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Honeywell R7140G manual

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Table of contents for the manual

  • Page 1

    INSTALLATION INSTRUCTIONS 66-1153-03 R7140G,L,M Burner Contr ol Modules APPLICATION The Honeywell R7140G,L,M Bur ner Control Modules are microprocessor-based integrat ed burner controls fo r automatically fired gas , oil or combination fuel single burner applications. The Bur ner Control Module system consists of a Relay Module , Q520A Subbase, Amp[...]

  • Page 2

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 2 Fig. 1. Burner Contr ol Module and sequ ence status LE Ds. SPECIFICATIONS Electrical Ratings (See T able 1): V oltage and F reque ncy: 120 V ac (+10%/-15%), 50 or 60 Hz (±10%). P ower Dissipation in the Run Mode: 10W maximum. Maximum T otal Connected Load: 2000V A. Fusing—T otal Connected Load: [...]

  • Page 3

    R7140G,L,M BUR NER CONTROL MODULES 3 66-1153—03 T able 1. Flame Detection Systems. a Flame F ailure Response Time (FFR T) depends on selection of amplifier and 7800 SERIES and R7140 Relay Module. b R7824C is used only with the 24 Vdc RM7824 Relay Module and C7024E,F Flame Detectors. c Circuitr y tests all electronic co mponents in flame detection[...]

  • Page 4

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 4 Abov e times cov er the Purg e timings of the R4140/50 Pro- grammers and PM720. Other timings exist—consult the T radeline catalog f or com- plete list of ST7800 Purge timers. Accessories: The follo wing accessori es enhance the R7140 Bur ner Control Module and are availab le through local 7 800 [...]

  • Page 5

    R7140G,L,M BUR NER CONTROL MODULES 5 66-1153—03 a The R7140 m ust ha v e an ear th ground pro viding a con nection between the subbase and t he control panel or the equip ment. The eart h ground wi re must b e capab le of conduc ting the c urrent to b lo w the 15A f ast blow fuse (or break er) in t he e v ent of an internal s hort circuit. The R7[...]

  • Page 6

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 6 a 30 seconds with JR2 clipped and ju mper from terminal 8 to terminal 15. * ST ANDBY an d R UN can be an inf inite time period. ** PURGE will be determined by whic h ST7800A purge card is selected; 15 timings are a v ailab le from 2 seconds to 30 min utes. NO TE: All owab le inrush can be up to ten[...]

  • Page 7

    R7140G,L,M BUR NER CONTROL MODULES 7 66-1153—03 Location Humidity Install the relay module where the relative humidity ne ver reaches the saturation point. The relay module is designed to operate in a maximum 85 percent relativ e humidity continuous, noncondensing moisture environment. Condensing moisture may cause a saf e ty shutdown. Vibration [...]

  • Page 8

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 8 * Check terminal 8 and 15. If jumpered, ST7800A1031 (7 second purge). If not jumpered, ST7800A 1039 (30 second purge). Mounting R7140 Rela y Module Installing the Pr og rammer (Fig. 3) WARNING Electrical Shock Hazar d. Can cause severe injury , dea th or pr operty damage . Disconnect power bef ore [...]

  • Page 9

    R7140G,L,M BUR NER CONTROL MODULES 9 66-1153—03 Fig. 4. Operating sequ ence , R7140G1000/R7140G2008. R7140G POWER OPERA TING CONTROLS AND INTERLOCKS BURNER FLAME SIGNAL FIRING RA TE MOTOR INITIA TE (INITIAL POWERUP ONL Y) POWER ST ANDBY PREPURGE HOLD DRIVE TO LOW FIRE POWER PILOT FLAME MAIN POWER PFEP 10 SEC. (4 SEC. IF JR1 CLIPPED PILOT FLAME MA[...]

  • Page 10

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 10 Fig. 5. Internal bloc k diag ram of the R7140G1000. (See Fig. 8 for detailed wiring.) CONFIGURA TION JUMPERS MICROCOMPUTER RESET PUSHBUTTON RUN/TEST SWITCH ST A TUS LEDs PLUG-IN PURGE TIMER CARD SAFETY RELA Y CIRCUIT POWER SUPPL Y KEYBOARD DISPLA Y MODULE HIGH FIRE COMMON MODULA TE LOW FIRE PLUG-I[...]

  • Page 11

    R7140G,L,M BUR NER CONTROL MODULES 11 66-1153—03 Fig. 6. Internal bloc k diagram of the R7 140G2008. (See Fig. 7 for detailed wiring.) CONFIGURA TION JUMPERS MICROCOMPUTER RUN/TEST SWITCH PLUG-IN PURGE TIMER CARD POWER SUPPL Y HIGH FIRE COMMON MODULA TE LOW FIRE PLUG-IN FLAME AMPLIFIER CONTROL POWER TEST JACK INDICA TES FEEDBACK SENSING OF RELA Y[...]

  • Page 12

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 12 Fig. 7. Wiri ng diagram f or R7140G20 08 for application replacing R4140G with star t Interlock or BC7000L1000 with PM720G. RECTIFYING FLAME ROD, OR INFRARED (LEAD SULFIDE) FLAME DETECTOR C7027A, C7035A, OR C7044A UL TRA VIOLET FLAME DETECTOR C7012A, C, C7061, OR C7076A UL TRA VIOLET FLAME DETECTO[...]

