplifier, provides

means of plugging in a microammeter to measure the

flame signal with system operating.

■Easy mounting and removal through use of captive

mounting screws, which also serve as electrical

connections.

■Durable thermoplastic mounting base.

■Models available with -40°F (-40°C) temperature

rating.

S.Y. • Rev. 12-94 • ©Honeywell Inc. 1994

60-2285-7

CONTENTS

Specifications ................................................. 2

Ordering Information ..................................... 2

Installation ..................................................... 4

Checkout ......................................................... 8

Operation ..................................................... 11

Troubleshooting ........................................... 11

Service .......................................................... 13

60-2285—7 2

R4795A

SPECIFICATIONS • ORDERING INFORMATION

Specifications

R4795A Flame Safeguard Primary Control recycles once

after flame failure to try to re-establish pilot before lockout.

Use with R7289A Amplifier and rectifying flame rod, recti-

fying photocell, or C7012A,C Purple Peeper Ultraviolet

Flame Detector; or with R7290A Amplifier and C7027A,

C7035A, or C7044A Minipeeper Ultraviolet Flame Detector.

AMBIENT TEMPERATURE RATINGS:

Minimum: -20°F (-29°C). Special models to -40°F (-40°C).

Maximum: +125°F (52°C) at 60 Hz; +115°F (46°C) at

50 Hz. -40°F (-40°C) models have maximum ambient

of +115°F (46°C) at 60 Hz, +105°F (40°C) at 50 Hz.

Subtract 10°F (6°C) when optional alarm contacts are

included.

ELECTRICAL RATINGS:

Voltage and Frequency: Single voltage models only:

100V, 120V, 200V, 220V, 50/60 Hz. As ordered.

Power Consumption (at 60 Hz):

6.0W max using rectifying flame rod or photocell.

8.0W max using ultraviolet flame detector.

FLAME FAILURE RESPONSE TIME: 0.8 or 3 seconds

nominal, as ordered.

SAFETY SWITCH TIMING (LOCKOUT TIMING): 15 sec-

onds nominal.

RECYCLE TIME: Almost immediate after Flame Failure

Response Time.

FLAME ESTABLISHING PERIOD: May last up to safety

switch lockout time or until flame is recognized by

device.

ALARM CONTACTS (Optional): Isolated spdt contacts.

Male quick-connect terminals (female quick-connects

included). See Terminal Ratings. –40°F (–40°C) models

have isolated spdt alarm contacts.

Ordering Information

When purchasing replacement and modernization products from your TRADELINE®wholesaler or your distributor, refer to the

TRADELINE®catalog or price sheets for complete ordering number, or specify:

1. Order number. 3. Flame failure response time.

2. Voltage and frequency. 4. Alarm contacts, if desired (included with -40°F [-40°C] models.)

Order separately:

1. R7289A Rectification Amplifier, 3. Plug-in prepurge timer model number

or R7290A Ultraviolet Amplifier. and timing (7, 10, 30, 60, or 90 seconds).

Specify flame failure response time. 4. Q270A1024 Mounting Subbase.

2. Flame detector to match amplifier. 5. Accessories, if desired.

If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:

1. Your local Honeywell Home and Building Control sales office (check white pages of phone directory).

2. Home and Building Control Customer Logistics

Honeywell Inc., 1985 Douglas Drive North

Minneapolis, Minnesota 55422-4386

In Canada—Honeywell Controls Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9. International

sales and service offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan,

Mexico, Netherlands, Taiwan, United Kingdom, U.S.A.

360-2285—7

R4795A

SPECIFICATIONS

TERMINAL RATINGS:

Terminal Load Rating

3 Pilot Valve 125 VA pilot duty.

Intermittent Ignition

360 VA.

4 Interrupted Ignition 360 VA.

5 Main Fuel Valve(s) 125 VA pilot duty, or 25 VA pilot duty plus one or more motorized

valves with total rating up to 400 VA opening, 200 VA holding.

6-7 Airflow Switch 0.6A at 30 Vdc.

8 Fan or Burner Motor 9.8A full load, 58.8A locked rotor (inrush) at 120 Vac. 4.9A full

load, 29.4A locked rotor (inrush at 220 and 240 Vac.

