Honeywell R7140G Installation Instructions Manual Download Page 24

R7140G,L,M BURNER CONTROL MODULES

66-1153—2

24

1.

In Pre-Purge Drive To High Fire Position (R7140L), the 

Run/Test 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 sequence, the Run/Test 

Switch, when placed in the TEST position, causes the 

PREPURGE timing to stop. The firing rate motor is in 

the High Fire position.

3.

In Pre-Purge Drive to Low Fire position, the Run/Test 

Switch, when placed in the TEST position, holds the 

burner sequence in PREPURGE with the firing rate 

motor in the Low Fire position.

4.

In PFEP, the Run/Test Switch, when placed in the TEST 

position, stops the timer during the first 8 seconds when a 

10-second PFEP is selected or during the first 3 seconds 

when a 4-second PFEP is selected, allowing pilot-turn-

down test and other burner adjustments to be made. This 

activates a 15-second flameout timer that permits pilot 

flame adjustment without nuisance safety shutdowns. The 

Run/Test Switch is ignored during PFEP for the R7140L if 

terminals 5 and 7 or 7 and 6 are jumpered.

5.

During Run, the Run/Test Switch, when placed in the 

TEST position, drives the firing rate motor to the Low 

Fire position.

NOTE: When R7140 is switched to the Test mode, it stops and 

holds at the next Run/Test Switch point in the operating 

sequence. Make sure that the Run/Test Switch is in the 

RUN position before leaving the installation.

SETTINGS AND ADJUSTMENTS

Selectable Site-Configurable Jumpers

The R7140 has three site-configurable jumper options; see 

Fig. 19 and Table 7. If necessary, clip the site-configurable 

jumpers with side cutters and remove the resistors from the 

Relay Module.

The R7140M has two additional jumpers located on the back 

of the chassis. These must be cut if a spring return damper 

motor is used.

Fig. 19. Selectable site-configurable jumpers.

Table 7. Site Configurable Jumper Options.

a

Pilot Valve/First Stage Oil Valve (Valve/Start) terminal 6.

b

A 30 second MFEP can be accomplished by adding a jumper wire between terminals 15 and 8.

SERVICE NOTE

: Clipping and removing these site-configurable jumpers enhances the level of safety. Removal after 200 hours 

of main valve operation will result in a hard lockout, Code 110.

RUN/TEST SWITCH

NOTE:  CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.

SELECTABLE CONFIGURATION JUMPERS

M12301

Jumper Number

Description

Intact

Clipped

RM7800/RM7840 Type

JR1

Pilot Flame Establishing 

Period (PFEP)

10 seconds

4 seconds

All

JR2

Pilot Valve

a

/Main Flame 

Establishing Period (MFEP)

10 seconds

Intermittent

15 or 30 seconds Interrupted

b

R7140G

JR3

Start-up Interlock Check

Disabled

Enabled

All

Summary of Contents for R7140G

Page 1: ...ubleshooting FEATURES Device status available to ModBus through S7810M card or S7800A1001 Series 5 Keyboard Display Safety features Interlock check Closed loop logic test Dynamic AMPLI CHECK Dynamic input check Dynamic safety relay test Dynamic self check logic Expanded safe start check High Fire Purge Switch test R7140L only Internal hardware status monitoring Low Fire Start Switch test Tamper re...

Page 2: ...anel mounting Required Components Plug in Flame Signal Amplifier See Table 1 Plug in Purge Timer Cards See Table 2 SEQUENCE STATUS LEDs RESET PUSHBUTTON FLAME SIMULATOR INPUT FLAME CURRENT TEST JACKS RUN TEST SWITCH PLUG IN PURGE CARD DUST COVER RELAY MODULE FLAME AMPLIFIER M7552B Table 1 Flame Detection Systems Plug in Flame Signal Amplifiers Applicable Flame Detectors Type Color Self Checking Mo...

Page 3: ...004 Network Interface Unit with universal 100 to 250 Vac 50 60 Hz external power supply external modem required QS7800A1001 ControlBus Module standard QS7800B1000 ControlBus Module multidrop QS7850A1001 ControlBus Module General Purpose Interface ZM7850A1006 Combustion System Manager software S7810A1009 Data ControlBus Module if no KDM is used S7810B1007 Data ControlBus Module Multi Drop Switch Mo...

Page 4: ...L1 120 Vac 10 15 50 or 60 Hz 10 3 Lockout Running Interlock 120 Vac 8A run 43A inrush 4 Pre Ignition Interlock Input 120 Vac 1 mA 5 Pilot Valve Ignition 120 Vac See Table 4 6 Interrupted Intermittent Pilot Valve First Stage Oil Valve 120 Vac See Table 4 7 Main Fuel Valve 120 Vac See Table 4 8 Burner Motor 120 Vac 9 8 AFL 58 8 ALR inrush 9 Alarm 120 Vac 1A pilot duty 10 Firing Rate High Fire 120 Va...

