R7140G,L,M
Burner Control Modules
INSTALLATION INSTRUCTIONS
FEATURES
•
Device status available to ModBus™ through S7810M
card or S7800A1001 Series 5 Keyboard Display.
•
Safety features:
—
—
—
—
—
—
—
—
—
—
—
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.
•
•
Application flexibility.
0.8 or 3.0 second Flame Failure Response Time (FFRT),
depending on amplifier selected.
•
Dependable, long-term operation provided by
microcomputer technology.
•
•
•
•
Five LEDs for sequence information. See Fig. 1.
Five function Run/Test Switch.
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).
Interchangeable plug-in flame amplifiers.
Nonvolatile memory; history files and sequencing
status are retained after loss of power and can be
viewed using the Keyboard Display Module
S7800A1001 (sold separately).
•
Report generation (optional) through modbus™.
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.
NOTE: Check Service Notes on page 7 and Static Check-
out on page 26 prior to installation of R7140.
•
Burner controller data (optional):
—
—
—
Lockout/alarm status.
Total cycles of operation.
Total hours of operation.
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.
•
•
Status of configuration jumpers.
Status of Run/Test Switch.
Functions provided by the R7140G,L,M include automatic
burner sequencing, flame supervision, system status
indication, system or self-diagnostics and troubleshooting.
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R7140G,L,M BURNER CONTROL MODULES
Table 1. Flame Detection Systems.
Plug-in Flame Signal Amplifiers
Applicable Flame Detectors
Flame
Failure
Response
a
Type
Color Self-Checking
Model
Time (sec)
Fuel
Type
Models
C7024E,F
b,c,h
Rectification Green Dymanic Self-
Check
3
Gas, oil, Ultraviolet (Purple
coal Peeper®)
R7824C
g
No
0.8/1 or 2/3 Gas
Rectifying Flame Rod C7004, C7007, C7011
R7847A
i
Complete Assemblies:
C7008, C7009, Q179
Holders
g
No
2/3
Gas, oil, Ultraviolet (Purple
C7012A,C.
R7847A
R7847B
coal
Peeper®)
d,g
Dynamic Ampli-
Check®
0.8/1 or
2/3
Gas
Rectifying Flame Rod C7004, C7007, C7011
Holders
i
Complete Assemblies:
C7008, C7009, Q179
d,g
c,h
Dynamic Ampli-
Check®
2/3
3
Gas, oil, Ultraviolet (Purple
coal Peeper®)
C7012A,C
R7847B
Dynamic Self
Check
Gas, oil, Ultraviolet (Purple
coal Peeper®)
C7012E,F
R7847C
Infrared
Ultraviolet
Optical
Red
No
R7848A
2/3
2/3
2/3
2/3
Gas, oil, Infrared (Lead Sulfide) C7015
coal
d
b
Dynamic Ampli-
Check®
Gas, oil, Infrared (Lead Sulfide) C7015
coal
R7848B
Red/
White
No
R7852A
Gas, oil, Infrared (Lead Sulfide) C7915
coal
Dynamic Ampli-
Check®
Gas, oil, Infrared (Lead Sulfide) C7915
coal
R7852B
R7849A
f
f
Purple No
0.8/1 or
2/3
Gas, oil Ultraviolet
(Minipeeper)
C7027, C7035, C7044
d
Dynamic Ampli-
Check®
0.8/1 or
2/3
Gas, oil Ultraviolet
(Minipeeper)
R7849B
R7861A
R7886A
C7027, C7035, C7044
C7061
c,e
c,e
Dynamic Self-
Check
0.8/1 or
2/3
Gas, oil, Ultraviolet
coal
Blue
Dynamic Self-
Check
2/3
Gas, oil, Ultraviolet (Adjustable C7076
coal Sensitivity)
White Dymanic Ampli- R7851B
Check®
0.8/1 or 2/3 Gas, oil, Optical (UV, Visible
coal Light)
C7927, C7962
c
Dynamic Self-
Check
2/3
Gas, oil, Optical (UV only)
coal
C7961
R7851C
a
b
c
Flame Failure Response Time (FFRT) depends on selection of amplifier and 7800 SERIES and R7140 Relay Module.
R7824C is used only with the 24 Vdc RM7824 Relay Module and C7024E,F Flame Detectors.
Circuitry tests all electronic components in flame detection system (amplifier and detector) 12 times a minute during burner
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.
200/220/240 Vac applications require a 120 Vac, 10 VA minimum stepdown transformer (not provided) to drive the shutter.
Applies to R7886A series 2 or greater; R7861 series 1 or greater. Fig. 2 shows flame detector wiring.
Use C7027, C7035 and C7044 Flame Detectors only on burners that cycle on-off at least once every twenty-four hours. Use
C7061A Ultraviolet Detector with R7861A Amplifier or C7076A Flame Detector with R7886A Amplifier as ultraviolet flame detec-
tion system for appliances with burners that remain on continuously for twenty-four hours or longer.
R7847A,B Amplifiers with 0.8/1 second FFRT should NOT be used with C7012A,C Solid State Ultraviolet Detectors.
R7824C Series 2 and greater and R7847C Series 4 or greater, check flame detector system when flame reaches 1.5 Vdc or at
4.5 seconds, whichever occurs first.
d
e
f
g
h
NOTE: R7824C Series 2 or greater and R7847C Series 4 or greater, pulse the shutter when signal of 1.5 Vdc is sensed. Display
readings of 0.7 to 2.4 Vdc are common.
i
Order flame rod separately; see flame detector Instructions for holder.
3
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R7140G,L,M BURNER CONTROL MODULES
S7800A1068 Spanish language.
Table 2. Plug-in Purge Timer Cards.
S7800A1118 Katakana (Japanese) language.
S7800A1126 Portuguese language.
S7800A1142 English language.
Pre-Purge Timing
Product Number
ST7800A1013
ST7800A1039
ST7800A1047
ST7800A1054
ST7800A1062
7
Communications:
30
40
60
90
S7810A1009 Data ControlBus Module™ (if no KDM is
used).
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.
50023821-001 Keyboard Display Module Cover, NEMA 4,
clear.
50023821-002 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.
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.
123514A Rectification Flame Simulator.
203659 Ultraviolet Flame Simulator.
BURNER CONTROL
5
(127)
6-5/32
(156)
POWER
PILOT
FLAME
MAIN
ALARM
RESET
_
S
+
5
1-1/4
(32)
(127)
7
(177)
5-3/4 (146)
M22604
Fig. 2. Mounting dimensions of R7140G,L,M Burner Control Module with Q520A Subbase, in in. (mm).