Isolated Spdt Alarm

Terminals (Optional) Alarm 3A at 24 volts, or 1A at 120 volts, in a suitable wiring enclosure.

aWhen ignition is connected to terminal 3, terminal 4 cannot be used.

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

duty rating.

Example:

Pilot duty rating = 125 VA.

At 120V, running current is 125/120 = 1.05A.

Maximum allowable inrush is 10 times 1.05 = 10.5A.

DIMENSIONS (Includes Cover and Subbase): Approxi-

mately 5 x 5 x 5 in. (127 x 127 x 127 mm).

MOUNTING: Q270A1024 Subbase. Ordered separately.

APPROVALS:

Underwriters Laboratories Inc Listed: 120V models us-

ing 30, 60, or 90 second prepurge timers including –

40°F (–40°C) rated models; file no. MP268, guide

no. MCCZ.

Underwriters Laboratories Inc. Component Recognized:

120 volt models using 7 or 10 second prepurge timers

including -40°F (-40°C) rated models; file no. MP268,

guide no. MCCZ2.

Canadian Standards Association Certified: 120V mod-

els only, including -40°F (-40°C) rated models; file

no. LR95329.

Factory Mutual Approved: R4795A 120V models; re-

port no. 18774. -40°F (-40°C) rated models; report

no. 19608.1.

American Gas Association Design Certified: File no. 21-6

(F and F1).

ACCESSORIES:

W136A Test Meter (includes 117053 Meter Connector

Plug).

Flame Simulator:

203659 Ultraviolet

121708 Rectification

123514B Ultraviolet

117053 Meter Connector Plug

FSP1535 Tester for operational check

Q624 Solid State Spark Generator

118702E Remote Reset Cover, 120 Vac, 60 Hz

202471C Reset Cover for R4795A

ADDITIONAL CONTROLS:

Order all additional controls separately:

Q270A1024 Mounting Subbase.

Plug-In Flame Signal Amplifiers, Rectification Type

(Green Backplate): For use with C7004B C7005A,

and B, C7008A, or Q179A,C Rectifying Flame Rods

(for gas); C7003A, C7010A, C7013A or C7014A

Photocells (for oil); or C7012A,C Purple Peeper Ul-

traviolet Flame Detectors (for gas or oil).

R7289A1004 Amplifier: 3 sec nominal flame failure

response.

R7289A1012 Amplifier: 0.8 sec nominal flame failure

response.

R7289A1020 Amplifier: 3 sec nominal flame failure

response, -40°F (-40°C) ambient temperature.

UltravioletType(PurpleBackplate): Foruse withC7027A,

C7035A or C7044A Minipeeper Ultraviolet Flame

Detectors (for gas or oil).

R7290A1001 Amplifier: 3 sec nominal flame failure

response.

R7290A1019 Amplifier: 0.8 sec nominal flame failure

response.

R7290A1027 Amplifier: 3 sec nominal flame failure

response, -40°F (-40°C) ambient temperature.

ST71A Plug-In Prepurge Timer (ordered separately):

Minimum Timings: 7, 10, 30, 60, and 90 seconds (as

ordered).

Maximum Timings: 8.4, 12, 36, 72, and 108 seconds

at room ambient temperature.

RecommendedLimits: L404A;L604A,L;L4006A,C,E;

L4008A,E,F; L6006A,B: These controllers were

Underwriters Laboratories Inc. tested for breaking

loads only, at 120 Vac, for the total rating of 9.8A

full load, plus 360VA ignition, plus 250 VA pilot

duty.

Flame Detector: As specified in Plug-In Flame Signal

Amplifiers listed above.

60-2285—7 4

R4795A

INSTALLATION

Installation

Vibration

Do not install the R4795A where it could be subject to

excessive vibration. Vibration shortens the life of the elec-

tronic and mechanical components.

Weather

The R4795A is not designed to be weathertight. If it is

installed outdoors, use a suitable weathertight enclosure.

Mounting The Subbase

Locate the subbase where ambient temperature is within

the specified rating.

Mount the subbase so the top and bottom are horizontal

and the back is vertical. The subbase can lean backward as

much as 45 degrees when necessary. See Fig. 1.

Fig. 1—Subbase mounting dimensions in in.

