Checkout; Checkout Summary; Preliminary Inspection (All Installations) - Honeywell R4140G Installation Instructions Manual

CHECKOUT

WARNING
FIRE OR EXPLOSION HAZARD
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY OR DEATH.
Do not manually operate relays.
WARNING
Do not allow fuel to accumulate in the combustion
chamber. If fuel is allowed to enter the chamber for
longer than a few seconds without igniting, an
explosive mixture could result. It is recommended
limiting the trial for pilot to ten seconds, and limiting
the attempt to light the main burner to five seconds. In
any case, do not exceed the normal lightoff time
specified by the burner manufacturer; close the
manual fuel shutoff valves if the flame is not burning
at the end of the specified time.
CAUTION
1. Use extreme care while testing the programmer;
line voltage is present on most contacts when
power is on.
2. Open the master switch before removing the
programmer from the subbase, before reinstalling
the programmer, before installing or removing
any jumpers, and before making any
adjustments.
3. Make sure all manual fuel shutoff valves are
closed before starting the Initial Lightoff Check
and the Pilot Turndown Test.
4. If low fuel pressure limits are bypassed for any of
the tests, make sure you remove the jumpers
from these limits before putting the system into
service.
5. Do not put the system into service until you have
satisfactorily completed all applicable tests
described in this Checkout section and any
others required by the burner manufacturer.
IMPORTANT
a. If the system fails to perform properly, note the point
at which trouble occurs and refer to the
Troubleshooting section.
b. Before you reset the lockout switch, wait at least one
minute to allow the heater to cool.
c. Repeat ALL required Checkout tests after all
adjustments are made. ALL tests must be satisfied
with the flame detector(s) in its FINAL position.
Equipment Required
1. Voltmeter (Honeywell W136A or equivalent) with 0 to
300 Vac scale.
2. Microammeter (Honeywell W136A or equivalent) with
0 to 25 microampere range and SPL scale with
damping.
3. Part no. 196146 Meter Connector Plug or equivalent.
4. Jumper wires (2) of No. 14 wire, insulated, 12 in.
(304.8 mm) long, with alligator clips at both ends.
5. Watch or clock with second hand.
R4140G, L AND M FLAME SAFEGUARD PROGRAMMING CONTROLS
6. Manometer (or pressure gauge) to measure pilot gas
pressure.
7. Thermometer or thermocouple to measure temperature
at the flame detector(s).
8. Orifice plates (aperture disks) or filters, as necessary, to
adjust sensitivity of flame detector(s).

Checkout Summary

The following list summarizes the checkout tests required for
each type of installation. Instructions for each test are
included in this section; also consult the burner installation
instructions.
• Preliminary Inspection—all installations.
• Flame Signal Measurement—all installations.
• Initial Lightoff Check for Proved Pilot—all installations
using a pilot.
• Initial Lightoff Check for Direct Spark Ignition of Oil—oil
burners not using a pilot.
• Pilot Turndown Test—all installations using a pilot.
• Ignition Interference Test—all installations using flame rods.
• Hot Refractory Saturation Test—all installations using
infrared (lead sulfide) flame detectors.
• Hot Refractory Hold-in Test—all installations using rectifying
photocells or infrared (lead sulfide) flame detectors.
• Ultraviolet Response Tests—all installations using
ultraviolet flame detectors.
• Flame Signal with Hot Combustion Chamber—all
installations.
• Safety Shutdown Tests—all installations.
Refer to Fig. 1 or 2 for locations of component parts, and to
Fig. 7 or 8 for terminal locations.

Preliminary Inspection (All Installations)

Perform this inspection to avoid common problems. Make
certain that:
Wiring connections are correct and all terminal screws
are tight.
Voltage rating of the flame detector(s) matches the
voltage rating of the R4140.
Flame detector(s) is clean, installed and positioned
properly. Consult the appropriate Instructions.
Correct combination of amplifier and flame detector(s)
is used. Refer to Table 1 in the Installation section.
Spring clip on relay/timer cover is holding the plug-in
flame signal amplifier securely in the receptacle.
Burner is completely installed and ready to fire (consult
burner manufacturer's instructions); fuel lines are
purged of air.
Combustion chamber and flues are clear of fuel and
fuel vapor.
Power is connected to the system disconnect switch
(master switch).
Lockout switch is reset (push in lockout switch reset
button, see Fig. 1 or 2).
Timer switch is in NORM position (Fig. 9).
The large dot between PURGE and PREPURGE on the
timer dial is at the index notch (Fig. 14). If not, manually
rotate the timer dial to the proper position. Rotate the
timer only in the direction shown by the arrow on the
relay/timer cover.
NOTE: The timer dial on the R4140L1030 cannot be
11
rotated manually, and there is no arrow on its
relay/ timer cover.
60-0770—2