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R7140G,L,M BURNER CONTROL MODULES
Table 3. Terminal Ratings.
Description
Terminal No.
Ratings
a
G
—
Flame Sensor Earth Ground
a
Earth G
—
Earth Ground
L2(N)
L1
3
Line Voltage Common
Line Voltage Supply (L1)
Lockout/Running Interlock
Pre-Ignition Interlock Input
Pilot Valve/Ignition
—
120 Vac (+10/-15%), 50 or 60 Hz (±10%).
120 Vac, 8A run, 43A inrush.
120 Vac, 1 mA.
4
5
120 Vac. See Table 4.
6
Interrupted/Intermittent Pilot Valve/First Stage Oil Valve 120 Vac. See Table 4.
7
Main Fuel Valve
Burner Motor
120 Vac. See Table 4.
120 Vac, 9.8 AFL, 58.8 ALR (inrush).
120 Vac, 1A pilot duty.
120 Vac, 75 VA pilot duty.
120 Vac, 75 VA pilot duty.
120 Vac, 75 VA pilot duty.
120 Vac, 1 mA.
8
9
Alarm
10
11
12
13
14
15
16
17
18
Firing Rate High Fire
Firing Rate Common
Firing Rate Modulate
Low Fire Switch Input
Firing Rate Low Fire
High Fire Switch Input
Burner Controller and Limits
Shutter
120 Vac, 75 VA pilot duty.
120 Vac, 1 mA.
120 Vac, 1 mA.
120 Vac, 0.5A.
Ignition
120 Vac, 4.5A ignition.
F
Flame Sensor
60 to 220 Vac, current limited.
a
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.
Table 4. Terminal Ratings.
Terminal
Typical Load
Maximum Rating at 120 Vac, 60 Hz
4.5A ignition and 50 VA pilot duty, or
2.5A ignition and 75 VA pilot duty.
5 or 6
Ignition
Transformer/Pilot
Valve/First Stage Fuel Valve
7
Main Fuel Valve(s) (solenoid/ 250 VA pilot duty or 65 VA pilot duty in parallel with motorized valve(s) using a total of
motorized/diaphragm) and
Vent Valve, if required
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.
5
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R7140G,L,M BURNER CONTROL MODULES
Table 5. Sequence Timing for Normal Operation.
Flame
Establishing
Period
Post
Firing
Rate
Energy
Saving
Approval
Code
Purge
Device Initiate Standby Purge Pilot
Main
Run Timing Interlock Circuits Circuit Pre-Purge Bodies
R7140G 10 sec.
*
** 4 or 10 10, 15
*
15 sec. Pre-Ignition,
4-wire
No
UL/CSA
Modulating
a
sec.
Running, Low Fire modulating
sec. or
intermittent.
R7140L
R7140M
10 or 15
sec.
Pre-Ignition,
Lockout High and
Low Fire
FM/IRI
a
Modulating
10 sec. or
intermittent
Pre-Ignition,
Running, isolated isolated
Low Fire. On-Off-On
contacts
2-wire
UL/CSA
On-Off.
a
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.
NOTE: Allowable inrush can be up to ten times the pilot
duty rating.
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.
EXAMPLE: Pilot duty rating = 50 VA.
At 120 V, running current is:
50/120 = 0.42A.
2. Wiring must comply with all applicable codes,
ordinances and regulations.
3. Wiring must comply with NEC Class 1 (Line Voltage)
wiring.
Maximum allowable inrush is ten times 0.42A = 4.2A.
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).
INSTALLATION
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 C7927, 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 A 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.
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.
10.This digital apparatus does not exceed the Class A
limits for radio noise for digital apparatus set out in
the Radio Interference Regulations of the Canadian
Department of Communications.
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
Make sure the wiring subbase of the old device is a
20-terminal Q520 (four rows of 5 terminals).
Location
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).
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.
Make sure there is an electrical service ground wire
connection to the G terminal in the wiring subbase.
R4140G or BC7000 with PM720G replacement.
Vibration
—
If the application was a dual burner ignition, check the
Q520 subbase for a jumper between terminals 6 to 7,
discard the jumper and move the main valve connec-
tion (terminal 7) to terminal 6.
Do not install the relay module where it could be subjected to
vibration in excess of 0.5G continuous maximum vibration.
Weather
Replacing GP201 or GP301 devices:
—
High Fire (or Purge Rate) Switch may be connected to
terminal D.
The relay module is not designed to be weathertight.
When installed outdoors, protect the relay module using an
approved weathertight enclosure.
—
Identify, remove, and connect to terminal M.
Replacing GP101 devices:
Check wiring subbase. If D is jumpered to 8, remove
the jumper.
—
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.
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.
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.
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.
Service Notes:
—
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.
Per industry standards, a conduit seal or a cable type that is
sealed is required to be installed in a device that can result in
flammable gas or flammable liquid flow through a conduit or
cable to an electrical ignition source in the event of a seal
leakage or diaphragm failure. This could be on the gas valves,
or gas or oil pressure regulators.
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 jump-
ered 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.
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.
Generally, the following table will apply to select
the R7140M1007 model and the status of jumpers
J1 and J2.
7
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R7140G,L,M BURNER CONTROL MODULES
Table 6. J1/J2 Jumper Configuration for R4140M/PM720M.
Model
R4140M1004/M1012
R4140M1020/M1038
R4140M1046/M1053
R4140M1079 (GP101)
R4140M1103/M1111
R4140M1145/M1152
R4140M1160/M1178
R4140M1186
Purge Timer
A1039
Leave J1 & J2
Remove J1 and J2
X
A1047
X
X
A1062
A1062
X
X
A1039
A1047
X
X
X
A1062
A1047
R4140M1194
ST7800A1062
BC7000L1000 w/PM720M2002 ST7800A1062
BC7000L1000 w/PM720M2036
X
*
X
* Check terminal 8 and 15.
If jumpered, ST7800A1031 (7 second purge).
If not jumpered, ST7800A1039 (30 second purge).
Removing the Programmer
1. Open the master switch.
Mounting R7140 Relay Module
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.
Installing the Programmer (Fig. 3)
WARNING
KNIFE-BLADE
CONTACTS (20)
Electrical Shock Hazard.
SPRING
CONNECTORS
CHASSIS
RETAINING
SCREW
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.
PROGRAMMER
CHASSIS
WIRING
SUBBASE
PIVOT PIN (2)
HINGE
BRACKET (2)
M22605
Fig. 3. Mounting the programmer on the subbase.