(mm).

CAUTION

1. Installer must be a trained, experienced, flame

safeguard control service technician.

2. Disconnect power supply before beginning in-

stallation to prevent electrical shock and equip-

ment damage.

3. All wiring must comply with applicable local

electrical codes, ordinances, and regulations.

4. Voltage and frequency of the power supply

connected to this control must agree with those

marked on the device.

5. Loads connected to the control terminals must

not exceed those listed in the Specifications

section.

6. All external timers must be Listed or Compo-

nent Recognized by authorities having jurisdic-

tion for the specific purpose for which they are

used.

7. Some authorities having jurisdiction prohibit

the wiring of any limit or operating contacts in

series with the main fuel valve(s).

8. Perform all required checkout tests after instal-

lation is complete.

Follow the burner manufacturer’s instructions, if sup-

plied. Otherwise proceed as follows.

CAUTION

Ultraviolet sensing tubes have a life expectancy of

40,000 hours of continuous use within the ambient

temperature and voltage ratings. Worn out ultra-

violet sensing tubes can result in failure of the

sensingtube toproperlydiscriminate betweenflame

conditions.

For systems using R4795A with R7290 Amplifiers, use

C7027, C7035 and C7044 Flame Detectors only on burners

that cycle On and Off at least once every 24 hours. Appli-

ances with burners that remain on for 24 hours continuously

or longer should use the C7012E Flame Detector with the

R7247C Amplifier or the C7076A Flame Detector with the

R7476A Amplifier as the ultraviolet flame detection system.

LOCATION

Temperature

Install the R4795A where the surrounding temperatures

remain within the Ambient Operating Temperature Ratings

listed in the Specifications section.

Humidity

Install the R4795A where the relative humidity never

reaches the saturation point. Condensation of moisture on

the R4795A may cause enough leakage to short the flame

signal to ground and prevent the burner from starting.

M8681

HORIZONTAL

VERTICAL

2-7/8

(73.0)

4-1/8 (104.8)

KNOCKOUTS (9) FOR

1/2 IN. (13) CONDUIT

45 DEGREES

MAXIMUM LEAN

WIRING TO SUBBASE

1. All wiring must comply with applicable codes, ordi-

nances, and regulations. All wiring to the Q270A Universal

Mounting subbase must be NEC Class 1.

2. When wiring the Q270A for use with the R4795A, use

the terminal designations 8, 7, and 6 (printed in yellow).

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

wire suitable for at least 167°F (75°C).

4. For high temperature installations, use moisture-re-

sistant No. 14 wire selected for a temperature rating above

the maximum operating temperature for all but the ignition

and flame detector F leadwires.

a. For the ignition, use Honeywell Specification no.

R1061012 Ignition Cable or equivalent. This wire is

rated at 350°F (175°C) for continuous duty, and up to

500°F (260°C) for intermittent use.

b. For the flame detector F leadwire, use Honeywell

Specification no. R1298020 or equivalent. This wire

is rated up to 400°F (205°C) for continuous duty. It is

tested for operation up to 600V and breakdown up

to 7500V.

560-2285—7

R4795A

INSTALLATION

IMPORTANT: Do not run high voltage ignition trans-

former wires in the same conduit with the flame

detector wiring.

5. For ignition installations in a contaminating environ-

ment, use Honeywell Specification no. R1239001 High Ten-

sion Ignition Cable or equivalent. This wire is very resistant

to severe conditions of oil, heat, and corona, and is tested to

withstand high voltages up to 25,000V rms in a salt bath for

one minute without breakdown. It is rated at 200°F (93°C)

for continuous duty and up to 350°F (75°C) for intermittent

use.

Wiring Hookups

The typical wiring hookups in Fig. 2 and 3 show the

internal line voltage schematic. Contact 3K2 closes when the

controller calls for heat. 1K4 closes when prepurge is com-

plete. 2K2 breaks and 2K3 makes when flame is proven.

Also see the Operation section.

Fig. 2—Wiring hookup of gas system with

interrupted ignition and intermittent pilot.

M8682

(HOT)

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

FOR INTERMITTENT IGNITION, CONNECT IGNITION TO TERMINAL 3.

