Nội dung

R4138C,D INDUSTRIAL FLAME SAFEGUARD CONTROLS (FIG. 65) On safety shutdown. the pilot and main fuel valve(s) are de-energized. 11 used, the exlernal alarm is energized. The STAAT bulton must be manu8JJy pressed to restart the system. "the lockout switch trips. the load relay 1K drq:>s Oul and the lockout switch must be manually reset to rEt­ start the system. These controls directly replece older R4138A and B models to meet the lates! rElQJirements. They are espe­ cially Suitable where Icng petilXi3 01 burner operation with· out s/'lulc:bwn are normal, such as in heat-treating ovens and kilns. The R4138D is (he same as the R4138Cwl!hthe adc:lilion 01 a jXl'I'Ver failure override circuit 10 prevent shut­ down during very short;power outages (,oower line switch­ Ing of. 1 Second or less). The A4138C is available in 120, 220, and.24O volt rtlOdeIS; the A4138D Is available only in a 120 vol'model. OTHER FEATURES " A plu~in $4.27D Purge Timer is available as an ac· cessory (0 provide e timed purge period prior to the manual startup. " An optionei remole reset assembly allows resetting the lockout switch from a remote location. " Irlcandescent indicator lamps (FLAME OFF, PURGE COMPLETE, FLAME ON) prOVide a visual check: 011he system condl1ion. • The R4138C or D plugs into a subbase or cabinet ElQJiA?OO with quick-connect C'-ontacts. • All field wirinQ (except for the optional remote reset assembly) is connected to a terminal strip on the subbase or In the cabinet. The R4138 can be re­ moved easily withoul disconnecting any w·lring. " Clear plastic relay covers help prevent conlamina­ tion, damage, end lamperinQ. " An ALARM terminal Is available to operate an exler­ nalline voltage alarm on salety shutdown. " A zinc-dichromate finish resists the corrosive ef­ fects 01 most induslrial atmospheres. SAFETY FEATURES The A4138C and D provide a Safe Start Check for a flame, or a condition simulating a flame, at startup. If the flame"relay 2K is pulled in before the STAAT button is pressed• .2K.2 is open, preventing the load relay 1K from pulling in. The system cannol be started until the condition Is corrected and 2K drops PUt. They also prOVide safety shutdown on­ - failure to Ignite the pilor. (lockout will occur t1the START button is held in IClIlg9f than the 10ckPUt switch liming.) -loss 01 flame during the rUl"l period. -failure in the flame detectiCfl system, If e sell· cheCking system is' used-see Table II. (L.ockoul will occur it lhe START b...rIlon is held in longer than the lockout switch timinQ.) PlUG·I", FlAME SIGNAl KEYED IIECEPTA(L[ FOR PlUG·IN AMPliFIER SPRI",!> CL'P 01'1 CHASSI~ INCANDESCENT INDICATOR ~,,"PlIFIEpR lAMPS(J)I\•••_~--\ ,_ '\C<'" .....--.s'! ~ FLAME 5IGI\IAL METER JACK RELAY ZK \ THREADED ""OU",TI,,,G STUD fl.ELAY11( RELAY JI( RECEP'TACLE: FOR PVRGE TIMER FIG. 55-COMPONENTS OF THE R4138C OR O. 186 on a C7012E or F Purple Peeper Ultraviolel Flame Deteclor. The lad:ler diagram (Fig. 66) shows all relay contaclf; In the d&energized position. Refer to the S8QJence of 0p­ eration on the following 4 pages. SEOUENCE OF OPERATION FOR THE R4138C OR D (FIG. 66) The cperalion orlhe 120voll models oflhe R4138Cand D win be described. Theseq.Jel1ceofoperalion for a 220 or 240 volt model ot the R4138C is the same; it just has an aci:jitionaltransformer 10 provide 120 volts tor the sMutler .. ---­ ------------: If·~.""n.,~...,o~ "I ... 1 1 , .MO ~'SC€L""M€OUS IM'U.OC'" , , ; , , , , 5 , , , , 00 , " ,, ,, , I \r, , , , , ,, --- -- - --- ,---~ ,, -- -------- -- --,, ,,, ~---; '""(') 'u..... ." O''' 2 r ~ .l ,~, , T, I __ , I D€1r(ftI. I • & I, , CO."(T.) , , -- ...."'".'N ....... '~'u '-;'c--" ,.." , ,", y , co.. ~,., RI _'..........e 10"f€1'I) I,U ..... ........10\ & , I ,­ fn'l ,., I •• AI....... o•••• 'O€ "L.CI'U.Y€ I ,otU.............CU1. , - .. 