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Honeywell SV2 Series User Manual Download Page 201

SV2 Series Safety Shut-off Valves

 

201

V2F, V2V

SV2 SERIES SAFETY SHUT-OFF VALVES USER MANUAL

Fault 

Category

Fault 

Description

Detailed Description

Remediation Steps

Comments Fault 

#

POC

POC 1 (proof 
of closure) 
incorrect 
position 
detected

POC 1 switch output does 
not match valve seat 1 
powered/not powered status.

Could be due to swapped 
internal SOLENOID 1/
SOLENOID 2 connections 
or swapped internal POC 
1/POC 2 connections. Can 
occur if valve electronics 
orientation is swapped 
in field or electronics is 
replaced in field.

May also be due to failures 
of POC switch, solenoid or 
electronics.

Remove power and shut-off gas supply as 
necessary.

1.) Remove valve front electrical and rear 
solenoid enclosures.

2.) Inspect internal wiring between 
solenoids and valve electronics. The 
solenoid number is indicated by the 
direction of flow arrow and number (1) in 
the valve casting. Ensure the appropriate 
solenoid connector is placed in the 
appropriate terminal (SOLENOID 1) on 
the valve electronics assembly.

3.) Inspect internal wiring between 
solenoid proof of closure switch(es) and 
valve electronics. The solenoid number 
is indicated by the direction of flow arrow 
and number (1) in the valve casting. 
Ensure the appropriate solenoid proof 
of closure connector is placed in the 
appropriate terminal (POC 1) on the valve 
electronics assembly.

4.) Replace cover and restore power and 
gas. Reset valve and burner management 
system, monitoring for proper POC 
operation in conjunction with valve LEDs 
and burner management system inputs.

5.) If fault persists, replace valve main 
electronics.

6.) If fault persists, replace entire valve.

80

Summary of Contents for SV2 Series

Page 1: ...reOperation 60 Valve Proving Sequence VPS Operation 62 Field Replacement 64 Flanges 65 Specifications 65 Introduction and Flange Selection 66 Mounting Valve to Flange s and Piping 66 Replacement Electronics 67 Specifications 67 IntroductionandReplacementAssemblySelection 67 Field Replacement 68 Replacement Solenoids 69 Specifications 69 IntroductionandReplacementSolenoidSelection 69 Field Replacem...

Page 2: ... THIS PRODUCT 1 Read these instructions and the appropriate product literature carefully Failure to follow them could damage the product or cause a hazardous condition 2 Installer must be a trained experienced combustion service technician 3 Check the ratings given in the instructions and on the product to make sure the product is suitable for your application Do not exceed the valve ratings 4 Dis...

Page 3: ... communication used is an open protocol the SV2 Series valves may be wired to a building automation system master directly or through a secondary port on the HMI Tool The building automation system master control must be programmed to recognize the various SV2 Series valve Modbus registers however Refer to the MODBUS COMMUNICATION section of this manual for the Modbus addressing and the HMI Tool i...

Page 4: ...lve Connectors Customers may purchase the Honeywell SV2 Series valve with or without required electrical connectors included continent dependent If purchased with electrical connectors they may be found in a bag assembly housed in the box that contains the literature and spare screws for mounting the Pressure Module or C6097 pressure switch If the valve is not purchased with the required electrica...

Page 5: ...b 8 5 kg Fuel Air 20 0 lb 9 1 kg 1 5 and 2 in DN40 50 valves On Off 46 1 lb 20 9 kg Fuel Air 50 2 lb 22 8 kg Dimensions See Figs 2 6 Approvals cULus Underwriters Laboratories Electrically operated valves Vol 11 valve body Vol 12 control boards 24VAC 100 120 VAC valves File MH1639 UL429 UL353 and UL1998 NEMA 1 IP20 valves Recognized NEMA 4 IP66 valves Listed FM7400 Approved 100 120VAC 24VAC PENDING...

Page 6: ...r interface or the secure Modbus layer USER ACCESS LEVELS A 3 level user access level framework has been implemented into the SV2 Series valves consisting of the User Installer and OEM levels OEM Read write rights with the ability to assign read write parameter groups for the OEM and Installer levels OEM is defined at the original provider programmer of the valve Installer Read write rights as ass...

Page 7: ...LE SV20 6 STANDARD EXTERNAL VPS SV200 FUEL AIR CONTROL MODULE RANGE7 AMPLIFICATION FACTOR N NOT APPLICABLE 4 0 25 0 8 PRESSURE REGULATING VALVE RANGE N NOT APPLICABLE V2F 2 B N 0000 NOTES 1 V2F MAX INLET PRESSURE 10 0PSI 0 7 KG CM2 689MBAR V2V MAX INLET PRESSURE 1 45 PSI 0 1 KG CM2 100MBAR 2 ALL VOLTAGES ARE 15 10 VAC ALL VOLTAGES CLASS A RATED EN161 3 PORT THREAD INCLUDES PRESSURE TAPS AND NOVV P...

Page 8: ...ESSMOD12 000 For NEMA 1 IP20 enclosure pressure range 2 6 160 mBar 1 1 64 in wc 0 038 2 3psi PRESSMOD13 000 For NEMA 1 IP20 enclosure pressure range 8 4 600 mBar 3 4 241 in wc 0 12 8 7 psi PRESSMOD14 000 For NEMA 1 IP20 enclosure range range 16 8 1000 mBar 6 7 401 in wc 0 25 14 5 psi PRESSMOD41 000 For NEMA 4 IP66 enclosure pressure range 1 3 40 mBar 0 51 16 in wc 0 018 0 58 psi PRESSMOD42 000 For...

Page 9: ...ic feedback tubing fittings kit 90 degree Contains 300 swivel push in fittings V2MUFITPLTEE 000B Plastic feedback tubing fittings kit tee Contains 100 push in fittings V2MUTUBEAL 000B Metal feedback tubing kit Contains 200 aluminum tubes 7mm ID 8mm OD 1000mm long V2MUFITMESTR 000B Metal feedback tubing fittings kit straight Contains 300 compression fittings V2MUFITME90D 000B Metal feedback tubing ...

Page 10: ...n Closed Self Test Fault LGP HGP Open Closed Reset 1 2 10 11 32 263 14 15 64 362 10 43 64 271 3 9 16 91 3 5 8 92 7 15 64 184 9 37 64 243 2 29 64 62 5 3 4 146 4 5 16 109 2X 1 31 32 50 2 11 64 55 M35706C ON OFF VALVE WITH NEMA 4 IP66 ENCLOSURE Fig 2 1 in DN25 On off valve with NEMA 4 IP66 enclosure M35697C 1 2 Open Closed Self Test Fault LGP HGP Open Closed Reset 8 9 16 217 13 15 64 336 5 5 32 131 8...

Page 11: ...33 8 3 8 212 Open Closed Self Test Fault LGP HGP Open Closed Reset Fig 4 1 5 2 0 in DN40 50 On off valve with NEMA 4 IP66 enclosure 10 3 64 255 7 47 64 197 8X M8 SCREWS 8 9 16 218 4 11 16 119 5 17 64 133 5 31 32 152 2X 3 35 64 90 9 5 64 231 10 15 32 266 3 7 64 79 2X 2 7 16 62 13 7 16 341 2 1 C 9 51 64 249 15 11 16 398 5 20 32 150 M37080 Open Closed Self Test Fault LGP HGP Open Closed Reset Fig 5 1...

Page 12: ...TY RATINGS The SV2 Series valve ratings shown below are for both 4 in w c and 1 in w c Table 2 Valve Capacity Rating Valve Capacity Designation Internal Port Size 4 in w c pressure drop1 2 10 mbar 1 in w c pressure drop1 2 2 5 mbar kW MMBTU hr SCFH ft3 hr M3 hr kW MMBTU hr SCFH ft3 hr M3 hr B 1 0 in DN25 300 1 0 1 000 28 150 0 5 500 14 C 1 5 in DN40 750 2 6 2 600 74 380 1 3 1300 37 D 2 0 in DN50 1...

Page 13: ...1 sp gr relative density 1 550 1 67 1 Per EN437 MCR37082 1 2 INCH DN15 FLANGE 3 4 INCH DN20 FLANGE 1 INCH DN25 FLANGE 1 1 4 INCH DN32 FLANGE 2 832 28 32 283 2 0 1 1 0 10 0 100 0 100 1 000 10 000 1 0 IN DN25 ON OFF VALVE CAPACITY CURVES 300 0 747 249 24 9 2 49 0 249 PRESSURE DROP MBAR INCHES W C NATURAL GAS FLOW CFH CUBIC FEET PER HOUR M3 HR METERS CUBED PER HOUR 1 PRESSURE DROP FORMULAS PER FLANGE...

Page 14: ...ND UNIT TYPES A CFH AND IN W C 1 IN DN25 0 000000838 X FLOW2 1 1 4 IN DN32 0 000000592 X FLOW2 1 1 2 IN DN40 0 000000578 X FLOW2 2 IN DN50 0 000000539 X FLOW2 B M3 HR AND MBAR 1 IN DN25 0 002601 X FLOW2 1 1 4 IN DN32 0 001838 X FLOW2 1 1 2 IN DN40 0 0001795 X FLOW2 2 IN DN50 0 0001673 X FLOW2 23 000 PRESSURE DROP MBAR INCHES W C 300 1 INCH DN25 FLANGE 1 1 4 INCH DN32 FLANGE 1 1 2 INCH DN40 FLANGE ...

Page 15: ...2 INCH DN40 FLANGE 2 INCH DN50 FLANGE NATURAL GAS FLOW CFH CUBIC FEET PER HOUR M3 HR METERS CUBED PER HOUR 1 PRESSURE DROP FORMULAS PER FLANGE SIZE AND UNIT TYPES A CFH AND IN W C 1 IN DN25 0 000000522 X FLOW2 1 1 4 IN DN32 0 000000290 X FLOW2 1 1 2 IN DN40 0 000000240 X FLOW2 2 IN DN50 0 000000193 X FLOW2 B M3 HR AND MBAR 1 IN DN25 0 001620 X FLOW2 1 1 4 IN DN32 0 000900 X FLOW2 1 1 2 IN DN40 0 0...

Page 16: ...RIED WITH SMALLER FLANGES CAPACITY CURVE REPRESENTS A VALVE TYPICAL GUARATEED MAXIMUM AND MINIMUM FLOW WHEN THE FUEL CONTROL VALVE IS FULLY OPEN AND FULLY CLOSED THE CAPACITY COVERS A 95 POPULATION CONFIDENCE NATURAL GAS FLOW M3 HR METERS CUBED PER HOUR CFH CUBIC FEET PER HOUR INCHES W C MBAR 401 6 0 4016 4 016 40 16 35 3 353 3 531 35 315 M37241A VALVE OPERATING RANGE 1 2 PRESSURE DROP Fig 10 1 0 ...

Page 17: ...E DROP NATURAL GAS FLOW M3 HR METERS CUBED PER HOUR CFH CUBIC FEET PER HOUR VALVE CAPACITY IS MEASURED WITH 1 5 IN DN40 FLANGES ASSEMBLED THE VALVE CAPACITY WILL VARY WHEN PAIRIED WITH SMALLER FLANGES CAPACITY CURVE REPRESENTS A VALVE TYPICAL GUARATEED MAXIMUM AND MINIMUM FLOW WHEN THE FUEL CONTROL VALVE IS FULLY OPEN AND FULLY CLOSED THE CAPACITY COVERS A 95 POPULATION CONFIDENCE 1 2 VALVE OPERAT...

