C7007A, C7008A, C7009A Flame

Rod Holder & Flame Rod

Assemblies
INSTALLATION INSTRUCTIONS

IMPORTANT
The specifications given in this publication do not
include normal manufacturing tolerances. Therefore,
this unit may not match the listed specifications
exactly. Also, this product is tested and calibrated
under closely controlled conditions, and some minor
differences in performance can be expected if those
conditions are changed.

SPECIFICATIONS
Tradeline Models:
C7008A Flame Rod Assembly, straight pattern, with cover
(can be used with or without cover).
The small size of these devices enable their application to
flame detection in installations where space is limited. The FLAME RODS
holder and flame rod assemblies facilitate flame proving on C7008A1174, 12 inch [305 mm] Kanthal A1 C7008A1182, 24
gas burners or gas-ignited oil burners which are controlled by inch [610 mm] Kanthal A1 see also, Accessories.
electronic flame safeguard systems.

• The C7007A, C7008A, and C7009A may be used with DIMENSIONS:

flame safeguard controls utilizing the rectification principle See Fig. 2.
of flame detection.
• The C7007A is a small, sturdy holder for a 3/16 inch [4.8 ELECTRICAL CONNECTION:
mm] diameter flame rod (flame rod ordered separately). Rajah male with companion connector.
• The holder is externally threaded (1/2-14 NPT) for pipe
mounting. MOUNTING:
• A collet chuck and setscrew position a flame rod securely. Equipped with external 1/4-18 NPT threads.
If additional support of the flame rod is required, the
C7007A extension assembly is internally threaded (1/8-27 STANDARD MODELS
NPT) to accept a 1/8 inch iron support pipe. C7007A Flame Rod Holder.
• The C7008A is a miniature flame rod assembly with a
threaded (external 1/4-18 NPT) base, snap-on cover, and C7008A Flame Rod Assembly:
flame rod. Miniature flame rod assembly.
• The C7008A can be used without the cover and a C7009A Flame Rod Assembly: small diameter flame rod
coverless model is available. assembly.
• The C7008A is available with several lengths of flame rod.
One end of the flame rod is threaded for insertion into the MOUNTING MEANS:
C7008A and the other end may be cut to an exact size. C7007A-external 1/2-14 NPT for pipe mounting.
• The C7009A is a smaller diameter flame rod assembly with C7008A-external 1/4-18 NPT for pipe mounting.
an externally threaded (1/8-27 NPT) base and readily C7009A-external 1/8-27 NPT for pipe mounting.
accessible Rajah electrical connection.
• The C7009A has a 12 inch (305mm) flame rod which one FLAME ROD:
end is threaded and the other capable of being cut to an C7007A-Not furnished, refer to ACCESSORIES.
exact size. C7008A-Kanthal in 6, 12, 18, 24 inch [152, 305, 457, 610 mm]
lengths.
C7009A-Kanthal in 12 inch [305 mm] lengths.

SIL3 60-2024-06
Capable
C7007A, C7008A, C7009A FLAME ROD HOLDER & FLAME ROD ASSEMBLIES

ELECTRICAL CONNECTION:
C7007A-Terminal screw. 2
3
[56]
16
C7008A and C7009A-Rajah male, with companion connector. 1
3
32
1
15
16
[49]
[28]

SIL 3 Capable:
The C7008 or C7009 when used with a R7847B Ampli-check 2
9
amplifier in Relay Module EC7810A, 20A, 30A, 40L, 50A; 16
[65]
RM7800[E,G,L,M], 30A, 38[A,B,C], 40[E,G,L,M] 50A, 5
1
90[A,B,C,D], 97[A,C], 98A is SIL 3 Capable in a properly 8
[41]
designed Safety Instrumented System. See form number
65-0312 for Certificate Agreement.
5
[16]
8
APPROVALS:
1/8-27 NPT
Underwriters Laboratories listed: File No. MP268, Canadian 1/2-14 NPT
Standards Association Certified: Master File No. LR 95329-1, M1844
Factory Mutual approved: C7008A, C7009A, Swiss Re
(formerly Industrial Risk Insurers): acceptable. Fig. 1. Dimensions in inches [mm] of C7007A flame rod
holder.
ACCESSORIES:

Table 1. Flame Rods (Kanthal A1, 2200° F [1204° C] MAX.) 9 [4]

1/4 - 18 NPT
64 7
[22]
8
Length in 7
Part Inches 8
[22]
Use With Number [mm] Thread
3 5
3 [79] [16]
C7007A 102709A 12 [305] None 32 8 M1840

102709B 18 [457] None

Fig. 2. Dimensions in inches [mm] of C7008A flame rod
102709C 24 [610] None assembly.