00 • '" " ------­ O'sc_.C"I.l.O... ..;.., ..... .'QU'.'C1. I Gil ~ L.CI.O~.O...CT'O..... & '..n .......o' .....,"". c""11 D.' ""....... I"II:UO:. ULT .....IOUT ........ LlJ. "H'" uTTl" ......-,.1::1 1 ""LV", .... C"',,, D•• "''' ...... 1"11: U., v, <:Ct'ltTO" 'u"'­ o.n~TO". "LF cOT.O Cl<_....IFI.", CO TO . ' """ & tF .'" • "0 R ~ "'''0 ~ TH, ...."ou..UV1n:.... ,(~.C., "" .>,.>c Ov 'C .. u.o""".U'" "'.c"' . TO OOS' ........ _'TIl ~=,:.~~,':;'~': ':':'~~~'~;;~Uc'=:"~;;.'Jo~~J ~"u."'''u...........f. l'H€ -..,..... ... Tell ,. cL.Dloll.o. &. ca.H'C'l"'D IF • ...,.. ..". ST••' ' . "••""" ,. roar ..... 0. IT""" ""'TC" ,. OI••CTL v TO . ." .. & _ ..,.....·."'.51.T"", TII '....."N. . 'U...... OR •• u,v.. .... _ 0 """ "lMOn: 0l"l T1001. & ,...O CUD D''''CT.V ' ..,Te" It 100. U"O, ,~ ••,"" ST" nOOl "'u. "' . ."., """ nR.. L . "'L.CIT UN. Ju.......M; .., .... II:(U_O '0"'" ce.... OO.... I" ... 'IOCIl """T ..........eAT>t.t? ....'n • • ._---_. '" .......€ D" 1.'Ol I r• .u., l ..----1 "'\IT1"'• (£, , , ~....T ." ,. ... , ,.. l~ , , , II ~TO. or"II: ••u, "f ~'''N.e "H'. ,.CO 0 ....If€ /:::~~..~~.& ,..". & ---­ " ,., T.0'."" e'•• ..0<"'''0''10' ...... v CO"T .cn, (.... 00.•• ,.., "'O'OTO. "'".........VOL.CI..D CO ..... . A ""n"", •.". F~ '1< TOIUU, ,,, ,"" OI "'OHTTl", .'''.'",..IlLOC UUCl.u.lO .~.N v ,. """c()HT.~T ,., "'ND ....._R .. , ,.......'N...... 11 A . '~ KTtO TO e, ........ ~ 'H'.OS"• .... fC~ ..... O UX><5­ V u ""'0 v •••' C,otUIT _ ",,"o.,...v. "T _R.., ..,...... ..., "TN ..' - . TN'...... .......,U.'....v ..... .~. ~u C''''''"''O .. 0.........v '"~ FIG. 66- SIMPLIFIED SCHEMATIC DIAGRAM OF TME 120 VOLT MODELS OF THE R4138C AND D SHOWING TYPICAL FIELD WIRING FOR A GAS OR OIL CUTOFF SYSTEM. '87 71-97sss..1 SEQUENCE OF OPERATION FOR THE R4138C, D NOTE: Italics denote special 8HJlications. NORMAL OPERATION R41J8 OPERATION OPERATOR ACTION TO START­ 1. RElsel tI111 Ioc~ut switch on tile R4138. Reset all limrts. and inter­ 'bcks. Close the maste!" SWitch. 1, a. .." • SYSTEM OPERATION ap~lied terminal Ihrough thE! il1lerlocks and limits, and to terminal 3 Ihrough the jumper Irom larminal L 1: the plug-in amplifier is 8f\o " " " ,. a. The lan(5) s\lIrts ergized. b. Po- i' applied terminal ('tHough the alarm silaneing switl:hl, and ID I8rmineJ 16 ('through 3K1). - , "'""' • app"ed " " " terminal b. The alarm 115 energized, bU1 may be turned off by opening the alarm si!enc­ ing switch (If u~d) , 18 None. (through 3K3): ltle FlAME OFF (RED) lamp fights. 2. Open the damper D high fire posi­ lion (rt mahually operated). 2. a. None. damper Is open. (The damper may 5. Push In the START button and t1:Ild it In. NOTE: To avoid nuisance shutcbwns when not using a purge liry'let, wait at lea$!' 10 seconds after the tan interlock closes before pushing in the START bullon. • tI. The purge perod belilins: the lan(s) c. At the end 01 lhe preset time. PT1 opens and ll1e purga timer stops. PT2 ctJses, IlPPtyinll power Ie terminal 6 (Trom terminal L1); the PURGE COMPLETE (GREEN) lamp li'ilhts. Relay 1 R pulls In: 1 R1 closes to bypass the nigh fira jnter10ck end keep power applied Ie the purlle timer. (If power is removed In:m the pur'ile timer, it will reset, PT2 will open. anll tile system cannot be started.) Pow" ~gh 4. Close the alarm silencing switch (II" it WIlS opened in step 1). open eu1on'lalicalty.) appfled terminal 17 the high fire irrtBr1ock) and to lhe mobr ofltle pur~e timer (through PT1): 1he purge timer starts. b. 3. When the PURGE COMPLETE (GREEN) I8mp II'ilhts. close tile damper t:J low fire posi1ion (' manualo/ operated). 2. a. The high fil"ll interlock closes Whe!1 the " clean the combustion chamber of un­ bU!l19d fuel and fuel vapor. ,. inler10ck ,,,.., "co "'"Is Closed. damper (The damper"""" may cbse "'" 3. Nono. 3. The hl'ilh fire inter10ck opens. and the 'uw , ,. None. 5. e. ~er is applied Ie the i'ilniOOn trans· former and to terminal 6 tthrou'ilh the low lire start lnlertock and the srART statkJn). b. , Is applied to tarmir.al 7ln:m te!'