66-1190-03_C YP900A Delphi Combustion
Contents
1. 62 86 25 10 Operation Manual for HercuLine 2001 100 200 400 090 EC actuator 62 86 24 14 Quick Start Guide for HercuLine 2001 100 200 400 090 EC actuator SPECIFICATIONS Electrical Ratings Power Supply 110 120 Vac 50 60 Hz 20 A For individual ratings see component literature for details Environmental Ratings Enclosure NEMA 12 For individual ratings see component literature for details General Overall panel size 30 in high x 24 in wide x 10 5 in deep including emergency stop button Panel weight 80 pounds Mounting holes are 0 44 in typical diameter 22 5 in on center Approval Components are individually approved by the nationally rec ognized agencies Please see component literature for details The panel has UL 508 approval Panel is assembled and wired to the UL Standards 66 1190 03 YP900A DELPHI COMBUSTION EFFICIENCY PANEL Table 1 Panel component list Honeywell OS number Description YP900A1004 ABC900A1000 The ABC900 Advanced Boiler Control is a loop and logic based boiler control Included platform The ABC900A1000 OS number includes the CPU30 control power supply shield kit resistor kit 4 slot I O rack and 4 I O cards Analog input module Analog output module Digital input module Vac and Digital output module Vac RM7840L 1075 Programmable flame safeguard control with VPS Valve Proving System capability Included Q7800A1005 Flame safeguard wiring subbase panel mount for2. For further information refer to the Quick Start Guide form 66 1191 The database save backup and restore features can be found in the Control Panel Utilities screen which is reach by selecting the following buttons in order from the Home page Settings and then Utilities Troubleshooting The system has a series of Alarms Limits amp Interlocks ALI that will shut the boiler down Some of the ALIs are generated by the RM7840L 1075 Burner Controller and some of the ALIs are generated in the ABC900A loop and logic controller Each ALI will be displayed on the Touch Screen Interface with a plain English descriptor timestamp and ALI origin The Touch Screen provides first out annunciation For troubleshooting the RM7840L and ABC900A please refer to the respective product sheets for instructions Recommended Action Reset the Burner Controller Locate troubleshooting manual for the transmitter and perform required steps to eliminate the problem Locate troubleshooting manual for the transmitter and perform required steps to eliminate the problem The System Alerts is located on most screens It informs the user why the burner is not running due to a fault hardware input or software limit or interlock problem Alarm flashes when there is an unacknowledged alarm which indicates a current alarm The cause of the alarm and lockout must be fixed acknowledged and reset if necessary before the system can resume its normal oper
3. RM7840L control Included 57800 1142 Keyboard Display Module for Modbus RTU communication VPS and or post purge Included timing programming NOTE When replacing the KDM the modbus address must be set to 21 in the field 50050785 001 Fuel transfer delay printed circuit board Included MF020 1 LC3 Oxygen sensor high temperature 15 7 inch 400mm probe length 0 01 to 3 6 psi 1 Included to 250mbar pressure range 0 1 to 25 volume oxygen measuring range 24Vdc input 4 20mA or 0 10Vdc output NOTE See Oxygen Sensor in Operation section for application details 99 4218 14 07 Female cable connector 7 pin for MF020 oxygen sensor RD 24 DIN 405 threaded Included locking screw termination IP67 protection non shielded Pg 13 5 cable gland SS 14M0 1 12BT Compression tube fitting for MF020 oxygen sensor mounting Stainless steel 14mm Included date bore through with 3 4 inch male connection code dependent SS 810 1 12BT Compression tube fitting for MF020 oxygen sensor mounting Stainless steel 1 2 inch bore through with 3 4 inch male connection Included date code dependent LCZA460 30 ECC Hall effect zero speed sensor Used for VFD speed measurement Included SNDJ CNT G02 Tachometer with single channel relay and 0 10Vdc output Used for VFD speed Included ECC measurement and feedback S900A1000 Dynics FX 12 touchscreen 12 inch with Dynics BIXO chassis industrial panel PC or Included equivalent