Page 18: ...APACITY IS MEASURED WITH 2 0 IN DN50 FLANGES ASSEMBLED THE VALVE CAPACITY WILL VARY WHEN PAIRIED WITH SMALLER FLANGES CAPACITY CURVE REPRESENTS A VALVE TYPICAL GUARATEED MAXIMUM AND MINIMUM FLOW WHEN THE FUEL CONTROL VALVE IS FULLY OPEN AND FULLY CLOSED THE CAPACITY COVERS A 95 POPULATION CONFIDENCE NATURAL GAS FLOW M3 HR METERS CUBED PER HOUR CFH CUBIC FEET PER HOUR 1 2 VALVE OPERATING RANGE Fig ...

Page 19: ...apacity is listed in in KW H convert to M3 H by the following formula Capacity in M3 H KWH from burner nameplate KW M3 from gas utility 4 For gases with specific gravities relative densities other than 0 64 correct the burner CF H or M3 H from step 3 by multiplying it by the proper conversion factor found in Table 3 Table 3 Gas Conversion Factors Type of Gas Specific Gravity Relative Density avera...

Page 20: ...RD MCR37137 NEMA 4 IP66 WITH CONDUIT CONNECTIONS FLANGES NPT OR BSP ORDERED SEPARATELY WIRING PORTS 6 FOR 1 2 INCH 1 27 CM CONDUIT 6 M16X1 5 LOWVOLTAGE CORD GRIPS SOLENOID COVER FLANGE PRESSURE TOP 1 8 3 NPT OR BSP ELECTRICAL ENCLOSURE MOUNTING LOCATION BOTH SIDES PRESSURE PORT COVERS NOVV CONNECTION NORMALLY OPEN VENT VALVE BOTH SIDES NOTE NEMA 4 IP66 solenoid covers contain vents to dissipate he...

Page 21: ...lenoids with less heat generation while saving electrical energy Run current is reduced via duty cycling of the voltage applied across the solenoids The power saving circuitry is designed as Class C fail safe to avoid full power application and thus over heating of the solenoids per EN13611 6 6 4 class C to fulfill the requirements in EN161 8 11 120 4 1 Valve Interface The valve interface contains...

Page 22: ...ude circuit check during initial power up external and internal VPS leak detection test manual low gas or high gas pressure tests NOTE On BASIC 5 intelligence valves this only indicates a circuit check Fault Indicates a fault condition exists Refer to the VALVE FAULT CODES section of this manual for detailed fault descriptions LGP Indicates a Low Gas Pressure fault condition exists when a SV2 Seri...

Page 23: ...cations are labeled as A B C and D Locations A and B reside on one side of the valve body under valve seats V1 and V2 respectively Locations C and D reside on the other side of the valve body under valve seats V1 and V2 respectively Since the valve body is symmetrical locations A and C under valve seat V1 and are identical to each other and locations B and D under valve Seat 2 are identical to eac...

Page 24: ...etection R Regulator Servo Future usage Valve Seat2 B D M Mid Mid valve seat pressure measurement between V1 and V2 O Outlet Outlet pressure measurement C6097 flange mount pressure switch for high gas limit Pressure Module for low high gas limits R Regulator Servo Future usage Outlet Flange Outlet Outlet pressure measurement C6097 flange mount pressure switch for high gas limit 1 Locations A B C a...

Page 25: ...ss location cover the tightening torque should be between 1 36 to 1 82 Nm 12 to 16 in lbf PORT I INLET PRESSURE PORT M MID PRESSURE PORT R REGULATOR SERVO PORT M MID PRESSURE PORT O OUTLET PRESSURE PORT R REGULATOR SERVO MODULE LOCATING HOLES MODULE LOCATING HOLES PORT M MID PRESSURE PORT O OUTLET PRESSURE PORT R REGULATOR SERVO PORT I INLET PRESSURE PORT M MID PRESSURE PORT R REGULATOR SERVO MODU...

Page 26: ...functions listed in Table 5 or general pressure measurement Each pressure access tap location on the valve body is either 1 8 in 3mm NPT or BSP depending on what is ordered from the factory Typically for 24VAC or 100 120VAC taps are NPT and for 200 240VAC taps are BSP Refer to Fig 1 Valve nomenclature for further information Digit 6 in the valve model identifies the port thread type The flange pre...

Page 27: ...nstallation to prevent electrical shock and equipment damage 5 All wiring must comply with the National Electric Code NEC and any applicable local electrical codes ordinances and regulations 6 After installation is complete carry out a thorough checkout of product operation as laid out in the valve installation instructions document WARNING Explosion Hazard and Electrical Shock Hazard Can cause ex...

Page 28: ...cessary in the field CAUTION If valve has been dropped do not use it Dropping the valve may cause permanent damage to the valve Replace entire valve and associated modules before use Installation Quick Start Guide The SV2 Series valve installation steps are illustrated below in the Quick Start Guide NOTE Elaboration of each step is detailed in the SV2 Series Safety Shut Off Valves Installation Ins...

Page 29: ...re Module HMI or PC Tool Mixing unit Pulse lines Pulse line fittings Heat Exchanger 1 Remove from box 2 Installation and Mounting A Orientation planning B Mounting flanges C Mount valve to flanges and piping 1 inch DN20 25 valve bodies have drilled and tapped holes 1 inch DN40 and larger valve bodies with embedded slots for flange retaining nuts D Vent valve connection E Premix mixing unit pulse l...

Page 30: ...alves D String wires String wires through conduit NEMA 4 IP66 enclosure entry points cord grips and nuts before wiring to connectors String wires through NEMA 1 IP20 enclosure rear opening or bottom slot before wiring to connectors E Connect wires Observe terminal labeling and proper electrical connector placement Connect wires to the wire connectors Plug electrical connectors into their proper so...

Page 31: ...lve and HMI or PC Tool C Complete setup as required and run on board test procedures as required 6 Wiring Checkout A Test Cycle the valve several times to verify proper function Each limit and interlock Following burner management system checkout guidelines Any other recommended or required tests 7 Finish A Replace the electrical enclosure cover B Replace solenoid cover if removed C Your valve is ...

Page 32: ... D Flanges Valve and NOVV Mounting After planning for the valve orientation the flanges should be mounted to the gas connection following the pipe preparation guidelines set forth in the SV2 Series Valves Installation Instructions document 32 00018 NOTE Ensure the gap left between the flanges when installed on the pipes does not exceed the valve body width otherwise the valve piping may be over st...

Page 33: ... lines to the pulse line fittings to Port A B and C of the FARMOD as indicated in Fig 43 following the instructions of the burner or boiler manufacturer Attach each pulse line to its corresponding fitting on the mixing unit or burner Premix Air Pre Filter The air pre filter is included with every premix valve The air pre filter MUST be installed in every premix system The filter must be mounted be...

Page 34: ...and fitting kits Premix Start Up The FARMOD Fuel Air Ratio Module is standard equipped with a heating device The heater will be powered whenever the valve electronics are powered The FARMOD will feel warm after 1 hour of being powered This is normal As part of the appliance adjustments during commissioning the site specific calibration of the SV2 Series valve appliance should be performed when the...

Page 35: ... is not purchased with the required customer wiring connectors all 5 may be purchased from Honeywell as a bag assembly under part number CONNECTORKIT 000 or purchased externally For purchasing externally the appropriate connector information is shown in Table 6 Table 6 SV2 Valve Electrical Connectors Identification Vendor Description Vendor Part Number SV2 Series Valves Purpose Required Quantity L...

Page 36: ...signal interference If using conduit run line voltage and low voltage in separate conduit B C Remove Electrical Enclosure Cover and Estimate Wiring To access the customer wiring terminals remove the valve front electrical enclosure retaining screws with the appropriate tool Set the cover aside Note that the SV2 Series valves have unique line voltage limit interlock and VPS valve proving sequence w...

Page 37: ...terminals and designations can be found in Table 8 A summary of the possible field wiring connections is shown below relative to the callouts in the illustration above 1 Mains Supply L1 and N 2 Ground Mains and Chassis 3 ILK Out In VPS Switch output POC output Main Valve 1 2 4 RS 485 Modbus not present on BASIC Intelligence models 5 Modbus termination and bias resistors not present on BASIC Intell...

Page 38: ...GP Open Closed Reset MCR35487 SOLENOID 1 SOLENOID 2 L1 N MAINS SUPPLY MAINS CHASSIS GROUND ILK ILK VPS POC MV2 MV1 OUT IN RS 485 MODBUS C OFF BIAS TERMIN BIAS ON 1 2 3 MODBUS GND IN1 GND IN2 A N A L O G FIRE RATE O2 SENSOR MOTOR PRESSURE FUEL AIR Fig 21 NEMA 1 IP20 STANDARD 6 valve electronics interface NOTES Electrical connections are the same for NEMA 1 IP20 electrical assembly with the omission...

Page 39: ...ough all valve models for solenoid power saving feature Dry contact output input also used for flame safeguard control ILK string with Pressure Module for low gas pressure and high gas pressure functions 24 100 240VAC 8A All ILK IN VPS SW Line voltage output for Valve Proving System switch using the Pressure Module for external VPS conducted by a separate device 24 100 240VAC 0 1A All models with ...

Page 40: ...PS using Pressure Module D Stringing Wires If purchased with the valve the electrical connectors will be included in the valve accessory box NEMA 4 IP66 valve models will also have line voltage and low voltage nuts plugs and cord grips in the accessory box Depending on the NEMA IP rating of the valve there are different steps for stringing and connecting the wires to the proper terminals The wires...

Page 41: ... the bottom of the front electrical enclosure Strain relief is via a loop on the electrical enclosure fixation tab Line voltage wiring entry is at the bottom of the rear electrical enclosure Route wires between the solenoids and through two rectangular openings at the top of the front electrical enclosure Wires may be secured to hooks embedded into the plastic on the rear exterior of the front ele...

Page 42: ...s valve can communicate via Modbus RTU communication with any compatible device Only RTU communications with 1 start bit 8 data bits 1 stop bit and no parity is supported Refer to the SV2 Series Valves Installation Instructions 32 00018 and CHAPTER 3 COMMUNICATION CONNECTIVITY in this manual for details on Modbus setup G Install Plugs Install the low and line voltage plugs in any unused wire entry...

Page 43: ...n one disconnect may be involved Power the system only when requested in the test procedure M9547H GAS SUPPLY UPSTREAM MANUAL GAS VALVE DOWNSTREAM MANUAL GAS VALVE BURNER M O A B C E F PRV MANUAL TEST PETCOCK SSOV 1 4 IN 6 MM FLEXIBLE TUBING 1 4 IN 6 MM ALUMINUM OR COPPER PILOT TUBING JAR OR GLASS WITH WATER CUT AT 45 DEGREE ANGLE CAN ALSO BE A PERMANENT PETCOCK PRV PRESSURE REGULATING VALVE SSOV ...

Page 44: ...o complete the setup of all applicable intelligent items as required You may reference the HMI PC Tool User manual 32 00031 6 FINAL WIRING AND STATIC CHECKOUT OVERVIEW A Test CAUTION Cycle the valve several times with the manual fuel shut off valve closed Verify that the valve accessory modules and control system function properly Test each limit and interlock to ensure system operates correctly a...

Page 45: ...disconnect all electrical power to the valve before servicing Only trained experienced combustion service technician should attempt to service or repair flame safeguard controls burner assemblies or valve trains Refer to the ACCESSORIES FIELD REPLACEMENTS AND INTELLIGENT FEATURES section of this manual for advice on component field replacements 7 FINISH A Replace the valve electrical enclosure cov...

