• Fast burner setup via PC or laptop.
• Fuel, air, FGR profile download capability. • Two independent fuel profiles with or without FGR.
• 7 to 24 point profiles. • Programmable behaviors of all actuators during Purge and Standby. • Programmable behavior of nonselected fuel actuator.
• Independent lightoff and minimum modulation positions.
• Wide power voltage input range (50/60 Hz); two APPLICATION models cover global applications. • Auto/Manual input. The R7999 ControLinks? Controller uses the latest • Manual mode firing rate input.
• Pluggable controller to wiring subbase.
• Multipurpose communications port. microprocessor-based technology to simultaneously control Copyright ? 2004 Honeywell International Inc.
up to four actuators. The device, when used with the ML7999 All Rights Reserved Universal Parallel Positioning Actuators, represents a value-added replacement of mechanical cam and linkage assembly controlling the relationship between fuel, airflow and flue gas recirculation (if used) on a power burner. The Honeywell ControLinks? System consists of the R7999
ControLinks? Controller, Q7999 Universal Subbase and
ZM7999 commissioning software.
The R7999, with one communications port, provides communications capabilities similar to those found in the 7800 SERIES controls.
? U.S. Registered Trademark
• Field-configurable device. CONTENTS • Integrated boiler shock protection algorithms: Application ........................................................................ 1 — Water temperature low fire hold. Features ........................................................................... 1
Specifications ................................................................... 2 — Stack temperature low fire hold. POUR COMMANDER ...................................................... 2 — FGR and low fire hold. French • Selectable FGR hold based on stack temperature. Installation ........................................................................ 3 • Programmable behavior of FGR actuator during purge. Wiring ............................................................................... 3 • Maximum modulation limit capability. Operation .......................................................................... 6
Checkout and Troubleshooting ......................................... 8 • Remote reset input. • Automated actuator endpoint seeking process.
• UL, FM, CSA, CE Approved, CSD-1 and NFPA acceptable. 65-0238-5
R7999A,B CONTROLINKS? CONTROLLER
• Negative/flatline FGR. • Step size enforcement during commissioning.
• Nonvolatile memory stores operating history • Point plausibility algorithms.
and current lockout and alarm status. • Password protected. • Six light-emitting diodes (LED) provide: • Weld-resistant algorithm for LCI-LCO contact set.
— System status. • Dual time base. — Fault information. • Built-in self-test and safety relay circuits. — Status of four actuator channels.
• Component anti-swap protection.
Safety Features • Off curve checking algorithm.
• Class C operating software system. • 1 million cycle count.
• Fail-safe feedback potentiometer circuitry. • 250,000 hour count.
• Curve verification algorithms.
A-1, F1-1, F2-1, FG-1: Model:
Source: 4.25 to 5.25V minimum at 5 mA R7999A,B ControLinks? Controller, consisting of a four-channel actuator drive Input/Output (I/O) and (counterclockwise [CCW] drive command). hardware interface for a variety of burner controllers. Sinking: 0 to 0.6V maximum at -5 mA (Clockwise [CW] drive command). Electrical Ratings: A-2, F1-2, F2-2, FG-2:
Input Power: Source: 4.25 to 5.25V minimum at 5 mA (Clockwise [CW] drive command). R7999A: 100 to 120 Vac (+10/-15%), 50/60 Hz (?10%), 10VA maximum. Sinking: 0 to 0.6V maximum at -5 mA
(Counterclockwise [CCW] drive command). R7999B: 200 to 240 Vac (+10/-15%), 50/60 Hz (?10%),
10VA maximum. Inputs: Outputs:
Limit/Control OUT (LCO): Limit/Control In (LCI) R7999A: 120 Vac, 8A run, 42A inrush (UL). R7999A: 120 Vac, 8.0A run, 42A inrush (UL). R7999A: 120 Vac, 6.0A run; 26A inrush (CE). R7999A: 120 Vac, 6A run, 26A inrush (CE). R7999B: 240 Vac, 4.0A run, 26A inrush (CE). R7999B: 240 Vac, 4A run, 26A inrush (CE). Fuel 1 Select (FS1): Alarm (ALR): R7999A: 120 Vac, 1A pilot duty (UL). R7999A: 120 Vac at 2 mA (UL/CE). R7999A: 120 Vac, 1.0A at PF = 0.4, 6A inrush (CE). R7999B: 240 Vac at 2 mA (CE). Fuel 2 Select (FS2) R7999B: 240 Vac, 1.0A At PF = 0.4, 6A inrush (CE). High Fire (HFP): R7999A: 120 Vac at 2 mA (UL/CE). R7999A: 120 Vac, 1A pilot duty (UL) R7999B: 240 Vac at 2 mA (CE). Remote Reset (RR): 5V at 5 mA. R7999A: 120 Vac, 1A at PF = 0.4, 6A inrush (CE). R7999B: 240 Vac, 1A at PF = 0.4, 6A inrush (CE). Feedback Potentiometer input (per channel): Light-Off Position: CW: 5 Vdc at 1 mA. S: 5 Vdc at 1 mA. R7999A: 120 Vac, 1A pilot duty (UL) R7999A: 120 Vac, 1A at PF = 0.4, 6 A inrush (CE). CCW: 5 Vdc at 1 mA.
