Product Datasheet
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1. 5004 01 connect with the black lead connects to the F terminal and the white lead connects to the G terminal Note Route sensor wiring a sufficient distance away from any type of ignition or other wiring to avoid electrical noise interference Each sensor wiring must be run separate from all other wires including other sensors In some cases shielded cable or coax may be required for long distances or high electrical interference environments Each pair of sensor leads should be in their own shielded or coaxial pair and terminated at the control 5004 890 Chassis GN Electronics 5004 01 Ultraviolet Scanner Page 16 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments Wiring For Flame Rod Flame rod connects to F terminal and a wire from the burner ground connects to the G terminal Note Route sensor wiring a sufficient distance away from any type of ignition or other wiring to avoid electrical noise interference Each sensor wiring must be run separate from all other wires including other sensors In some cases shielded cable or coax may be required for long distances or high electrical interference environments Each pair of sensor leads should be in their own shielded or coaxial pair and terminated at the control 5004 890 Chassis Flame Rod rectification Testing the Installation This section describes the te2. The main burner will not be ignited as long as the control is in this mode This permits the service technician to adjust and inspect the pilot flame To enter this mode hold the reset button down until the limit light begins to flash 10 seconds To exit the pilot test mode press the reset button and the control will rest into the normal run mode Interrupted pilot the pilot will ignite and be turned off 10 seconds after the main burner valve is opened Intermittent non interrupted pilot The pilot will ignite and remain lit for the entire duration of the main burner run cycle Pilot verification feature the ignitor will be de energized 5 seconds before the main valve is energized to insure the pilot flame is stable before lighting the main burner False flame indication If the control senses a flame out of the proper sequence the sequence will stop and wait for 30 seconds for the false flame signal to disappear During this time the Flame Fail light and the Alarm light will blink on and off If the signal disappears the lights will cease blinking and the sequence will continue If the false flame signal is present for more than 30 seconds the lights will stay on and stop blinking and the control will go into lockout Flame signal analog meter jacks Two test probe inputs are located on the front of the control By inserting the meter probes from a high impedance 100k ohm volt DC volt meter the control will indicate the relative flame signal l
3. the control will reset back to the beginning of the control sequence The green limit light flashes more than 9 times Note Pressing the reset button during a cycle to access the history log will also reset the control Flame Detection Options Ultraviolet Scanner Model 5004 01 The UV sensor detects light emitted from the flame within the Ultraviolet light spectrum Ultraviolet Self Check Scanner Model 5002 01 The UV Self Check sensor detects light emitted from the flame within the Ultraviolet light spectrum This sensor is intended for applications that continuously operate the burner 24 hours The self check scanner interrupts the UV light from the burner every ten seconds to verify the proper operation of the sensing element and the internal components Flame rod The flame rod works on the principle of Flame rectification and senses a small direct current flowing through the flame between the flame rod and the burner ground Installation Notes read before installing control All installation wiring or service activities must only be performed by knowledgeable and qualified technicians All system wiring should be run in accordance with the National Electrical Code and all local code requirements Page 12 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments i re Always remove all power
4. used then a jumper must be placed between T amp T in the base to complete the circuit High voltage applied to terminals T1 or T2 will damage control and void the warranty Flame Sensor Terminals F amp G Sensor inputs Flame rod connects to Terminal F UV sensor connects to F amp G see wiring schematics Page 5 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments Outputs Pilot Terminal P Output to energize the burner pilot valve Ignition Terminal I Output to energize the ignition transformer Main Terminal M Output to energize the burner main valve Alarm NO NC C This is a dry contact output which closes when an alarm condition occurs rated up to 230VAC 2 amp max Control Configuration Setup Dipswitches There is a set of 8 dipswitches under the right side cover on the control Switches 5 through 8 top 4 switches are not used on this control Dipswitches 1 and 2 set the desired trial for pilot ny This value can be 3 5 10 or 15 seconds Dipswitch 3 selects Non Recycle or Recycle mode Recycle mode permits the controller to shut down and start the burner startup sequence again when a flame failure has occurred during the burner run cycle In order for this to occur the main burner has to be up and running before a recycle can occur A flame failure that happens before that time