Page 46: ...d rate and Modbus addressing Refer to the Valve Modbus Bias Setup section of this document for more information as well as the reference documents listed at the end of this section for proper SV2 Series valve and Programming Tools Modbus wiring and setup The HMI or PC Tools automatically communicate with the valve once properly connected Either of these tools is required for initial setup of any i...

Page 47: ...e programming activities referencing these documents is imperative IMPORTANT When intending to connect more than 1 valve to the HMI or PC Tool or an external Modbus master each valve must be individually connected and programmed first with each valve given a unique Modbus address Once this is complete all valves may be wired in a daisy chain fashion to a single HMI Tool port PC Tool USB to RS485 c...

Page 48: ... The TERMIN termination resistor in the ON position helps to improve signal integrity for the best performance in regards to EMC electromagnetic compatibility The termination resistor may be especially helpful to improve communication when the SV2 Series connected valve is at the end of the communication BUS The BIAS resistors in the ON position provide differential resistance for some older commu...

Page 49: ... The SV2 Series valves are built on a flexible modular platform including modular components that could be added and or replaced in the field plus several accessories Additionally there are intelligent features which can be utilized when certain accessories are used with the SV2 Series valves Accessories and field replacement parts include C6097 pressure switches HMI or PC programming tools for an...

Page 50: ...ns may be used for low gas pressure mounted via piping and reducing means C6097 Pressure Switch Selection C6097A models break a control circuit at setpoint on pressure fall and are used for low gas pressure and VPS switches C6097B models break a control circuit at setpoint on pressure rise and are used for high gas pressure switches C6097 pressure switches are available in several pressure ranges ...

Page 51: ...NPT or BSP depending on which port thread is ordered from the factory Refer to Fig 1 Valve nomenclature for further information Digit 6 in the valve model identifies the port thread type Flange pressure taps are 1 8 27 in 3mm if an NPT flange is ordered or 1 8 28 in 3mm if a BSP flange is ordered from the factory C6097 pressure switches cannot be used for VPS on valve models with external VPS func...

Page 52: ...he valve is mounted in the valve train If you need to replace a pressure access location cover the tightening torque should be between 1 36 to 1 81 Nm 12 to 16 in lbf If you need to replace a pressure access port plug the tightening torque should be 6 8 Nm 53 71 in lbf WARNING Explosion Hazard and Electrical Shock Hazard Can cause explosion serious injury or death Turn off gas supply before starti...

Page 53: ...4VAC nominal 50 60Hz Input Current 500mA max Power Consumption 12W max HMI Operating Temperature Range 4 to 158 F 20 to 70 C HMI Storage Shipping Temperatures 22 to 176 F 30 to 80 C HMI Humidity Max 90 relative humidity continuous non condensing HMI Environmental Ratings NEMA 1 IP20 HMI Approvals FCC Part 15 Class A Digital Device Underwriter s Laboratories Inc UL cUL Component Recognized for non ...

Page 54: ...uded in the PCTOOLKIT 000 External Modbus master device communication with valve s via the HMI Tool second port with Gateway Connect to External Systems selection With this communication option the HMI Tool would likely be permanently installed The HMI or PC Tools automatically read all appropriate connected valve Modbus registers The HMI or PC Tools are required for initial setup of any intellige...

Page 55: ...r detailed valve programming instructions 4 If using the HMI Tool make sure its 8 pin connector is properly aligned and pressed firmly into place 5 Make sure the wires between the HMI or PC Tool connector and the SV2 valve s are properly wired and secured 6 Make sure the HMI power supply is connected securely to the power source NOTES The HMI and PC Tools will timeout from the commissioning mode a...

Page 56: ... 65 C Approvals The Pressure Module is not a stand alone product and must be used with a SV2 Series valve and thus is specified as part of the valve approvals Contact Ratings Contact wiring connections for the flame safeguard control interlock string are contained within the valve main electrical enclosure Refer to VALVE SPECIFICATIONS section of this manual for contact ratings and the BURNER CONT...

Page 57: ...ve a cord grip to mate with the valve NEMA 4 IP66 electrical enclosure to maintain the enclosure rating Due to the different NEMA IP ratings and associated temperature range when paired with SV2 Series valves the applicable pressure measuring range varies between the NEMA 1 IP20 and NEMA 4 IP66 Pressure Module versions as shown in Table 11 Table 11 Available Pressure Modules Pressure Module Enclos...

Page 58: ...ical enclosure Available pressure port locations for V1 and V2 valve seats on both sides of the valve are shown in Fig 16 and Fig 18 Pressure Module placement and associated functionality can be found in Table 12 Note that available mounting locations and functions are valve model and intelligence level dependent NOTES Accessing the Inlet I port of mounting locations A and C on V1 for Pressure Mod...

Page 59: ...shed via embedded software algorithms As a result any low gas pressure condition that occurs while the valve is de energized is ignored and allows the low gas pressure limit to be located in the intermediate position between the two valve seats or after the two valve seats The high gas pressure limit is measured from the same location when both valve seats are powered with non zero flow As a resul...

Page 60: ...me for HGP LGP is 2 seconds The HMI or PC Tool is used to program all available functions using the Pressure Module via an embedded set up wizard Programming includes the low and high gas pressure lockout type limit settings VPS leakage limit along with any associated connected pipe volume and VPS contact action Additionally the HMI and PC Tools have built in testing mechanisms for the limit setti...

Page 61: ...y intelligent features are setup YOU MUST KEEP THE HI GAS AND LO GAS LOCKOUT TYPE IN DISABLED STATUS WHILE PROGRAMMING THE PRESSURE LIMITS if the wiring between the valve and burner management system is in place ALSO YOU MUST KEEP THE EXTERNAL VPS CONTROL DISABLED IF USED The burner needs to be run in order to properly measure the pressure at the valve and thus set the Hi Gas and Lo Gas limits acc...

Page 62: ... selected Leakage Limit threshold and based on that comparison will toggle the VPS SW output as selected during setup pressure to close or open The contact output action is the same as in a traditional VPS system using a separate pressure switch Based on the VPS contact output the external device performing VPS will determine if the VPS test passed or failed The valve leakage test results along wi...

Page 63: ...tarting over 50 l h and up to a maximum value of 0 1 of the burner heat input 0 1 of the fuel flow rate in l h NOTE Maximum valve leakage value is limited to 50 l h for 1 in DN25 valves 142 l h for 1 5 2 in DN40 50 valves 283 l h for 2 5 3 in DN65 80 valves NOTES YOU MUST KEEP THE EXTERNAL VPS CONTROL DISABLED WHILE PROGRAMMING THE VPS SETUP AND PRESSURE LIMITS if the wiring between the valve and ...

Page 64: ...del used PRESSMODx1 5mbar 2 0 in wc 0 07 psi PRESSMODx2 5mbar 2 0 in wc 0 07 psi PRESSMODx3 8mbar 3 2 in wc 0 12 psi PRESSMODx4 16mbar 6 4 in wc 0 23 psi In case the SV2 Series valve cannot take reliable pressure readings during the external VPS sequence the SV2 Series valve will lockout Very low leakage levels of less than 2 liters hour 33 3 ml min 0 07 CFH which are well below any allowed level ...

Page 65: ...essure Module and plug in the electrical connector To make the valve operational Accept the new Pressure Module and serial number either via the Guided Valve Set Up or the Pressure Module tab in the Setup Tests Settings menus If this step is not performed 3 faults will occur upon entering the Hi Gas Lo Gas Pressure or VPS setup screens In order to allow setup functions the Pressure Module must be ...

Page 66: ...the flanges Reference documents 32 00028 for 1 in DN25 valve bodies and 32 00036 for 1 and 2 in DN40 and DN50 valve bodies The entire mounting and installation process is covered in detail in the valve installation instructions 32 00018 packed with each valve The process for mounting the 1 inch DN25 valves flanges differs from the process for mounting the 1 and 2 inch DN40 and DN50 valves flanges ...

Page 67: ...NEMA 1 IP20 and NEMA 4 IP66 Voltages 24 100 240VAC Mounting Two 2 6 x in Plastite slotted Torx screws Retaining tabs embedded into valve electrical enclosure Documentation 32 00039 Replacement Electronics Installation Instructions Introduction and Replacement Assembly Selection The SV2 Series valves were designed for application flexibility including modular components that could be replaced in th...

Page 68: ...connect power supply before beginning installation More than one disconnection can be involved WARNING Explosion Hazard and Electrical Shock Hazard Can cause explosion serious injury or death Disconnect the power supply making wiring connection to prevent electrical shock and equipment damage More than one power supply disconnect can be involved CYBER SECURITY NOTICE SV2 Series products contain el...

Page 69: ... Ratio Module programmed settings should occur unless those accessories are replaced at the same time as the main valve electronics assembly It is recommended however to perform verify the valve programming as was done during the original installation The HMI PC Tools have embedded guided setup wizards for easy commissioning Detailed step by step programming instructions are provided in the HMI PC...

Page 70: ...ginning installation More than one disconnect can be involved WARNING Electric Shock Hazard Can cause serious personal injury or death Disconnect power supply before beginning installation More than one disconnection can be involved WARNING Explosion Hazard and Electrical Shock Hazard Can cause explosion serious injury or death Disconnect the power supply making wiring connection to prevent electr...

Page 71: ...ER 5 SV2 SERIES PREMIX TECHNOLOGY Fuel Air Module Specifications Dimensions Refer to Figures 31 and 32 Fig 31 FARMODxx 000 without insulation NOTE FARMOD standoff is approximately 2 5mm from valve body Fig 32 FARMODxx 000 with insulation NOTE FARMOD standoff is approximately 17 5mm from valve body ...

Page 72: ...ed length of cable against EMC standard FCC 15 Part B Class A EN UL 60730 1 and EN 13611 at industrial levels Environmental Ratings NEMA 1 IP20 or NEMA 4 IP66 with sealing cord grip Operating Temperature Range All versions 5 F to 145 F 15 C to 63 C Air Pressure Differential 15 Pa to 3200 Pa 0 059 to 12 6 in w c Delta P across FARMOD air inlet to the Pref outlet Gas Pressure Differential FARMOD14 4...

Page 73: ...e appropriate tested calibrated and mounted FARMOD Note that factory stepper motor full stroke calibration is stored in the main electronics board and the FARMOD At each shutdown the valve will check the actual full stroke against the stored value If the stored value is bad or out of tolerance the value cannot be used and the valve will lockout Field Replacement of FARMOD or Valve Main Electronics...

Page 74: ...e user should exercise caution when doing so as it could result in reliability issues if the usage history of the FARMOD is unknown The SV2 Series valves have internal algorithms that prevent the accidental or intentional removing of the Fuel Air Ratio Module once the valve has been fully setup and is in use If the FARMOD cable is disconnected the valve will lockout The fuel air valves V2V FARMOD ...

Page 75: ...e FARMOD the mixing unit air filter and heat exchanger if used Refer to Fig 45 The pulse line tubing can be plastic or metal depending on the connection point and approval body requirement The Honeywell preferred pulse line connection for the air and reference pressure is aluminum or stainless steel Refer to the specifications that follow Honeywell offers several fittings and tubing kits to facili...

Page 76: ...ould not restrict the inner preferred pulse line diameter 1 Alternatively other tubing materials such as PUN can be used noting that the maximum temperature of 140F 60C shall not be exceeded NOTE Aluminum tubing shall preferable fulfill the following requirements to mate with the recommended fittings Diameter and wall thickness 8 x 1 mm Dimensions and tolerances according DIN EN754 7 8 Material AW...