R7999B: 240 Vac, 1A at PF = 0.4, 6A inrush (CE).
When purchasing replacement and modernization products from your TRADELINE? wholesaler or distributor, refer to the
TRADELINE? Catalog or price sheets for complete ordering number. If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Honeywell Automation and Control Products Sales Office (check white pages of your phone directory). 2. Honeywell Customer Care
1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9.
International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
R7999A,B CONTROLINKS? CONTROLLER
Environmental Ratings: INSTALLATION Temperature Range: Ambient: -40?F to +140?F (-40?C to +60?C).
Storage: -40?F to +150?F (-40?C to +65?C). When Installing This Product... Humidity: 1. Read these instructions carefully. Failure to follow 5 to 95 percent relative humidity, noncondensing. them could damage the product or cause a hazardous Vibration: condition. 0.0 to 0.5g continuous (V2 level). 2. Check the ratings given in the instructions and on the Mounting: Mounts on Q7999 Universal Subbase. product to make sure the product is suitable for your application.
3. Installer must be a trained, experienced service Enclosure: NEMA1/IP40. technician. 4. After installation is complete, check out product Accessories: 32002515-001 Three-Pin Electrical Connector operation as provided in these instructions. (RS-485). QM4520A1006 RS-232/RS-485 Converter.
32005354-001 Port Expander. S7999A1002 Display Module. WARNING
Electrical Shock Hazard. Dimensions: See Fig. 1. Can cause serious injury or death.
Disconnect power supply before installation.More than 5-3/16 1-15/16 (131) (48) one disconnect can be required to remove line voltage power completely. Location Mount the R7999 on a Q7999 Universal Subbase. The subbase is secured to a panel by four number 8 screws. Secure the R7999 to the subbase by tightening the two 7-3/16 (182) captive screws. WIRING All wiring for the R7999 is connected to the Q7999 Subbase. There is no direct wiring to the controller. Tables 1 and 2 provide the R7999 input and output terminal descriptions, respectively. Table 3 provides the R7999 maximum field wiring lengths. A block hookup diagram for the ML7999 Actuator is shown in Fig. 2 and a typical wiring diagram is shown in Fig. 4. Earth Ground 2-13/16 3 (76) R7999 Earth ground is required for proper operation of the (71) INSTALLED ControLinks? system. Earth ground provides a connection ON Q7999 between the subbase and the control panel of the equipment. M16548 The earth ground must be capable of conducting enough Q7999 current to blow the fuse or breaker in the event of an internal
short. Fig. 1. Approximate dimensions of R7999 ControLinks? Controller in in. (mm). 1. Use wide straps or brackets to provide minimum length, maximum surface area ground conductors. If a leadwire Weight: 12oz (0.35 kg). must be used, use 14 AWG copper wire. 2. Make sure that mechanically tightened joints along the Approvals: ground path are free of nonconductive coatings and Underwriters Laboratories Inc. (UL)(cUL): Component protected against corrosion on mating surfaces. Recognized; File Number MH17367. Factory Mutual (FM). Shield Ground CE. CSD-1 and NFPA: Acceptable. Connect the shield ground of the ML7999 Actuator(s), Remote Reset, Manual Potentiometer, Controller 4-to-20 mA Required Components: and Auxiliary 4-to-20 mA inputs to the earth ground strip Q7999 Universal Mounting Subbase. provided in the Q7999 Universal Subbase. Connect the shield ML7999 Universal Parallel Positioning Actuators (number at the controller end only. See Fig. 2. as required by application). ZM7999 ControLinks? Software Configuration Tool.