REFER TO SPECIFICATIONS SECTION FOR RECOMMENDED LIMITS.

BURNER

MOTOR

AIR FLOW

SWITCH

TO FLAME

DETECTOR

(FLAME ROD

OR UV

DETECTOR)

FLAME

AMPLIFIER

1K4

3K2

2K2

2K3

MAIN FUEL

VALVE(S)

IGNITION

PILOT

VALVE

CONTROLLER

LIMIT(S)

R4795A

Fig. 3—Wiring hookup of oil system with

interrupted ignition.

M8683

(HOT)

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

FOR INTERMITTENT IGNITION,CONNECT IGNITION TO TERMINAL 3.

IMMEDIATE OPENING OIL VALVE V4046B.

OPTIONAL DELAYED OPENING OIL VALVE V4046A OR V4046B WITH

ST70A ELECTRONIC TIME DELAY.

REFER TO SPECIFICATIONS SECTION FOR RECOMMENDED LIMITS.

BURNER

MOTOR

AIR FLOW

SWITCH

TO FLAME

DETECTOR

(PHOTOCELL

OR UV)

FLAME

AMPLIFIER

1K4

3K2

2K2

2K3

2ND STAGE

OIL VALVE(S)

IGNITION

1ST STAGE

OIL VALVE(S)

CONTROLLER

LIMIT(S)

R4795A

Retrofitting R4795

CAUTION

Make wiring connections as specified in Fig. 2, 3,

or 4. Do not simply plug the R4795 into the old

subbase without first changing the wiring at the

subbase.

Observe the following when retrofitting the R4795:

1. Requires a line voltage controller capable of switching

the entire connected electrical load.

2. Delayed opening oil valve may be retained but its

delay is not necessary. Integral ST71A Purge Timer meets

the intent of a delayed opening valve.

3. Refer to Fig. 2, 3 or 4 for proper wiring connections.

60-2285—7 6

R4795A

INSTALLATION

Replacing RA890E,F,G with R4795A

1. Disconnect all wires from terminal 1, and splice with

solderless connector. (If RA890 has no terminal 1 wiring,

disregard this step.)

2. Remove line voltage controller wire from terminal 6

and connect to terminal 1.

3. Move burner motor connection from terminal 3 to ter-

minal 6 on subbase.

4. Remove jumper from T and T and install air switch. If

low voltage control was wired to RA890 T-T, remove low

voltage control and install line voltage control as shown in

Fig. 4.

5. If R482D Relay was used with RA890E, remove it.

The R482D is redundant when R4795D is used.

6. Checkforproper operation through atleasttwocycles.

Fig. 4—Replacing RA890E,F,G with R4795A on

gas or oil burner.

(HOT)

REPLACING RA890 WITH R4795 ON GAS OR OIL BURNER

CONTROLLER HIGH LIMIT MAIN GAS

VALVE OR

2ND STAGE

OIL VALVE

IGNITION

TRANSFORMER

BURNER

MOTOR

PILOT OR

OIL VALVE

RA890 WITH Q270

BEFORE

FLAME

DETECTOR

(HOT)

CONTROLLER HIGH LIMIT MAIN GAS

VALVE OR

2ND STAGE

OIL VALVE

IGNITION

TRANSFORMER

BURNER

MOTOR

PILOT OR

OIL VALVE

RA4795 WITH Q270

AFTER

FLAME

DETECTOR

AIR FLOW

SWITCH

SODERLESS

CONNECTION

120V

M8684

R4795C Replacement

In most cases, the R4795A can directly replace the

R4795C. For standing pilot applications where the pilot

flame was detected during the off cycle, install a relay as

shown in Fig. 5.

Flame Detector Wiring

See Fig. 6.

Alarm Contacts

Models with alarm contacts have three male quick-con-

nect terminals. Three female quick-connect terminals are

provided for field installation. To connect leadwires to the

female quick-connects, strip 1/4 inch (6.4 mm) insulation

from end of leadwire; insert into the quick-connect, and

crimp securely with a crimping tool. Fig. 7 shows proper

alarm terminal connections.

If a line voltage alarm is used with the R4795, mount the

entire control in a suitable enclosure.