Page 77: ... Values for natural gas G20 IMPORTANT For optimal fuel air ratio performance it is recommended to assemble an extension pipe between the V2V gas valve and V2MU Mixing Unit as indicated in Table 19 and Fig 34 Fig 35 and Fig 36 Alternatively a 90 degree elbow with an inner diameter as specified in Table 19 can be used NOTES If a manual safety shut off valve is assembled between the gas valve and the...

Page 78: ... 35 1 5 2in DN40 50 valve to V2MU0500 0800 1000 Fig 36 1 5 2in DN40 50 valve to V2MU2000 Mixing Unit Part Number M5 x 16 mm M8 x 16 mm M8 x 20 mm Nut M8 Washer V2MU0300 4 V2MU0500 V2MU0800 V2MU1000 4 4 4 V2MU2000 4 4 Table 20 Provided fastening materials ...

Page 79: ...SV2 Series Safety Shut off Valves 79 V2F V2V SV2 SERIES SAFETY SHUT OFF VALVES USER MANUAL Fig 37 V2MU0300 Dimensional information ...

Page 80: ...SV2 Series Safety Shut off Valves 80 32 00029 02 Fig 38 V2MU0500 V2MU0800 V2MU1000 Dimensional information ...

Page 81: ...djust the gas flow to create a leaner mixture which eventually could result in flame loss or lockout due to permanent FARMOD damage Such a condition would also be identified at the next call for heat The Heat Exchanger Kit in addition to the heater embedded within the FARMOD work together to prevent condensate from entering the FARMOD for conditions as indicated above If the potential of condensat...

Page 82: ...nnect the Heat Exchanger to the FARMOD are sold separately in kits Tubing is available in aluminum or plastic Fittings are available for connection to the aluminum or plastic tubing in straight tee and 90 degree configurations Refer to Table 17 for information Fig 40 Heat Exchanger dimensional information Air Pre Filter The air pre filter is included with every premix valve and is available as a f...

Page 83: ...ng is complete and the appliance is running the Fuel Control Valve is controlled modulated by a comparison of the actual sensor readings against the setpoint which is derived from the stored amplification settings to accurately control the lambda O2 CO2 behavior against the burner load The ability of the SV2 Series Fuel Air Ratio control system to store up to 24 burner load dependable amplificatio...

Page 84: ...ratios of the S1 and S2b signals which are derived from the stored amplification values at different burner loads during the commissioning of the appliance The FARMOD sensor S2a and the valve CV are part of the built in safeguards to assure the plausibility of the sensor signals All sensor signals are fed to the SV2 Series electronics which actuates the stepper motor controlled gas Flow Control Va...

Page 85: ...essories section of this document Fig 43 PORT C P AIR PORT B P CC PORT A P GAS M36228 Fuel Air Ratio Module and Mixing Unit pulse line connections IMPORTANT The Fuel Air Ratio Module operates properly only if the pulse line fittings are properly tightened and the flow through the pulse lines is un obstructed During connection of the pulse lines ensure that the pulse lines are not twisted or kinked...

Page 86: ... contained in the sealed chamber it is allowed to not use the air pressure pulse line The air pre filter is included with every premix valve and is available as a field replacement part as well The air pre filter MUST be installed in every premix system regardless of whether the Heat Exchanger is used The air pre filter filter must be mounted between the V2MU mixing unit and the valve FARMOD in th...

Page 87: ...nes and the FARMOD due to moisture laden air It is comprised of a FARMOD embedded heater with an available insulation shoe and an available external heat exchanger as well as appropriate insulation for the pulse lines All components must be used together as necessary in applications where there is a potential for moisture content or condensation in the combustion air If the potential of condensate...

Page 88: ...Heater The heater is built into the FARMOD design The Heat Exchanger kit includes a FARMOD insulation shoe which encases the metal surfaces of the FARMOD Along with the Heat Exchanger these items provide a complete dehumidification solution Refer to Fig 32 and Fig 47 Fig 48 Fig 48 FARMOD with insulation shoe ...

Page 89: ...Series HEATEXCHANGER 000 kit for a complete condensation dehumidification solution to avoid permanent damage to the FARMOD and the system When using the Honeywell HEATEXCHANGER 000 kit the valve FARMOD may be installed above or below the mixing unit Heat Exchanger but above is preferred If the potential for condensation exists and the full Honeywell dehumidification system is not used Honeywell ca...

Page 90: ...ough room to assemble the recommended metal reference pulse line tubing fitting on the same side of the mixing unit unless the Heat Exchanger is slightly rotated out of the way With the plastic tubing fittings all orientations are possible V2MU0500 010 V2MU0800 010 and V2MU1000 010 Can mount the Heat Exchanger in this location orientation if a 90 degree metal fitting is used and rotated slightly s...

Page 91: ... the assembly of the fittings and aluminum tubing follow the recommended procedure of the fitting manufacturer The shape of the aluminum tubing MUST allow for continuous drainage of the condensate over the entire length from the Heat Exchanger to the V2MU IMPORTANT The SV2 series premix valve and its accessories have been developed to provide an optimum fuel air ratio performance Honeywell cannot ...

Page 92: ...signals provide information about the actual air flow through the appliance The SV2 Series control offers settings in the OEM Setup to store the expected airflow level during burner pre ignition with user specified thresholds If the measured airflow signal is outside of the specified limits the SV2 Series control will lockout The air proving ignition values are set via the OEM parameters of S1 pre...

Page 93: ...e Learnt Pos 2 refer to Fig 53 The Learnt Pos 2 stepper motor start position value or adjustment is limited by the user entered value for Default Pos 2 in that it can vary up to 20 of the entered Default Pos 2 value or a maximum of 10 full steps In practice the value that needs to be entered for Default Pos 2 depends on the start capacity and the available inlet pressure to the valve The best way ...

Page 94: ...its for S1 to rise above this value The valve does not lockout S1 maximum threshold Sets the percentage that the air S1 signal can be over the recorded commissioned maximum air signal during normal RUN mode The commissioned maximum air signal during normal RUN mode the air signal recorded during the commissioning of the Correction Curve usually at the installed site at maximum load If the S1 signa...

Page 95: ... performed in the laboratory during development By selecting a short Ramp Period and an extra startup delay of 0 Ignition Period the control is started almost directly after opening of the two safety valves During the first ignition trials the ignition amplification setting Ignition Setpoint parameter is best set to 100 to prevent flame loss when jumping to a leaner mixture after the ignition peri...

Page 96: ...rol feedback following the Ramp Period The Fuel Control Valve is held at the controlled valve position for the specified time before it starts to modulate As with the Ramp Offset and Ramp Period this control startup delay helps to make the system less sensitive to pressure pulses caused by ignition of the burner During the Hold On Period the control loop is not active so that fluctuations in the m...

Page 97: ...his self adjustment behavior helps to accommodate the valve and appliance for gas pressure changes NOTE The correction of the Learnt Pos 2 is limited to 10 steps per start This means that it can take a few starts until the value of the Learnt Pos 2 has stabilized Position 3 Value Illustrates the stepper motor position for normal burner operation RUN mode relative to the current ignition load Posit...

Page 98: ...SV2 Series Safety Shut off Valves 98 32 00029 02 Fig 54 Load Saved Curves ...

Page 99: ...r and location is done via the Correction Curve refer to the next section The Base Curve can have up to 25 load points distributed over the modulation range of the appliance and be shaped to give the desired CO2 O2 content in the combustion products over the modulation range via individual amplification settings The curve should be recorded in the laboratory and can be saved to the hard HMI or PC ...

Page 100: ... buttons and selecting the Set Initial button The value only becomes effective after pressing the Set Initial button It is recommended to determine the initial amplification factor during the development of the appliance and list the initial amplification factors per gas type in the appliance installation manual Alternately a Base Curve which was defined on a similar appliance can be uploaded to t...

Page 101: ...alue for the minimum and or maximum needs to be defined to be able to run the system in normal operation mode Not Installer or OEM mode All points of the curve can be deleted at once by selecting Delete all button The amplification setting will default back to the earlier entered initial amplification curve To be able to run the system in normal operation mode a minimum of 4 points need to be defi...

Page 102: ...the arrow keys until the excess air level has stabilized at the right level Select the Set Min button to store the gain factor for this point Increase the appliance load and repeat this process for maximum and intermediate loads The Set Max button records the maximum load point while the Add Generic button records any intermediate load points While defining the gain setting for various loads addit...

Page 103: ...em in normal operation mode Not Installer or OEM mode All points of the curve can be deleted at once by selecting Delete all button The gain setting will default to 1 To be able to run the system in normal operation mode a minimum of 4 points need to be defined Minimum Maximum and two intermediate points Fuel Air Curves Summary Refer to Fig 58 After completing setup of the Base and Correction Curv...

Page 104: ...amount of gas supplied for ignition does not exceed the amount of gas set by the Ignition amplification Ignition Setpoint parameter In addition to the startup delay of the Ramp Period the startup of the fuel air control i e mass flow sensors being active can be delayed further up to 1 second before the end of the Ignition Period by entering a value greater than 0 for the Hold On Period parameter T...

Page 105: ...equired during normal burner operation RUN mode For example this setting can be used to assure a successful burner ignition during extreme start up conditions Fig 60 Control startup delay with enriched mixture increased amplification factor Control Startup Delay and Leaner Mixture Ramp Period Hold On Period Ignition Period Ignition Setpoint parameters The SV2 Series control also offers the possibi...

Page 106: ... to the Learnt Pos 2 position Note that Learnt Pos 2 is re learned with every burner start The Ramp Period in seconds governs the speed with which the stepper motor opens from the offset idle start position to the Learnt Pos 2 during the ignition sequence While the burner igniter is on the air and gas mixture enriches until a mix occurs for light off The Hold On Period sets the time that the contr...

Page 107: ...n factor This occurs after the Ramp and Hold On Periods have expired Refer to Fig 62 If the Ignition Setpoint is below 100 it causes a leaner fuel air mixture during ignition with a decreased amplification factor This occurs after the Ramp and Hold On Periods have expired Refer to Fig 63 NOTES If the Ramp Period is set to a relative long time the ignition of the burner will occur during the ramp u...

Page 108: ...E Checking and unchecking the Record Ign Air Level check box will erase the recorded ignition air levels and causes a lockout of the SV2 Series valve when installer mode is exited Stepper Motor Fuel Control Valve Full Stroke Check Every time the two SSOVs close the full stroke of the fuel valve is checked the stepper motor is driven to its maximum open position then to its fully closed position wh...

Page 109: ... Correction Curve might typically be created and or adjusted in the field NOTE The valve must be powered for 1 hour in order for the embedded FARMOD heater to effectively warm up the device If the full hour is not provided the programmed lambda and the excess air values might vary from the desired values While in the Base Correction Curve setup screen to add more points select the Start Point Comm...

Page 110: ...plification factor control Base Curve Fig 66 Gain factor Correction Curve after Set Max Completed NOTE If the Enter Optional Data box is checked you will be asked to enter the measured O2 level and fan speed values before storing the individual amplification factors Valve Production Cloning Provisions for customer production cloning of established valve parameters have been added to the HMI and PC...

Page 111: ...p and Ignition Setup parameters and Base Curve The fuel air Correction Curve and the recorded pre ignition air values as well as the LGP HGP and POC settings are not part of the cloned configuration because they are related to the valve with which they were created After the configuration is uploaded to the valve the safety parameter verification procedure will need to be completed When all questi...

Page 112: ...t OEM or Installer password immediately after logging in with it The user will need to enter the new main password for their access level Additionally the OEM will need to enter their reset password if enabled in order to advance though the valve setup sequence If either the Valve Production Cloning for Open Valve is chosen the OEM may login using the default OEM password and change any settings t...