R7999A,B CONTROLINKS? CONTROLLER
Table 1. R7999 Input Terminal Description.
Name (Abbreviation) Number Description
Ground (G) 2 Earth ground.
Line Power (L1) 1 Line Voltage Power: 100 to 120 Vac, 50/60 Hz (R7999A) or 200 to 240 Vac, 50/60 Hz
(R7999B), 10 VA maximum power consumption. NOTE: NOTE: The Fuel Air control must be on the same phase as the burner control. Power Supply Neutral L2 (N) 3 Power Supply Neutral.
High Fire (HF) 10 Purge Position is activated by line voltage ac signal. Upon activation of the input, R7999
commands the air damper to the programmed purge position. NOTE: 120 Vac, 2 mA maximum or 240 Vac 2 mA maximum per device model type. NOTE: NOTE: LF and HF may not be energized at the same time. Operation will be halted if the condition is introduced and will not start if the condition exists at power up. Main (MV) 11 Main Valve Input, activated by line voltage ac signal. Activation of this input releases the R7999 to position all actuators to the programmed position curve. Maximum values same as High Fire. Improper insertion of the main valve input during the sequence can cause lockouts, recycles or initiate holds. Auto/Manual (AM) 4 Auto/Manual Input, activated by line voltage ac signal. Activation of this input during the Modulate phase of the RUN state changes the input control variable from the CMA(+/-) to the MNC input. Maximum values same as High Fire. Low Fire is activated by line voltage ac signal. Upon activation, R7999 commands the air Low Fire (LF) 12 damper to the programmed Light-Off position in addition to causing the selected fuel actuator to move to the light-off position. Maximum values same as High Fire. NOTE: NOTE: LF and HF may not be energized at the same time. Operation will be halted if the condition is introduced and will not start if the condition exists at power up. Limit/Ctrl In (LCI) 13 Line voltage input that signals limits are satisfied and that a demand exists to run the burner. Provides power to energize Burner Control. Voltage present equates to function selected. Firing Rate input: 4 to 20 mA positive input from temperature or pressure controller. Controller Input (CmA+) 39
Firing Rate input: 4 to 20 mA negative input from temperature or pressure controller. Controller Input (CmA-) 40
Use for manual control potentiometer. Resistance range: 0 to 5000 ohms, ?10%. Manual Ctrl (MNC) 36/38
200 ohms or less equates to the 4.0 mA controller input. 4500 ohms or more equates to the 20 mA controller input. Use linear interpolation for all other values. Programmable also as the maximum modulation limit, if so configured. Fuel 1 Select (FS1) 5 Line voltage input that selects fuel 1 when activated. Voltage present equates to function selected.
Line voltage input that selects fuel 2 when activated. Voltage present equates to function Fuel 2 Select (FS2) 6 selected.
