Troubleshooting - CleaverBrooks CFC-500 Operation, Service And Parts Manual

simulate a flame signal for 10 seconds to 30 seconds
for PREPURGE.
b. *Flame Detected out of sequence* fault is displayed
on the Operator Interface Module.
c. Safety shutdown occurs.
4. Failure to ignite pilot or Main Burner (DBI setup).
a. Close pilot and main fuel manual shutoff valve(s).
b. Cycle burner on.
c. Automatic pilot valve(s) or main valves (DBI) should
be energized but the pilot or main burner (DBI) can-
not ignite.
d. *Ignition Failure* fault is displayed on the Operator
Interface to indicate the fault.
e. Safety shutdown occurs.
5. Failure to ignite main (only interrupted pilot application).
a. Open the manual pilot valve(s); leave the main fuel
manual shutoff valve(s) closed.
b. Depress the RESET button.
c. Start the system.
d. The pilot should ignite and the flame signal should be
above the flame threshold value but the main burner
cannot light.
e. The flame signal should drop below the flame thresh-
old value within the FFRT after the interrupted pilot
goes out.
f. *Ignition Failure* fault is displayed on the Operator
Interface Module.
g. Safety shutdown occurs.
6. Loss of flame during RUN.
a. Open the main fuel manual shutoff valve(s) and open
manual pilot shutoff valve(s).
b. Depress the RESET button.
c. Start the system. Start-up should be normal and the
main burner should light normally.
d. After the sequence is in the normal RUN period for at
least 10 seconds with the main burner firing, close the
manual main fuel shutoff valve(s) to extinguish the
main burner flame. (On intermittent pilot applications,
also, close the pilot manual shutoff valve.)
e. The flame signal should drop below the flame thresh-
old value within the FFRT of the Falcon module after
the main flame and/or pilot goes out.
f. *Main Flame Fail* fault is displayed on the Operator
Interface Module.
g. Safety shutdown or recycle, then lock out on failure to
light the pilot depending on the configuration the Fal-
con module.
7. Open a Pre-Ignition Interlock after the first 5
seconds of POSTPURGE.
a. Open the main fuel manual shutoff valve(s) and open
manual pilot shutoff valve(s).
b. Depress the RESET button.
c. *Pre-Ignition ILK* fault is displayed on the Operator
Interface Module.
d. Safety shutdown occurs.
IMPORTANT
If the Falcon module fails to shut down on any of
these tests, take corrective action; refer to Trouble-
shooting and the Falcon module diagnostics and
return to the beginning of all checkout tests.
When all checkout tests are completed, reset all switches to
the original status. Remove any jumpers that you may have
installed for testing.

TROUBLESHOOTING

System Diagnostics
Troubleshooting control system equipment failures is easier
with the Falcon's self-diagnostics and first-out annunciation. In
addition to an isolated spst alarm relay (audible annunciation),
the Falcon module provides visual annunciation by displaying
a fault code and fault or hold message at the 833-3577
Display/Operator Interface. The Falcon modules provide many
diagnostic and alert messages for troubleshooting the system.
Self-diagnostics of the Falcon modules enables them to detect
and annunciate both external and internal system problems.
Fault messages, such as interlock failures, flame failures and
false flame signals are displayed at the Operator Interface
Module and annunciated at the Falcon by the ALARM LED.
The Operator Interface displays a sequence status message
indicating: STANDBY, PURGE, PILOT IGN, MAIN IGN, RUN
and POSTPURGE. The selectable messages also provide
visual indication of current status and historical status of the
equipment such as: Flame Signal, Total Cycles, Total Hours,
Fault History, Diagnostic Information and Expanded
Annunciator terminal status (if used). With this information,
most problems can be diagnosed without extensive trial and
error testing.
Diagnostic Information Lockout and Alert History Data are
available to assist in troubleshooting the Falcon module.
The module provides diagnostic information to aid the service
mechanic in obtaining information when trouble-shooting the
system.
Diagnostic Information Index
The Falcon modules monitor digital and analog input/output (I/
O) terminals and can display the status of the terminal at the
Operator Interface Module. The display shows the actual
status of the terminal. If voltage is detected at a digital I/O
terminal, the LED turns green next to the terminal energized,
but if no voltage is detected at the terminal, the LED will be red.
Actual analog I/O values are displayed on the operator
interface module.
Historical Information Index
The Falcon modules have nonvolatile memory that allows
them to retain historical information for the fifteen most recent
lockouts. Each of the fifteen lockout files retains the cycle when
the fault occurred, the hour of operation when the fault
occurred, a fault code, a fault message and burner status when
the fault occurred. In addition to the lockout files, the Falcon
modules retain fifteen alert files.
SERVICE NOTES:
1. Reset the device module by pressing the RESET push-
button on the device or pressing a remote reset pushbut-
ton wired into connector J10 or through the display. A
power-up reset causes an electrical reset of the module
but does not reset a lockout condition.
2. Use the connector screw terminals to check input or out-
put voltage.
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CB FALCON
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