4. Solid state drive 24Vdc Islatrol Elite model El 105 5 amps 120Vac high frequency noise filter surge Included suppressor line conditioner Advantech model EKI 2525 AE 5 port industrial ethernet switch Included IDEC Izumi model PS5R SD24 120Vac to 24Vdc 60Watt 2 5 amps switching power Included supply for sensor power plus a second one to power panel PC Finger Safe Relay 120V Relay SPDT IDEC RJ1S CL A120 Included Finger Safe Relay Base SPDT IDEC SJ1S 07L Finger Safe Relay 120V Relay SPDT Veris Industries VMD1B F120A Finger Safe Relay Base SPDT Veris Industries VBD1B F Finger Safe Relay 120V Relay DPDT Veris Industries VMD2B F120A Finger Safe Relay Base DPDT Veris Industries VBD2B F Emergency Off Switch Square D XBAXBS8445 Alarm Reset Switch Square D XB4BA61 System On Off Switch Square D XB4BD21 Supplemental circuit breaker Square D 60112 15A OTHER OTHER OTHER OTHER Replacement is not available directly from Honeywell It can be sourced from local supply house Supplemental circuit breaker Square D 60106 5A 66 1190 03 2 Other Honeywell Required System Components Order separately 7800 SERIES Flame Detector 7800 SERIES Flame Amplifier ST78xx Plug in Purge Timer 30 seconds or longer for automatic O2 sensor calibration NXS Series Variable Frequency Drive c w with add on 32006630 002 Modbus connection card NXL Series Variable Frequency Drive
5. When ML 7999 is used jumper 4 20mA and FB terminals Feedback signal Air Actuator Channel 3 position feedback ML7999 red wire 20 lt 5 Vdc ML7999B 0 5Vdc HercuLine Feedback signal Air Actuator Channel 3 feedback common ML7999 common When ML7999 is used jumper 4 20mA and FB terminals Feedback high ref Air Actuator Channel 3 feedback pot high reference voltage ML7999 black wire When HercuLine actuator is used no connection to PH is needed 4 20mA Fuel 1 Actuator command 4 20 mA E k 20mA Fuel 1 Actuator command common When ML7999 is used jumper 4 20mA and FB terminals 22 FB Feedback signal Fuel 1 Actuator position feedback ML7999 red wire gt 0 lt 5 Vdc ML7999B 0 5Vdc HercuLine 23 FB Feedback signal Fuel 1 Actuator feedback common ML7999 common When ML7999 is used jumper 4 20mA and FB terminals Feedback high ref Fuel 1 Actuator feedback pot high reference voltage ML7999 black wire When HercuLine actuator is used no connection to PH is needed 4 4 20 Fuel 2 Fuel 2 Actuator command 4 20 mA command 4 20 mA E 20 _ 2 Actuator command common When ML7999 is used jumper 4 20mA and FB terminals Feedback signal Fuel 2 Actuator position feedback ML7999 red wire 20 5 Vdc ML7999B 0 5Vdc HercuLine 28 FB Feed
6. and Passwords On each startup password is required to log into the system This is to prevent unauthorized users from modifying the system configuration There are 3 password protected access levels Installer Manager and User The factory default Username and Password are listed as below Table 8 Usernames and Passwords as Installer Level Manager Level User Level Username eroe eero mm _ 1 For security reasons passwords for Installer and Manager levels are included in separate postcard like caution cards included with the panel assembly When commissioning is complete and or the access level needs to be changed the user must log out and sign back in with the desired password access level for general operation Access Points The three different access levels Installer Manager and User