Provides position feedback for the Air actuator: Feedback Air Damper 17 (CW) Clockwise rotational endpoint of the feedback potentiometer. (CW) 18 (S) Variable resistance signal from potentiometer. (S) 19 (CCW) Counterclockwise rotational endpoint of the feedback potentiometer. (CCW) Provides position feedback for the Fuel 1 Actuator: Feedback Fuel 1 22 (CW) Clockwise rotational endpoint of the feedback potentiometer. (CW) 23 (S) Variable resistance signal from potentiometer. (S) 24 (CCW) Counterclockwise rotational endpoint of the feedback potentiometer. (CCW)
Provides position feedback for the Fuel 2 Actuator: Feedback Fuel 2 27 (CW) Clockwise rotational endpoint of the feedback potentiometer. (CW) 28 (S) Variable resistance signal from potentiometer. (S) 29 (CCW) Counterclockwise rotational endpoint of the feedback potentiometer. (CCW) Provides position feedback for the FGR Actuator: Feedback FGR (CW) Clockwise rotational endpoint of the feedback potentiometer. (CW) 32 (S) Variable resistance signal from potentiometer. (S) 33 34 (CCW) Counterclockwise rotational endpoint of the feedback potentiometer. (CCW)
Temperature Sensor (XmA+) 37 Configurable Sensor Input: 4 to 20 mA positive input from temperature sensor. For the
temperature input application the endpoints are programmable from -40?F to +1400?F. Minimum span must exceed 100?F. Configurable Sensor Input: 4 to 20 mA negative input from temperature sensor. Temperature Sensor (XmA-) 38
Remote Reset (RR) 35/38 Remote Reset Input. A cycled contact on this terminal indicates a reset condition.
Normally-open momentary switch. 65-0238—5 4
R7999A,B CONTROLINKS? CONTROLLER
Table 2. R7999 Output Terminal Description. Terminal Name (Abbreviation) Number Description
Limit/Ctrl OUT (LCO) 14 Line voltage output that signals limits are satisfied and that a demand exists to run the
burner and R7999 is operational. Provides power to energize Burner Control.
Alarm Output. Alarm (ALR) 7
8 High Fire Proved normally open contact is activated when the HF input terminal has been High Fire (HFP)a energized and the R7999 has successfully moved the air/fuel damper (and FGR, if so configured) to the programmed Purge Position. aLow Fire Proved normally open contact is activated when the LF input terminal has been Low Fire (LFP) 9 energized and the R7999 has successfully moved the Air, selected fuel, and FGR damper to the programmed Light-Off Position. A-1 A-1: Output when combined with A-2 is used to modulate the Air damper. The resultant 15 push-pull current flow of the two outputs causes the motor to advance, reverse, or hold.
A-2: Output when combined with A-1 is used to modulate the Air damper. The resultant A-2 16 push-pull current flow of the two outputs causes the motor to advance, reverse, or hold.
F1-1: Output when combined with F1-2 is used to modulate the Fuel 1 valve. The F1-1 20 resultant push-pull current flow of the two outputs causes the motor to advance, reverse, or hold. 21 F1-2 F1-2: Output when combined with F1-1 is used to modulate the Fuel 1 valve. The resultant push-pull current flow of the two outputs causes the motor to advance, reverse, or hold. F2-1: Output when combined with F2-2 is used to modulate the Fuel 2 valve. The F2-1 25 resultant push-pull current flow of the two outputs causes the motor to advance, reverse, or hold. F2-2: Output when combined with F2-1 is used to modulate the Fuel 2 valve. The 26 F2-2 resultant push-pull current flow of the two outputs causes the motor to advance, reverse, or hold. FG-1: Output when combined with FG-2 is used to modulate the FGR damper. The FG-1 30 resultant push-pull current flow of the two outputs causes the motor to advance, reverse, or hold. FG-2 31 FG-2: Output when combined with FG-1 is used to modulate the FGR damper. The resultant push-pull current flow of the two outputs causes the motor to advance, reverse, or hold.
a HFP and LFP are not fail-safe outputs. Authorities having jurisdiction may require additional contacts on the air damper to prove HFP and LFP.
R7999A,B CONTROLINKS? CONTROLLER
Table 3. R7999A,B Maximum Wiring Lengths.