Page 5: ... a control is installed on a burner WARNING Electrical Shock Hazard Can cause serious injury or death Disconnect the power supply before beginning installation More than one power supply disconnect may be required Table 4 Terminal Ratings Terminal Typical Load Maximum Rating at 120 Vac 60 Hz 5 or 6 Ignition Transformer Pilot Valve First Stage Fuel Valve 4 5A ignition and 50 VA pilot duty or 2 5A i...

Page 6: ... installed outdoors protect the relay module using an approved weathertight enclosure Mounting Wiring Subbase 1 Mount the subbase in any position except horizontally with the quadfurcated contacts pointing down The standard vertical position is recommended Any other position decreases the maximum ambient temperature rating 2 Select a location on a wall burner or electrical panel The Q520A can be m...

Page 7: ...ch may be connected to terminal D Identify remove and connect to terminal M Replacing GP101 devices Check wiring subbase If D is jumpered to 8 remove the jumper Replacing R4140 programmers on Carlin 1050 and 1150 burners Remove jumper from 6 to 7 Remove jumper from L2 to 12 and wire nut the wires together Note There will be no wire on terminal 12 R4140M replacements Check terminal 13 of the Q520 w...

Page 8: ...4 Operating sequence R7140G1000 R7140G2008 CHASSIS RETAINING SCREW SPRING CONNECTORS KNIFE BLADE CONTACTS 20 WIRING SUBBASE PIVOT PIN 2 HINGE BRACKET 2 PROGRAMMER CHASSIS M22605 R7140G POWER OPERATING CONTROLS AND INTERLOCKS BURNER FLAME SIGNAL FIRING RATE MOTOR INITIATE INITIAL POWERUP ONLY POWER STANDBY PREPURGE HOLD DRIVE TO LOW FIRE POWER PILOT FLAME MAIN POWER PFEP 10 SEC 4 SEC IF JR1 CLIPPED...

Page 9: ...TEST JACK REMOTE RESET DDL DDL COMMUNICATIONS INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS IGNITION PILOT PILOT V2 MAIN VALVE 1K 9K RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS LIMITS CONTROLLER RUNNING LOCKOUT INTERLOCK PRE IGNITION INTERLOCK 1K1 2K1 5K1 8K1 8K2 9K1 9K2 120 Vac 50 60 Hz FLAME SIGNAL TEST LOW FIRE SWITCH PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION ...

Page 10: ...ER CONTROL POWER TEST JACK INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS FIELD WIRING INTERNAL WIRING IGNITION PILOT PILOT V2 MAIN VALVE LIMITS CONTROLLER RUNNING LOCKOUT INTERLOCK PRE IGNITION INTERLOCK 1K1 2K1 5K1 8K1 8K2 9K1 9K2 120 Vac 50 60 Hz FLAME SIGNAL TEST LOW FIRE SWITCH PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED L1 HOT L2 L1 16 4 3 4K1 7K1 2K...

Page 11: ... 10 11 W R B W R B LIMITS PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE ALL NEC CLASS 1 WIRING START INTERLOCKS IF USED BECOME PREIGNITION INTERLOCKS MUST REMAIN CLOSED UNTIL IGNITION TRIALS BEGIN TERMINAL 6 HAS THE FOLLOWING OPTIONS AS RECEIVED INTERMITTENT PILOT JR2 CLIPPED 15 SECOND MAIN FLAME ESTABLISHING PERIOD JR2 CLIPPED AND JUMPER FROM 8 15 30 SECOND MAIN FLAME ESTABLISH...

Page 12: ...SPARK IGNITION OF OIL CONNECT IGNITION TO TERMINAL 5 AND MAIN OIL VALVE SOLENOID TO TERMINAL 7 JUMPER TERMINAL 7 T0 TERMINAL 6 SEE INSET SOLENOID MUST NOT EXCEED THE ELECTRICAL RATINGS OF TERMINAL 7 1 1 2 2 3 4 4 5 L2 FOR THE C7015A INFRARED LEAD SULFIDE FLAME DETECTOR EITHER LEADWIRE CAN BE CONNECTED TO THE F TERMINAL RUN THE C7015A LEADWIRES ALONE IN CONDUIT ALL THE WAY TO THE WIRING SUBBASE AND...

Page 13: ...OWER MFEP PILOT FLAME MAIN RUN POWER POSTPURGE POWER STANDBY 00 00 10 25 00 15 20 SWITCHING MOTOR ACTION BURNER BLOWER MOTOR IGN LIMITS AND BURNER CONTROLLER CLOSED LOCKOUT INTERLOCKS CLOSED PII CLOSED LOW FIRE SW SAFE START CHECK FLAME PROVING 10 SEC IGN PILOT 5 18 8 5 SEC 16 TO 16 TO 16 TO 8 13 TO 10 11 TO 10 11 TO M23322 HIGH FIRE SW 15 TO 10 14 TO 10 14 TO 8 4 3 L1 MAIN VALVE 7 TIMED PREPURGE ...