­ minal 6 (II1rou~h the low lire start InlBr­ lock, START statkJn, intemal jl.M"lper, STOP staOOn, ,"d alarm silencil\l;l switch). RBlIlY 1K pulls In throu'ilh LS1, 2K2, LS HTR (\oCkout aNl 1'I9lIter1. thus provin'il lhlt continuity of ~er ... The alarm is ener'ilized. 5. a. Tha i~nrtion transformer Is 9n9r~lZall b. None. ...,h lhlt heater. (1l 1K1 ebses. applyin'il power minai'S tro-n terminal 3. to tur· ,. (1) TI"MI pilot vllive (or 1st sta~e oil valve) ener~lled. The valve opens and the pilol: (or 191 sta'ila Oil burner) Is I~n~ed. • (2) Jt the pilfJl/lnlc lumper wi/1l I'!~s been clipped fr:T 8 continurxJs (sr~ng) (2l 1K2 closes. ...,h automatically.) (3) lK3 cbses; the LS HTR (lockoul be'ilins heatin'il (tty autJtransfonner action of 1K thf'OU'ilh 1K3 and 21<2). piJfJl app/iC81ion, the tfame derec­ rion circUit fO the amp/if/Sf is com-­ pleted. (3) None. hea"" d. If an Rrn7C DpIarric Self ChecJc Am­ pJiffet"Js used, power is applied from ter­ rrifllll 7 t!roUgl'! Itle Jumper to trJm"inaJ 13, t!roU¢ the sr:iid "'are swircfl in the 81tfJIiffet" (between ampli~B>' tfJi"trlnaJs 16 fIftd 17), 10 ttrrTinaJ 12. '" d. If 8 C7012E cr F PurpJe Peeper U/tfit-­ vir:itJt FlsmtJ DBtacta (NitI'! seIf-eheck· Ing feature) is used, the shtmer is ener· gized. SEQUENCE OF OPERATION FOR THE R4138C. 0 (Continued) NORMAL. OPERATION (cOflrinued) OPERATOR ACTION .. R4138 OPERATION SYSTEM OPERATION • None. r. The "arne detector detects the nlllT!8 lor llrt stage oiIl1ame). ."" When the llama is detected. relay 2K pull, in. (1) 2K1 closes, bypassing the purtle ~m8f contact PT2, low nre stan . l. (1) None. interbck. START slam, and inter­ nal jumpel". Power will be applied t:I terminal 7 {tmm terminal 3. tt1rcugh 2Kl ID tenninal e, and tI1rough tI1e STOP stillion and alarm sileJ'ICing !Witchl tJ tvJld in relay 1K (unl", Ih8 limb open. the STOP button il pressed. occurs. , oc safetj shulQaoNn (2) 2K2 opens; the LS HTR stJps heat· Ing. (2) None. (3) 210 cloS85, applying power lD tar· minal 20 (frt:rn terminal 3 throUgh 1Kl). Relay 3K pulls in and the FLAME ON (WHITE) IlImp Wghts. (3) The aubnatic main fuel vaMl(a) jljI energized. The valwl(s) Optms and When relay 3K pulls in­ (1) 3K1 opens. rel'TlOVing power fn:m terminal 15. (2) R4138D only: 3K2 closes, bypass­ ing 110. Relay 11< can pull back in after e fT'OTIenlary power failure if 31< is still pulled in. the main burner is ignited. The sys- lern is in the run conditbn. (If II mat1lJ8Ify opened vahe i, usBa', fhe main l:IUmet will not be igrittKi unrif step 7 is compleuKf.' ,. (2) None. _, PI 310 opens, rel'TlOVing power fn:m 18. Th. FLAME OFF {REO) lamp goes out The purge resets ~, F'T2 rerroving power fn:m terminal 5. The PUAGE COMPLETE (GREEN) lamp goes out P} Retay 1R drops out and 181 opens. self~l1eck- 5, The ignib't ltanmlTl'lel" is de-energIUld, '''"'''. 'n" 5. When the FLAME ON (WHITE) lamp lights. relaase ltle START bullon. 7. Open manual main Iw/ valve(s) (it used). (1) The alarm is de-energized. 5. Normal operation, including ing of the name deteeiion system (rl a selfchecking system is used). 7. Normal operetion. 7. The main burlJ8f is igrrlfKi. Too system is in 100 fUn condition. 8. a. Power Is rer'l'W:'Ved lmm terminal 7. b. Relay 11< drops out lKl operul. removing power lmm terminal$ 19 and 20. Relay 31< drops out and the FLAME ON (WHITE) lamp g.oes oul. 8. a. C7012E, F shtJrtBt' is ~D1d, b. The pilol valve (or lsi stage oil valve) and the main fuel valwlfsJ ere de-ener­ gized. The valves Close end a11l1ames go out. TO SIOP' a. Push in the STOP button ;tnd hold it in until the FLAME OFF IiQhls or U!TtII all (REO) relays drop out 1=. c. When relay 31< drops oul­ (1) 31<1 close:9. (2) 310 ck:ls&6: ltle FlAME OFF (REO) IlIrnp lightll. Vv'tlen the lIames go oul. reilly 2K drops out. e. All relay contacts are resellor the next , startup. 