Terminal Name Wiring Length (Maximum) Wire Type Wire Size ab b Ground (G) Short as possible
b b Line Power (L1) No Restrictionc
b b Power Supply Neutral L2 (N) No Restriction
b b High Fire (HF) 100 Feet
b b Modulate (MOD) 100 Feet
b b Low Fire (LF) 100 Feet
b b Limit/Ctrl Input (LCI) No Restriction
b b Limit/Ctrl Output (LCO) No Restriction
d 1000 FeetController input (CmA+) Belden 9502, 2-conductor, 100% 18 to 24 AWG Controller input (CmA-) shield coverage, 300V 80C (UL 2464, CSA PCC FT 4) or equivalent. dBelden 9502, 2-conductor, 100% Manual Ctrl (MNC) 18 to 24 AWG 10 Feet shield coverage, 300V 80C (UL 2464, CSA PCC FT 4) or equivalent. b No Restriction b Fuel 1 Select (FS1)
b b Fuel 2 Select (FS2) No Restriction
dBelden 9535, 5-conductor, 100% 18 to 24 AWG Actuator Interface 100 Feet (A1, F1-1, F2-1, FG-1) shield coverage, 300V 80C (UL (A2, F1-2, F2-2, FG-2) 2464, CSA PCC FT 4) or equivalent. (CW) (S) (CCW) Belden 9535, 2-conductor, 100% 18 to 24 AWG 1000 Feetd Configurable Sensor (XmA+) Configurable Sensor (XmA-) shield coverage, 300V 80C (UL 2464, CSA PCC FT 4) or equivalent. eRS485 DDL Commissioning port 18 to 24 AWG 10 Feet
aUse wide straps or brackets to provide minimum length, maximum surface area ground conductors. If a leadwire must be used,
use 14 AWG copper wire. Make sure that all mechanically tightened joints along the ground path are free of nonconductive coatings and protected against corrosion on mating surfaces. bFollow local and NEC 1 codes.
cImplies no limitations beyond voltage (current times resistance) drop considerations versus wire size constraints.
dRequires ground shield at controller end. See Fig. 2, 4. eGround shield to digital ground terminal C at controller end and and PC or laptop end.
L2 L1 ML7999 GND The R7999 ControLinks? Controller provides communication
capabilities similar to those found in the 7800 SERIES L2 equipment. Fault annunciation is available through a R7999 L1 connection to the communication data output (DDL). Operating history is kept in nonvolatile memory as is the 3 1 2 current lockout status. G DR1 DR2 The ZM7999 ControLinks? Commissioning Software tool is CW necessary for the field commissioning prior to operation. Refer S CCW to the configuration software help screens for commissioning
procedures. 1/2 IN. MAXIMUM
The R7999 ControLinks? Controller tracks the firing rate 1 TERMINATE WIRE SHIELD AT THE CONTROLLER (R7999). input value and drives the ML7999 Actuators according to 2 SEE FIGURE 5 FOR ACTUATOR WIRING. the commissioned profile and maintains the relative programmed positions. 3 RUN LOW/LINE VOLTAGE IN SEPARATE CONDUIT. M16469A
Fig. 2. R7999/ML7999 hookup block diagram.
R7999A,B CONTROLINKS? CONTROLLER
the burner control causes the air actuator and the FGR
actuator (if configured) to drive to the purge or light-off WARNING positions, respectively. The selected fuel, air and FGR Explosion Hazard. actuators track the firing rate input versus the Improper configuration can cause fuel buildup and programmed profile once the main valve terminal is explosion. energized. The ZM7999 ControLinks? Commissioning Software 7. Lockout State. The R7999 enters this state when critical is to be used only by experienced and/or licensed internal faults are detected. The controller retains the burner-boiler operators and mechanics. lockout state via nonvolatile memory. To exit this state,
press the reset button. Operators of this software may move fuel and/or air 8. Alarm Initiate State. Essentially an Initiate state, except actuators to positions that can create hazardous that the alarm terminal is energized. A controller will burner conditions. Improper user operation can result remain in this state as long as the fault exists. The in property loss, physical injury or death. R7999 will automatically restart once the fault is removed. The user may restart the system by pressing The R7999 must go through an Initiate state whenever the the Reset button. fuel select switch is changed.
