Honeywell R4560 User manual

AUTOMATIC IGNITION CONTROLLER
R4560
INSTRUCTION SHEET
EN1R--9102 9402R1--NE
Description
The R4560 is a solid state automatic
direct burner ignition as well as
intermittent ignition controller with
excellent performance and high
reliability standard.
Application
The R4560 provides automatic
sequence control for:
- Power burners up to 350 kW in
accordance with DIN 4788 part 2
and 3 including flame supervision
and non volatile lockout for
intermittent operation.
- Power burners in accordance with
European safety standards EN 298.
- Warm air heaters in accordance with
DIN 4794 part 3 (-- 20 EC).
FEATURES
- Integral reset alarm push button
- Accurate safety timer.
- Individual timers for safety and
prepurge timing.
- Supply voltage range 220 ... 240 V.
- Full operating sequence after flame
loss.
- Optional internal medium power
50 Hz spark igniter with 20 cm cable
and 2,8 x 0,8 mm spade terminal for
extended wiring.
- Connection for external high power
igniter (S720)
- Lockout in case of air proving switch
detects no air.
- Lockout in case of flame simulation
before start or during prepurge.
- Sequence status diagnostic
indicators by 4 LED’s.
Subject to change without notice. Printed in the Netherlands.

EN1R--9102 9402R1--NE
2
WIRING DIAGRAMS
V2
12 34
L
1011
N
56
V1
y
78
Py
1A 1A 1A
Fig. 1 Intermittent pilot ignition
G
912 34
L
1011
N
56
y
78
Py
1A 1A 1A
G
V2V1
Fig. 2 Direct burner ignition
OPERATION SEQUENCES
t0t1t2t3
Ts
t5
Tp
t6t7
Ts Tp
5smax.
t4t0t1t2t3
Ts
t5
Tp
t6t7
Ts Tp
5smax.
t4
Fig. 3 Intermittent pilot ignition Fig. 4 Direct burner ignition
P
y
P
y
MV1
MV2
MV1
MV2
Thermostat Gas valve Ignition Flame rod Fan Limiter Reset switch Alarm Air proving
switch
yG
Gas pressure
switch
yP
91,5 62 39 35
63,5
20
20
21
50
15
65
3
3
3
Retaining
screw
Conduit knockout
Reset button
Subbase
15
Fig. 5 Dimensions
Sequence status
LED’s (see fig . 6)
y
G
y
Flame established
V1energized
Air proving switch
closed
Gas pressure switch
closed
Fig. 6 Sequence status LED’s
P
MV1

3
EN1R--9102 9402R1--NE
SPECIFICATIONS
Model
R4560: 220 ... 240 V, 50 Hz.
Suffix M: For power burners.
Manual reset according to
DIN 4788 part 3.
Warm air heaters according
to DIN 4794 part 3
Lock--out on false flame.
Lock--out on no air.
Dimensions
See fig. 5
Ambient temperature
--20 ... 60
E C
Relative humidity
90% max. at 40
E C (non condensing)
Supply voltage
Line voltage, 220 V (--15%) ... 240 V
(+10%), 50 Hz (
p 2Hz)
Power consumption
10 VA maximum.
Electrical rating
Valve output: 1 A cos ϕ=0.6
Fan: 1 A cos ϕ=0.6
Alarm output: 1 A cos ϕ=0.6
Ignition transformer: 1 A cos ϕ=0.4
Timing (depending on O.S. number)
Prepurge time (Tp): 10, 20 or 30 s
Safety time (Ts): 3 or 5 s
Flame sensing
Flame sensing is based on the
rectification principle.
Minimum flame current: 1 µA
Response time ”ON”
(at 2 µA flame current): < 200 ms
Responsetime”OFF”: <1s
Ignition
: Integral electronic spark generator
with 2,8 x 0,8 mm spade terminal for
extended wiring (terminal/cable 11,
in fig. 1 and 2).
Spark voltage: 12 kV at 40 pF
load
Repetition rate: 50 Hz
Max. cable length: 100 cm
: An external (more powerful) ignition
transformer (S720) can be wired in
the system.
Recommended flame sensor
Q354 Flame sensor
Recommended spark igniter
Q375 Spark igniter
Fusing
Automatic ignition controller should be
externally fused to prevent damage to
automatic ignition controller, wiring or
periferals.
External fuse: 16 A slow max.
Enclosure
IP 40
Accessories (tobeorderedsepara-
tely)
High voltage ignition cable with length
of 50 cm.
order number:............ 45.900.411--001
Subbase
ordernumber:............. Q632A 1124
SYSTEM OPERATION
Automatic ignition controller for po-
wer burners (see fig. 3 and 4)
When thermostat calls for heat, fan is
energized if air proven switch is in the
no air position.
When sufficient air flow is proven by the
air proving switch, a prepurge period
(Tp) elapses before the optional built--in
spark igniter or the external ignition
transformer and the pilot gas valve (V1)
is energized in case of intermittent pilot
ignition or both gas valves (V1and V2)
are energized in case of direct burner
ignition.
The ignition spark ignites the gas and
the resulting flame is detected by the
flame rod.
Ignition is switched off immediately
after flame is established.
If flame is not established within the
safety time (Ts), the automatic ignition
controller locks out.
If air flow is not proven by the air
proving switch, the automatic ignition
controller will lockout after Tp+Ts.
If flame is lost during normal run, the
automatic ignition controller repeats the
start sequence.
Lockout reset
The auto ignition controller will be reset
by depressing the reset button.
Press the button completely down.
If a first reset is not succesful wait at
least 15 seconds before making
another attempt.
Control behaviour during loss of air flow and flame signal
Air flow loss during:
Prepurge time
(Tp) Safety time (Ts)Normal run
Loss of air flow
0,5 s < Tlost <1s Restart Lockout Lockout
Flame lost -- Restart Restart
Note: Air flow loss < 0,5 second is not considered as air flow loss