9. Open the alarm silern:ing svwiIch (ll used). 10. Open Ihe masler swilr::h 9. Power ~ retro'tIed from tel'min4l:9 1S end c. (11 The alarTn is en8l:gizlld. (2) None. , •• None. None, 9. The alarm is 4e-e08f"9iZIJd 15. 10. Power is rllr1'DWd from tel'miMIs L 1 and 3. The plug..n amplifier is de-energized. and the FLAME OFF (RED) lamp goes '0 The lan(9) stipe end the systIlm is de­ 808I'"glzed. ,," 189 71·97558·1 SEQUENCE OF OPERATION FOR THE R4138C, D (Continued) SAFETY OPERATION R4138 OPERATION SYSTEM OPERATION Raley 2K puns In when the name (or flamesimulating condition) is detected. Contact 2K2 opens, prewnlirlg relay 1K fran pul~ng in when the START button. is pressed. The system cannot be started unm the con· ditiol'l is corrected and 2K drops out. • , K1 stays open; no IlOM'I' can be ap­ plied D tlIrminals 19 and 20. • The pilot valw (or 1st stage oil valve) and the automatic main fuel vatve(s) cannot be energized. • Relay 3K cannot pull in; 3K1 and 310 re­ main closed. The FLAME OFF (RED) lamp remains on. The PURGE COM· PLETE (GREEN) lamp may also cane • The alarm remains energized. ABNORMAL CONDITION Safe Stan Dleck-A flame, or a condi· tion simulating a name, is present belore !he STAAT button Is pressed. NOTE: c.heck does not apply if us· inrJ a.cootinuous (st8flding) pilat. r,.s - , The pilot (or 1st stage oil buma" is not ignitBd. DO. No name is detected. so relay 2K does not The system pull in. transtormer is de-enerllized START bbltlDn is released. ,. wheo th. lockout switch must be manually re" The set to try to restart !he syslem. a. lS1 opens and relay 1K drops out. 1K1 opens, removinll power from Ier­ minaJ 19. b. 210 stays open; power cannot be applied to 18nTIinaJ 20. a. The pilot valve (or 1st stalle oil valve) is de-energized, eo' th. valve Salety shutdown with lockout occurs. ,"""" b. The automa1ic main fuel vslve(s) cannot be energized, ,. Relay 3K cannot pull in; 3K1 and 310 remain closed. Tho FLAME OFF (RED} lamp remains on. 2. If the START button is released before The slerm remains enerllized 2. Safely shutdown occurs. The START button must be manually pressed to try restart the system, the Iockolll swill:h trips- to .. 2K1 stays open: the START station is not bypassed. When the START but­ ton is released, power is removed fn:m terminal T. b. Relay 1K drops out end 1K1 opens, removing IlOM'I' fn:m terminal 19. a. When the START button is released, the ignition transtormer is de-ener· gized. , ,. ,. A limit or interlock opens. be started. The ignrtion Contact 2K2 stays Cbsed; the LS HTR (lockout II'I'o'itc:h heater) heats until !he lockout switch 1I1ps (If the START button is held in longer !han the 'Ockout switch timing). ,. The flame \lOBS out during the run period. NOTE: Safely operation is the same if the mllin burner is rxrt ig nired in a system w;th an interrupted pilot (obtained only by the addition 01 eJdemal circuitry). c~ b. The pilot valve (or 1st stage oil valve) th. de-enerllized, closed, 210 stays open; IlOM'I' cannot be epplied to terminel 20. Relay 3K cannot puK in; 3K1 and 310 remain closed. Th, FLAME OFF (RED) lamp remains 011, ,. • ,,' ,,"'" The eutomatic mein fuel valve(s) can­ not be __glzed. The elarm remains energized. Relay 2K drops out. System shutdown occurs • 2K1 opens, removinll power fn:m termi­ nsls 8 and 7. Relay 1K drops out and 1K1 opens, removing JXlwer from terminals 19 and 20. The FLAME ON ('NHITE) lamp goes out. • The pilot vlllve (or 1st stall~ oii valve) and the automlltic mllin luel vsive(s) are deenergized, and the valves close. • Relay 3K drops out; 3K1 and 310 close. The FLAME OFF (RED) lamp lights. • Thll alarm is energized. Power is fllITW:M'Id fn:m all terminliis except 15. All indicator lemps go out and all relays drop out. 3K1 closes, applying power 10 ler­ minal16. 190 ---~.