  • Page 13

    R7140G,L,M BUR NER CONTROL MODULES 13 66-1153—03 Fig. 8. Field wiring for R7140G100 0 used for replacing R4140G Progra mmers with pre-ignition interlocks. RECTIFYING FLAME ROD, OR INFRARED (LEAD SULFIDE) FLAME DETECTOR C7027A, C7035A, C7927 OR C7044A UL TRA VIOLET FLAME DETECTOR C7067A,D OR C7061 UL TRAVIOLET FLAME DETECTOR LOW FIRE SWITCH BURNER[...]

  • Page 14

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 14 Fig. 9. Operating sequen ce , R7140L1009 and R7140L2007. R7140L POWER 00 OPERA TING CONTROLS AND INTERLOCKS BURNER FLAME SIGNAL FIRING RA TE MOTOR INITIA TE (INITIAL POWERUP ONL Y) POWER ST ANDBY POWER PREPURGE HOLD DRIVE TO HIGH FIRE PREPURGE HOLD DRIVE TO LOW FIRE POWER PILOT FLAME MAIN POWER PF[...]

  • Page 15

    R7140G,L,M BUR NER CONTROL MODULES 15 66-1153—03 Fig. 10. Internal bloc k diagram of the R7140L1009. (See Fig. 12 for detailed wiring.) CONFIGURA TION JUMPERS MICROCOMPUTER RESET PUSHBUTTON RUN/TEST SWITCH ST A TUS LEDs PLUG-IN PURGE TIMER CARD SAFETY RELA Y CIRCUIT POWER SUPPL Y KEYBOARD DISPLA Y MODULE HIGH FIRE COMMON MODULA TE LOW FIRE HIGH F[...]

  • Page 16

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 16 Fig. 11. Internal b loc k diagram o f the R7140L2007. ( See Fig. 13 f or detailed wiring.) CONFIGURA TION JUMPERS MICROCOMPUTER RESET PUSHBUTTON RUN/TEST SWITCH ST A TUS LEDs PLUG-IN PURGE TIMER CARD SAFETY RELA Y CIRCUIT POWER SUPPL Y KEYBOARD DISPLA Y MODULE HIGH FIRE COMMON MODULA TE LOW FIRE H[...]

  • Page 17

    R7140G,L,M BUR NER CONTROL MODULES 17 66-1153—03 Fig. 12. Sample block diagram of fiel d wiring for the R7140L1009, used for replacing R41 40L Programmers with pre-ignition interlocks. RECTIFYING FLAME ROD,OR INFRARED (LEAD SULFIDE) FLAME DETECTOR C7027A, C7035A, OR C7044A UL TRA VIOLET FLAME DETECTOR C7061, C7927 OR C7076A, D UL TRA VIOLET FLAME[...]

  • Page 18

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 18 Fig. 13. Bloc k dia gram of field wiring for the R7140L2007, used f or replacing BC7000L1000 with PM720L. RECTIFYING FLAME ROD, RECTIFYING PHOTOCELL, OR INFRARED (LEAD SULFIDE) FLAME DETECTOR C7027A, C7035A, OR C7044A UL TRA VIOLET FLAME DETECTOR C7012A, C, C7076A, OR C7061 UL TRA VIOLET FLAME DET[...]

  • Page 19

    R7140G,L,M BUR NER CONTROL MODULES 19 66-1153—03 Fig. 14. Operating sequence, R 7140M. R7140M POWER OPERA TING CONTROLS AND INTERLOCKS BURNER FLAME SIGNAL DAMPER MOTO R INITIA TE (INITIAL POWER UP ONL Y) POWER ST ANDBY PREPURGE HOLD DRIVE TO LOW FIRE POWER PILOT FLAME MAIN POWER PFEP 10 SEC. (4 SEC. IF JR1 CLIPPED PILOT FLAME MAIN POWER MFEP PILO[...]

  • Page 20

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 20 Fig. 15. Internal bloc k diagram of the R7140M1007 wi th start interlocks. (See Fig. 17 fo r detailed wiring.) Fig. 16. Internal block dia gram of the R7140M1007 with pre-ignition interloc ks. (See Fig. 18 f or detailed wiring.) INTERNAL ELECTRONICS M23335 CONFIGURA TION JUMPERS PURGE TIMER FLAME [...]

  • Page 21

    R7140G,L,M BUR NER CONTROL MODULES 21 66-1153—03 Fig. 17. R7140M1007 used on applic at ions replacing R4140M Prog rammers with Start Interlocks or BC7000 with PM720M. RECTIFYING FLAME ROD, RECTIFYING PHOTOCELL, OR INFRARED (LEAD SULFIDE) FLAME DETECTOR C7027A, C7035A, OR C7044A UL TRA VIOLET FLAME DETECTOR C7012A, C, E, OR F UL TRA VIOLET FLAME D[...]