have different sets of setup and access points 1 The Installer level allows for full system parameter setup configuration and commissioning 2 The Manager level allows for monitoring making changes to the system non safety related control set points fuel selection and alarm acknowledgement 3 The User level allows for monitoring fuel selection and alarm acknowledgement only Saving and Restoring Profile Curves Delphi has curve save and restore features in the panel PC Refer to Fig 29 in the Delphi User Quick Start Guide form 66 1191 Saving a fuel air ratio curve makes it the default curve Restoring the cu
7. seconds or longer is used for the RM7840L control The O gt Setpoint has two options for control The first is Basic which allows for the same setpoint to be used regardless of the Firing Rate In some applications it may be desired to have a different setpoint at each of the 11 steps in the curve The Multi Advanced setpoint mode allows the user to set individual setpoints based on the Firing Rate and is set up in the settings section of the Touch Screen Interface The setting page is similar to the table 1 below The default setting for Setpoint is 4 0 in Basic and Multi Advanced Mode Table 7 O5 Setpoint 4 0 66 1190 03 12 Table 7 O5 Setpoint Firing Rate O gt Setpoint NE NEGEM NNNM po e E When the Transmitter is disabled O gt Trim is also disabled and the O Transmitter Shutdown commands are disabled This allows the system to run on the curve entered by boiler technician during commissioning Delphi monitors feedback of all enabled servos VFD and will shut down the burner if the servo VFD feedback does not match the commanded position This is done to prevent an unsafe condition should a mechanical failure occur Communication Modbus RTU The communication between the ABC900A loop and logic controller and the RM7840L Burner Controller is dependent on the S7800A1142 Keyboard Display Module being properly installed on the RM7840L controller Delphi is pre configured and functionally ready The boi
8. setpoint changes The ABC900A loop and logic controller and RM7840L 1075 burner safety controller are responsible for the runtime operation This document provides installation instructions and operation information Other applicable publications are 66 1191 YP900A Quick Start Guide 65 0084 Q7800A 22 Terminal Wiring Subbase Product Data 66 1162 RM7840L 1075 Relay Module with Valve Proving Installation Instructions 65 0229 7800 Series Relay Module Checkout and Test 65 0288 S7800A1142 Keyboard Display Module Product Data 65 0089 ST7800 Plug in Purge Timer 60 2026 C7027 C7035 C7044 C7927 Minipeeper UV Flame Detector Honeywell Efficiency Panel INSTALLATION INSTRUCTIONS 65 0267 C7961 Dynamic Self checking Solid State UV Flame Detector 60 0292 C7915 Infrared Flame Detector 65 0277 C7962 Visible Light Flame Detector 60 2024 C7007 C7008 C7009 Flame Rod Detector 95 8269 C7076 Adjustable Sensitivity UV Flame Detector 60 2398 C7012 Ultraviolet Flame Detectors 50030542 1 EN MF020 Oxygen Sensor Installation Instructions 000670 1 EN MF010 and MF020 Series Oxygen Sensors 51 52 03 31 HC900 ABC900 Hybrid Controller Specification sheet 009558 1 EN SNDJ CNT Series Tachometers 005886 2 EN LCZ Series Hall effect Zero Speed Sensors 65 0264 ML7999B Direct Coupled Actuator 63 2600 NXS VFD User Manual and Application Manual