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R7140G,L,M BURNER CONTROL MODULES
R7140G
INITIATE
(INITIAL
POWERUP
ONLY)
PREPURGE PFEP
HOLD
10 SEC.
00
(4 SEC. IF
00
00
10
20 25
MFEP
00
15
TIMED
DRIVE TO
PREPURGE
STANDBY
POWER
LOW FIRE JR1 CLIPPED
RUN
POSTPURGE STANDBY
POWER
POWER
POWER
POWER
POWER
PILOT
POWER
PILOT
POWER
POWER
LED
DISPLAY
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
FLAME
MAIN
FLAME
MAIN
ALARM
ALARM
ALARM
ALARM
ALARM
BURNER/BLOWER MOTOR
18 IGN.
10 SEC. IGN./PILOT
15 SEC. INTERRUPTED PILOT VALVE
MAIN VALVE
8
BURNER
5 SEC.
5
6
1
7
OPERATING
CONTROLS
AND
TO
TO
LIMITS AND BURNER CONTROLLER CLOSED L1
16
16
3
3
3
INTERLOCK. CHECK
RUNNING INTERLOCKS CLOSED
IC
INTERLOCKS
16
PII CLOSED
4
TO
2
13
8
LOW FIRE SW.
TO
FLAME PROVING
10
FLAME
SIGNAL
SSC
SAFE START CHECK
R7140G SWITCHING
11
TO
TO
11
14
11
14
TO
10
11
TO
FIRING
RATE
MOTOR
MOTOR ACTION
1
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)
M23319
PII MEANS PRE-IGNITION INTERLOCK.
2
3
FOR R7140G1000:
L1 TO 4
4 TO 3
Fig. 4. Operating sequence, R7140G1000/R7140G2008.
9
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R7140G,L,M BURNER CONTROL MODULES
L1
(HOT) L2
1
L1
120 Vac,
50/60 Hz
PLUG-IN PURGE
TIMER CARD
CONFIGURATION
JUMPERS
TEST
JACK
FLAME SIGNAL
RUN/TEST
SWITCH
F
G
PLUG-IN
FLAME
AMPLIFIER
MICROCOMPUTER
TEST
RESET
PUSHBUTTON
17
2K
3K
4K
RELAY
5K
6K
7K
8K
DRIVE
RELAY
STATUS
CIRCUIT
FEEDBACK
AND LINE
VOLTAGE
INPUTS
9K
SAFETY RELAY
CIRCUIT
1K
STATUS LEDs
CONTROL
POWER
POWER SUPPLY
R1
R1
RUNNING/
LOCKOUT
INTERLOCK
L2
PRE-IGNITION
INTERLOCK
LIMITS CONTROLLER
1K1
2K1 5K1
IGNITION
3
4
16
18
5
4K1
7K1
2K2
PILOT
6
PILOT/V2
LOW FIRE SWITCH
13
7
MAIN VALVE
BLOWER
ALARM
6K1
3K1
8
9
HIGH FIRE
10
KEYBOARD
8K1
8K2
9K2
DISPLAY MODULE
DDL
COMMON
INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLT INPUTS
11
12
14
RS485
MODULATE
1
9K1
LOW FIRE
DDL
COMMUNICATIONS
2
3
FIELD WIRING
INTERNAL WIRING
REMOTE
RESET
1
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
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
L1
(HOT)
L2
1
L1
L2
120 Vac,
50/60 Hz
PLUG-IN PURGE
TIMER CARD
CONFIGURATION
JUMPERS
TEST
JACK
FLAME SIGNAL
RUN/TEST
SWITCH
F
PLUG-IN
G
FLAME
MICROCOMPUTER
AMPLIFIER
TEST
17
CONTROL
POWER
POWER SUPPLY
PRE-IGNITION
INTERLOCK
4
RUNNING/
LOCKOUT
INTERLOCK
CONTROLLER
LIMITS
1K1
2K1 5K1
16
3
IGNITION
18
5
4K1
7K1
2K2
PILOT
6
PILOT/V2
MAIN VALVE
BLOWER
ALARM
LOW FIRE SWITCH
13
7
8
9
6K1
3K1
HIGH FIRE
12
8K1
8K2
9K2
COMMON
INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLT INPUTS
13
15
14
MODULATE
9K1
LOW FIRE
FIELD WIRING
INTERNAL WIRING
1
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
M23321
Fig. 6. Internal block diagram of the R7140G2008. (See Fig. 7 for detailed wiring.)
11
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R7140G,L,M BURNER CONTROL MODULES
FOR DIRECT SPARK IGNITION (OIL OR GAS)
IGNITION
TRANSFORMER
5
1ST STAGE
FUEL VALVE
6
7
TO
L2
2ND STAGE
FUEL VALVE
(OPTIONAL)
5 SECOND IGNITION
(EARLY SPARK
2
WIRING
SUBBASE
TERMINAL
STRIP (4)
TERMINATION)
RUNNING
INTERLOCKS
(INCLUDING
AIRFLOW SWITCH)
10 SECOND
INTERRUPTED
PILOT/IGNITION
5
6
3
4
PREIGNITION
INTERLOCK(S)
3
18
4
BURNER
CONTROLLER
PILOT/IGNITION
LIMITS
L1
L2
12
MAIN FUEL
VALVE(S)
17
16
7
8
120V ALARM
9
BURNER MOTOR
(BLOWER)
HIGH FIRE
10
11
LOW FIRE
START SWITCH
15
14
COMMON
G
13
F
4
RECTIFYING FLAME
ROD, OR
INFRARED
(LEAD SULFIDE)
FLAME DETECTOR
B
R
B
R
MODULATE
LOW FIRE
OR
W
W
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
WHITE
BLUE
BLUE
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
OR
YELLOW
5
C7012A, C, C7061, OR
C7076A ULTRAVIOLET
FLAME DETECTOR
1
L1 (HOT)
L2
120V, 60 HZ
POWER
SUPPLY
WHITE
WHITE
MASTER
SWITCH
L2
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
AS REQUIRED.
1
2
3
4
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
5
Fig. 7. Wiring diagram for R7140G2008 for application replacing R4140G with start Interlock or BC7000L1000 with
PM720G.