Page 113: ...s must be configured in order to clear the individual fault codes Refer to Fig 69 for the active faults OEM main password not changed fault code 97 Valve will not be operational unless the user is logged in using the default OEM password OEM reset password feature is enabled and password not change fault code 102 Valve will not be operational unless the user is logged in using the default OEM pass...

Page 114: ...lve characters long Use a combination of numbers lower case letters and upper case letters At least one upper case and one lower case letter At least one number No special characters Special characters such as and have been disabled and are not allowed to be used in passwords A passphrase is recommended since it is easier to remember An example would be HelloWorld2017 ...

Page 115: ... is lost the OEM will not be able to reset the password and will effectively be locked out of editing the valve at the OEM level If the Installer level main password is known the OEM can access the valve using it and edit the parameters to which they have granted the Installer access In order to make OEM level editing possible again the valve main electronics would have to be replaced and the valv...

Page 116: ...accordance with best practices The OEM RESET password CAN be the same for all OEM valves appliances For security reasons the OEM Reset password should be more robust and longer than the OEM Main password The OEM main and reset passwords CANNOT be the same Do not print passwords in manuals for cyber security reasons The procedure to configure the OEM main password is as follows 1 Select OEM in the ...

Page 117: ...he new password by selecting the second blank field entering the password and selecting save again 5 When the Change Password dialog box reappears refer to Fig 73 select Change Password Fig 73 Change OEM password dialog box with entered password 6 When the OEM password is changed the Password Changed dialog box opens Refer to Fig 74 ...

Page 118: ...l stay logged in with the old password with the Change Password dialog box open refer to Fig 73 8 Log in using the newly created OEM password by selecting the padlock symbol in the upper right hand corner of the Security page Refer to Fig 70 a Enter the new password by selecting the blank field and entering it when the keyboard pops up Refer to Fig 75 b Select Login to log in with the new password...

Page 119: ...e in the current OEM Password if it exists When the OEM password is not configured the default OEM password is automatically filled in SV2OemKey2017 5 Enter the new Installer Password by selecting the blank field When the keyboard pops up enter the new Installer password and select Save Refer to Fig 72 6 Confirm the new password by selecting the second blank field entering the password and selecti...

Page 120: ... therefore the access selection at the top of the Change Password dialog box is pre selected as Installer 3 Type in the current Installer Password if it exists Refer to Fig 79 When the Installer password is not configured the default Installer password is automatically filled in SV2InstallerKey2017 Fig 79 Change Installer as Installer password dialog box 4 Enter the new Installer Password by selec...

Page 121: ...ack to the Security page refer to Fig 70 a The user can then log in with the newly created Installer password see next step b If No is selected the Password Changed confirmation dialog box will close and the user will stay logged in with the old password with the Change Password dialog box open refer to Fig 80 9 Log in using the newly created Installer password by selecting the padlock symbol in t...

Page 122: ...ons the OEM Reset password should be more robust and longer than the OEM Main password Do not print passwords in manuals for cyber security reasons The OEM can choose to enable or disable the OEM and Installer password reset functions Refer to Fig 70 If it is enabled the user can follow the reset instructions in the Installer and OEM Password Reset section that follows It is disabled and the main ...

Page 123: ...ssword by selecting the blank field When the keyboard pops up enter the new password and select Save Refer to Fig 72 5 Confirm the new password by selecting the second blank field entering the password and selecting Save again 6 When the Change OEM Reset Password dialog box reappears refer to Fig 84 select Change Password Fig 84 Change OEM Reset Password dialog box with entered password 7 When the...

Page 124: ...OEM If Read Only is chosen neither the Installer nor the OEM can make changes to the associated parameters In order to make changes possible the OEM would have to change the Access Level to the OEM or Installer levels For the Remote Reset parameter group only there is also an Anonymous selection which allows anyone to remotely reset the valve via the user interface Therefore the access level can b...

Page 125: ...r Table 23 Access Level Groups Category Contents Valve Body Valve body size Valve General Valve Name Modbus Address Baud Rate LED Indication for electronics side change Installer Security Installer password configuration whom is allowed to assign this password Remote Reset Remote reset function via user interface POC Setup of POC 1 and POC 2 configuration acceptance PRESSMOD Pressure Module replac...

Page 126: ...ill vary between the Installer and OEM levels as indicated below Note that cycling of the valve or user interface power will not defeat this methodology NOTES The password reset mechanism simply allows the appropriate user to reset the current password s back to the Honeywell factory default value s Once the password s are reset the user can then log in and assign new password s After reset to the...

Page 127: ...nstructions below If it is disabled and the main Installer password is lost the Installer will not be able to reset the main password and will effectively be locked out of editing the valve In order to make editing possible the OEM would have to login and enable the Installer password reset function or set a new Installer password To access the Installer reset code on back of the valve main electr...

Page 128: ...e for passwords entry change or reset 3 On the Security page select the Reset Installer OEM password button a If the user is logged in when this button is selected the dialog box shown in Fig 90 will appear In this case select No log out and perform the above steps again ...

Page 129: ...er is logged out the Password Reset dialog box is opened Refer to Fig 91 Fig 91 Reset Password dialog box 4 Select Installer in the dialog box 5 In the blank field type in the 12 character random code from the card that shipped with the valve and or the label on back of the electronics assembly 6 Select the Reset Password button Refer to Fig 92 ...

Page 130: ... of this manual for details OEM Password Reset Procedure During initial valve commissioning the OEM will be required to assign a main password and a reset password for the valve if enabled These 2 passwords CANNOT be the same However the reset password CAN be the same for all individual OEM valves appliances If enabled the reset password allows the OEM to reset the current OEM main password back t...

Page 131: ... the valve using it and edit the parameters to which they have granted the Installer access In order to make OEM level editing possible again the valve main electronics would have to be replaced and the valve completely re programmed at both the OEM and Installer levels Procedure 1 To reset the OEM password access the valve using either the HMI Tool touchscreen display or the PC Tool 2 Navigate to...

Page 132: ... 5 In the blank field type in the established OEM Reset password 6 Select the Reset Password button Refer to Fig 96 Fig 96 Reset Password dialog box with entered password 7 When the OEM Reset password has been successfully reset the acknowledgement dialog box will appear Refer to Fig 97 Select OK to exit this mode ...

Page 133: ...g screens may be accessed one of two ways Selecting the icon of a connected valve and selecting the Valve Production Cloning button from the pop up screen Refer to Fig 100 Selecting the Valve Production Cloning button in the Setup Tests menu for a connected valve Refer to Fig 113 The cloning feature allows the Installer or OEM user to load a previously saved fuel air valve configuration to use for...

Page 134: ...le Disable password reset functionality Installer Access Level is set to OEM and cannot be changed OEM Access Level is set to OEM and cannot be changed Main passwords OEM optional Installer optional OEM Reset password optional can only be configured and cloned when OEM Password Reset functionality is Enabled Remote Reset Access Level for Remote Reset via user interface POC Proof of Closure Access ...

Page 135: ... Slow Gear parameters are not on the FAR OEM Setup page and are accessible via the Modbus Editor page only FAR Ignition Ramp Offset Access Level Ramp Period Access Level Hold On Period Access Level Ignition Period Access Level Ignition Setpoint Access Level FAR Base Curve Base Curve Access Level FAR Correction Curve Access Level of Curve commissioning Access Level of Curve Name Access Level of Cur...

Page 136: ...connected to the user interface HMI Tool or PC Tool navigate to the Home page The attached unconfigured valve s are identified via the text Unconfigured at the bottom of the valve tile s Refer to Fig 99 Fig 99 Unconfigured valve tile on user interface 2 Select the appropriate connected valve tile The unconfigured valve selection screen will pop up Select the Valve Production Cloning button Refer t...

Page 137: ...op up a The page look and next steps will depend on whether passwords have not been assigned Refer to Fig 102 or have been assigned Refer to Fig 103 Valve Configuration Without Passwords The steps for selecting and uploading the valve configuration groups without and with passwords is the same with one exception the user does not need to fill in the OEM password if passwords have not been assigned...

Page 138: ...ed when the selected configuration was created Typically this password would be specific to a particular valve appliance configuration and would be the same for valves appliances of that configuration from an OEM manufacturer in accordance with best practices For further information on password access levels and best practices refer to CHAPTER 6 ACCESS LEVELS NOTE The last entered and valid OEM ma...

Page 139: ...ing the selected configuration to the valve the progress bar pops up to show download progress Refer to Fig 106 Fig 106 Load valve configuration progress bar 7 Once the data is successfully sent and verified the text Data sent successfully is displayed at the top of the progress bar Refer to Fig 107 Fig 107 Load valve configuration successful completion 8 Select the OK button Fig 107 to proceed to...

Page 140: ...ion page 9 Perform the Safety Parameters Verification by selecting the Begin button Fig 109 Safety Parameters Verification completed 10 Select the Finish Setup button to complete the valve cloning procedure Fig 110 Setup Complete page 11 There are two options on the Setup Complete page ...

Page 141: ...plete start the valve in the Installer or OEM mode and set the new fuel air Correction Curve and record the Ign Air Level to make the valve fully operational Configured Valve Procedure 1 With the valve connected to the user interface HMI Tool or PC Tool navigate to the Home page The attached configured valve s are identified via a date stamp at the bottom of the valve tile s Refer to Fig 111 Fig 1...

Page 142: ... Select the appropriate valve configuration to load to the valve by pressing the Open button beside it Refer to Fig 114 The configuration cloning groups page will pop up a The page look and next steps will depend on whether passwords have not been assigned Refer to Fig 116 or have been assigned Refer to Fig 117 Valve Configuration Without Passwords The steps for selecting and uploading the valve c...

Page 143: ...roups selection without passwords Valve Configuration With Passwords Fig 116 Valve Production Cloning configuration groups selection with passwords Valve Security group selected Fig 117 Valve Production Cloning configuration groups selection with passwords Valve Security group selected and OEM configuration password automatically pre filled ...

Page 144: ...in password is temporarily stored for the selected valve configuration If the same valve configuration is opened again the OEM main password is automatically prefilled refer to Fig 117 If a different valve configuration is selected the OEM main password must be entered again b If the Valve Security group is unchecked the OEM main password does not need to be entered on this page Refer to Fig 118 F...

Page 145: ... configuration successful completion 10 Select the OK button to proceed to the Safety Parameters Verification step Refer to Fig 121 and Fig 122 Fig 121 Safety Parameters Verification page 11 Perform the Safety Parameter Verification by selecting the Begin button Fig 122 Safety Parameters Verification completed ...

Page 146: ...ion s will result The user needs to confirm acceptance of the replaced FARMOD on the FARMOD tab in the Setup Tests menu or they can use the guided setup routine to complete all setup functions When the FARMOD is replaced The FARMOD back up data stored on the valve main electronics board is automatically loaded onto the replacement FARMOD once the valve is powered Normal operation of the valve will...

Page 147: ...RMOD and main electronics CANNOT be replaced at the same time or all Honeywell and OEM factory field data will be lost including the valve specific stepper motor full stroke calibration If both components must be replaced the installer must replace 1 at a time Follow the Fuel Air Ratio Module Change Out Procedure outlined in this chapter restoring power after to preserve the configuration Then fol...

Page 148: ...ig 124 Active faults with new FARMOD 3 Navigate to the Setup Tests menu and select the Settings tile See Fig 125 Fig 125 Setup Tests menu 4 Go to the FARMOD tab and Accept the newly attached FARMOD by pressing the Accept button Refer to Fig 126 Fig 127 ...