  • Page 22

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 22 Fig. 18. Block diagram of field wiring for the R7140M1007, used for replacing R4140M Pr ogrammers with Pre-Ignition Interlocks. RECTIFYING FLAME ROD OR INFRARED (LEAD SULFIDE) FLAME DETECTOR C7027A, C7035A, OR C7044A UL TRA VIOLET FLAME DETECTOR C7061, C7012A, C, UL TRA VIOLET FLAME DETECTOR LOW F[...]

  • Page 23

    R7140G,L,M BUR NER CONTROL MODULES 23 66-1153—03 SAFETY SHUTDO WN Safety Shutdo wn (Loc k out) occur s if any of the f ollowing occur during the indicated period: 1. INITIA TE P eriod: a. Purge card is not installed or is remov ed. b . Purge card is bad . c. Configur ation jumpers are changed (after 200 hours of operation). d. A C l ine power err[...]

  • Page 24

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 24 Normal Star t-Up Pre-Purge The R7140 provides a pre-purge timing selectable from two seconds to 30 minutes with pow er applied and the R7140 operating control indicating a call for heat: a. Running Interlocks, Pre-Ig nition Interlocks , Burner Switch, Run/T est Switch, Lock out Interlocks and all [...]

  • Page 25

    R7140G,L,M BUR NER CONTROL MODULES 25 66-1153—03 1. In Pre-Purge Drive T o High Fire P osition (R7140L), th e Run/T est Switch, when placed in the TEST position, holds in PREPURGE with the firing rate motor in the High Fire position. 2. In the measured PREPURGE seq uence, the Run/T est Switch, when placed in the TEST position, causes the PREPURGE[...]

  • Page 26

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 26 STATIC CHEC K OUT After checking all wiring, perform this checkout bef ore installing the R7140 on the subbase. These tests verify the Q520A Wir ing Subbase is wired correctly , and the external controllers, limits, interlocks , actuators, va lves , transf ormers, motors and other devices are oper[...]

  • Page 27

    R7140G,L,M BUR NER CONTROL MODULES 27 66-1153—03 6 All L1-5 — 1. Ignition spar k (if ignition transf ormer is connected to terminal 5). 2. A utomatic pilot valv e ope ns (if connected to terminal 5). NO TE: Refer to wiring dia- gram of system being tested. 1. W atch f or spark or listen for b uzz. a. Ignition electrodes are clean. b . Ignition [...]

  • Page 28

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 28 SYSTEM CHEC K OUT IMPORT ANT P erform all Static Checkout Procedures f or the applicable rela y module shown in T able 8 bef ore star ting these procedures. WARNING Explosion Hazar d. Can cause serious injur y or death. Do not allow fuel to accu mulate in the combustion chamber for longer than a f[...]

  • Page 29

    R7140G,L,M BUR NER CONTROL MODULES 29 66-1153—03 7. P ower is connected to the system disconnect switch (master s witch). 8. Lock out is reset (reset button) only if the Rela y Modul e is powered. 9. Run/T est Switch (if present) is in RUN position. 10. System is in ST ANDBY condition. ST ANDBY message is display e d in the S7800 K eyboard Displa[...]

  • Page 30

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 30 20. Run the burner through another se quence, observing the flame signa l f or: a. Pilot flame alone. b . Pilot and main flame together . c. Main flame alone (unless monitorin g an intermittent pilot). Also obser ve the time it takes to light the main flame . Ignit ion of main flam e shoul d be sm[...]

  • Page 31

    R7140G,L,M BUR NER CONTROL MODULES 31 66-1153—03 6. After the PILO T LED turns on in inte rrupted pilot applications, set the Run/T est Switch to the TEST position to stop the sequence. The FLAME LED comes on when the pilot ignites. NO TE: If the sequence does not stop, re set the system and make sure y ou set the Run/T est Switch to TEST within [...]

  • Page 32

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 32 If hot refractor y saturation occurs, the condition must be corrected. Add an or if ice plate in fr ont of the cell to restrict the viewing area, lengthen the sight pipe or decrease the pipe size (diameter). Continue adjustments until hot refractor y saturation is eliminated. Hot Refractory Hold-i[...]

  • Page 33

    R7140G,L,M BUR NER CONTROL MODULES 33 66-1153—03 8. If the response time is still too slow , replace the Plug-in Flame Signal A mplif ier . 9. If the detector is relocated or resighted, or the amplif ier is replaced, repeat all required Check out tests. SAFETY SHUTDO WN T ESTS (ALL INSTALLATIONS) P erform these tests at the end of Check out, af t[...]

  • Page 34

    R7140G,L,M BUR NER CONTROL MODULES 66-1153—0 3 34[...]

  • Page 35

    R7140G,L,M BUR NER CONTROL MODULES 35 66-1153—03[...]

  • Page 36

    R7140G,L,M BUR NER CONTROL MODULES Automation and Co ntrol Solutions Honeywell Internationa l Inc. 1985 Douglas Drive North Golden Valley, MN 55422 customer.honeywell.com ® U .S. R egistered T rademark © 2013 Hone ywell International Inc. 66-1153—03 M.S. R ev . 01-13 Printe d in United States[...]