Page 14: ... REMOTE RESET DDL DDL COMMUNICATIONS INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS FIELD WIRING INTERNAL WIRING IGNITION PILOT PILOT V2 MAIN VALVE 1K 9K RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS 1K1 2K1 5K1 8K1 8K2 9K1 9K2 120 Vac 50 60 Hz FLAME SIGNAL TEST LOW FIRE SWITCH PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED RS485 1 2 3 L1 HOT L2 L1 4K1 7K1 2K...

Page 15: ...NTROL POWER TEST JACK REMOTE RESET DDL DDL COMMUNICATIONS INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS FIELD WIRING INTERNAL WIRING IGNITION PILOT PILOT V2 MAIN VALVE 1K 9K RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS LIMITS CONTROLLER RUNNING LOCKOUT INTERLOCK PRE IGNITION INTERLOCK 1K1 2K1 5K1 8K1 8K2 9K1 9K2 120 Vac 50 60 Hz FLAME SIGNAL TEST LOW FIRE SWITCH PROVIDE ...

Page 16: ...RING FOR DIRECT SPARK IGNITION OIL OR GAS CONNECT THE IGNITION TRANSFORMER AND MAIN FUEL VALVE S AS SHOWN IN INSET FOR THE C7015A INFRARED LEAD SULFIDE FLAME DETECTOR EITHER LEADWIRE CAN BE CONNECTED TO THE F TERMINAL RUN THE C7015A LEADWIRES ALONE IN CONDUIT ALL THE WAY TO THE WIRING SUBBASE AND GROUND THE CONDUIT AT THE SUBBASE REFER TO PUBLICATION 60 2306 FOR DETAILED INSTRUCTIONS 1 1 2 2 3 4 5...

Page 17: ...IRFLOW SWITCH PREIGNITION INTERLOCKS BURNER CONTROLLER 120V ALARM MASTER SWITCH 120V 60 HZ POWER SUPPLY L1 HOT L2 TO MAIN FUEL VALVE S L2 5 6 7 FOR DIRECT SPARK IGNITION OIL OR GAS 5 6 7 8 G L1 L2 12 13 F 3 4 9 10 11 W R B W R B 5 SECOND IGNITION EARLY SPARK TERMINATION LIMITS PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE ALL NEC CLASS 1 WIRING IN SOME INSTALLATIONS THE LOW FIRE...

Page 18: ...BURNER BLOWER MOTOR IGN INTERMITTENT PILOT VALVE LIMITS AND BURNER CONTROLLER CLOSED RUNNING INTERLOCKS CLOSED PII CLOSED LOW FIRE SW SAFE START CHECK FLAME PROVING 10 SEC IGN PILOT 5 18 8 5 SEC 6 4 TO 3 TO 16 TO 8 13 TO 10 L2 TO 10 L2 TO M23331 4 16 L1 MAIN VALVE 7 TIMED PREPURGE POWER FLAME MAIN PILOT ALARM POWER FLAME MAIN PILOT ALARM ALARM ALARM ALARM 00 SSC LED DISPLAY R7140M SWITCHING 1 1 WH...

Page 19: ...GN XFMR INTERMITTENT PILOT 1R1 3K1 6K1 9 8 6 MAIN VALVE 7 LF 13 F G 17 L1 L1 L2 L2 15 SECOND INTERMITTENT PILOT VALVE 18 5 5K1 4K1 2K1 7K1 2K2 1K1 3 AIRFLOW 4 16 LIMITS CONTROLLER 1R1 10 11 START INTERLOCKS 12 J1 8K2 9K1 14 J2 9K2 INTERNAL ELECTRONICS M23336 CONFIGURATION JUMPERS PURGE TIMER FLAME AMPLIFIER ALARM BLOWER IGN XFMR INTERMITTENT PILOT 1R1 3K1 6K1 9 8 6 MAIN VALVE 7 LF 13 F G 17 L1 L1 ...

Page 20: ...E DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE ALL NEC CLASS 1 WIRING START INTERLOCKS IF USED BECOME PRE IGNITION INTERLOCKS MUST REMAIN CLOSED UNTIL IGNITION TRIALS BEGIN PM720M 16 TO 4 IS A PRE IGNITION INTERLOCK USE 2 POSITION SPRING RETURN MOTOR WHITE LEADWIRES ON C7012 U V FLAME DETECTORS REPLACE C7012 WITH C7061 UV DETECTOR AND R7861A1026 AMPLIFIER MAKE SURE CONNECTOR IS ON TERM...

