Overview of Primary Product

PILOT FLAME FAILURE TEST

1. Manually shut off the fuel supply to one individual pilot and main burner, or all burners if the

system has a single fuel supply.

2. Place system in pilot test mode.

3. Start the system normally. The controller should lock out*; if it doesn’t, then the controller is

detecting a false flame signal. Find the problem and correct it before resuming normal opera-

tion.

4. Repeat steps 1 through 4 until all burners have been tested.

MAIN FLAME FAIULRE TEST (For Interrupted Pilot Systems)

1. Manually shut off the fuel supply to the main burner, or all burners if the system has a single

fuel supply, but not to the pilot.

2. Start the system normally. This should ignite the pilot and lock out

after pilot interruption. If

the system does not lock out, the controller is detecting a false flame signal. Locate the problem

and correct it before resuming normal operation.

3. Repeat steps 1 through 3 until all burners have been tested.

SPARK SIGHTING TEST

1. Manually shut off the fuel supply to the pilot and main burner.

2. Start the system normally.

3. Measure the flame signal as described in “Flame Signal Strength” in this section.

4. If a flame signal greater than 4 VDC is measured for more than three seconds during the trial for

ignition, then the sensor is picking up a signal from the spark plug. Refer to Sensor Installation.

SENSOR INSTALLATION

SENSOR WIRING

Route sensor wiring a sufficient distance from ignition and other high voltage or high current wiring

to avoid electrical interference. Interference from ground currents, nearby conductors,

radio-frequency emitters (wireless devices), and inverter drives can induce false flame signals.

Shielded cables can help reduce interference with the shield connected to ground at the control end

only. The wire type and its capacitance (picofarads or microfarads) to ground may cause low signal

problems, so a grounded shield may decrease the signal due to the cable’s internal capacitance.

Multiple UV tube-type sensor leads run together without shielding may interfere or “cross talk”, so

the shield or flexible armor must be grounded to prevent this situation. For flame rod sensor runs

approximately 100 feet (30 meters) or greater, use Belden P/N 8254-RG62 coax cable. To achieve

the maximum wiring distance, the shield should not be grounded (keep in mind that an underground

shield provides less protection against electrical interference). Depending on field connections,

sensor wiring can be up to 200 feet (61 meters).

Do not ground the shield to terminal GND.

Unshielded sensor wiring must not be run in common with other wires; it must be run in separate

conduit. Multiple flame sensor wiring must not be run together in a common conduit or wireway.

Use #14 to #18 AWG wire suitable for 90°C (194°F) and 600 volt insulation, and run each pair of

WARNING: Incorrect sensor installation may cause the sensor to generate a false flame sig-

nal, causing unburned fuel to collect in the combustion chamber. The result can be explo-

sions, injuries and property damage. Be certain that the flame sensor detects only pilot and

main flames, not glowing refractory, burner or ignition parts.