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Honeywell R7140G Installation Instructions Manual

Burner control modules
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R7140G,L,M
Burner Control Modules
APPLICATION
The Honeywell R7140G,L,M Burner Control Modules are
microprocessor-based integrated burner controls for
automatically fired gas, oil or combination fuel single burner
applications. The Burner Control Module system consists of a
Relay Module, Q520A Subbase, Amplifier and Purge Card.
Options include S7800 Keyboard Display Modules (KDM).
The R7140 Burner Control Modules directly replace many
BC7000 PM720G,L,M, and many R4150G,L,M and
R4140G,L,M units using the existing Q520A 20-terminal
Wiring Subbase.
The R7140 can be demonstrated or tested on the FSP5004
tester. Note that the R7849 UV Amplifier or the R7851 Optical
Flame Amplifier cannot be tested.
The R7140G,L,M is programmed to provide a level of safety,
functional capability and features beyond the capacity of
conventional controls.
Functions provided by the R7140G,L,M include automatic
burner sequencing, flame supervision, system status
indication, system or self-diagnostics and troubleshooting.
INSTALLATION INSTRUCTIONS
FEATURES
• Device status available to ModBus™ through S7810M
card or S7800A1001 Series 5 Keyboard Display.
• Safety features:
— Interlock check.
— Closed loop logic test.
— Dynamic AMPLI-CHECK™.
— Dynamic input check.
— Dynamic safety relay test.
— Dynamic self-check logic.
— Expanded safe-start check.
— High Fire Purge Switch test (R7140L only).
— Internal hardware status monitoring.
— Low Fire Start Switch test.
— Tamper resistant timing and logic.
• Access for external electrical voltage checks.
• Application flexibility.
• 0.8 or 3.0 second Flame Failure Response Time
(FFRT), depending on amplifier selected.
• Dependable, long-term operation provided by
microcomputer technology.
• Five LEDs for sequence information. See Fig. 1.
• Five function Run/Test Switch.
• Interchangeable plug-in flame amplifiers.
• Nonvolatile memory; R7140 retains history files and
sequencing status after loss of power and can be
viewed using the Keyboard Display Module
S7800A1001 (sold separately).
• Report generation (optional).
NOTE: Check Service Notes on page 7 and Static Checkout
on page 25 prior to installation of R7140.
• Burner controller data (optional):
— Lockout/alarm status.
— Total cycles of operation.
— Total hours of operation.
• Status of configuration jumpers.
• Status of Run/Test Switch.
66-1153-2

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  Summary of Contents for Honeywell R7140G

  • Page 1 Note that the R7849 UV Amplifier or the R7851 Optical Flame Amplifier cannot be tested. — Lockout/alarm status. — Total cycles of operation. The R7140G,L,M is programmed to provide a level of safety, — Total hours of operation. functional capability and features beyond the capacity of conventional controls.
  • Page 2: Specifications

    R7140G,L,M BURNER CONTROL MODULES Maximum Total Connected Load: 2000VA. Fusing—Total Connected Load: 15A fast blow, type SC or RUN/TEST SWITCH equivalent. Environmental Ratings: Ambient Temperature: PLUG-IN Operating: -40°F to +140°F (-40°C to +60°C). PURGE Storage: -40°F to +150°F (-40°C to +66°C).
  • Page 3 R7140G,L,M BURNER CONTROL MODULES Table 1. Flame Detection Systems. (Continued) Plug-in Flame Signal Amplifiers Applicable Flame Detectors Flame Failure Response Type Color Self-Checking Model Time (sec) Fuel Type Models Ultraviolet Purple R7849A 0.8 or 3 Gas, oil Ultraviolet C7027, C7035, C7044...
  • Page 4 ALARM RESET 1-1/4 (127) (32) 5-3/4 (146) (177) M22604 Fig. 2. Mounting dimensions of R7140G,L,M Burner Control Module with Q520A Subbase, in in. (mm). Table 3. Terminal Ratings. Terminal No. Description Ratings — Flame Sensor Earth Ground Earth G —...
  • Page 5: Installation

    R7140G,L,M BURNER CONTROL MODULES Table 4. Terminal Ratings. Terminal Typical Load Maximum Rating at 120 Vac, 60 Hz 5 or 6 Ignition 4.5A ignition and 50 VA pilot duty, or Transformer/Pilot 2.5A ignition and 75 VA pilot duty. Valve/First Stage Fuel Valve...
  • Page 6: Mounting Wiring Subbase

    R7140G,L,M BURNER CONTROL MODULES Mounting Wiring Subbase IMPORTANT 1. Wiring connections for the relay modules are unique; 1. Mount the subbase in any position except horizontally therefore, refer to Fig. 4–11 or the correct with the quadfurcated contacts pointing down. The Specifications for proper subbase wiring, and standard vertical position is recommended.
  • Page 7: Final Wiring Check

    R7140G,L,M BURNER CONTROL MODULES Final Wiring Check Replacing GP201 or GP301 devices: — High Fire (or Purge Rate) Switch may be connected to 1. Check the power supply circuit. The voltage and terminal D. frequency tolerance must match those of the R7140. A —...
  • Page 8: Mounting R7140 Relay Module