4EN1R--9102 9402R1--NE
INSTALLATION AND CHECKOUT
Important
: Before connecting the controller to
main supply, wait for at least one
hour.
: Installer must be a trained
experienced service man.
: Disconnect power supply to
prevent electrical shock and/or
equipment damage.
: Before installing or replacing any
control check that type number is
correct for the application.
: The appliance manufacturer’s
instructions should always be
followed when provided.
If such instructions are not
provided see fig. 3 and 4 for typical
systems.
: Ensure combustion chamber is free
of gas before start up.
: At the first start the automatic
ignition controller can be in lock
out; depress reset button to free
control.
: Never open the upper part, which
includes the electronics
Mounting
The automatic ignition controller should
be mounted on a flat surface by means
of 2 screws in the mounting holes of the
subbase.
Mounting position
The automatic ignition controller
functions position independently and
such can be mounted in any position.
Spark gap
Refer to the appliance manufacturer’s
instructions for recommended ignition
electrode position.
Maximum allowable spark gap: 4 mm
Wiring
: Wiring must be in accordance with
local regulations
: Use leadwire which can withstand
105
E C ambient.
: Use leadwire which is proven against
moisture.
: Wiring between automatic ignition
controller and spark sensing probe
should have good quality insulation,
suitable for the temperatures encoun-
tered.
Supply voltage polarity
Warning
If automatic ignition controller seems
to operate normally but does not
detect ignition flame, check for right
polarity of power supply (line,
neutral).
Checking flame current
: The minimum value should be 1 µA.
: To check flame current connect a DC
micro--Ampèremeter between flame
sensing wire and flame sensing rod.
(see fig. 1 and 2).
: If flame current is insufficient, check
that:
-- proportion of flame touching the
grounded portion of the burner
is3to4timestheproportion
enveloping the flame rod.
-- there is a good ground
connection to the controller.
Checkout
After installation, set burner system in
operation and observe through a
complete cycle to ensure that burner
system components function correctly.
See fig. 6 for sequence status LED’s
GENERAL CONSIDERATIONS
The automatic ignition controller should
be externally fused.
If, due to a short circuit, the internal
fuse is blown, the automatic ignition
controller must be repaired by
Honeywell.
When the automatic ignition controller
is built in an appliance, the total
protection must be IP40 at least.
To ensure reliable long term operation,
mount automatic ignition controller at a
positionintheappliancewithalow
ambient temperature and a low thermal
radiation.
High temperatures will affect product
life negatively.
For safety a high limit thermostat must
be connected in series with the
thermostat to de--energize the
automatic ignition controller in case of
overtemperature.
To suppress Radio Frequency
Interference (RFI) the automatic ignition
controller including spark igniter
cabling should be mounted in sufficient
shielded environment.
Note
Electrical rating of connected controls
should be appropriate for the load
that is switched by the automatic
ignition controller.