66-1153—03
12
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R7140G,L,M BURNER CONTROL MODULES
FOR DIRECT SPARK IGNITION (OIL OR GAS)
5
IGNITION
JUMPER
TO
L2
6
7
MAIN OIL VALVE
SOLENOID
4
2
WIRING
SUBBASE
TERMINAL
STRIP (4)
RUNNING
INTERLOCKS
(INCLUDING
10 SECOND
INTERRUPTED
PILOT/IGNITION
AIRFLOW SWITCH)
5
3
PREIGNITION
INTERLOCK(S)
3
6
18
6
BURNER
PILOT/IGNITION
LIMITS
L1
L2
12
4
CONTROLLER
MAIN FUEL
VALVE(S)
17
16
7
8
120V ALARM
9
BURNER
MOTOR
HIGH FIRE
10
11
15
14
LOW FIRE
SWITCH
6
COMMON
G
13
F
RECTIFYING FLAME
ROD, OR
INFRARED
(LEAD SULFIDE)
FLAME DETECTOR
B
R
B
R
5
MODULATE
LOW FIRE
OR
W
W
C7027A, C7035A, C7927 OR
C7044A ULTRAVIOLET
FLAME DETECTOR
WHITE
BLUE
BLUE
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
OR
C7067A,D OR
C7061 ULTRAVIOLET
FLAME
YELLOW
1
L1 (HOT)
L2
120V, 60 HZ
POWER
SUPPLY
5
DETECTOR
WHITE
WHITE
MASTER
SWITCH
L2
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.)
4
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
AS REQUIRED.
1
2
3
USE ALL NEC CLASS 1 WIRING.
C7012 MUST BE UPDATED TO C7061.
5
6
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.
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.
SOLENOID MUST NOT EXCEED THE ELECTRICAL RATINGS OF TERMINAL 7.
4
M22608B
Fig. 8. Field wiring for R7140G1000 used for replacing R4140G Programmers with pre-ignition interlocks.
13
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R7140G,L,M BURNER CONTROL MODULES
R7140L
INITIATE
(INITIAL
POWERUP
ONLY)
PREPURGE
HOLD
PREPURGE PFEP
HOLD
10 SEC.
00
(4 SEC. IF
JR1 CLIPPED
00
00
00
10
20 25
MFEP
00
POSTPURGE STANDBY
POWER POWER
15
TIMED
DRIVE TO
HIGH FIRE
DRIVE TO
LOW FIRE
PREPURGE
STANDBY
POWER
RUN
POWER
POWER
POWER
POWER
POWER
POWER
PILOT
POWER
PILOT
LED
DISPLAY
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
FLAME
MAIN
FLAME
MAIN
ALARM
ALARM
ALARM
ALARM
ALARM
BURNER/BLOWER MOTOR
IGN.
8
BURNER
5 SEC.
18
10 SEC. IGN./PILOT
15 SEC. PILOT
5
6
MAIN VALVE
7
OPERATING
CONTROLS
AND
TO
LIMITS AND BURNER CONTROLLER CLOSED
LOCKOUT INTERLOCKS CLOSED
L1
16
3
1
1
16 TO
INTERLOCKS
PII CLOSED
TO 15 HIGH FIRE SW.
4
TO 16
2
13
8
8
LOW FIRE SW.
TO
FLAME
SIGNAL
FLAME PROVING
10
SSC
SAFE START CHECK
SWITCHING
11
TO
TO
14
10
14
10
TO
10
11
TO
FIRING
RATE
MOTOR
MOTOR ACTION
M23322
FOR R7140L1009:
L1 TO 4.
1
2
4 TO 3.
PII MEANS PRE-IGNITION INTERLOCK.
Fig. 9. Operating sequence, R7140L1009 and R7140L2007.
66-1153—03
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R7140G,L,M BURNER CONTROL MODULES
L1
(HOT) L2
1
L1
120 Vac,
50/60 Hz
PLUG-IN PURGE
TIMER CARD
CONFIGURATION
JUMPERS
TEST
JACK
FLAME SIGNAL
RUN/TEST
SWITCH
F
PLUG-IN
FLAME
G
MICROCOMPUTER
AMPLIFIER
TEST
RESET
17
PUSHBUTTON
2K
3K
4K
RELAY
DRIVE
5K
RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS
6K
7K
8K
CIRCUIT
9K
SAFETY RELAY
CIRCUIT
1K
STATUS LEDs
CONTROL
POWER
POWER SUPPLY
R1
R1
PII
RUNNING/
LOCKOUT
LIMITS CONTROLLER
INTERLOCK
L2
1K1
2K1
5K1
18
IGNITION
4
16
(3)
4K1
7K1
2K2
LOW FIRE SWITCH
13
(D)
5
6
7
PILOT
PILOT/V2
MAIN VALVE
BLOWER
ALARM
HIGH FIRE SWITCH
15
(8)
6K1
8
(M)
9
3K1
(A)
HIGH FIRE
10
(X)
11
(10)
12
(11)
14(
12)
KEYBOARD
DISPLAY MODULE
8K1
8K2
9K2
DDL
COMMON
INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLT INPUTS
RS485
MODULATE
1
2
9K1
LOW FIRE
DDL
COMMUNICATIONS
FIELD WIRING
INTERNAL WIRING
REMOTE
RESET
3
1
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
NOTE: ( ) NUMBERS ON GP201, GP301 SUBBASE.
M23323
Fig. 10. Internal block diagram of the R7140L1009. (See Fig. 12 for detailed wiring.)
15
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R7140G,L,M BURNER CONTROL MODULES
L1
(HOT) L2
1
L1
L2
120 Vac,
50/60 Hz
PLUG-IN PURGE
TIMER CARD
CONFIGURATION
JUMPERS
TEST
JACK
FLAME SIGNAL
RUN/TEST
SWITCH
F
PLUG-IN
FLAME
G
MICROCOMPUTER
AMPLIFIER
TEST
RESET
17
PUSHBUTTON
2K
3K
4K
RELAY
DRIVE
5K
RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS
6K
7K
8K
CIRCUIT
9K
SAFETY RELAY
CIRCUIT
1K
STATUS LEDs
CONTROL
POWER
POWER SUPPLY
PRE-IGNITION
INTERLOCK
4
3
RUNNING/
LOCKOUT
INTERLOCK
LIMITS CONTROLLER
1K1
2K1 5K1
18
5
IGNITION
16
4K1
7K1
2K2
LOW FIRE SWITCH
13
PILOT
6
PILOT/V2
HIGH FIRE SWITCH
15
MAIN VALVE
7
8
9
6K1
3K1
BLOWER
ALARM
HIGH FIRE
10
11
12
14
KEYBOARD
DISPLAY MODULE
8K1
DDL
COMMON
INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLT INPUTS
RS485
8K2
9K2
MODULATE
1
9K1
DDL
COMMUNICATIONS
2
3
FIELD WIRING
INTERNAL WIRING
REMOTE
RESET
LOW FIRE
M23329
1
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
Fig. 11. Internal block diagram of the R7140L2007. (See Fig. 13 for detailed wiring.)