Page 149: ...pted 5 By accepting the new FARMOD the partial FARMOD data is automatically loaded into the new FARMOD from the valve main electronics where it is backed up The data includes the Base Curve and valve specific modulation motor full stroke data The OEM Setup and Ignition Setup parameters are always stored in the main board 6 There will be an Ignition parameter fault since the recorded pre ignition a...

Page 150: ...nd repeat this process for any intermediate load points The maximum load point should be commissioned last c While defining the gain setting for various loads additional commissioning data can be entered To enable this function select Enter Optional Data d The commissioning of any point can be interrupted by selecting the Stop Point Commissioning button NOTE The user can choose to modify the exist...

Page 151: ...be a FARMOD mismatch active fault present Refer to Fig 130 Fig 130 Active faults with previously configured used FARMOD 3 Navigate to the Setup Tests menu and select the Settings tile See Fig 131 Fig 131 Setup Tests menu 4 Go to the FARMOD tab and Accept the attached used FARMOD by pressing the Accept button Refer to Fig 128 Fig 129 ...

Page 152: ...MOD the partial FARMOD data is automatically loaded into the new FARMOD from the valve main electronics where it is backed up The data includes the Base Curve and valve specific modulation motor full stroke data The OEM Setup and Ignition Setup parameters are always stored in the main board 6 There will be an Ignition parameter fault as shown in Fig 133 since the recorded pre ignition air value Re...

Page 153: ...evel has stabilized at the right level Select the Set Min button to store the gain factor for this point b Increase the appliance load and repeat this process for any intermediate load points The maximum load point should be commissioned last c While defining the gain setting for various loads additional commissioning data can be entered To enable this function select Enter Optional Data d The com...

Page 154: ...e valve configuration 22 Lo Hi Gas pressure not configured 47 Safety parameter verification 77 POC proof of closure of MV1 not verified 78 POC proof of closure of MV2 not verified IMPORTANT If the Valve Production Cloning procedure is not performed BEFORE replacing the valve main electronics parameters will be lost including the valve body size Additionally the premix fuel air OEM Setup Ignition S...

Page 155: ...ction Cloning screen 2 Remove power to the valve and replace electronics assembly per instructions in the SV2 Series Replacement Electronics installation instruction document 32 00039 which is packed with the replacement electronics assembly Fig 137 NEMA 1 IP20 and NEMA 4 IP66 replacement electronics assemblies ...

Page 156: ... for detailed cloning steps a If all of the items shown in Fig 138 are checked the following items are cloned Valve name Modbus address baud rate Valve General Settings Units Access Levels Settings Valve Security Settings Proof of Closure setup Pressure Module Lockout Types and VPS Setup Fuel Air OEM Setup Ignition Setup b Note that the user will need to re commission the Pressure Module Hi Gas an...

Page 157: ...essure Module Lo Gas and Hi Gas settings if used to make the valve fully operational a Note that the Fuel Air valve V2V models Base Curve Correction Curve and Pre Ignition calibration settings are restored from the connected FARMOD upon valve power up b Pressure Module Lo Gas and Hi Gas limit settings Refer to Fig 142 Navigate to the Setup Tests menu Select the Hi Gas Lo Gas Pressure tile Accept t...

Page 158: ...kings A B C D and guide posts for mounting the Pressure Module and C6097 pressure switches to the pressure access ports Also each body has a valve chassis ground connection as well as tapped and threaded holes to affix the electrical enclosure in place Each body ordered with NPT port threads has an appropriately sized NOVV normally open vent valve connection If the valve mounting in the field is s...

Page 159: ...l applicable electrical codes ordinances and regulations Wiring must comply with NEC Class 1 line voltage wiring Use lead wire which can withstand 90 C 194 F ambient temperatures Voltage and frequency of the power supply connected to this control must agree with those marked on the device Loads connected to the VPS valve proving sequence Switch and or POC proof of closure contacts if used must not...

Page 160: ... 485 MODBUS and ANALOG b Loosen the MOTOR cord grip and remove the connector from the electrical enclosure It will need to be relocated to the other side of the valve c Make note of wire connections for each connector Also reference the as built electrical drawings and or the electrical drawings in the BURNER CONTROL INTERFACE WIRING section of this manual 6 Loosen factory lock nuts and their mati...

Page 161: ... b Fasten side mounted components to appropriate location s 1 or 2 Recommended tightening torque is 1 8 2 2 Nm 16 20 in lbf c Optional Fasten the pressure access cover to the un used side of the valve Recommended tightening torque is 1 8 2 2 Nm 16 20 in lbf 12 Tighten chassis ground wire on opposite side of valve Recommended tightening torque is 4 5 Nm 35 44 in lbf 13 Thread MOTOR connector throug...

Page 162: ...L AIR Open Closed Self Test Fault LGP HGP Open Closed Reset Fig 145 Proper SOLENOID POC connection association relative to valve body casting markings 17 Re install the flex conduits threading wires into electrical enclosure as required and tighten conduit to manufacturer s recommendations SOLENOID 1 PROOF OF CLOSURE POC 1 POC 2 SOLENOID 2 MAINS SUPPLY L1 N MAINS CHASSIS GROUND ILK ILK VPS POC MV2...

Page 163: ...b Select the drop down menu for the LED Indication parameter to change the selection In order to change this selection the user must be logged in with the appropriate user access level as assigned by the OEM the OEM can select the access level for the Valve General settings as OEM or Installer Refer to Fig 86 in CHAPTER 6 ACCESS LEVELS 1 Press and hold the valve Reset button for 10 seconds until a...

Page 164: ...ernal relay diagnostics are complete The valve POC Proof of Closure output terminal is energized when both valve seats are sensed closed and open if one or both valve seats are sensed as not closed On BASIC and STANDARD electronics versions the valve POC output will remain energized even during a valve lockout condition When using the Pressure Module for the Lo Gas Hi Gas limits the software is on...

Page 165: ... PROGRAMMED AND USED FOR LOW GAS PRESSURE AND HIGH GAS PRESSURE LIMITS THE LIMITS ARE INCLUDED IN THE INTERNAL ILK INTERLOCK VALVE STRING BASIC 5 ELECTRONICS VALVES DO NOT HAVE THE ABILITY TO INTERFACE WITH THE SV2 SERIES VALVE PRESSURE MODULE AN EXTERNAL PRESSURE SWITCH MUST BE USED WITH THESE VALVE MODELS OBSERVE FLAME SAFEGUARD WIRING PER ITS MANUAL FOR RM7838 CONTROLS WIRE THE SV2 SERIES VALVE...

Page 166: ...S DO NOT HAVE THE ABILITY TO INTERFACE WITH THE SV2 SERIES VALVE PRESSURE MODULE AN EXTERNAL PRESSURE SWITCH MUST BE USED WITH THESE VALVE MODELS OBSERVE FLAME SAFEGUARD WIRING PER ITS MANUAL FOR THE EC7810 WIRE THE SV2 SERIES VALVE ILK INTERLOCK IN SERIES WITH THE LIMITS AND CONTROLLER AS THIS MODEL DOES NOT HAVE AN AIRFLOW SWITCH 2 2 EC7810 EC7820 EC7830 RM7830 EC7850 RM7850 ILKOUT MV1 MV2 ILKIN...

Page 167: ...IMITS ARE INCLUDED IN THE INTERNAL ILK INTERLOCK VALVE STRING BASIC 5 ELECTRONICS VALVES DO NOT HAVE THE ABILITY TO INTERFACE WITH THE SV2 SERIES VALVE PRESSURE MODULE AN EXTERNAL PRESSURE SWITCH MUST BE USED WITH THESE VALVE MODELS OBSERVE FLAME SAFEGUARD WIRING PER ITS MANUAL IF SOLA INTERNAL OPERATING CONTROL IS USED EXTERNAL CONTROL WIRING NOT APPLICABLE 2 2 RM791X SOLA ILKOUT MV1 MV2 ILKIN PO...

Page 168: ... MODELS FOR RM7838 CONTROLS WIRE THE SV2 SERIES VALVE ILK INTERLOCK AHEAD OF THE LOCKOUT INTERLOCKS AND COMBUSTION AIR BLOWER SWITCHES INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLTAGE 1 MATCH SV2 SERIES VALVE AND FLAME SAFEGUARD VOLTAGES ILK INTERLOCK WIRING RUN THROUGH THE SV2 SERIES VALVE FOR SOLENOID POWER SAVING FEATURE APPLICABLE TO ALL SV2 SERIES VALVE MODELS 2 3 6 OTHER C...

Page 169: ...RNAL ILK INTERLOCK VALVE STRING BASIC 5 ELECTRONICS VALVES DO NOT HAVE THE ABILITY TO INTERFACE WITH THE SV2 SERIES VALVE PRESSURE MODULE AN EXTERNAL PRESSURE SWITCH MUST BE USED WITH THESE VALVE MODELS OBSERVE FLAME SAFEGUARD WIRING PER ITS MANUAL IF SLATE INTERNAL OPERATING CONTROL IS USED EXTERNAL CONTROL WIRING NOT APPLICABLE 2 2 SLATE R8001B2001 ILKOUT MV1 MV2 ILKIN POC VPS L1 N GROUND 3 3 5 ...

Page 170: ... valves As well per European standards the burner management control used shall have two line voltage switching elements in series that switch power to the valve coils If the burner control does not have two switching elements in series the following alternatives may be used in the European Union per KIWA For systems where VPS is not used MV1 and MV2 may be jumpered and powered together Option 1 A...

Page 171: ...t the secondary is an accessible voltage Use a 240 240VAC transformer ILKIN is only energized if both relays are ON Transformer may also be used to convert 240 120 24VAC as desired Match to appropriate SV2 Series valve model 24 120 240VAC NOTE EN61558 2 6 specifically requires that the secondary does not exceed 50 VAC or 120 V ripple free VDC whereas EN61558 2 16 does NOT have such a requirement I...

Page 172: ...BLE WHEN THE SV2 SERIES PRESSURE MODULE IS USED FOR EXTERNALLY INITIATED VALVE PROVING SEQUENCE BY BURNER MANAGEMENT OR OTHER CONTROL THIS FEATURE MUST BE ENABLED AND PROGRAMMED VIA THE HMI OR PC TOOLS WHEN COMMISSIONING THE VALVE WHEN THE SV2 SERIES VALVE PRESSURE MODULE IS ENABLED PROGRAMMED AND USED FOR LOW GAS PRESSURE AND HIGH GAS PRESSURE LIMITS THE LIMITS ARE INCLUDED IN THE INTERNAL ILK IN...

Page 173: ...ILK INTERLOCK AHEAD OF THE LOCKOUT INTERLOCKS AND COMBUSTION AIR BLOWER SWITCHES LINE VOLTAGE RELAY SPDT WITH NC CONTACT WIRE INTO THE LINE FROM RM EC SUBBASE MAIN VALVE TERMINAL 9 AND R7999 SUBBASE TERMINAL 11 RELAY NEEDED FOR VPS APPLICATION IF BEFORE SPLIT OR BOTH SELECTED NOT REQUIRED WHEN AFTER IS SELECTED INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLTAGE 1 MATCH SV2 SERIES ...

Page 174: ...E LIMITS ARE INCLUDED IN THE INTERNAL ILK INTERLOCK VALVE STRING BASIC 5 ELECTRONICS VALVES DO NOT HAVE THE ABILITY TO INTERFACE WITH THE SV2 SERIES VALVE PRESSURE MODULE OR VPS FUNCTIONALITY AN EXTERNAL PRESSURE SWITCH MUST BE USED WITH THESE VALVE MODELS OBSERVE FLAME SAFEGUARD WIRING PER ITS MANUAL 2 2 SLATE R8001B2001 ILKOUT MV1 MV2 ILKIN POC VPS L1 N GROUND 4 3 6 5 6 5 5 7 CONTROL LIMITS INTE...