~------ The system shuts down. All valves lire deenergized, and the valves c!osB. The IIlarm is energized. SEQUENCE OF OPERATION FOR THE R4138C, D (Continued) SAFETY OPERATION (continued) R4138 OPERATION SYSTEM OPERATION Power ~ r9IT'QYed from all tanninals. aN lndl­ calor lamps go out. and all r8l6y, drop out. The system shut:l down. The alarm is aner­ ABNORMAL CONDITION Momentaty power "fsHure. .. . B4138C; llized wherI power Is restored. llill& Power is rerooved Irem all terminals. all indio calor lamps go out, and aU relays except 3K . drop out The charge on capacitor Cl will hold in 3K tJr about 1 second. • It poWllf' is restored before 3K drops out end before lila plot flame (or 1st stage oil !IamEI) ~ • out­ -3K2 will stay cbsed. bypassing lK3; 3Kl and 3K3 Will stay open. - rllfey 2K will pUll bacl( in: 2Kl and 2K3 will cbse. and 2K2 will open. -the STAAT staliol1 will be bypassed through 2Kl, the STOP statkm, anl:l the alarm silencing switch. - po.....er .....ill be reappliel:l to lerrninal If pc:JYIIer is re:Jlored within 1 second llnd the pilot llama (or 1st stage cil name) is still burning (1l1e \/lWe must be sbw cbsino), rormal OPer4OOr1 will be resumed. The aJarm 'l¥ill not be en­ ergi2ed. lIthe main burner name hal gone out, it will be reionifed by the pi­ lot nama. (Power failure override eir· cuits may ha~e b be al:ll:lel:l b the pilot valve and me,in vaNe(s) b enS\J{e lt1al they 1:10 not close on a mctr\EIntary power interruption) 7. - relay 1K ..... 111 pull back in thrtluOh LS1 ani:! 3K2. - operation Will re!lJm to normal. • If 3K l:lrops OU1 before power is r&­ stored­ - 3K2 will open, so 110 will nat be by­ passed; 3K1 ani:! 310 will cbse. - relay 1K cannot puU back In since both 110 8Il1:l 3K2 are open. ~ 1K1 stays open. so 3K cannal puJf beck In. -!he FLAME OFF (RED) lamp win liOh1 when poWllf' is rr.mred. • • II the pilot flame (or 1st staOe oU name) ooes CM before power Is reslDred­ - relay 2K C8Il1WJ1 pu~ back in. 80 2Kl stays open. - the START sta1bn cannot be by­ passel:l. - paMll'" will not be respplied b terml­ • _. _. The systBrn ~huts llown. All valVes are I:IlHIn«gizel:l, anl:l the ~a'- cbse. The alarm is 8I18rO~ed lIltlen PQ't¥er is The system ~huts llown. Ad valves are l:Ie-energizeG, 8111:1 the valves clow. The alann Ie 8l'18fO~ed when poWllf'ilI r.a17. - relay 1K cannot pull be,ck In. - relay 3K willl:lrop out; 3K1 anl:l JIC will close. -lhe FLAME OFF (RED) IM'lp will light when paMll'" is restJrel:l. IF USING A SELF-CHECKING FLAME DETECTION SYSTEM' The naome l:Ietec:tion system falle \fIthi1e the system is turnel:l all or l:Iuri~ the puroe perlol:l. Relay 2K canrot pull in when the 9)'SI&'n is startel:l-sarne OperllOOt'l as it lhe pibt (or 1~ stage oil burner) is nat ignrtel:l. Safety sl'w.1l'lSoWn occurs. LJx:kout'l¥ill occur it the STAAT bllltCn is hell:l in IongBf than the b:toJl: switch timing. The name l:Ietection system lails l:IurIno the run periol:l with the bumBf tiring. Aelay 2K l:lrop~ out-same operation as if the name goee out Safety shutdown «CUI'S, 191 71-97558-1 this section does not cover all possible maintenance ac­ livlties tllat are req;ired for every system. Again, its pur· pose Is to help tl'lE! service technician develop ettective and efficienl preventive mainlenance programs thaI can be applied 10 all installations. This sectlon provides I;lBneral Information about troubleshooting and maintaining Flame safeguard sys­ lems. Its PlJrp:lSe is not to allow the service technician to perform specifiC troubleshooting q)Elrations, but to help the technician develop a consistent, analytical approach to Flame safeguard system troubleshooting. Likewise, TROUBLESHOOTlNG--------------­ Troubleshooting of control and burner system prob­ TABLE I-BC7000 SYSTEM ANNUNCIATION AND DIAGNOSTIC CODES Iem6 is made easier Ihrough the BC7000 MicroCorTlJuter Burner Control Syslam self-dla\1lOSlic and 1irst-out annun­ clallon funclions. In addition 10 a line voltal;lB