Normal operating sequence for the R7999 is: Initiate The R7999 has the following operating states: (ac power up or internal or external reset), Standby, 1. Non-Configured State. The controller is shipped from Processing Demand and Run. The Non-Configured State may the factory in this condition and will not respond to any also occur. input other than the DDL port (configuration tool port). 2. Commissioning State. The control er enters this state An LED status panel provides visual status of the operating once communications with a configuration tool is condition of the R7999 and associated components. established. Actuators are placed in pseudo-manual See Fig. 3. Table 4 provides the LED condition and meaning. control mode during this state. Commands from the Table 5 provides the Channel Status LED condition and configuration software increment or decrement motor meaning. positions. The R7999 write the values for the valve
and damper positions, as a function of firing rate, during At power up, all LED will automatically turn on to verify this state. operation. 3. Initiate State. This state exists for a minimum of ten
seconds after an internally- or externally-initiated reset. If all LED remain on, make sure one fuel select input is made, The R7999 performs internal checks during this state. not two or zero. 4. Standby State. This state occurs whenever the LCI input
(terminal 13) is not active. All actuators move to the
Programmed Standby Stop Position (PSTP) or return to RESET MOTOR the light-off position, except for the FGR actuator, which PWR ALRM moves to the closed position. 1 2 3 4 5. Processing Demand State. The R7999 enters this state when the LCI has just become active. The R7999 M16607 makes sure the firing rate command inputs are valid before advancing to the next state. Fig. 3. LED Status Panel. 6. Run State. The R7999 enters this state when the LCI
input is active. The high fire or low fire command from
Table 4. R7999 Status LED Blink Patterns.
Meaning Power (Green) LED State
Always Off Control has failed, or has no power.
Always On Control cannot run or communicate until a critical fault has been corrected. This state occurs at
each power up or reset. Control is in the Initiate State or Alarm Initiate State or Alarm Hold State.
Check that only one fuel has been selected, or that HF and LF are not active at the same time. If HF and LF are active at the same time, the red LED will also be on. 1 short blink every interval Control is in Postpurge or Standby State.
2 short blinks every interval Control is in a low voltage condition.
3 short blinks every interval Control is in the non-configured state.
4 short blinks every interval Control is in the commissioning state.
Steady medium blink Control is in the Run State.
Control is in manual mode. Steady fast blink
A red LED, normally off, indicates a Lockout State when lit.
R7999A,B CONTROLINKS? CONTROLLER
Table 5. R7999 Channel Status LED Blink Patterns.
aMotor (Amber) LED State Meaning
Always Off Actuator is not being commanded to move or is not configured. On Actuator is in motion.
1 short blink every interval. Actuator Failure: Failed timing plausibility check.
2 short blinks every interval. Actuator Failure: Failed actuator ID process.
3 short blinks every interval. Actuator Failure: Analog/Digital reading of potentiometer out of range. 4 short blinks every interval Actuator Failure: Potentiometer failure—wiper resistance.
Medium speed blink. Actuator Warning: Wiper resistance high.
a The four amber motor LED provide status for the individual ML7999 Actuators; e.g., Motor 1 LED is Air Actuator Status, Motor 2
LED is Fuel 1 Actuator Status, Motor 3 LED is Fuel 2 Status, and Motor 4 LED is FGR Actuator Status.
Place the R7999 in a manually commanded firing rate Port Expander RS-232 (PC) RS-232 condition by applying a line voltage signal to terminal 4. The 32005354-001 9-PIN SERIAL R7999 will derive the desired firing rate control position by the CABLE value of the resistance set at terminal 35/36. A 200-ohm value RS-232 (Ext) TO RS-485 A7999 equals minimum modulation; 4500 ohms equals maximum a b c ANALYZER modulation. Linear interpolation exists for all other values. RS-485 1 TO R7999
1 RS-485 USES A 3 CONDUCTOR SHIELDED CABLE Commissioning Process (BELDEN 9608, BELDEN 9939 OR EQUIVALENT) OR The primary tasks to be accomplished by the commissioning (2) TWISTED PAIR SHIELDED CABLE (BELDEN 8302 OR EQUIVALENT). M19665A process are as follows:
1. Establish the endpoints of each actuator within the Fig. 4. Connecting the 32005354-001 Port Expander to the system. R7999 ControLinks? Controller and the laptop PC. 2. Establish the purge position.
3. Establish the lightoff position. Table 6. RS-485 to R7999 Hookup Data. 4. Establish minimum and maximum modulation positions.
5. Establish a fuel, air, FGR mixture profile for up to 20 RS-485 Connects to R7999 points between the minimum and maximum modulation Data+ A points for each fuel source within the system.