5. 72 RA890G 1112 RA890G 1120 RA890G 1179 RA890G 1187 RA890F 1262 RA890F 1437 RA890F 1510 Features include Optional plug in diagnostic display Standard relay alarm contact Easy mounting in control panels Pilot Test Mode Selectable Trial for Ignition times 3 5 10 or 15 seconds Selectable interrupted or intermittent pilots Selectable recycle or non recycle modes Page 2 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments ORDERING INFORMATION Controllers Catalog Number Delivery Description List Price Discount i No purge primary control Accept UV scanner or IRRA Pie flame rod input 120 VAC supply No purge primary control Accept UV scanner or cia elOce diame tod input 24 VDC supply No purge primary control with history logging oes Bleek Requires an optional display 5004 216 No purge primary control for continuous standing 5 EAD ee pilot applications Works with flame rod input only 5004 890A Stock No purge primary control Automatically resets on burner shutdown Scanners Catalog Number Delivery Description List Price Discount 5004 01 C Stock Ultraviolet scanner for the 5004 series and the 5003 series controls with cable 5004 01 Stock Ultraviolet scanner for the 5004 Series and the 5003 series controls without cable 5002 01 Stock Self checking UV Scanner 120V AC Relay amp Flame Amplifi
6. GN ELECTRONICS A division of Preferred Instruments lt Quanta Flame Model 5004 890 MechtTronics Primary Control www hvacusa com Phone 877 632 4876 Compatible with most Honeywell RA890F amp G Series Controls USER MANUAL Note All rights and privileges to the design of this product including the circuit layout and software are the exclusive property of GN Electronics a division of Preferred Instruments No part of which can be sold used or modified without the expressed written permission of Preferred Instruments Revised June 1 2007 Page 1 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments DESCRIPTION The Quanta Flame 5004 890 is a state of the art flame safeguard controller designed for single burner applications The controller sequences the burner through Purge Ignition and Release to Modulate It monitors the burner flame and interlocks and safely shuts down the burner in the event of an unsafe operating condition The 5004 890 controller is a direct replacement for most Honeywell RA890 controls e No re wiring or sensor changes required when replacing an RA890 controller e Operates with existing UV sensors and flame rods The 5004 890 replaces the following models of Honeywell Controls RA890F 1288 RA890G 1260 RA890F 1031 RA890G 1047 RA890F 1056 RA890G 1062 RA890F 10
7. U_ SCANNER INPUT SEE BELOW ALARM CONTACTS Note 1 Itis not necessary to connect 120VAC to Terminal L If 120VAC is already connected it must be from the same source as voltage connected to Terminal LM Note 2 Model 5004 890 24V is not applicable to 120VAC wiring shown above Supply voltage for this model must be 12 to 24VDC Note 3 The 5004 890 is not suitable for standing pilot applications Model 5004 890S can be used with a standing pilot with Flame Rod sensor only NOTE Alarm connection are made ee through the bottom of the control board on the left terminal side 2 Page 15 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments E i Typical UV Scanner Wiring Honeywell Scanners C7027A connect with the blue lead connects to the F Terminal and the white lead connects to G terminal Note Route sensor wiring a sufficient distance away from any type of ignition or other wiring to avoid electrical noise interference Each sensor wiring must be run separate from all other wires including other sensors In some cases shielded cable or coax may be required for long distances or high electrical interference environments Each pair of sensor leads should be in their own shielded or coaxial pair and terminated at the control 5004 890 Chassis Honeywell C7027 Ultraviolet Scanner GN Electronics Scanners
8. ay just manages to pull in This is the minimum pilot If you don t think this flame will be able to safely light the main burner realign the sensor so that it requires a larger pilot flame and repeat steps 2 through 5 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 7 When the sequence reaches the main flame trial for ignition smoothly restore the fuel supply to the burner If the main burner does not light within five seconds immediately shut off the burner supply to shut down the system Re align the sensor so that it requires a larger pilot flame Repeat steps 1 through 6 until the main burner lights off smoothly and reliably Pilot Flame Failure Test 1 Manually shut off the fuel supply to the pilot and the main burner 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 operation Main Flame Failure Test 1 Manually shut off the fuel supply to the main burner 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 Find the problem and correct it before resuming normal operation Spark Sighting Test 1 Man