Page 21: ...MINAL STRIP 4 LIMITS POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE ALL NEC CLASS 1 WIRING WHEN USING A 2 POSITION SPRING DAMPER MOTOR CLIP AND REMOVE J1 AND J2 LOCATED ON R7140 SUBBASE FOR DIRECT SPARK IGNITION OIL OR GAS CONNECT THE IGNITION AND MAIN FUEL VALVE S AS SHOWN IN THE INSET FOR THE C7015A INFRARED LEAD SULFIDE FLAME DETECTOR EITHER LEADWIRE MAY BE CONNEC...

Page 22: ...MAIN FLAME ESTABLISHING Period MFEP a Low Fire Switch Opens b Lockout Interlock opens R7140L c Ignition pilot valve intermittent pilot valve terminal is not energized d Main valve terminal is not energized e No flame is present at the end of MFEP f Internal system fault occurs g Purge card is removed h Purge card is bad 6 RUN Period a No flame is present b Lockout Interlock opens R7140L c Interrup...

Page 23: ...ed throughout the Ignition Trial state b Flame must be proven by the end of the 10 second PFEP four if JR1 is clipped to allow the sequence to continue If flame is not proven by the end of PFEP a safety shutdown occurs c After five seconds the ignition terminal 18 is de energized for early spark termination 2 Main Flame Establishing Period MFEP a Terminal 7 is energized when the presence of flame ...

Page 24: ...R7140 is switched to the Test mode it stops and holds at the next Run Test Switch point in the operating sequence Make sure that the Run Test Switch is in the RUN position before leaving the installation SETTINGS AND ADJUSTMENTS Selectable Site Configurable Jumpers The R7140 has three site configurable jumper options see Fig 19 and Table 7 If necessary clip the site configurable jumpers with side ...

Page 25: ... of the operating controller to simulate a call for heat 5 For each test open the master switch and install the jumper wire s between the subbase wiring terminals listed in the Test Jumpers column 6 Close the master switch before observing operation 7 Read the voltage between the subbase wiring terminals listed in the Voltmeter column 8 If there is no voltage or the operation is abnormal check the...

Page 26: ...g rate motor and transformer 12 R7140G L L1 8 and 10 11 15 L2 Firing rate motor drives open line voltage at terminal 15 after motor is in High Fire position 1 High Fire Purge Switch 2 Firing rate motor and transformer 13 R7140L L1 8 and 14 11 15 L2 Firing rate motor drives closed zero volts at terminal 15 after motor starts driving closed 1 Low Fire Start Switch 2 Firing rate motor and transformer...

Page 27: ... required Checkout tests after all adjustments are made All tests must be satisfied with the flame detector s in their final position Equipment Recommended S7800A Keyboard Display Module Volt ohmmeter 1M ohm volt minimum sensitivity with 0 300 Vac capability 0 6000 ohm capability 0 10 Vdc capability Checkout Summary Table 9 provides an overview of checkout steps performed for each applicable syste...

Page 28: ...nergize both the ignition transformer and the pilot valve i If the pilot does not ignite and if the ignition spark is still continuous adjust the pressure regulator until a pilot is established j When the pilot ignites properly and stays ignited open the master switch and remove the jumper s from the terminals of the subbase k Check for adequate bleeding of the fuel line l Reinstall the R7140 Rela...

Page 29: ...s used go to step 18 16 Shut down the system by opening the burner switch or by lowering the setpoint of the operating controller Make sure the burner flame goes out and all automatic fuel valves close 17 If used remove the bypass jumpers from the low fuel pressure limit and subbase 18 If a second stage is used make sure the automatic second stage fuel valve s opened Check the lightoff as follows ...

Page 30: ... or pressure gauge and turn up the pilot gas flow to that recom mended by the equipment manufacturer 16 If used remove the bypass jumpers from the subbase terminals limits controls or switches 17 Run the system through another cycle to check for normal operation 18 Return the system to normal operation IGNITION INTERFERENCE TEST ALL FLAME RODS Ignition interference can subtract from decrease or ad...

Page 31: ...NITION SPARK RESPONSE TEST ALL ULTRAVIOLET DETECTORS Test to make certain that the ignition spark is not actuating the FLAME LED 1 Close the pilot and main burner manual fuel shut off valve s 2 Start the burner and use the Run Test Switch if available to stop the sequence in the PILOT IGN period Ignition spark should occur but the flame signal should not be more than 0 5 Vdc 3 If the flame signal ...

Page 32: ...lve 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 at least 1 25 Vdc but the main burner cannot light e The flame signal should drop below 1 25 Vdc within the FFRT of the amplifier and the relay module after the interrupted pilot goes out f Safety shutdown occurs 6 Loss of flame during RUN a...

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