102709D 36 [914] None

102709E 48 [1219] None 1/4 - 18 NPT 7

[22]
8

C7008A 105478A 6 [152] 6-32 UNS-

2A

105478B 12 [305] 6-32 UNS-

5 5
2A 2
8
[67]
8
[16]
M1841

105478C 18 [457] 6-32 UNS-

2A Fig. 3. Dimensions in inches [mm] of C7008A flame rod
assembly, coverless model
105478D 24 [610] 6-32 UNS-
2A
1/8 - 27 NPT THREAD
C7009A 105644Ca 12 [305] 3-56 NF-2A
3 [10]
8
a 105479B electrical terminal and 21107 washer included.
3 3
2 [56]
16 16
R1061012 Ignition Cable: [5] M1839
For ignition installations in a high temperature environment.
Rated at 350° F [177° C] for continuous duty, and up to
500° F [260° C] for intermittent use. Tested to 15,000 V. Fig. 4. Dimensions in inches [mm] of C7009A flame rod
assembly.
R1298020 Cable:
For flame detector "F" lead wire installations in a high temper-
ature environment. Rated up to 400° F [204° C] for continu-
ous duty. Tested for operation up to 600 V and breakdown
up to 7500 V.

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 C7007A, C7008A, C7009A FLAME ROD HOLDER & FLAME ROD ASSEMBLIES

INSTALLATION
CAUTION
Wrong position will provide inadequate pilot
WARNING flame.
Read these instructions carefully. Failure to follow
them could damage the product or cause a WRONG POSITION OF ROD
hazardous condition.
1. Check the ratings given in the instructions and on the
product to make sure the product is suitable for your
application.
2. Installer must be a trained, experienced flame safe- ROD
guard technician.
3. After installation is complete, check out product opera-
tion as provided in these instructions.

MOUNTING
If the manufacturer of the burner has not provided a place for PILOT BURNER M818
mounting the flame rod holder, the installer should select a
suitable place on the burner faceplate or a place at the front of
the boiler. See Figs. 6, 7, 8, and 9 for typical mountings on Fig. 5. Positions of flame rod with horizontal type pilot
various burners. When selecting a location: burner.

1. Locate the unit so that the flame rod will only prove a
pilot flame that will safely and quickly light the main TOP
flame. VIEW
2. Locate the unit so that it will be clear of the fire door
opening radius.
3. Locate the unit so that drafts will not blow the pilot flame
away from the flame rod. BURNER
4. t is preferable to locate the unit so that the flame rod will
be vertical or at least angled downward. A rod so
installed is less likely to sag at high temperatures.
C7008A
NOTE: For extra electrode support, couple a length of 1/8 FLAME ROD
ASSEMBLY
inch iron pipe to the extension assembly, which is
already threaded (internal 1/8-27 NPT, C7007A
only).
PILOT M1838
5. The unit may also be installed so the flame rod is hori-
zontal or angled upward, but extra support is needed for Fig. 6. Suggested installation of flame rod used to prove
rods over 12 inches [305 mm] long. both main and pilot burners.
6. If the flame rod will be used to supervise a gas pilot for
an oil burner installation, the rod must be located far
enough from the oil flame to prevent oil spray from
C7007A
impinging and burning on the surface of the rod. HOLDER
7. A horizontal or inclined flame rod should enter the pilot WITH FLAME
ROD
flame from the side. If the rod is located above and par-
allel to a horizontal or semi-horizontal pilot burner, it
PILOT
may falsely indicate that a weak or candling pilot flame
is adequate for igniting the main burner. See Fig. 5.

BURNER

TOP
VIEW

M1837

Fig. 7. Suggested installation on tunnel burner.