alarm termi­ nal (audible armuncialion), the BC7000 Microcomputer Burner Control System prOVides visual annunciation by displaying a 3<:ligit alphanumeric code and one or two se­ quence status lig,ts. SELF· DIAGNOSTICS of the BC7000 detect and an­ nunciatel:xJlh external and internal BC7000 system prob­ lems. Exlernal faults such.as interlock failure, 11ame failure, false flame Sib'f\8l, and damper motor problems, and internal faults associated wllh (he BC7000 chassis, the PM72Q Program Module, or the flame amplifier are all reporfed through tl'lE! Multi-function Annunciator Display. FIRST-OUT ANNUNCIATION is aChieved through the 3<:ligit alphanumeric Multi-function Annunciator Display thaI rep:lrts the cause 01 a safety shutdown, failure to slarl, or a failure to continue in the burner sequence. The cause of a safety shutdOwn is displayed as an "F" (faulll, fol­ lowed by a 2-digil nurTt:ler. The cause of failure to ~ontinue with the burner sequence is displayed as an "H" (hold), followed by a 2-digil nurTt:ler. SElquence status lights (LEOs) provide pOsilive visual indication of the program sequence: STANDBY /power on), PREPURGE, HOLD IGN TRIAL. FLAME ON, RUN, POSTPURGE, and safety shutdown (illuminated reset bullon). Momentary power loss erases this annunciation and requires resel. Safety shutdown (lockout) is indicated by the illuminated reset bullon and an "F" (fault) code followed by a 2-digit num­ ber. safety shutcbwn (lOCkout) d&-energizes all loads. en­ ergizes the alarm terminal (atter a 1Q..second delay) and requires a rest. With this information, most problems can be diagnosed without axlansive triat-and-error testing. Table 1 shows the codes used to annunciate and dia~ nose system problems with the BC7000. For the Interpre­ lation and possible remedies for each code, as well as cOf1l)lete systam troubleshooting and CJ;lElrating Instruc­ lions, refer to form 65.()()14 For syslems without self-dia\1lOStic and annunciation; (or for problems tllat are not annunciatedl Ihe I;lBneral SYSTElol MOLD CODES M70 _ FlAME SIGNAL OURING STANDeY M73 - OPEN PRE-IGNITION INTERLOCK H74 _ OPEN RUNNING I~ERLOCK SYSTEM FAULTA-OCKOUT CODES FCQ _ FALSE FLAME SIGNAL DURING PREPURGE FD, _ MIGM FIRE PURGE SWITCH FAULT FlU -_ PRE-IGNITION INTERLOCK OPENEO OURING PREPURGE LOCKOUT/RUNNING INTERLOCK OPENED DUR'NG FREPURGE FlO _ FALSE FLAlolE SIONAL DURING LOW FI."E HOLD F11 - LOW FIRE START SWITCH FAULT F'3 - PRE·IGNITION INTERLOCK OPENED DURING LOW FIRE F()oO - HOLO Fl" _ LOCKOUT/RUNNING INTERLOCK OPENEO DURING LOW FIRE HOLD F30 - PILOT (FIRST STAGE OIL) FLAME FAILURE F31 - LOW FIRE START SWITCH OPENED OURING PILOT TRIAL F34 _ LOCKOUT/RUNNING INTERLOCK OPENEO DURING PJl..OT TRIAL FJ,S _ PILOT FLAr.lE FAILURIO IN TEST r.lODE F4(J _ MAIN FLAME FAILEO TO 'GNITE F .... _ LOCKOUT/RUNNING INTERLOCK OPEN EO DURING MAIN FLAME TRIAL F~ -_ FLAr.lE FAILURE DURING RUN PERIOO F!l4 _ LOCKOUT/RUNNING Ih'TERLOCK OPENED DURING RUN PERIOD F70 - FALSE FLAME SIGNAL OURING STANDBY F73 - P~E·IGNlnON INTERLOCK FAILED TO CLOSE Fe' _ INTE~lolrnENT (eOUNDING) PRE·IGNITION INTERLOCK F82. FB.3. F~} INTERr.lITIENT IBOUNCING) BURNER F8!I, Fe7 CONTROLLEAr...Ir.lIT F80 _ INTERr.llrTENT (BOUNDING) LOCKOuT/RUNNING INTERLOCK FIlO - PROGRAM r.lODULE FAULT FIl7 _ eYNCH~DNIZATION ILiNE FREOUENCYI FAULT F99 - INTERNAL CIRCUIT FAULT trotbleshooling approach presented below is deslgn&d 10 emphasize the similarities involved in troubleshooting dif· lerent types 01 systems. '92 shuts down. Start by asking all the questions possible of anyone lhat mi~t have some knowle6;)e of what hap­ pened. When cbeS the shutdown occur? What part of the CYCle? How lonQ after the startup? Does a shutdown occur following every start? How Is the lightoff? These are only sarrple questions-the lnformation needed will depend on the Individual situation. Be sure the operator 01' the SyStem is contacted and questioned. Re­ tTlQrrOer, they were present and involved when the shut­ down occurred. In any troubleshooting situation, il is necessary to con­ sider the entire system-Including not only the burner, controls, wiring, etc., but also air sUWly, /\Jel sUW1y, and the condition and characterisllcs 01 the flame Itsel1. In or­ der to cover all areas 01' bUrner operallon, lha troubleshoOting proceoJre is broken down into a series of specific sleps. The first general step in approaching a system failure is to doitermine whaiher Ihe shutdown occurs repeatedly or at random. 