9. e When the main burner is in the run mode the flame signal level will be indicated in a range of 0 to 5 VDC The display constantly refreshes itself with new information from the control This refreshing is indicated by the slight periodic blink of the messages During the trial for ignition period the display may show a blank line across the top row This indicates the presences of an electrical noise field generated by the ignition circuit This in no way affects the display or the control The display will revert to the proper message when the electrical noise ends SPECIFICATIONS Mechanical Enclosure 134 H by 3 L by 3 D 1 8 DIN Area Classificaton NEMA type 4 Membrane Front Electrical Supply 120 VAC 50 60 Hz Power consumption 2VA Output Relay reset contact 15 Amps communication cable to 5004 control Environmental Temperature rating 20 C to 60 C 0 F to 140 F Page 9 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS g x A division of Preferred Instruments n q gt o E A MADAAN ri 1 Insert control connector carefully line up small pins with holes 3 Attach cable to controller 5 Wire 120 VAC power to the three pin terminal block on the back of the display Note the five pin terminal block on the back of the 5004 216RN display is not wired when used in conjunction with the 5004 890 controller Not
10. e all power must be removed from the control when installing or removing the display Failure to do so may damage the display and or the control CACERES Page 10 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments w Contrast adjustment Note The contrast is previously adjusted and set at the factory It is unlikely that any adjustments will be required except in unusual lighting situations or in high or low ambient temperature environments On the front of the control immediately to the left of the LIMITS light is a contrast adjustment which can be used to vary the contrast To adjust the contrast insert a small instrument screw driver into the hole and turn the screw clockwise for more contrast or counterclockwise for less contrast Once installed the display will show the steps of the control sequence and indicated when an alarm has occurred After the start up sequence the display will indicate the flame signal level as a range between 0 to 5VDC Alarm History Optional Feature Display also required The Alarm History option allows the user to view the previous alarms occurring in the control which caused a lockout In the case where recycling is selected the control will also indicated the alarm that occurred to initiate the recycle of the control sequence to relight the burner With this option the res
11. er Output 1 2 Self checking IR Scanner 120V AC A wks Relay amp Flame Amplifier Output Accessories Catalog Number Delivery Description List Price Discount 5004 270 Stock Wiring base for model 5004 890 5004 795 5004 216 Stock Plug in display for the 5004 series controls 5004 216 R Stock Remote display package remote display interface amp 6 foot cable Annunciator with Operator Interface Display QD485QA16 Stock 1 8 DIN panel mount 16 point analog digital inputs Remote display package remote display NEMA 4 front membrane interface amp 6 foot cable 5000 02 10 Stock Scanner cable for 5002 01 and 5002 11 self checking scanner 5004 890 Tester Stock Tester amp demonstrator for 5004 890 amp 5004 795 5004 216 RN Stock Page 3 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 MechTronics www gnelectronics com pie he asri www hvacusa com Phone 877 632 4876 GN ELECTRONICS A division of Preferred Instruments re FUNCTIONAL SUMMARY Recycle mode When selected the control will recycle the burner through purge and startup when the main burner has shutdown with a flame failure alarm The recycling of the burner will only occur after the main burner has been in operation There is no recycle on pilot flame failure Pilot turndown test mode this mode permits the pilot to ignite and remain burning regardless if interrupted or intermittent pilot has been selected