    R7140G,L,M BURNER CONTROL MODULES Mounting R7140 Relay Module Removing the Programmer 1. Open the master switch. 2. Loosen the chassis retaining screw. Installing the Programmer (Fig. 3) 3. Pull outward on the top of the chassis. 4. Disengage the chassis hinge brackets from the subbase pivot pins.
  • Page 9 R7140G,L,M BURNER CONTROL MODULES (HOT) 120 Vac, 50/60 Hz PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN FLAME MICROCOMPUTER AMPLIFIER TEST RESET PUSHBUTTON RELAY DRIVE RELAY CIRCUIT STATUS FEEDBACK AND LINE VOLTAGE INPUTS SAFETY RELAY...
  • Page 10 R7140G,L,M BURNER CONTROL MODULES (HOT) 120 Vac, 50/60 Hz PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN FLAME MICROCOMPUTER AMPLIFIER TEST CONTROL POWER SUPPLY POWER PRE-IGNITION INTERLOCK RUNNING/ LOCKOUT INTERLOCK LIMITS CONTROLLER 2K1 5K1 IGNITION...
  • Page 11 R7140G,L,M BURNER CONTROL MODULES FOR DIRECT SPARK IGNITION (OIL OR GAS) IGNITION TRANSFORMER 1ST STAGE FUEL VALVE 2ND STAGE FUEL VALVE (OPTIONAL) 5 SECOND IGNITION (EARLY SPARK WIRING TERMINATION) SUBBASE RUNNING TERMINAL INTERLOCKS STRIP (4) (INCLUDING 10 SECOND AIRFLOW SWITCH)
  • Page 12 R7140G,L,M BURNER CONTROL MODULES FOR DIRECT SPARK IGNITION (OIL OR GAS) IGNITION JUMPER MAIN OIL VALVE SOLENOID WIRING SUBBASE RUNNING TERMINAL INTERLOCKS STRIP (4) (INCLUDING 10 SECOND AIRFLOW SWITCH) INTERRUPTED PILOT/IGNITION PREIGNITION INTERLOCK(S) BURNER PILOT/IGNITION LIMITS CONTROLLER MAIN FUEL VALVE(S)
  • Page 13 R7140G,L,M BURNER CONTROL MODULES R7140L INITIATE PREPURGE PREPURGE PFEP (INITIAL HOLD HOLD 10 SEC. TIMED POWERUP DRIVE TO DRIVE TO (4 SEC. IF PREPURGE ONLY) STANDBY HIGH FIRE LOW FIRE JR1 CLIPPED MFEP POSTPURGE STANDBY POWER POWER POWER POWER POWER...
  • Page 14 R7140G,L,M BURNER CONTROL MODULES (HOT) 120 Vac, 50/60 Hz PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN MICROCOMPUTER FLAME AMPLIFIER TEST RESET PUSHBUTTON RELAY DRIVE RELAY CIRCUIT STATUS FEEDBACK AND LINE VOLTAGE INPUTS SAFETY RELAY...
  • Page 15 R7140G,L,M BURNER CONTROL MODULES (HOT) 120 Vac, 50/60 Hz PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN MICROCOMPUTER FLAME AMPLIFIER TEST RESET PUSHBUTTON RELAY DRIVE RELAY CIRCUIT STATUS FEEDBACK AND LINE VOLTAGE INPUTS SAFETY RELAY...
  • Page 16 R7140G,L,M BURNER CONTROL MODULES FOR DIRECT SPARK IGNITION (OIL OR GAS) IGNITION TRANSFORMER JUMPER MAIN FUEL VALVE 5 SECOND IGNITION WIRING (EARLY SPARK SUBBASE TERMINATION) LOCKOUT TERMINAL INTERLOCKS STRIP (4) (INCLUDING 10 SECOND AIRFLOW SWITCH) INTERRUPTED PILOT/IGNITION PREIGNITION INTERLOCKS 15 SECOND...
  • Page 17 R7140G,L,M BURNER CONTROL MODULES FOR DIRECT SPARK IGNITION (OIL OR GAS) IGNITION TRANSFORMER JUMPER MAIN FUEL VALVE (S) 5 SECOND IGNITION WIRING (EARLY SPARK SUBBASE TERMINATION) LOCKOUT TERMINAL INTERLOCKS STRIP (4) (INCLUDING 10 SECOND AIRFLOW SWITCH) INTERRUPTED PILOT/IGNITION PREIGNITION INTERLOCKS...
  • Page 18 R7140G,L,M BURNER CONTROL MODULES R7140M INITIATE PREPURGE PFEP (INITIAL HOLD 10 SEC. TIMED POWERUP DRIVE TO (4 SEC. IF PREPURGE ONLY) STANDBY LOW FIRE JR1 CLIPPED MFEP POSTPURGE STANDBY POWER POWER POWER POWER POWER POWER POWER POWER POWER PILOT PILOT...
  • Page 19 R7140G,L,M BURNER CONTROL MODULES CONFIGURATION PURGE JUMPERS TIMER FLAME AMPLIFIER INTERNAL ELECTRONICS ALARM BLOWER START INTERLOCKS LIMITS CONTROLLER AIRFLOW IGN XFMR INTERMITTENT PILOT 15 SECOND INTERMITTENT PILOT VALVE MAIN VALVE M23335 Fig. 15. Internal block diagram of the R7140M1007 with start interlocks. (See Fig. 17 for detailed wiring.)
  • Page 20 R7140G,L,M BURNER CONTROL MODULES FOR DIRECT SPARK IGNITION OF OIL OR GAS IGNITION 1ST STAGE FUEL VALVE 2ND STAGE FUEL VALVE (OPTIONAL) WIRING SUBBASE RUNNING TERMINAL INTERLOCKS STRIP (4) (INCLUDING 5 SECOND IGNITION AIRFLOW SWITCH) (EARLY SPARK TERMINATION) 10 SECOND...
  • Page 21 R7140G,L,M BURNER CONTROL MODULES FOR DIRECT SPARK IGNITION (OIL OR GAS) IGNITION TRANSFORMER 1ST STAGE FUEL VALVE 2ND STAGE FUEL VALVE (OPTIONAL) 5 SECOND IGNITION WIRING (EARLY SPARK SUBBASE RUNNING TERMINATION) TERMINAL INTERLOCKS STRIP (4) (INCLUDING AIRFLOW SWITCH) 10 SECOND...
  • Page 22: Safety Shutdown