66-1153—03
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R7140G,L,M BURNER CONTROL MODULES
FOR DIRECT SPARK IGNITION (OIL OR GAS)
IGNITION
5
TRANSFORMER
6
TO
L2
JUMPER
7
MAIN FUEL VALVE
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
2
WIRING
SUBBASE
TERMINAL
STRIP (4)
LOCKOUT
INTERLOCKS
(INCLUDING
AIRFLOW SWITCH)
10 SECOND
INTERRUPTED
PILOT/IGNITION
5
3
PREIGNITION
INTERLOCKS
4
6
15 SECOND
INTERRUPTED
PILOT/IGNITION
18
BURNER
CONTROLLER
LIMITS
L1
L2
12
4
MAIN FUEL
VALVE(S)
17
16
7
8
7
120V ALARM
9
BURNER MOTOR
(BLOWER)
LOW FIRE
SWITCH
HIGH FIRE
10
11
15
14
HIGH FIRE
SWITCH
COMMON
G
13
F
RECTIFYING FLAME
ROD,OR
INFRARED
(LEAD SULFIDE)
FLAME DETECTOR
B
B
4
R
R
MODULATE
LOW FIRE
OR
W
W
WHITE
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
BLUE
SERIES 90
CONTROLLER
SERIES 90
FIRING RATE
MOTOR
OR
C7061, C7927 OR
C7076A, D
ULTRAVIOLET
YELLOW
BLUE
1
5
L1 (HOT)
L2
120V, 60 HZ
POWER
SUPPLY
FLAME DETECTOR
WHITE
MASTER
SWITCH
6
WHITE
L2
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.)
5
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
1
2
3
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.
WHITE SHUTTER LEADWIRES ARE ONLY ON THE C7061A, E
ULTRAVIOLET FLAME DETECTORS; C7076A, D ADJUSTABLE SENSITIVITY
ULTRAVIOLET FLAME DETECTORS DO NOT HAVE LEADWIRES.
6
7
4
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.)
TERMINAL 17 IS USED ONLY FOR THE SHUTTER ON SELF-CHECKING
C7061A, E, F OR C7076A, D FLAME DETECTORS.
M22610
Fig. 12. Sample block diagram of field wiring for the R7140L1009, used for
replacing R4140L Programmers with pre-ignition interlocks.
17
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R7140G,L,M BURNER CONTROL MODULES
FOR DIRECT SPARK IGNITION (OIL OR GAS)
IGNITION
5
TRANSFORMER
6
TO
L2
JUMPER
7
MAIN FUEL VALVE (S)
5 SECOND IGNITION
2
WIRING
(EARLY SPARK
TERMINATION)
SUBBASE
LOCKOUT
TERMINAL
STRIP (4)
INTERLOCKS
(INCLUDING
AIRFLOW SWITCH)
10 SECOND
INTERRUPTED
PILOT/IGNITION
5
6
3
4
PREIGNITION
INTERLOCKS
15 SECOND
INTERRUPTED
PILOT
18
BURNER
CONTROLLER
L1
L2
12
LIMITS
MAIN FUEL
VALVE(S)
17
16
7
8
120V ALARM
9
BURNER MOTOR
(BLOWER)
LOW FIRE START
SWITCH
HIGH FIRE
3
10
11
15
14
HIGH FIRE
PURGE SWITCH
COMMON
G
13
F
RECTIFYING FLAME
ROD, RECTIFYING
PHOTOCELL, OR
INFRARED
(LEAD SULFIDE)
FLAME DETECTOR
B
R
B
R
MODULATE
LOW FIRE
OR
W
W
WHITE
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
BLUE
BLUE
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
OR
C7012A, C, C7076A, OR
C7061
ULTRAVIOLET
FLAME DETECTOR
YELLOW
1
L1 (HOT)
L2
120V, 60 HZ
POWER
SUPPLY
WHITE
WHITE
MASTER
SWITCH
L2
BLACK
BLACK
L1
L2
PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
1
2
4
M22611B
USE ALL NEC CLASS 1 WIRING.
IN SOME INSTALLATIONS THE LOW FIRE INTERLOCK IS BETWEEN
TERMINALS L1 AND 13.
3
C7076 COMES WITHOUT LEADWIRES; C7061 DOES NOT HAVE BLACK LEADWIRES.
4
Fig. 13. Block diagram of field wiring for the R7140L2007, used for replacing
BC7000L1000 with PM720L.
66-1153—03
18
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R7140G,L,M BURNER CONTROL MODULES
R7140M
INITIATE
(INITIAL
POWERUP
ONLY)
PREPURGE PFEP
HOLD
DRIVE TO
LOW FIRE
10 SEC.
00
(4 SEC. IF
00
00
10
20 25
MFEP
00
POSTPURGE STANDBY
POWER POWER
15
TIMED
PREPURGE
STANDBY
POWER
JR1 CLIPPED
RUN
POWER
POWER
POWER
POWER
POWER
PILOT
POWER
PILOT
LED
DISPLAY
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
FLAME
MAIN
FLAME
MAIN
ALARM
ALARM
ALARM
ALARM
ALARM
BURNER/BLOWER MOTOR
18 IGN.
10 SEC. IGN./PILOT
8
BURNER
5 SEC.
5
INTERMITTENT PILOT VALVE
MAIN VALVE
6
7
OPERATING
CONTROLS
AND
TO
LIMITS AND BURNER CONTROLLER CLOSED L1
RUNNING INTERLOCKS CLOSED
16 TO
PII CLOSED TO 16
LOW FIRE SW.
4
3
3
3
INTERLOCKS
4
2
13
8
TO
FLAME PROVING
11
FLAME
SIGNAL
SSC
SAFE START CHECK
R7140M SWITCHING
12
TO
1
TO
14
11
14
11
TO
10
12
TO
MOTOR ACTION
DAMPER
MOTOR
1
2
3
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.
M23331B
Fig. 14. Operating sequence, R7140M.