12. et button functions as follows Pressing the reset button for less than 6 seconds The control will reset an alarm lockout condition and restart the sequence when limits are closed During this operation the green limit light will also flash every 2 seconds to indicate the time Pressing the reset button more than 6 seconds but less than 12 seconds The control will enter the pilot turndown test mode as described on page 9 This will be indicated on the display as Test Mode The green limit light flashes more than 3 times but less than 6 When the button is released the green limit light will continue to flash to indicate Pilot turndown test mode Pressing the reset button more than 12 seconds but less than 18 seconds The control will enter the History Log mode This will be indicated on the display as History Log The green limit light flashes more than 6 times but less than 9 History Log mode The display will indicate up to 16 previous shutdown lockout conditions with the first condition displayed being the most recent Page 11 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments Pe L mA u Pressing the reset button more than 18 seconds the history log will be reset and the previous entries will be deleted This will be indicated on the display as History Reset for 2 seconds and
13. evel in the range of 0 to 5 VDC The positive probe goes into the jack labeled Signal 0 to S5VDC The negative probe goes into the jack labeled GND Control Reset When the control enters a lockout condition the red alarm light will light and begin blinking To reset the control press the reset button on the front of the control The control will not reset on power interruption Lockout conditions for the control are e Flame failure e False flame present for more that 30 seconds e Relay failure and internal fault Page 4 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments LED Indicators Flame Proven Limits Made Pilot Gas Valves Energized Main Gas Valves Energized Flame Failure Lockout Condition Occured Power Applied to Unit 1 Limits light will blink during internal circuit self check Light will remain on when self check is complete Limit light will blink during pilot test mode Inputs Power Terminal L Input that energizes the control electronics and sensor Neutral Terminal N Grounded neutral connection to control Limits Terminal LM Power and interlocks including the control start switch Low Voltage Control Contact Terminals T1 amp T2 Input is connected to contact switch This must be a dry contact No voltage can be applied to these terminals If this input is not
14. her sensors In some cases shielded cable or coax may be required for long distances or high electrical interference environments Each pair of sensor leads should be in their own shielded or coaxial pair and terminated at the control Page 13 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments Wiring Considerations Depending on the output option used the wiring requirements will vary somewhat Output type Suggested wire Wiring run considerations Contact 14 to 16 AWG THHN or equivalent Nothing special can be run with other wires in conduit Oto 12VDC 14 to 16 AWG THHN if wire is Sensor Signal run in separate conduit Shielded cable if multiple wires are in One conduit Coax cable if long distance runs are required or if high level of electrical noise is present Note All wiring runs to the field on or near hot surfaces should be rated for 90 C 195 F or at least 25 C 50 F higher than the surface temperature Bh E Ve Bi H mS 5 Sea P2 G N Electronics Inc gnelectronics com 5004 270 Rev 01 5004 270 Wiring Base Page 14 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments Wiring Diagram 120 VAC GAS VALVES IGNITION XMR DRY CONTACT NO VOLTAGE
15. ising in connection with the sale installation use of inability to use or the repair or replacement of GN Electronics products Defective units should be returned to G N Electronics Controls should be well packed in a suitable container encased in appropriate stuffing Units should be returned to G N Electronics Controls should be well packed in a suitable container encased in appropriate stuffing All items should be shipped prepaid to G N Electronics Inc A Division of Preferred Instruments 31 35 South Street Danbury CT 06810 Page 19 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com
16. ponent Trial for Ignition Check for Trial for Main Pilot off if due to flame Check Check Time set by DIP Pilot Flame Flame intermittent not fail or limit Terminals Function 6 Secs 10 Secs Switch selection 5 Secs 10 Secs selected trip Inputs LM Limit Input T1 T2 Dry Contact Input Outputs P Pilot Valve i a es es 7 I Ignition M Main Valve SPECIFICATIONS Mechanical Enclosure 5 H by 5 W by 13 D Shipping weight 2 Ibs for all models Area classification Temperature range Electrical Voltage Power consumption Load ratings pilot amp main Total connected load Alarm contact Approvals UL Recognized CSA Certified NEMA 1 40 F to 140 F 40 C to 60 C 120 VAC 50 60Hz 12 to 24VDC Model 5004 890 24V 2VA 10 amps 1 4 HP inductive 15 amps 1800VA 230VAC 2 amps maximum File No E233069 Number 204571 1435343 Page 8 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments D re Display Description The optional 5004 216RN display is a panel mounted display for the 5004 Series Quanta Flame Controls It mount in a control panel through a 1 8 DIN mounting hole and is secured with the included mounting clips During operation the display will indicate each step in the control sequenc