'RecUrring shutdowns are the result of permanent con­ difl'Ons in the system that can usually be identified by CJb. servation or by a few simple tests. Random shU1downs are more difficult to identify, Since they are caused by marginal or intermittent condiUons (oc­ cur one time but not the next), they do not always occur at atime when they can be observed. Frequer1tly, the only methOO of Identifying them is to be present when they oc­ cur and be fortunate enOUQh to see what has h ~ . Often, a shutdown occurs buttha evidence needed cannot be obtained. TIlis results in the need for repeated attempts before the correct solution can be found. TIlese two types 01 shutdOwn-recurring and ran­ dom-will be discussed separately, since the procedure lor identifying the causes of each are somewhat different. Recurring Shutdowns are obviously much better suiled to solution using a step-by·step procedure. STEP 3-EVALUATE YOUR INFORMATION Usa Table II, together With your personal experience, to herp evaluate any information you have concernillQ the shutdown. The conclusions drawn at this stage only pro­ vide an idea of where 10 look tor the exaCI solullon 10 the prOOlem. STEP 4-MAKE A TRIAL RUN Observe the operation of the burner system through a corrprete cyCle. Was each slep of the startup in accor­ dance with the design sequence? Did any deviations occur? Did the shutdown occur exactly as described? Did anything else happen? Have any new facts been established? AlSO. refer 10 information on measuring the flatTlQ signal during lest runs below. STEP 5-RE-EVALUATE The re-evaluation of availabie facts can often be made during the trial run. Mentaily check the possible causes and eliminate all except those that could b6 resoonsible for lhe shutdown. Remember ,that in some instances, more than one factor may be contributing to the prOblem and must be considered in the solution. RECURRING SHUTDOWNS After determining the generall'1?9 at failure, determine the point In the operating cycle al which trouble occurs, , and the specific symplom. To get this informaUoo and to determine the proper corrective action, aiways complete the following seven steps; STEP 2-ASK OUESTIONS STEP 6-VERIFY THE ASSUMED CAUSE BY A TEST RUN After determining the a,warent causa(s) at eqJipmenl matltnction, perform a second test run to see if the evalu­ ation is cOfree!. lithe answer has not been found, a new evaluation must be made that Includes any new In1Drma­ tion thaI has been obtained cllrlng the second lest run. More than one ra-evaluation lest may be necessary to get all 01' the information needed to positively Identify the cause(s) 01 lhe Shutdown. Usually, Ihe information available on arrival at the in­ stallation consists of a sirrple stalemenl that a burner STEP 7-CORRECT THE CONOITION(S) STEP 1 - KNOW THE SYSTEM AND EQUIPME~T Effective troubleshooling requires a knowledge 01 the complete SyStem and its normal sequence, as well as the Indi....idual devices and equipment that make l4' the sys­ tem. TIle availability of a schemallc diagram of the syslem is a necessity. A written sequence 01' the normal operation of the SyStem is also desjr~le. 193 71-97558-1 TABLE II-TROUBLESHOOTING RECURRING SHUTDOWNS To assist In delermining lhe cause of a system shutdown, Ihis tabte lists possible causes and