Fig. 5—When R4795A replaces R4795C in a

standing pilot application, install relay 1R to

prevent detection of pilot flame during burner

off cycle.

M8685

(HOT)

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

REFER TO SPECIFICATIONS SECTION FOR RECOMMENDED LIMITS.

LOW VOLTAGE CIRCUIT OMITTED.

BURNER

MOTOR

AIR FLOW

SWITCH

TO FLAME

DETECTOR

(FLAME ROD

OR UV

DETECTOR)

FLAME

AMPLIFIER

1K4

3K2

1R1

2K2

2K3

MIAN FUEL

VALVES

CONTROLLER

LIMIT(S)

R4795A

760-2285—7

R4795A

INSTALLATION

Fig. 6—Flame detector wiring.

M8686

BLUE

WHITE

C7027, C7035, OR C7044

ULTRAVIOLET FLAME DETECTOR

BLUE

YELLOW

BLACK

C7012 ULTRAVIOLET DETECTOR

FLAME ROD

PHOTOCELL

1C7027, C7035, AND C7044 FLAME DETECTOR LEADS ARE COLOR

CODED BLUE AND WHITE. THE BLUE LEAD MUST BE CONNECTED

TO THE F TERMINAL AND THE WHITE LEAD MUST BE CONNECTED

TO THE G TERMINAL. THIS CIRCUIT IS DC AND THE UV SENSING

TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN

MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.

POWER

SUPPLY

Fig. 7—Alarm terminal connections.

Mounting R4795 On Subbase

Make sure that the power supply is disconnected.

Loosen the thumbscrew and remove the cover (see Fig. 8).

Position the R4795 over the Q270 Subbase. Start all ten

mounting screws and tighten uniformly. These screws com-

plete electrical circuits (terminal 1 excepted) and hold the

R4795 to the subbase.

(HOT)

IF A LINE VOLTAGE ALARM IS USED, THE R4795 MUST BE

MOUNTED IN A SUITABLE ENCLOSURE.

POWER SUPPLY MUST MATCH THE ELECTRICAL RATINGS OF THE

ALARM. PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

LINE OR

LOW VOLTAGE

ALARM

ALARM TERMINALS (OPTIONAL)

N.C. N.O. COM

M8687

R4795

ALARM

POWER

SUPPLY

CAUTION

Do not overtighten the mounting screws because

damage to the circuit board can result. Maximum

recommended torque is 10 lb-in. (1.13 N•m).

Replace cover and securely tighten thumbscrew.

Fig. 8—R4795 and Q270 Subbase.

TERMINAL

BLOCKS

PURGE TIMER

AMPLIFIER

COVER THUMBSCREW

SAFETY SWITCH

RESET BUTTON

IN COVER

CAPTIVE MOUNTING

SCREWS (10)

Q270

SUBBASE

M8688

60-2285—7 8

R4795A

CHECKOUT

Checkout

Fig. 10—Internal view showing amplifier and

test jack for flame current test.

CAUTION

Use extreme care while testing the R4795; line

voltage can be present on most terminals when the

power is On.

CHECKOUT SUMMARY

The following list summarizes the checkout tests re-

quired for each type of installation. Instructions for each test

are included in this section.

Preliminary Inspection: All installations.

Flame Current Check: All installations.

Pilot Turndown Test: If a pilot must be proved before the

main fuel valves can open.

Hot Refractory Hold-in Test: Photocell oil installations

only.

Ignition Spark Response Test: All ultraviolet detector

applications.

Safe Shutdown Tests: All installations.

Refer to Fig. 2 to 3 for terminal location, and to Fig. 9 and

10 for location of component parts. Loosen thumbscrew to

remove cover.

Fig. 9—Internal components of R4795A.

M8679

UNDER

COVER

PLUG-IN

PURGE

TIMER

(ST71A)

SPRING

CLIP FOR

AMPLIFER

PLUG IN AMPLIFIER

(R7289–GREEN–RECTIFICATION)

(R7290–PURPLE–ULTRAVIOLET)

TRANSFORMER

SAFETY

SWITCH

RESET

BUTTON

CAPTIVE

MOUNTING

SCREWS

(10)

M8680

ST71A

PLUG-IN

PURGE

TIMER

PURGE TIMER

CONNECTORS

PLUG-IN

AMPLIFIER

OPTIONAL

ALARM TERMINALS

AMPLIFIER

CONNECTORS

TEST JACK

ARC-GAP IGNITION INTERFERENCE

PROTECTION (R7289 RECTIFICATION

AMPLIFIER ONLY)

PRELIMINARY INSPECTION

Make certain that:

1. Wiring connections are correct and all terminal screws

are tight. Use a meter to check the continuity of all circuits.