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C7007A, C7008A, C7009A FLAME ROD HOLDER & FLAME ROD ASSEMBLIES

When the flame rod has been properly positioned, weld or

C7009A cement the pipe and/or flange permanently. Mount and screw
FLAME ROD
ASSEMBLY
BOSS PILOT the unit into the adapter pipe and tighten.
Connect the lead from the flame rod electrical connection to
the proper terminal on the flame safeguard control.
COOL
COMBUSTION
AREA NOTE: Even with high temperature stainless steel used in
FLAME ROD making grounding assemblies, the metal oxidizes
when it is exposed to temperatures exceeding 2000°
F [1093° C]. Where this deterioration cannot be
avoided, a scheduled replacement program should
be considered.
TOP
VIEW
FLAME GROUNDING
M1845
The installer must provide an adequate electrical ground for
the pilot flame. The grounding surface in actual contact with
the flame must be at least four times greater than the area of
Fig. 8. Flame rod installed in cool combustion area of the portion of the flame rod in contact with the flame. The ratio
industrial burner. of ground to flame contact area with a raw gas pilot is usually
less than a factor of four. In situations where the ground area
available is inadequate, the ground area must be increased.

There are three proven methods for providing an adequate

SIDE
VIEW grounding surface (area): a) the bomb fin assembly; b)
grounding rods threaded into the pilot nozzle; c) ground rods
welded to a collar.

BURNER The bomb fin assembly can be made by welding two sections
RING of high temperature stainless steel in the pattern illustrated in
Fig. 10-a. Then, this assembly is welded directly over the pilot
burner nozzle.

The threaded rod assembly is made by cutting a flame rod

PILOT into six or seven sections each about four inches in length.
The face of the pilot nozzle is to be tapped. The tappings
being located equidistant from each other around the
C7008A
FLAME ROD circumference of the nozzle (see Fig. 10-b). One end of the
ASSEMBLY M1836 four inch flame rod sections is threaded and screwed in place
as shown in Fig. 10-b.
Fig. 9. Suggested installation on ring type burner.
The welded rod assembly is made by cutting a flame rod into
After selecting the best location (if burner manufacturer has sections as described in the threaded rod assembly. The
not provided a mounting place on burner), cut a hole large flame rod sections are then welded to a high temperature
enough for the correct size pipe (See dimensions, Figs. 1-4) in stainless steel collar as illustrated in Fig. 10-c. The assembly
burner faceplate or in the front of the boiler. Be sure to cut the is then welded in place over the pilot nozzle.
hole at approximately the angle needed to bring flame rod into If the flame rod is used to prove only the main flame, the flame
proper position to prove the flame. contact area with the combustion chamber walls is generally
Tack weld or temporarily cement a pipe into hole cut in burner adequate for grounding. In some situations, it may be
faceplate or boiler wall. If a flange is used, place over hole and necessary to provide a grounding target. A stainless steel fin
weld the pipe to the flange. Do not mount permanently until or rod assembly similar to those illustrated in Fig. 10 should
checkout is complete. make an effective target.

Check out entire unit (see checkout section, page 6) to insure In all cases, make sure the grounding area is securely
that the flame rod is in proper position. Make this test under all connected to ground.
conditions of actual firing for the type of flame supervision that
will be used. In positioning the flame rod: WIRING
1. Avoid bending the flame rod.
2. Keep the flame rod as short as possible.
3. Keep the flame rod at least 1/2 inch [12.7 mm] away
from hot refractory material.
CAUTION
Disconnect power supply before making wiring
connections to prevent possible equipment
damage or electrical shock.

All wiring must conform to applicable codes.