Page 175: ...ral voltages will not work as is with the SV2 Series valves and require extra components plus wiring to make them work effectively with the SV2 Series valves As well per European standards the burner management control used shall have two line voltage switching elements in series that switch power to the valve coils If the burner control does not two switching elements in series the following alte...

Page 176: ...cs EEPROM is corrupt 1 Reset valve and burner management system then cycle power 2 If fault persists replace main electronics 3 Recommission all valve parameters 23 EEPROM lockout code mis match Main electronics EEPROM lockout code storage value incorrect 1 Reset valve and burner management system then cycle power 2 If fault persists replace main electronics 24 Valve body parameter missing Valve b...

Page 177: ...ept new Fuel Air Ratio Module on the FARMOD tab in the Setup Tests menu of user interface 7 Recommission partially or fully as desired 25 Air flow sensor S1 frozen The air flow sensor returns a fixed value to the valve electronics During normal operation the signal is fluctuating The missing fluctuation of the signal indicates a fault in the sensor 1 Replace Fuel Air Module 2 Reset valve and burne...

Page 178: ...ly high for the requested minimum gas volume Lower the gas inlet pressure to SV2 Series valve or increase minimum capacity Practically the stepper motor position should be above 80 steps for the 1 5in and 2in valves and above 50 steps for the 1in valve Below these values the gas flow will change very little with changing motor position Fault indicates gas supply pressure is too high and minimum lo...

Page 179: ... fault persists replace Fuel Air Ratio Module 5 Accept new Fuel Air Ratio Module on the FARMOD tab in the Setup Tests menu of user interface 6 Recommission partially or fully as desired 7 Reset valve and burner management system monitoring for proper operation 8 If fault persists replace valve and re commission Warning indication for SV2 Series valve This condition will likely cause a burner contr...

Page 180: ...r Ratio controlled gas pressure was not within the control setpoint window within the specified time of 30 seconds Lower the modulation speed of the appliance burner to avoid this fault This fault can occur independently or in combination with fault 38 If this occurs with fault 38 FARMOD target S2a not reached it is an indication the gas supply pressure is too low 1 Check gas supply pressure to ap...

Page 181: ...th fault 70 FARMOD rough target S2a not reached it is an indication the modulation speed is too high 1 Check gas supply pressure to appliance 2 Check Fuel Air Module signal connections for proper engagement 3 Reset valve and burner management system monitoring for proper operation 4 Check lower appliance burner modulation speed by decreasing fan control P factor or limiting its RPM change per time...

Page 182: ...in the Setup Tests menu of user interface 6 Recommission partially or fully as desired 7 Reset valve and burner management system monitoring for proper operation If this fault occurs independently the Fuel Air Module is corrupt 1 Replace Fuel Air Module 2 Accept new Fuel Air Module on the FARMOD tab in the Setup Tests menu 3 Recommission partially or fully as desired 4 Reset valve and burner manag...

Page 183: ...of the appliance air supply If ignition load has changed 1 Recommission light off sequence 2 If fault persists perform steps below If ignition fan speed change is known suspected 1 Check that air duct is clear free of any foreign bodies and pollution 2 Check that blower is running at a proper rate 3 Check Fuel Air Module signal connections for proper engagement 4 Reset valve and burner management ...

Page 184: ...r proper engagement 4 Reset valve and burner management system 5 If fault persists recommission light off sequence Record new pre ignition air proving values by checking the Record Ign Air Level box on the Ignition Setup page once system is stabilized 6 Check combustion by measuring O2 and CO2 levels 7 If fault persists replace Fuel Air Module 8 Accept new Fuel Air Ratio Module on the FARMOD tab i...

Page 185: ...signal connections for proper engagement 4 Reset valve and burner management system 5 If fault persists recommission light off sequence Record new pre ignition air proving values by checking the Record Ign Air Level box on the Ignition Setup page once system is stabilized 6 Check combustion by measuring O2 and CO2 levels 7 If fault persists replace Fuel Air Ratio Module 8 Accept new Fuel Air Ratio...

Page 186: ...in not defined This fault is ignored when the Installer or OEM are logged into the valve If the curve minimum was not defined during commissioning and commissioning mode is exited the valve will lockout on this fault Commission the Fuel Air curve ensuring the minimum firing rate is entered 52 Fuel Air motor driver Fuel Air stepper motor fault signal is active due to possible overheat or electrical...

Page 187: ...ace valve electronics 55 FARMOD fuel sensor is stuck The Fuel Air Ratio Module flow sensor returns a fixed value to the valve electronics During normal operation the signal is fluctuating The missing fluctuation of the signal indicates a fault in the sensor 1 Replace Fuel Air Module 2 Reset valve and burner management system 3 Accept new Fuel Air Ratio Module on the FARMOD tab in the Setup Tests m...

Page 188: ...is programmed in the OEM Setup parameters via the S1 maximum threshold parameter The default is 120 1 Check that air duct is clear free of any foreign bodies and pollution 2 Check that blower is running at a proper rate 3 Check Fuel Air Module signal connections for proper engagement 4 Reset valve and burner management system 5 Recommission Fuel Air curve 6 If fault persists replace Fuel Air Modul...

Page 189: ...PM change per time unit 5 If fault persists replace Fuel Air Module 6 Accept new Fuel Air Ratio Module on the FARMOD tab in the Setup Tests menu of user interface 7 Recommission partially or fully as desired 8 Reset valve and burner management system monitoring for proper operation 9 If fault persists replace valve and re commission Warning indication for SV2 Series valve This condition will likel...

Page 190: ... system monitoring for proper operation 4 If fault persists replace valve and re commission 79 FARMOD flow sensor S2b out of range Fuel Air Ratio Module flow S2b sensor value out of range 1 Reset valve and burner management system monitoring for proper operation 2 Check system filter for clogging and replace as necessary 3 If fault persists replace Fuel Air Ratio Module 4 Reset valve and burner ma...

Page 191: ...Control Valve Full Stroke Mismatch The recorded full stroke of the control valve does not match valve size Replace the valve and re commission 89 Fuel Air Base Curve Min not defined Fuel Air Ratio base curve minimum value has not been defined In installer mode this fault is ignored Commission or load the base fuel air curve ensuring the minimum firing rate is entered 91 Fuel Air Base Curve Max not...

Page 192: ... Ratio Module on the FARMOD tab in the Setup Tests menu of user interface 9 Recommission partially or fully as desired 10 Reset valve and burner management system monitoring for proper operation 94 New FARMOD detected New Fuel Air Ratio Module detected which has to be accepted and programmed before use 1 Accept new Fuel Air Ratio Module on the FARMOD tab in the Setup Tests menu of user interface 2...

Page 193: ... and burner management system 6 If fault persists replace FARMOD 7 Accept new Fuel Air Ratio Module on the FARMOD tab in the Setup Tests menu of user interface 8 Recommission partially or fully as desired 107 ILK Valve Interlock Out ILK OUT signal fault Valve ILK OUT terminal signal is not valid Frequency or duty is out of expected range Remove power and shut off gas supply as necessary 1 Remove v...

Page 194: ...and burner management system observing valve burner operation Measure ILK IN and ILK OUT voltages and verify proper values during a burner valve run state 3 Remove power and shut off gas supply as necessary 4 Verify no jumpers exist between L1 and valve ILK OUT terminals or ILK IN and ILK OUT terminals 5 Verify that ILK IN and ILK OUT are not reversed check against wiring diagrams in valve install...

Page 195: ... wiring connections for wire engagement seating pin engagement and cleanliness d Check for voltage between L2 neutral and earth ground at the valve and at the burner management system Correct any wiring errors providing a powered ground floating neutral or improper ground reference 3 Replace cover and restore power NOT gas Reset valve and burner management system monitoring for proper operation in...

Page 196: ...onics assembly for the Pressure Module and or Fuel Air Ratio Module Remove power and shut off gas supply 1 Remove valve front electrical enclosure and disconnect Pressure Module and Fuel Air Ratio Module connections if present 2 Restore power 3 Reset valve and burner management system 4 If fault persists replace valve main electronics 5 Reconnect Pressure Module if present to valve main electronic...

Page 197: ...l signal is not valid Frequency or duty is out of expected range Remove power and shut off gas supply as necessary 1 Remove valve front electrical enclosure and inspect MV1 L1 and N wiring connections for wire engagement seating pin engagement and cleanliness 2 Ensure MV1 is wired to proper terminals on burner management system 3 Replace cover and restore power and gas Reset valve and burner manag...

Page 198: ...leanliness Correct any errors 2 Check the valve power supply to make sure that both frequency and voltage meet the specifications 3 Replace cover and restore power and gas Reset valve and burner management system monitoring for proper POC operation in conjunction with valve LEDs and burner management system inputs 4 If fault persists replace valve main electronics 10 POC output signal mis match Va...

Page 199: ...oring for proper POC operation in conjunction with valve LEDs and burner management system inputs 4 If fault persists replace valve main electronics 5 If fault persists replace entire valve 75 POC proof of closure fault for MV2 Fault detected in POC 2 switch or its connection to valve circuit board Possible internal fault in electronics interface to POC 2 switch Remove power and shut off gas suppl...

Page 200: ...s assembly They also validate proper procedure was followed if the valve electronics orientation was swapped or the valve electronics assembly was replaced in the field 77 POC proof of closure of MV2 not verified Proof of closure verification procedure not completed 1 Ensure the Proof of Closure setup acceptance procedure has been performed Go to the Setup Tests screen select the Settings menu and...

Page 201: ... 2 Inspect internal wiring between solenoids and valve electronics The solenoid number is indicated by the direction of flow arrow and number 1 in the valve casting Ensure the appropriate solenoid connector is placed in the appropriate terminal SOLENOID 1 on the valve electronics assembly 3 Inspect internal wiring between solenoid proof of closure switch es and valve electronics The solenoid numbe...

Page 202: ...iring between solenoids and valve electronics The solenoid number is indicated by the direction of flow arrow and number 2 in the valve casting Ensure the appropriate solenoid connector is placed in the appropriate terminal SOLENOID 2 on the valve electronics assembly 3 Inspect internal wiring between solenoid proof of closure switch es and valve electronics The solenoid number is indicated by the...

Page 203: ...sion High gas pressure setting as necessary 21 Lo Hi Gas pressure not configured Pressure Module not configured for low and high gas pressure functions NOTE Low and High gas pressure settings must be configured before valve will be operational 1 Commission Low and High gas pressure settings as necessary Warning indication for SV2 Series valve 22 Pressure out of range Pressure out of the allowed Pr...

Page 204: ...e valve casting and the O ring is compressed 6 Verify the correct mounting location and pressure port are being used for the valve model refer to documents 32 00017 and 32 00029 7 Recommission Low and High gas pressure settings as necessary 19 Pressure Module Pressure Module over pressure System pressure above Pressure Module rating 1 Verify the Pressure Module rating is correct for the applicatio...

Page 205: ...t be trying to login Find this device and disable it before trying to login 99 Installer password reset feature temporarily disabled Installer password reset feature is temporarily disabled due to too many unsuccessful reset attempts Wait at least 1 minute before new attempt to reset password If message is present with no attempts to reset password another device on network might be trying to rese...