2. Flame detector is installed and positioned properly.

Consult the appropriate installation instructions.

3. Ambient temperature at flame detector does not ex-

ceed maximum rated temperature.

4. Correct combination of amplifier and flame detector is

used. Refer to Plug-In Flame Signal Amplifiers in Specifica-

tions section.

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

lines are purged of air.

6. Combustion chamber and flues are clear of fuel.

7. Power is connected to system disconnect switch (mas-

ter switch).

8. Safety switch is reset; push in and then release the

green safety switch.

9. All limits and interlocks are reset.

IMPORTANT: Anytime you reset the safety switch, wait at

leastoneminuteafter it tripstoallowtheheater to cool

before pushing in the reset button.

CAUTION

Make initial pilot lightoff with manual main fuel

shutoff cock closed.

960-2285—7

R4795A

CHECKOUT

2. The flame current is at least two microamperes for

R7289A Rectification Amplifier (color-coded green), or at

least 1.5 microamperes for an R7290A Ultraviolet Amplifier

(color-coded violet).

IF A STEADY READING OF AT LEAST MINIMUM

STRENGTH CANNOT BE OBTAINED, ONE OR MORE

OF THE FOLLOWING CONDITIONS CAN EXIST:

•Improper supply voltage.

•Defective flame detector wiring including:

—Open circuits.

—Short circuits.

—High resistance shorts caused by moisture, accu-

mulated dirt, or an improper choice of detector lead-

wire for the particular installation.

•Impropersighting,improper viewing window, ordirty

viewing window for optical detectors.

•Improper application of a flame rod including:

—Insufficient ground area.

—Poor location of flame rod in flame.

—Excessive heat on flame rod insulator, greater than

600°F (316°C).

—Ignition interference.

•Improper application of a vacuum photocell including:

—Temperature over 165°F (74°C) at photocell.

—Dirty photocell envelope.

•Defective sensor.

PILOT TURNDOWN TEST

IMPORTANT: If the R4795 is used to prove a pilot flame,

perform the following Turndown Test to assure that

the main burner can be lit by the smallest pilot flame

that will hold in the 2K (flame) relay.

1. Shut off the fuel supply to the main burner only by

closing the manual main burner shutoff cock. Do not shut off

fuel supply to the pilot valve.

2. Start the system by raising the setpoint of the control-

ler (or pressing the START button). After prepurge is com-

pleted, the pilot will light and pull in the flame relay.

3. Reduce the size of the pilot flame to the turndown

condition by slowly closing the manual valve on the pilot gas

line. At the turndown condition, the pilot will be small

enough so it just barely holds in the flame relay (2K).

a. Slowly turn down the pilot until the flame relay drops

out.

b. Allow the control to complete prepurge.

c. As the control attempts to restart the pilot, turn the

pilot back up slowly just until relay 2K pulls back in.

You will have 15 seconds to complete this step before

lockout occurs.

d. Again turn the pilot down slightly but not enough so

the flame relay drops out. If the relay drops out, simply

allow the control to complete the purge period and

then turn the pilot back up to pull in the flame relay as

in step c. above. The closer the pilot is to the dropout

condition, the more conclusive the test will be.

FLAME CURRENT CHECK

The flame current check is the best indicator of proper

flame detector application. Perform the check at the time of

installation, and at any time service is done on the system,

and at least once a month, or more often, while the system is

in operation. This prevents shutdowns due to poor flame

signal.

Test by connecting a W136 (or equivalent) to the ampli-

fier and reading the flame current while the burner is operat-

ing. (Fig. 11).

Fig. 11—Connecting meter to read flame

current.