19
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R7140G,L,M BURNER CONTROL MODULES
L1
L2
L2
L1
CONFIGURATION
JUMPERS
PURGE
TIMER
17
F
FLAME
AMPLIFIER
G
INTERNAL
ELECTRONICS
3K1
ALARM
9
8
1R1
6K1
LF
BLOWER
START
INTERLOCKS
13
4
LIMITS
1R1
16
CONTROLLER
2K1
5K1
4K1
AIRFLOW
1K1
3
18
5
IGN XFMR
INTERMITTENT
PILOT
11
12
J1
7K1
2K2
15 SECOND
INTERMITTENT
PILOT VALVE
8K2
9K2
6
7
9K1
J2
10
14
MAIN VALVE
M23335
Fig. 15. Internal block diagram of the R7140M1007 with start interlocks. (See Fig. 17 for detailed wiring.)
L1
L1
L2
L2
CONFIGURATION
JUMPERS
PURGE
TIMER
17
F
FLAME
AMPLIFIER
G
INTERNAL
ELECTRONICS
3K1
ALARM
9
8
1R1
6K1
LF
BLOWER
PRE-
IGNITION
13
16
LIMITS
1R1
4
CONTROLLER
AIRFLOW
2K1
5K1
4K1
1K1
3
18
5
IGN XFMR
INTERMITTENT
PILOT
11
J1
7K1
2K2
15 SECOND
12
INTERMITTENT
PILOT VALVE
8K2
9K2
6
7
9K1
J2
10
14
MAIN VALVE
M23336
Fig. 16. Internal block diagram of the R7140M1007 with pre-ignition interlocks. (See Fig. 18 for detailed wiring.)
66-1153—03
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R7140G,L,M BURNER CONTROL MODULES
FOR DIRECT SPARK IGNITION OF OIL OR GAS
5
IGNITION
1ST STAGE
FUEL VALVE
6
7
TO
L2
2ND STAGE
FUEL VALVE
(OPTIONAL)
2
WIRING
SUBBASE
RUNNING
TERMINAL
STRIP (4)
INTERLOCKS
(INCLUDING
AIRFLOW SWITCH)
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
3
4
4
3
10 SECOND
18
5
INTERRUPTED
PILOT/IGNITION
BURNER
CONTROLLER
LIMITS
L1
L2
12
INTERMITTENT
PILOT
6
7
17
16
120V ALARM
DAMPER
9
10
11
1
MAIN FUEL
VALVE(S)
7
BURNER MOTOR
CONTROL
5
8
15
LOW FIRE
START SWITCH
8
13
F
RECTIFYING FLAME
ROD, RECTIFYING
PHOTOCELL, OR
INFRARED
(LEAD SULFIDE)
FLAME DETECTOR
14
G
120V, 60 HZ
POWER
SUPPLY
L1 (HOT)
L2
MASTER
SWITCH
OR
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
BLUE
WHITE
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED.
1
OR
2
3
USE ALL NEC CLASS 1 WIRING.
YELLOW
BLUE
C7012A, C, E, OR F
ULTRAVIOLET
FLAME DETECTOR
START INTERLOCKS IF USED BECOME PRE-IGNITION
INTERLOCKS (MUST REMAIN CLOSED UNTIL IGNITION TRIALS BEGIN.)
WHITE
WHITE
4
5
6
PM720M 16 TO 4 IS A PRE-IGNITION INTERLOCK.
6
USE 2 POSITION SPRING RETURN MOTOR.
L2
WHITE LEADWIRES ON C7012 U.V. FLAME DETECTORS. REPLACE C7012
WITH C7061 UV DETECTOR AND R7861A1026 AMPLIFIER.
BLACK
BLACK
L1
L2
7
8
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.
Fig. 17. R7140M1007 used on applications replacing R4140M Programmers with Start Interlocks or BC7000 with
PM720M.
21
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R7140G,L,M BURNER CONTROL MODULES
4
FOR DIRECT SPARK IGNITION (OIL OR GAS)
IGNITION
TRANSFORMER
5
1ST STAGE
FUEL VALVE
6
7
TO
L2
2ND STAGE
FUEL VALVE
(OPTIONAL)
2
5 SECOND IGNITION
WIRING
(EARLY SPARK
TERMINATION)
SUBBASE
TERMINAL
STRIP (4)
RUNNING
INTERLOCKS
(INCLUDING
AIRFLOW SWITCH)
10 SECOND
INTERRUPTED
PILOT/IGNITION
7
PREIGNITION
INTERLOCKS
5
4
6
3
(P)
INTERMITTENT
PILOT/IGNITION
BURNER
LIMITS
L1
L2
18
17
4
CONTROLLER
(13)
MAIN FUEL
VALVE(S)
7
ALARM
9
(A)
6
BURNER
MOTOR
8
DAMPER
CONTROL
3
12
16
(3)
10
(M)
(11)
(X)
LOW FIRE
SWITCH
G
13
15
(8)
11
(S2)
(D)
(10)
RECTIFYING FLAME
ROD OR
1
14
F
L1 (HOT)
L2
120V, 60 HZ
POWER
SUPPLY
INFRARED
(12)
(S1)
5
(LEAD SULFIDE)
FLAME DETECTOR
MASTER
SWITCH
OR
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
WHITE
BLUE
BLUE
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
2
3
USE ALL NEC CLASS 1 WIRING.
OR
YELLOW
WHEN USING A 2-POSITION SPRING DAMPER MOTOR, CLIP
AND REMOVE J1 AND J2, LOCATED ON R7140 SUBBASE.
C7061, C7012A, C,
ULTRAVIOLET
FLAME DETECTOR
4
5
FOR DIRECT SPARK IGNITION (OIL OR GAS), CONNECT THE IGNITION
AND MAIN FUEL VALVE(S) AS SHOWN IN THE INSET.
WHITE
WHITE
6
L2
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.)
NOTE: ( ) NUMBERS ON GP101 SUBBASE.
6
7
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.)
M23338
REPLACEMENT R7140M. START INTERLOCK BECOMES PRE-IGNITION INTERLOCK.
Fig. 18. Block diagram of field wiring for the R7140M1007, used for replacing R4140M Programmers with Pre-Ignition
Interlocks.
66-1153—03
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R7140G,L,M BURNER CONTROL MODULES
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.
SAFETY SHUTDOWN
Safety Shutdown (Lockout) occurs if
any of the following occur during the
indicated period:
h. Purge card is bad.
6. RUN Period:
a. No flame is present.
1. INITIATE Period:
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.
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:
g. Purge card is bad.
7. POSTPURGE 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.
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.
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:
OPERATION
a. Pre-Ignition Interlock opens anytime during PRE-
PURGE 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 PRE-
PURGE (R7140L).
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. (Note: The Power LED is lit for 4 1/2 seconds
and off for 1/2 seconds, to indicate normal operation.)