Page 206: ...out of expected range Remove power and shut off gas supply as necessary 1 Remove valve front electrical enclosure and inspect SOLENOID 1 and MV1 wiring connections for wire engagement seating pin engagement and cleanliness 2 Ensure MV1 is wired to proper terminals on burner management system 3 Replace cover and restore power and gas Reset valve and burner management system 4 Measure MV1 voltage fo...

Page 207: ...ected mode do not match 1 Reset valve and burner management system observing valve burner operation 2 If fault persists replace valve main electronics 8 Verifi cation Needed Safety parameter verification One or more safety parameters have been modified and or waiting for verification procedure Perform safety parameters verification procedure Go to Setup Tests screen press button Verify Safety Para...

Page 208: ...able 27 SV2 Series maximum tightening torques Category Item Picture Maximum Tightening Torque Nm In lbf Valve enclosure Front electronics cover NEMA 1 IP20 and NEMA 4 IP66 M37170 Open Closed Self Test Fault LGP HGP Open Closed Reset Open Closed Self Test Fault LGP HGP Open Closed Reset 1 26 1 54 11 13 63 Rear solenoids cover NEMA 1 IP20 and NEMA 4 IP66 M37171 2 2 2 35 19 5 20 8 Electrical enclosur...

Page 209: ... the cord grip or factory provided plugs 4 5 5 1 40 45 6 NEMA 4 IP66 wiring ports in 1 27cm NPT low voltage cord grip for RS 485 Modbus wiring Cord grip sealing nut around the cord 5 6 6 2 50 55 6 NEMA 4 IP66 wiring ports M16x1 5 low voltage cord grips or factory provided plugs Includes field PRESSURE connector factory SOLENOID 1 2 POC 1 2 and CHASSIS GROUND wire cord grips 3 7 4 3 33 38 Flange to...

Page 210: ...SV2 Series valves include a Honeywell specific secure Modbus protocol Standard Modbus RTU protocol is used however safety related and writable parameters are covered by a secure layer As a result they are only writable when accessed using a valid user access level and appropriate user interfaces which are designed to work with the secure layer The Modbus addresses shown in this section are readabl...

Page 211: ...4 Reset User has pressed a push button during normal operation Gas valves are turned OFF and faults are cleared 15 Run Valve has gone through StartUp and is running 16 InterlockStringTest An interlock string test performed after power up or after lockout is cleared 17 SafetyRelayTest A safety relay test performed after power up or after lockout is cleared The SV2 Series valve Modbus address space ...

Page 212: ... value 0xAA55 is written and remaining number of resets 0 then reset action will be performed NOTE All national and local codes must be followed in regards to the allowance of remote reset 0 65535 5 90 5A SV2 valve Modbus slave address U16 Low byte contains address and high byte its negated value otherwise default address is used 0 65535 91 5B Modbus communication baud rate U16 9600 19200 38400 or...

Page 213: ...Dec Hex Min Max 107 6B Pressure Module All Standard Pressure Module factory data 62 x Char String of chars ended by either ASCII 0 or end of register array Two chars per register 108 6C 109 6D 110 6E 111 6F 112 70 113 71 114 72 115 73 116 74 117 75 118 76 119 77 120 78 121 79 122 7A 123 7B 124 7C 125 7D 126 7E 127 7F 128 80 129 81 130 82 131 83 132 84 133 85 134 86 135 87 136 88 137 89 ...

Page 214: ...ure LGP Limit Set Point in user selected pressure units Based on selected Lo Gas Limit of operating pressure and actual measured Operating Pressure during setup refer to Holding Register 160 U16 0 Invalid value Pressure in user selected units See Holding Register 74 for selected units 163 A3 Calculated High gas pressure HGP Limit Set Point in user selected pressure units Based on selected Hi Gas L...

Page 215: ... S16 This sets the number of steps that the Learnt Pos 2 is reduced or offset during ignition Once the valve seats are powered the stepper motor moves from this position to the Learnt Pos 2 position during the Ignition Ramp Period time HR341 Register content is scaled by 4 i e value of 4 is one full step 4 50 4 34 32768 67 43 Ignition Default Position 2 U16 In half steps Used for the first initial...

Page 216: ... x Char 315 13B 62 x Char 316 13C 62 x Char 317 13D 62 x Char 318 13E 62 x Char 319 13F 62 x Char 320 140 62 x Char 340 154 Ignition Hold On Period U16 In seconds Sets the time that the control ignores the fuel air control feedback following the Ramp Period HR341 The Fuel Control Valve is held at the controlled valve position for the specified time before it starts to modulate Register content is ...

Page 217: ...at the air S1 signal can be below the recorded commissioned minimum air signal of the Correction Curve during normal RUN mode at minimum load If the S1 signal drops below this value the valve is cycled off and waits for S1 to rise above this value The valve does not lockout 50 95 80 780 30C S1 maximum threshold U16 A that the air S1 signal can be over the recorded commissioned maximum air signal o...

Page 218: ...fer to Table 31 95 5F Valve VAC signal status Bit array Low status word Refer to Table 36 96 60 Bit array High status word Refer to Table 36 214 D6 Valve accumulated operation time in hours U16 Upper 2 bytes 215 D7 U16 Lower 2 bytes Resolution 0 25 hr 216 D8 Valve accumulated number of cycles Either MV1 or MV2 whichever is higher U16 Upper 2 bytes 217 D9 U16 Lower 2 bytes 225 E1 Valve factory data...

Page 219: ...essure Module used Shown in user selected pressure units U16 Pressure See Holding Register 74 for selected units 25 19 Maximum applicable pressure range for Pressure Module used Shown in user selected pressure units U16 Pressure See Holding Register 74 for selected units 63 3F Hi Lo Gas Pressure function status Enum 0 HGP and LGP function disabled 1 HGP and or LGP function enabled no pressure setu...

Page 220: ... EEPROM data matches RAM storage 0x81 Communication error 0x82 EEPROM writing failed 0x84 RW data inconsistency 0x88 RO data inconsistency 41 29 Pressure Module sensor 1 serial number U16 Number 43 2B Pressure Module sensor 2 serial number U16 Number 45 2D Pressure Module sensor 3 serial number U16 Number 320 140 POC All Standard Proof of Closure 1 POC 1 status Enum 0 POC reading and function disa...

Page 221: ...14 Valve 2 accumulated cycles recorded during last VPS sequence U16 Upper word 277 115 U16 Lower word 682 2AA VPS recorded leakage rate for MV1 S16 Expressed in units selected by user during setup 683 2AB Number of averaged VPS measurements for MV1 U16 Dimensionless number 684 2AC Recorded valve cycles during MV1 VPS test U16 Upper word 685 2AD U16 Lower word 686 2AE VPS test execution time for MV...

Page 222: ...A Fault code of 3rd previous fault U16 Number 155 9B Time stamp of 3rdprevious fault U16 Upper 2 bytes 156 9C U16 Lower 2 bytes 157 9D Cycle count of 3rd previous fault U16 Upper 2 bytes 158 9E U16 Lower 2 bytes 159 9F Fault code of 4th previous fault U16 Number 160 A0 Time stamp of 4th previous fault U16 Upper 2 bytes 161 A1 U16 Lower 2 bytes 162 A2 Cycle count of 4th previous fault U16 Upper 2 b...

Page 223: ...0th previous fault U16 Upper 2 bytes 193 C1 U16 Lower 2 bytes 194 C2 Fault code of 11th previous fault U16 Number 195 C3 Time stamp of 1th previous fault U16 Upper 2 bytes 196 C4 U16 Lower 2 bytes 197 C5 Cycle count of 11th previous fault U16 Upper 2 bytes 198 C6 U16 Lower 2 bytes 199 C7 Fault code of 12th previous fault U16 Number 200 C8 Time stamp of 12th previous fault U16 Upper 2 bytes 201 C9 ...

Page 224: ...ition scaled by 4 i e value of 4 is one full step 127 7F Full valve stroke in motor steps S16 Position scaled by 4 i e value of 4 is one full step run between end stops in the last detection cycle 297 129 Target amplification S16 Current gain value based on current fuel air curve and settings Value scaled by 1x104 298 12A Fuel air curve informational flags related to curve loading and saving U16 B...

Page 225: ...amplification value Amplification value is dimensionless 1 indicates an empty cell 382 17E Y coordinate 1 383 17F Y coordinate 2 384 180 Y coordinate 3 385 181 Y coordinate 4 386 182 Y coordinate 5 387 183 Y coordinate 6 388 184 Y coordinate 7 389 185 Y coordinate 8 390 186 Y coordinate 9 391 187 Y coordinate 10 392 188 Y coordinate 11 393 189 Y coordinate 12 394 18A Y coordinate 13 395 18B Y coor...

Page 226: ... control valve position 20 434 1B2 Fuel Air curve control valve position 21 435 1B3 Fuel Air curve control valve position 23 436 1B4 Fuel Air curve control valve position 24 467 1D3 Fuel Air V2V Standard Fault flag 0 U16 0 FARMOD fatal data not recoverable 1 Flow sensor related faults 2 Faults related to FARMOD 3 Stepper motor related faults 4 FARMOD control valve faults 5 Light off related faults...

Page 227: ...56 290 O2 reading data point 9 657 291 O2 reading data point 10 658 292 O2 reading data point 11 659 293 O2 reading data point 12 660 294 O2 reading data point 13 661 295 O2 reading data point 14 662 296 O2 reading data point 15 663 297 O2 reading data point 16 664 298 O2 reading data point 17 665 299 O2 reading data point 18 666 29A O2 reading data point 19 667 29B O2 reading data point 20 668 29...

Page 228: ...inate 0 U16 Y coordinate of BASE fuel air curve amplification value Amplification value is dimensionless 1 indicates an empty cell 733 2DD Y coordinate 1 734 2DE Y coordinate 2 735 2DF Y coordinate 3 736 2E0 Y coordinate 4 737 2E1 Y coordinate 5 738 2E2 Y coordinate 6 739 2E3 Y coordinate 7 740 2E4 Y coordinate 8 741 2E5 Y coordinate 9 742 2E6 Y coordinate 10 743 2E7 Y coordinate 11 744 2E8 Y coor...

Page 229: ...d via Modbus It is cleared as soon as the curve is verified via the safety verification procedure Bit 9 true indicates that a new curve point has just been successfully saved was accepted by SV2 valve 766 2FE Base curve current amplification S16 Current amplification value based on a current curve and firing rate Value scaled by 1x104 768 300 Fuel Air curve current gain S16 Current gain value base...

Page 230: ... feedback full power mode 11 12 Solenoid 1 feedback power save mode 13 14 Solenoid 2 feedback power save mode 15 16 Solenoid 1 feedback for MV1 relay test full power mode 17 Table 37 VPS valve body dependent parameter limits Valve Body HR149 Maximum of Leakage Limit HR151 Chamber Volume HR152 Maximum of Extra Volume HR153 Description 0 50 liters hour 0 0 7 Non defined value 1 50 liters hour 0 44 0...

Page 231: ...h electronics valve proving system 9841122 User interface for a valve controller D763921 A system for a valve setup 10502340B2 United Kingdom Gas valve with electronic valve proving system EP2604923 Gas valve with fuel rate monitor EP2604922 Gas valve with communication link EP2604924 A system for a valve setup EP3133345 Germany Gas valve with electronic valve proving system 602012015895 6 Gas val...

Page 232: ... Honeywell Sales Engineer Honeywell Process Solutions Honeywell Thermal Solutions HTS 1250 West Sam Houston Parkway South Houston TX 77042 ThermalSolutions honeywell com U S Registered Trademark 2019 Honeywell International Inc 32 00029 02 M S 12 19 Printed in U S A For more information on this product and the entire SV2 Series product line please refer to the SV2 Series User Guide located on our ...

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