Data- B The commissioning process requires the use of the ZM7999 Ground C ControLinks? Commissioning Software running on a laptop
or PC with a minimum operating system of Windows 95. Fig. 5 provides a standard block hookup diagram for the Additional minimum requirements include a Pentium? class R7999 and associated equipment. processor, or equivalent, with 16megabytes of RAM and a one gigabyte hard drive with 100 megabytes of free hard drive memory. The PC or laptop must have a RS232-to-RS485 CHECKOUT AND TROUBLESHOOTING converter to communicate with the R7999. Shielded cable is recommended as interface wiring. Fig. 4. shows the 32005354-001 Port Expander RS-232 to RS-485 hookup Fault Codes information. The R7999 ControLinks? Controller is designed so that only The R7999 requires the presence of one of the Fuel Select an unrecoverable internal related fault will cause lockout. inputs to start communications with the ZM7999 The R7999 will recycle when specific external problems are detected and then cleared. ControLinks? Commissioning Software. Additional wiring interface requirements include that HF and LF command When the R7999 locks out, obtain the fault code (a repeating inputs cannot be activated at the same time. series of blinks from the POWER LED) by pressing and NOTE: A stack gas analyzer is required to commission the holding the Reset button or using a laptop in monitor or ControLinks? Control System. commissioning mode. To interpret the LED flashes, for example, a Fault 11 would be one slow blink and one fast The PC or laptop must have a serial or USB port and an RS- blink, while a Fault 67 would be six slow blinks followed by 232 to RS-485 converter to communicate with the R7999. If seven fast blinks.
using a USB port, a Keyspan? or Belkin? USB to RS-232 converter is recommended.
R7999A,B CONTROLINKS? CONTROLLER
See Table 7 for fault codes and descriptions.
AUTO MANUAL A-1 1 Q7999 DR1 2 15 L1 L1 A-2 (HOT) 1 AIR DR2 16 L2 CW G CW 17 GND 2 ML7999 S S FUEL SELECT SWITCH 18 L2 CCW CCW 3 19 FUEL 1 mV 4 F1-1 A/M 1 20 DR1 4 FUEL 2 mV F1-2 FUEL 1 DR 21 2 FS1 CW 5 CW 22 S ML7999 S FS2 23 6 CCW CCW 24 ALR F2-1 7 ALARM 1 DR 25 MV 1 FUEL 2 F2-2 HFP DR HFS 26 2 8 19 CW L1 L2 G 9 CW 27 LFP S LFS S ML7999 18 9 28 CCW BURNER CCW HF HF 29 CONTROL 12 10 FG-1 (RM78XX) COM 1 13 30 DR1 MV FGR FG-2 15 11 DR 31 2 LF 14 CW LF 7 6 CW 32 12 CTRL S S ML7999 33 2 LCI CCW CCW ILK DMD 13 34 RR LIMITS IN LCO 5 35 14 RESET MNC MIN MANUAL FIRING RATE (REMOTE) 36 POTENTIOMETER 5K OHM MAX A7999 6 ANALYZER XmA+ Honeywell STACK OR 37 WATER TEMP. XmA– 4-20mA 38 1 CmA+ 39 SSLC PORT CmA– EXPANDER 4-20mA 40 Port E xpander 1 RS485 DDL 3 RS232 (PC) a b c RS232 (EXT)
1 GROUND SHIELD TO SUBBASE EARTH GROUND SCREW ON LOW VOLTAGE SIDE OF SUBBASE. 2 FUSE LINE VOLTAGE TO CONTROL SYSTEM WITH TYPE SC15 FUSE OR FUSE LIMIT INPUT WITH TYPE SC5 FUSE.
3 RS-485 DDL CONNECTOR IS ON R7999 CONTROLLER.
4 MUST USE APPROVED FUEL SELECT SWITCH (CENTER OFF POSITION).
5 NORMALLY OPEN MOMENTARY SWITCH (CONNECTION BETWEEN TERMINALS 35 AND 38).
M16550F MANUAL FIRING RATE POTENTI0METER (CONNECTION BETWEEN TERMINALS 36 AND 38). 6
Fig. 5. Hookup block diagram—R7999 and associated equipment.