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 PRE-
PURGE.
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.
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:
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.
a. AC line dropout is detected.
b. AC line noise prevents a sufficient reading of the line
voltage inputs.
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.
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.
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.
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.
5. MAIN FLAME ESTABLISHING Period (MFEP):
a. Low Fire Switch Opens.
b. Lockout Interlock opens (R7140L).
23
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R7140G,L,M BURNER CONTROL MODULES
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 Estab-
lishing Period (PFEP) (four seconds if JR1 is clipped).
b. Terminal 5 is turned off 10 seconds after terminal 7
is energized.
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.
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
(c)30 seconds after terminal 7 is energized and
terminals 8 and 15 are jumpered and jumper
JR2 is clipped.
NOTE: A jumpered High Fire Switch adds a 30-second
hold before the purge time starts.
(3) R7140M: Remain energized as long as call for
heat is present.
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.
Run
1. Fifteen seconds after the main valve terminal 7 is
energized and flame is maintained, the R7140 goes to
Run.
2. The firing rate motor releases to modulation
(R7140G,L). Damper motor is energized (R7140M).
3. 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
f. When the firing rate motor reaches low fire position,
the Low Fire Switch, terminal 13, is energized to
enter the Ignition Trial state.
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.
NOTE: A 30-second hold occurs for a jumpered Low Fire
Switch before the ignition trial period begins.
Ignition Trials
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.
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 intermit-
tent pilot valve, terminal 6, depending on the
selection of configuration jumper 2.
(b) The R7140L has a 15-second interrupted
pilot valve, terminal 6.
(c)The R7140M has an intermittent pilot valve,
terminal 6.
Run/Test Switch
NOTE: All of the R7140s have a ten-second interrupted
pilot valve/ignition, terminal 5.
WARNING
Explosion Hazard.
Can cause serious injury or death.
(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.
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.
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.
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:
66-1153—03
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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.
4. 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-turn-
down 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.
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
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.
NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.
M12301
Fig. 19. Selectable site-configurable jumpers.
Table 7. Site Configurable Jumper Options.
Jumper Number
JR1
Description
Intact
Clipped
RM7800/RM7840 Type
Pilot Flame Establishing
Period (PFEP)
10 seconds
4 seconds
All
a
b
JR2
10 seconds
Intermittent
R7140G
All
Pilot Valve /Main Flame
15 or 30 seconds Interrupted
Establishing Period (MFEP)
JR3
Start-up Interlock Check
Disabled
Enabled
a
b
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.
25
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R7140G,L,M BURNER CONTROL MODULES
3. When jumpered to Ignition, Pilot and Main Valves, use
STATIC CHECKOUT
ammeter in series and verify proper current draw.
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.
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.
WARNING
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.
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.
5. Replace all limits and interlocks that are not operating
properly. Do not bypass limits and interlocks.
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).
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.
WARNING
Explosion Hazard.
Can cause serious injury or death.
Make sure all manual fuel shutoff valves are closed
before performing static checkout.
Equipment Recommended
1. Voltmeter (1M ohm/volt minimum sensitivity) set on the
0-300 Vac scale.
2. Two jumper wires; no. 14 wire, insulated, 12 inches
(304.8 mm) long with insulated alligator clips at both ends.
Table 8. Static Checkout.
Test
Test
If Operation is Abnormal,
Check the Items Listed Below
No. R7140 Models Jumpers Voltmeter
Normal Operation
1
2
All
None
L1-L2
16-L2
Line voltage at terminal L1.
1. Master Switch.
2. Power connected to the Master Switch.
3. Overload protection (fuse, circuit breaker,
etc.) has not opened the power line.
Line voltage at terminal 16 (4 on 1. Limits.
Pre-Ignition Interlock devices).
2. Burner Controller.
3
4
4-L2
3-L2
Line voltage at terminal 16.
1. Pre-Ignition interlocks.
L1-8
1. Burner motor (fan or
blower) starts.
2. Line voltage at terminal 3
within 10 seconds.
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).
5
L1-18
—
Ignition spark (if ignition
transformer is connected to
terminal 18).
1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.
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R7140G,L,M BURNER CONTROL MODULES
Table 8. Static Checkout. (Continued)
Test
Test
If Operation is Abnormal,
Check the Items Listed Below
No. R7140 Models Jumpers Voltmeter
Normal Operation
6
All
L1-5
—
1. Ignition spark (if ignition
transformer is connected to
terminal 5).
1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.
2. Automatic pilot valve opens (if 2. Listen for click or feel head of valve for
connected to terminal 5).
activation.
a. Actuator, if used.
b. Pilot valve.
NOTE: Refer to wiring dia-
gram of system being
tested.
7
8
L1-6
L1-7
—
—
Same as test no. 6 for
connections to terminal 5. If
using direct spark ignition, check instead of the pilot valve.
the first stage fuel valve(s)
instead of the pilot valve.
Same as test no. 6. If using direct spark
ignition, check the first stage fuel valve(s)
Automatic main fuel valve(s)
open.
1. Listen for and observe operation of the
main fuel valve(s) and actuator(s).
If using direct spark ignition on a 2. Valve(s) and actuator(s).
model with intermittent pilot on
terminal 6, check the optional
second stage fuel valve, if used.
9
L1-9
—
Alarm (if used) turns on.
1. Alarm.
10
R7140G,L
R7140G,L
R7140G,L
R7140L
L1-8
and
10-11
13-L2
Firing rate motor drives open;
zero volts at terminal 13 after
motor starts driving open.
1. Low Fire Start Switch.
2. Firing rate motor and transformer.
11
12
13
14
L1-8
and
14-11
13-L2
15-L2
15-L2
Firing rate motor drives closed; 1. Low Fire Start Switch.
line voltage at terminal 13 after 2. Firing rate motor and transformer.
motor is in Low Fire position.
L1-8
and
10-11
Firing rate motor drives open;
line voltage at terminal 15 after 2. Firing rate motor and transformer.
motor is in High Fire position.
1. High Fire Purge Switch.
L1-8
and
14-11
Firing rate motor drives closed; 1. Low Fire Start Switch.
zero volts at terminal 15 after
motor starts driving closed.
2. Firing rate motor and transformer.
R7140G,L
11-12
—
1. Raise setpoint of Series 90
controller—firing rate motor
should drive toward open.
2. Lower setpoint of Series 90
controller—firing rate motor
should drive toward closed.
1. Series 90 Controller.
2. Firing rate motor and transformer.
15
16
R7140M with
open damper
contacts.