    AC line input or control input. e. No flame is present at the end of PFEP. Main valve terminal is energized (R7140G,M). Standby g. Internal system fault occurs. h. Purge card is removed.
  • Page 23: Run/Test Switch

    2. The firing rate motor releases to modulation recycle to the beginning of PREPURGE for the (R7140G,L). Damper motor is energized (R7140M). R7140G,M will happen or a safety shutdown for the 3. The R7140 is now in RUN and remains in RUN until the R7140L occurs.
  • Page 24: Settings And Adjustments

    R7140G,L,M BURNER CONTROL MODULES SETTINGS AND ADJUSTMENTS 1. In Pre-Purge Drive To High Fire Position (R7140L), the Run/Test Switch, when placed in the TEST position, holds in PREPURGE with the firing rate motor in the Selectable Site-Configurable Jumpers High Fire position.
  • Page 25: Static Checkout

    R7140G,L,M BURNER CONTROL MODULES STATIC CHECKOUT 3. When jumpered to Ignition, Pilot and Main Valves, use ammeter in series and verify proper current draw. After checking all wiring, perform this checkout before General Instructions installing the R7140 on the subbase. These tests verify the Q520A Wiring Subbase is wired correctly, and the external 1.
  • Page 26 R7140G,L,M BURNER CONTROL MODULES Table 8. Static Checkout. (Continued) Test Test If Operation is Abnormal, R7140 Models Jumpers Voltmeter Normal Operation Check the Items Listed Below L1-5 — 1. Ignition spark (if ignition 1. Watch for spark or listen for buzz.
  • Page 27: System Checkout

    R7140G,L,M BURNER CONTROL MODULES SYSTEM CHECKOUT Limit trial for pilot to ten seconds. Limit the attempt to light main burner to two seconds after fuel reaches burner nozzle. Do not exceed manufacturer nominal lightoff time. IMPORTANT Perform all Static Checkout Procedures in the...
  • Page 28: Flame Signal Measurement

    R7140G,L,M BURNER CONTROL MODULES 7. Power is connected to the system disconnect switch h. Close the master switch to energize both the ignition (master switch). transformer and the pilot valve. 8. Lockout is reset (reset button) only if the Relay Module If the pilot does not ignite and if the ignition spark is is powered.
  • Page 29: Direct Spark Ignition Systems

    R7140G,L,M BURNER CONTROL MODULES c. Main flame alone (unless monitoring an intermittent 17. If used, remove the bypass jumpers from the low fuel pilot). Also observe the time it takes to light the main pressure limit and subbase. flame. Ignition of main flame should be smooth.
  • Page 30: To Eliminate Ignition Interference

    R7140G,L,M BURNER CONTROL MODULES IMPORTANT Start the burner and measure the flame signal with both You have 0.8 second or three seconds, depending ignition and pilot (or main burner) on, and then with only the on PFEP selected, to position the Run/Test Switch to pilot (or main burner) on.
  • Page 31: Hot Refractory Hold-In Test (Rectifying Photocell, Infrared Detectors, Ultraviolet Detectors)

    0.5 Vdc. The ultraviolet detector can respond to hot refractory above NOTE: The Honeywell Q624A and Q652B Solid State Spark 2300°F (1371°C). Generators prevent detection of ignition spark when properly applied with C7027, C7035, C7044 or 1.
  • Page 32 Depress the reset button. 1. Opening a Preignition Interlock during the STANDBY or c. Start the system. Start-up should be normal and the PREPURGE period (R7140L - Lockout; R7140G and M - main burner should light normally. Standby Hold 40 seconds, then Lockout).

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