M8689

W136

117053 METER

CONNECTOR PLUG

(SUPPLIED WITH W136)

BLACK

RED

FLAME

CURRENT

TEST JACK

PLUG-IN

AMPLIFIER

IF 117053 METER CONNECTOR PLUG IS NOT AVALIABLE

(R7289A RECTIFICATION AMPLIFER ONLY)

FLAME

DETECTOR

F LEAD

G LEAD

RED F

W136

R4795

Insert a 117053 Meter Connector Plug, wired color-to-

color to the W136 leadwires, into the test jack on the ampli-

fier (Fig. 10). This automatically puts the microammeter in

series with the flame detector.

If an R7289A Rectification Type Amplifier is used and a

meter connector plug is not available, disconnect the flame

detector lead from the F terminal; then connect this lead to

the Black lead of the microammeter, and connect the Red

lead of the microammeter to the F terminal.

NOTE: If an R7290A Ultraviolet Type Amplifier is used, the

flame current cannot be read by connecting a micro-

ammeter in series with the F lead.

When reading the flame current, assure that the following

criteria are met:

1. The flame current is steady; meter does not vary more

than a needle width.

60-2285—7 10

R4795A

CHECKOUT

CAUTION

Do not manually push in the relays.

4. Check that the pilot is lit and relay 2K is pulled in.

5. Open the manual main burner shutoff cock. Main

flame should light within one second. If the burner does not

light within one second, close the shutoff cock and shut off

power to the relay. Proceed to step 7.

6. If the burner lights, repeat step 5 two or three times to

verify lightoff.

7. If the lightoff is unsatisfactory, readjust the flame

detector to require a larger pilot flame to hold in the flame

relay. This usually requires:

a. Resighting a photocell or UV type detector farther

out on the axis of a pilot flame, or

b. Adjusting a flame rod detector so that a larger mini-

mum pilot is required.

8. Repeat the entire turndown test until the flame is

established promptly in step 5.

9. Turn up the pilot to full flame at the test completion.

HOT REFRACTORY HOLD-IN TEST

(PHOTOCELL OIL INSTALLATIONS ONLY)

If hot refractory holds in the flame relay at the end of the

burner-on cycle, the system cannot restart until the relay

drops out. Check for hot refractory hold-in by observing the

flame relay for immediate dropout at the end of a long

burner-on period. If the relay does not drop out, resight the

photocell so it does not sight the refractory, or decrease

photocell sensitivity using aperture disks or filters.

IGNITION SPARK RESPONSE TEST

(UV DETECTORS)

The flame relay should not respond (pull in) to ignition

spark. To determine flame detector sensitivity to ignition

spark, perform the following test:

1. Shut the pilot and main fuel manual valves.

2. Start the system by raising the controller setpoint or

pressing the START button. This should energize the igni-

tion transformer so spark is produced between the electrode

and ground.

3. Check the flame relay 2K. The relay should not pull in.

The flame signal current should not be more than one-fourth

microampere.

4. If relay 2K does pull in, 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 flame

detector does not respond to the ignition spark.

IMPORTANT: Repeat ALL required checkout tests after all

adjustments are complete. ALL tests must be satisfac-

tory when the flame detector is in its FINAL position.

SAFE SHUTDOWN CHECKS

Limit Action

With the burner operating, lower the high limit setting to

simulate an overheated boiler or furnace. Normal shutdown

should occur. Restore the normal limit setting; the burner

should go through a normal prepurge and start.

Using manual reset limits is desirable to prevent the

system from cycling off the high limit and to assure that the

condition that caused the limit action is detected as soon as

possible.

Flame Failure

Let burner operate five minutes; then manually shut off

fuel supply to simulate flame failure. Relay should drop out

and fuel valve(s) close. The system will purge and then lock

out on safety. Let the safety switch cool for one minute;

reopen manual fuel valve, and reset safety switch. Burner

should start.

Power Failure

Let the burner run five minutes. Then simulate power

failure by opening the line switch. All relays should drop out

and the fuel valves should close. After a minimum of five

seconds, close the line switch. The R4795 should go through

a normal cycle.

IMPORTANT: At the completion of all Checkout tests,

make sure that the R4795 is not on safety lockout, that

the pilot is turned up to its normal level, and that all

limit settings are correct. Operate the system through

one normal cycle. Replace cover and securely tighten

thumbscrew.

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