17. results in a lockout regardless if recycle is selected or not Dipswitch 4 selects interrupted or intermittent or non interrupted continuous pilot An interrupted pilot will ignite during the trial for ignition time and be shut off 10 seconds after the main gas valve opens to light the main flame An intermittent pilot will ignite during the trial for ignition time and will stay lit when the main valve is open It will remain on as long as the main burner is on and will shut down at the end of the main burner cycle Page 6 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments Dipswitch Setup Table Dipswitch State Control Strategy 3 second PTFI 5 second PTFI 10 second PTFI Intermittent aaah on __Nowsintrmittent continuous pilot off Nonrecycle operation on Recycle operation Flame failure response time FFRT 2 5 to 3 5 seconds fixed Flame Detector Configuration J2 Terminal strip located under left side cover of controller UV Scanner Flame Rod Position Position O Page 7 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments E w Control Check Cycle Burner Start up Cycle Heat Cycle Limit Light Internal ON Internal Shutdown Memory Com
18. st procedures that must be performed after installation to insure that the 5004 890 and the connected sensor is operating properly These procedures are mandatory These tests are to be performed after any installation of the 5004 890 control regardless if it is a new installation or a replacement installation for an existing control Insert the positive probe of a 0 10 VDC digital voltmeter into the test point on the front cover of the 5004 890 insert the negative probe to ground point Good flame signal strength will read between 2 and 5 VDC anything below 1 VDC is inadequate Also the red flame light illuminates when a flame signal is indicated Page 17 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments Minimum Pilot Test Run the following test procedures to ensure that the sensor will not detect a pilot flame too small to reliably light the main flame 1 Manually shut off the fuel supply to the burner but not to the pilot 2 Start the system normally 3 To enter the pilot test mode press and hold the reset button for ten seconds on the front of the 5004 control 4 The control will hold the operating sequence at the pilot flame step Measure signal strength as described above 5 Reduce pilot fuel until the flame relay drops out Increase pilot fuel until the flame signal is greater than 1 VDC and flame rel
19. to the system before wiring The 5004 890 is secured to the wiring base by means of ten mounting screws located under the control side covers These mounting screws also are the electrical connection of the control to the base It is necessary for all of these screws to be securely fastened for the control to work properly s Do not run control wiring ignition wiring or sensor wiring in the same conduit Neutral must be grounded The 5004 890 is designed to work in a variety of applications and conditions however some applications may not be applicable due to the presence of high electrical noise lack of adequate ground connections floating neutrals or other known or unknown conditions It is therefore important to ensure proper system environment before installing these devices The signal levels and functionality of a particular brand of sensor will not be identical to the signal levels and functionality of a sensor when used with other burner control brands Due to variable manufacturing tolerances it is possible but unlikely for an individual sensor to not function in a 5004 890 system but still operate with it own branded control or vise versa In these cases the scanner may need to be replaced with a new Honeywell or GNE scanner Route sensor wiring a sufficient distance away from any type of ignition or other wiring to avoid electrical noise interference Each sensor wiring must be run separate from all other wires including ot
20. ually shut off the fuel supply to the pilot and the main burner 2 Start the system normally 3 Measure the flame signal Page 18 of 19 31 35 South St Danbury CT 06810 Phone 203 743 6741 Fax 203 798 7313 www gnelectronics com GN ELECTRONICS A division of Preferred Instruments 4 If a flame 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 Warranty and Returns The 5004 890 is warranted for one 1 year from the date of delivery against manufacturing defects only GN Electronics standards terms and conditions apply GN Electronics liability for its products whether due to breach of warranty negligence strict liability or otherwise is limited to the furnishing of replacement parts and GN Electronics will not be liable for any other injury loss damage or expenses whether direct or consequential including but not limited to loss of use income of or damage to material ar
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