corrective actions for each symptom: For- convenience, lhe lable Is divided inlo sections rapresanling lime perlcxE. The problems that could occur during a specific peric:d of the operating cycle are listed in each section. If specific information on service of a particular control or piece of equipment is required, refer 10 lhe instructional literature for the particular control. , - - - _ - - - - - ' - - - - - - - - IMPORTANT------------------, Repair or replace all defective comp::lrIents, as necessary. INITIAL STARTUP PROBLEM A. ~nce cbes not POSSIBLE CAUSE CHECK la. O1eck master switch and overload protection (fuse, circuit breaker, etc.). Reset or replace, as necessary. 1. No JXlMlr. start. Z L.ockwt (safety) switch tri~. 3. Limit switch open (in main JXlwer line or in series with the C(){ltroller). 20. Reset- find cause and make necessary repairs. 3a. Slack damper end switch not made. 30. Airflow switch open. 3c. low-waler-cutoff open. 3d. Fresh·air dal'11P9r (to boiler room) not open. 3e. Fuel pressure switch open. 31. Other interlocks opErI in JXlwer line. 4. Start or preignition interlock open. 4a. Check start or prlHgnition interlocks. 5. Process interlock open. sa. Check all process controls thaI are interconnected wilh the burner system. 6. Wiring open. 6a. CheCk wiring for breaks or open splices. FIRST 15 SECONDS AFTER START PROBLEM POSSIBLE CAUSE CHECK B. System cbes nol go 10 high fire during prepurge (Lo-Hi·Lo system). 1. Wiring-opens, shorts. grounds. 1,. O1eck voltages at the wiring sutbase terminals for firing rate switching. 2. No JXlMlr at firing rale molor. 20. Check for JXlwer at T·T terminals on firing rate motor. 3 Limit switches in firing rale motor 3a. Clean conlacls. ~ nol made. C. SElQU9nce stops about 4-15 seconds after prepurge starfS. 1. High fire switch open. 1a. Check switch. 1b. AdJlISt linkage. 1c. Check firing rale motor and its transformer. 2. Airflow switch open. la. Check switCh. 2b. No airflow. Check burner motor (blower) and associated corr-ponenls and circults. 2c. Plugged air line or filling. 194 DURING PREPURGE-AFTER 15 SECONDS-BEFORE IGNITION TRIALS POSSIBLE CAUSE PROBLEM CHECK 1. False flame detection. D. Flame relay pulis in during repurge. la. Flame rod: (1) Intermittent ground. (2) Unwanted flame on flame rod. lb. Visible light photocell: (1 ) Light striking cell. (2) Detecting hot felractory. 1c. Infrared (lead SUlfide) detector: (1) Electromagnetic piCkl4) on leads. Anchor solidly. Install coaxial cable if necessary. (2) Unwanted flame being detected. (3) Detecting hal refractory. ld. Ultraviolet detector: (1) Unwanted fire being detected. (2) X-rays. (3) Defective sensor (replaCe). le. Flame safeguard control: (1) Defec/ive amplifier (replace). -. , I E. Sequence stq:ls. la. 8l.Irner motor (blower) st~. lb. Restricted air passage from air d..Jct 10 airflow switch. 10. Plugged air line or titling. 1. Airflow switch open. 2. Preignilion, ruming, or lockout imerlock cpen. 2a. Check interlock. LAST FEW SECONDS OF PREPURGE BEFORE IGNITION TRIALS PROBLEM F. 5eq..Jence stq:lS. G. No ignition spark. POSSIBLE CAUSE CHECK 1. Timer switch on flame sat9lJ..lard control set al TEST. la. Set switch 10 NORM lXlSilion. 2. low fire switch open. 2a. Check switch. 2b. Adjust linkage. 2c. Qleck tiling rate controller (broken polentlometer). 2d. Check firing rate motor and its transformer. 1. No power 10 19lilion transformer. ta. Leadwires cpen, grounded, or not prcperly connected; insulation damagecl. lb. Flame saf9lJ..lard control not providing power. lc. Flame safeguard control recycling. 2. HiQh voltage Insulator(sj faulty. 28. Cracked. 2b. Covered with soot, dir1, or mOisture-causing a shor1to ground. 3. Ignition elecnode spaf1( gap selling Ja. Clean the electrodes. 3b. SpaCing incorrect-too wide or shorted. 3c. E!&ctrodeS not prcperly mounted. (cOI1t1nued 195 on IMxt parle) 71-97558-1