14-11
L1-8
—
If damper motor is used, motor Damper motor.
drives damper open.
R7140M with
open damper
contacts.
13-L2
If damper motor is used, motor 1. Low Fire Start Switch.
drives open; line voltage at
terminal 13 after motor is in Low
Fire position.
2. Damper motor.
17
R7140M with
open damper and
contacts. L1-11
L1-8
13-L2
If damper motor is used, motor 1. Low Fire Start Switch.
drives open; zero volts at
terminal 13.
2. Damper motor.
Final All
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.
27
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R7140G,L,M BURNER CONTROL MODULES
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.
SYSTEM CHECKOUT
IMPORTANT
Perform all Static Checkout Procedures for the
applicable relay module shown in Table 8 before
starting these procedures.
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.
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.
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.
WARNING
Equipment Recommended
Electric Shock Hazard.
S7800A Keyboard Display Module
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.
Volt-ohmmeter (1M ohm/volt minimum sensitivity) with:
•
•
•
0-300 Vac capability.
0-6000 ohm capability.
0-10 Vdc capability.
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.
Checkout Summary
Table 9 provides an overview of checkout steps performed for
each applicable system.
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.
See Installation Instructions for location of component parts
and terminal locations.
Table 9. Checkout Steps and Applicable Detection Systems.
Piloted
Infrared Flame Flame Rod
Ultraviolet
Checkout Step
Preliminary Inspection
Systems DSI Systems
Detectors
Systems Flame Detectors
X
X
X
X
X
X
X
X
X
X
X
Flame Signal Measurement
Initial Lightoff Check for Proved Pilot
Initial Lightoff Check for Direct Spark Ignition
Pilot Turndown Test
X
X
X
X
Ignition Interference Test
X
X
Hot Refractory Saturation Test
Hot Refractory Hold-in Test
X
X
X
X
X
X
X
Ignition Spark Pickup
Response to Other Ultraviolet Sources
Flame Signal with Hot Combustion Chamber
Safety Shutdown Tests
X
X
X
X
X
X
X
X
3. Combination of amplifier and flame detector(s) is
correctly used. See the amplifier specifications.
4. Plug-in amplifier and purge card (if required) are
securely in place.
Preliminary Inspection
Perform the following inspections to avoid common problems.
Make certain that:
5. Burner is completely installed and ready to fire; consult
equipment manufacturer instructions. Fuel lines are
purged of air.
6. Combustion chamber and flues are clear of fuel and fuel
vapor.
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.
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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.
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.
Flame Signal Measurement
See instructions provided with the amplifier.
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:
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. 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.
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.
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.
e. Make sure the ignition electrodes are clean.
f. Close the master switch and observe the spark.
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R7140G,L,M BURNER CONTROL MODULES
20. Run the burner through another sequence, observing
the flame signal for:
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.
a. Pilot flame alone.
b. Pilot and main flame together.
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.
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):
22. Return the system to normal operation.
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.
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.
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: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.
NOTE: On completing these tests, open the master
switch and remove all test jumpers from the
subbase terminals, limits/controls or switches.
22. Return the system to normal operation.
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.
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.
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 PRE-
PURGE (if applicable) should begin.
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.
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R7140G,L,M BURNER CONTROL MODULES
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.
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.
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.
IMPORTANT
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.
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.
7. 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.
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.
NOTE: If there is no flame for 15 seconds with the
RUN/TEST switch in the TEST position, the relay
module locks out.
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.
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.
IGNITION
TRANSFORMER
NOTE: This step requires two people, one to open the
manual valve(s) and one to watch for ignition.
BURNER ASSEMBLY
IGNITION
LEAD
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 light-
off 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.
BURNER
MODULE
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 recom-
mended 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.
FLAME ROD
LEAD
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.
18. Return the system to normal operation.
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R7140G,L,M BURNER CONTROL MODULES
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.
IGNITION SPARK RESPONSE
TEST (ALL ULTRAVIOLET
DETECTORS)
Test to make certain that the ignition spark is not actuating the
FLAME LED:
Hot Refractory Hold-in Test
(Rectifying Photocell, Infrared
Detectors, Ultraviolet Detectors)
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.
This condition can delay response to flame failure and also
can prevent a system restart if hot refractory is detected.
3. 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 neces-
sary 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.
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.
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.
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.
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)
1. With all initial start-up tests and burner adjustments com-
pleted, operate the burner until the combustion chamber
is at the maximum expected temperature.
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
2. Observe the equipment manufacturer warm-up
instructions.
combustion chamber caused by oil line purging.
3. 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.
4. Check the FFRT of the flame amplifier and relay module.
5. 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.
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).
6. If the flame signal is too low or unsteady, check the flame
detector temperature. Relocate the detector if the temper-
ature is too high.
7. If necessary, realign the sighting to obtain the proper sig-
nal and response time.
For details, refer to the detector Instructions and the
equipment Operating Manual. Continue adjustments until hot
refractory hold-in is eliminated.
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R7140G,L,M BURNER CONTROL MODULES
8. If the response time is still too slow, replace the Plug-in
Flame Signal Amplifier.
9. If the detector is relocated or resighted, or the amplifier is
replaced, repeat all required Checkout tests.
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.
6. Loss of flame during RUN.
SAFETY SHUTDOWN TESTS
(ALL INSTALLATIONS)
a. Open the main fuel manual shutoff valve(s) and open
manual pilot shutoff valve(s).
b. Depress the reset button.
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.
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.
1. 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.
2. 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.
f. R7140L goes to Safety Shutdown; R7140G, M
recycle after 15-second postpurge.
3. Detection of flame 40 seconds after entry to STANDBY
from RUN. Detection of flame from ten seconds up to 30
seconds into PREPURGE time.
g. Safety shutdown occurs. (R7140L only.)
7. Opening a Preignition Interlock after the first five seconds
of POSTPURGE.
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 sig-
nal for 10 seconds to 30 seconds for PREPURGE.
b. Flame LED is on.
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.
c. Safety shutdown occurs after 40 seconds.
4. Failure to ignite pilot.
d. Safety shutdown occurs.
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.
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.
d. Safety shutdown occurs.
5. 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.
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R7140G,L,M BURNER CONTROL MODULES
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R7140G,L,M BURNER CONTROL MODULES
Automation and Control Solutions
Honeywell International Inc.
1985 Douglas Drive North
® U.S. Registered Trademark
© 2013 Honeywell International Inc.
66-1153—03 M.S. Rev. 01-13
Printed in United States
Golden Valley, MN 55422
customer.honeywell.com
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