CleaverBrooks CFC-500 Operation, Service And Parts Manual page 191

k. If the pilot flame does not ignite and if the ignition
spark is still continuous, adjust the pilot gas pressure
regulator until a pilot flame is established.
l. When the pilot flame ignites properly and stays
ignited, open the master switch and remove the
jumper(s) from the J5 terminals.
m. Check for adequate bleeding of the fuel line.
n. Reinstall the J5 connector onto the Falcon module,
close the master switch and return to step 4.
INTERNAL IGNITION SOURCE
To check the internal ignition, the Falcon controller will
need to be cycled:
a. Open the master switch and remove connector J5.
b. Ensure both the manual pilot shutoff valve and the
manual main fuel shutoff valves are closed.
c. Cycle the Falcon controller and observe the ignition
spark. (To provide a longer ignition period, additional
time can be added to the pre-ignition time parame-
ter.)
d. If the ignition spark is not strong and continuous,
open the master switch and adjust the ignition elec-
trodes spark gap setting to the manufacturer's rec-
ommendation
e. Make sure that the ignition electrodes are clean.
f. Close the master switch and cycle the controller and
observe the spark.
g. After obtaining a strong spark, open the master
switch, remove the main valve wire from connector
J5 terminal 3 and re-install connector J5 to the con-
troller.
h. Open the manual pilot shutoff valve.
i. Close the master switch and change the pre-ignition
time parameter back to the original value if you
changed it in step C.
j. Cycle the controller to energize both the ignition trans-
former and the pilot valve.
k. If the pilot flame does not ignite and if the ignition
spark is still continuous, adjust the pilot gas pressure
regulator until a pilot flame is established.
l. When the pilot flame ignites properly and stays
ignited, open the master switch and reconnect the
main valve to the connector J5 terminal 3 (if removed
in step g).
m. Close the master switch and return to Step 4.
7. When the pilot flame ignites, measure the flame signal. If
the pilot flame signal is unsteady or approaching the
flame threshold value
parameter)
, adjust the pilot flame size or detector sight-
ing to provide a maximum and steady flame signal.
8. Recycle the system to recheck lightoff and pilot flame signal.
9. When the MAIN Valve energizes, make sure the auto-
matic 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 5
seconds or the normal lightoff time 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 ligh-
toff again. (The first 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 5
seconds or the normal lightoff time specified by the
equipment manufacturer, close the manual main fuel
shutoff valve(s). Check all burner adjustments.
(see flame threshold
14. If the main burner flame is not established after two attempts:
a. Check for improper pilot flame 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.
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 flame 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 flame signal through the RUN period. Check the
flame signal at both High and Low Firing Rate positions
and while modulating, if applicable.
20. Run the burner through another sequence, observing the
flame signal for:
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.
22. Return the system to normal operation.
NOTE: After completing these tests, open the master switch
and remove all test jumpers from the connector termi-
nals, limits/controls or switches.
Direct Burner Ignition (DBI) 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.
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 equip-
ment 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 control-
ler; see Falcon module sequencing. The program
sequence should start the INITIATE sequence.
5. Let the sequence advance through PREPURGE (if applica-
ble). Ignition spark should turn on during the ignition trial
period. Listen for the click of the fuel solenoid valve(s). The
Falcon module locks out and the ALARM LED turns on.
6. Let the Falcon module complete its cycle.
7. Open the manual fuel shutoff valve(s).
8. Push the reset button and the module recycles the
program sequence through PREPURGE (if applicable).
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CB FALCON
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