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 C7007A, C7008A, C7009A FLAME ROD HOLDER & FLAME ROD ASSEMBLIES

Protect the leadwire from excessive radiant or reflected heat. The Honeywell BCS 7700 and 7800 SERIES controls provide
If any portion of the wire will be exposed to temperatures in for a voltage flame signal measurement. A 20,000 ohm/volt
excess of 125° F [51.6° C], a heat-resistant wire should be meter with a zero to 5 or 10 Vdc scale is recommended for the
used (see Accessories). For wiring where temperatures do BCS 7700 measurement and a one megohm/volt meter is
not exceed 125° F [52° C], wire with thermoplastic insulation suggested for the 7800 SERIES controls. The flame signal
may be used. If wire is enclosed in conduit, install a two foot measurement is made by inserting the positive (red) meter
flexible connection to the head of the unit. This permits easy probe into the control positive (+) jack and the negative (black)
removal of unit from combustion chamber. probe into the negative (-) jack of the BCS 7700 or the (-Com)
jack of the 7800 SERIES control (see Figs. 12, 13). With the
system in operation, the minimum acceptable flame signal
FLAME ROD REPLACEMENT voltage is 1.25 Vdc for the 7800 SERIES controls and 2.2 Vdc
To replace flame rod in the C7008A: remove the cover, pull off for the BCS 7700 control.
the Rajah connector with the wiring, remove (unscrew) the
terminal nut and the lock washer at the base of flame rod A low flame signal reading indicates the photocell is not
assembly to free the flame rod. Pull out the old flame rod and receiving sufficient visible flame radiation. Low flame currents
insert the new rod. Then replace the lock washer, screw on can be the result of an improperly positioned sight pipe,
the terminal nut, push the wiring connector back on, and restricted field of view, contaminated protective window or
replace the cover. focusing lens, or a defective photocell. Flame signals of 4 to 6
microamperes for existing controls and up to 5 Vdc for the
Procedure is the same for C7009A except that there is no BCS 7700 and 7800 SERIES controls can be expected on
cover. good applications/installations.

To replace flame rod in the C7007A: Remove the cover,

loosen the flame rod setscrew, pull the flame rod out, insert W136A VOLT- W136A SELECTOR 196146 METER
the replacement rod, and tighten the setscrew. Replace the OHMMETER SWITCH CONNECTOR
PLUG
cover.

A NOTE ON OIL BURNER USAGE PLUG

If the flame rod is used to prove a gas pilot on an oil FLAME SIGNAL
METER JACK
installation, oil or soot deposits must not be allowed to form on
flame rod insulator. Such deposits might form leakage
resistance paths, which in turn could cause nuisance
shutdowns of main burner.
PLUG-IN FLAME
SIGNAL AMPLIFIER
RED (+)
Flame rod and porcelain insulators should be periodically METER RED CONNECTOR
LEAD
examined for oil or soot deposits. Such deposits should be BLACK (-) METER LEAD BLACK CONNECTOR
M6532A

cleaned off before unit is put back in replace.

Fig. 10. Measuring microamp flame signal.

The performance of the C7007A Holder (with flame rod) and

C7008A, C7009A Flame Rod Assemblies can be determined PROGRAM
RESET
by measuring the flame signal (current/voltage) during pilot B
BUTTON
MODULE

burner operation.

Most existing Honeywell flame safeguard controls incorporate

a flame signal jack on the amplifier or the control itself. The
flame current measurement is made with a volt-ohm-meter
20,000
such as the Honeywell W136A Meter or a microammeter with V
VOLT-
a zero to 25 microampere scale. A meter connector plug (part O
OHM METER

no. 196146, provided with the W136A) is used to adapt the

W136A to the flame current jack on the flame safeguard
control. The W136A Meter probes are connected to the two
ends of the connector plug (red to red, black to black). The METER
FLAME
AMPLIFIER
plug end of the connector inserts directly into the flame current P
PROBES
BCS 7700 CHASSIS MODULE FOOT MOUNT
M7860

jack of the flame safeguard control (see Fig. 11). If the flame
safeguard control does not have a meter jack, or if a meter
connector plug is not available, a meter can be wired in series Fig. 11. Measuring BCS 7700 controls flame signal
with the "F" lead of the flame detector circuit. During the voltage.
burner run cycle, the minimum acceptable flame current is two
microamperes.

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C7007A, C7008A, C7009A FLAME ROD HOLDER & FLAME ROD ASSEMBLIES

POSITIVE (+)
METER LEAD
ONE MEGOHM/VOLT
NEGATIVE (-) METER
METER LEAD

M7382

Fig. 12. Measuring 7800 SERIES controls flame signal

voltage.

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C7007A, C7008A, C7009A FLAME ROD HOLDER & FLAME ROD ASSEMBLIES

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60-2024—06 M.S. Rev. 06-11
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