5004-890 Quick Start Guide 5004-890 Quick Start Guide
STEP 3. INSTALL THE 5004-890 CONTROLLER
• Set the 5004-890 controller over the existing Q270A mounting base and tighten the ten mounting screws
securely.
• Restore power to the ame safeguard enclosure.
STEP 4. MINIMUM PILOT TEST
is test requires a digital multimeter capable of reading volts DC to measure ame signal strength. e
positive lead is plugged into the test jack labeled, “SIGNAL 0-5 VDC.” e negative lead is plugged into the test
jack labeled, “GND.”
e following test procedures ensures the ame sensor will not detect a pilot ame too small to
reliably light the main ame:
4.1 Manually shut o the fuel supply to the burner, but not to the pilot.
4.2 Start the system normally.
4.3 To enter the pilot test mode, press and hold the reset button for ten seconds on the front of the 5004
control.
4.4 e control will hold the operating sequence at the pilot ame step. Measure signal strength as
described above.
4.5 Reduce pilot fuel until the ame relay drops out. Increase pilot fuel until the ame signal is greater
than 1 VDC, and ame relay just manages to pull in. is is the minimum pilot. If you don’t think this
ame will be able to safely light the main burner, realign the sensor so that it requires a larger pilot
ame and repeat steps 4.2 through 4.5.
4.6 Push the reset button located in the lower right corner on the front cover to reset the control into the
normal and begin the normal start-up sequence again.
4.7 When the sequence reaches the main ame trial for ignition, smoothly restore the fuel supply to the
burner. If the main burner does not light within ve seconds, immediately shut o the burner supply to
shut down the system. Re-align the sensor so that it requires a larger pilot ame. Repeat steps 4.1
through 4.6 until the main burner lights o smoothly and reliably.
STEP 5. PILOT FLAME FAILURE TEST
• Manually shut o the fuel supply to the pilot and the main burner.
• Place system in pilot test mode
• Start the system normally. e controller should lock out; if it doesn’t, then the controller is detecting a
false ame signal. Find the problem and correct it before resuming normal operation.
STEP 6. MAIN FLAME FAILURE TEST
• Manually shut o the fuel supply to the main burner but not to the pilot.
• Start the system normally. is should ignite the pilot and lock out aer pilot interruption. If the
system does not lock out, the controller is detecting a false ame signal Find the problem and correct it
before resuming normal operation.
STEP 7. SPARK SIGHTING TEST
• Manually shut o the fuel supply to the pilot and the main burner.
• Start the system normally.
• Measure the ame signal.
• If a ame signal greater than 1 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.
Note: Periodically check all interlock and limit switches by manually tripping them during burner
operation to make sure they cause the system to shut down.
Warning: Never operate a system that is improperly adjusted or has faulty interlocks or limit
switches. Always replace faulty equipment with new equipment before resuming operation.
Operating a system with defective safety equipment can cause explosions, injuries, and property
damage.
e equipment covered in this manual is capable of causing property damage, severe injury, or death. It
is the responsibility of the owner or user to ensure that the dequipment described herein is installed and
commissioned in compliance with the requirements of all national and local codes, whichever may prevail.
e equipment covered in this manual is capable of causing property damage, severe injury, or death. It
is the responsibility of the owner or user to ensure that the dequipment described herein is installed and
commissioned in compliance with the requirements of all national and local codes, whichever may prevail.