9. this document for further details on remote setup 24Vdc loop powered transmitters with a 4 20mA output must be used for the optional monitor and stack temperature transmitters INSTALLATION When installing this product 1 Read these instructions carefully Failure to follow them could damage the product or cause a hazardous condi tion 2 Check the ratings given in the instructions and marked on the product to make sure the product is suitable for the application 3 Installer must be a trained experienced flame safe guard service technician 4 After installation is complete check out the product operation as provided in these instructions A WARNING Fire or Explosion Hazard Can cause property damage severe injury or death To prevent possible hazardous burner operation verify safety requirements each time a control is installed on a burner 66 1190 03 YP900A DELPHI COMBUSTION EFFICIENCY PANEL DELPHI O2 COMBUSTION 4 20 PROCESS EFFICIENCY PANEL hes L4079 L404 TRANSMITTER O2 TRIM mM SENSOR SS FUEL AIR RATIO CONTROL BURNER MANAGEMENT O2 TRIM DISPLAY C6097 C7005 C7024 C7915 C7008 C7027 C7927 AIRFLOW SWITCH LOW BOILER C7009 C7035 C7961 WATER C7012 C7044 C7962 CUTOFF BURNER MOTOR V5197A V51E MANUAL PRESSURE zm SPEED SHUT OFF REGULATOR KA MANUAL C437 SENSOR VALVE E E SHUT OFF C6097 E AT vae os 14
10. with internal modbus card ML7999B1002 Direct Coupled Actuator OR HercuLine 2001 Series Actuator and accessories 2001 100 090 EC Herculine actuator 100 Lb in 11 5N M torque 7 sec 90 degrees speed travel 100 130Vac 60 Hz 0 4 20mA or 0 1 5Vdc or 0 10Vdc input 0 4 20mA or 0 1 5Vdc or 0 16Vdc output UL CSA CCW rotation Modbus RTU RS485 2001 200 090 EC Herculine actuator 200 Lb in 22 5N M torque 15 sec 90 degrees speed travel 100 130Vac 60 Hz 0 4 20mA or 0 1 5Vdc or 0 10Vdc input 0 4 20mA or 0 1 5Vdc or 0 16Vdc output UL CSA CCW rotation Modbus RTU RS485 2001 400 090 EC Herculine actuator 400 Lb in 45N M torque 30 sec 90 degrees speed travel 100 130Vac 60 Hz 0 4 20mA or 0 1 5Vdc or 0 10Vdc input 0 4 20mA or 0 1 5Vdc or 0 16Vdc output UL CSA CCW rotation Modbus RTU RS485 51452354 501EC Mounting plate adapter for Barber Colman Series MP495 actuator 51452354 502EC Mounting plate adapter for Landis amp Staefa SQM53 56 actuator 51452354 503EC Direct couple valve hardware 51452354 504EC Linkage assembly ball joint for 5 16 in dia pushrod 51452354 505EC Pushrod 12 304 5 mm long 5 16 in dia 51452354 506EC Pushrod 18 in 457 2 mm long 5 16 in dia 51452354 507EC Pushrod 24 in 609 6 mm long 5 16 in dia 51452354 508EC Pushrod 48 1219 2 mm long 5 16 in dia 51452354 511EC North American valve retrofit kit 51452
11. 354 513 V51 valve mounting kit for 2 5 to 3 in valves 51452354 514 V51 valve mounting kit for 4 in valves Compatible Honeywell Accessory Components Order separately Q624 Q652 Ignition transformer High Limit Low Limit L404 L4079 L408 L4008 L6008 P7810C YP900A DELPHI COMBUSTION EFFICIENCY PANEL Operating Control L404 L408 14008 16008 P7810C C6097 Gas Air Pressure Switch C437 Gas Air Pressure Switch V4046C V8046C Pilot Gas Valve V4295 V8295 Solenoid Gas Valve V4297 Solenoid Gas Valve M5055 VA055 Fluid Powered Gas Valve and Actuator V5097 V4055 Fluid Powered Gas Valve and Actuator V5197 Firing Rate Valve V51E Butterfly Firing Rate Valve NOTE Unless the device is approved as a combination of Limit and Operating controller separate devices must be used for High limit Low limit and Operating control functions Process Variable Firing Rate Monitor and Stack Transmitters A 24Vdc loop powered transmitter with a 4 20mA output is required by Delphi for the process variable firing rate when temperature or pressure are selected Process variable set up is found on page 6 of the Software Settings pages The transmitter type and span is entered When remote is selected for the process variable an external 4 20mA signal is required for the firing rate Delphi automatically scales the remote input as 0 100 Refer to the firing rate section of
12. 5 LOW GAS WY M i HIGH GAS PRESS SW SAFETY SAFETY MODULATING PRESS SW SHUT OFF SHUT OFF V4297 VALVE VALVE 1 VALVE 2 V4295N 8295 V4046C V 8046C PILOT VALVE M31105D Fig 1 Typical boiler application with Delphi YP900A and other peripheral components 66 1190 03 4 YP900A DELPHI COMBUSTION EFFICIENCY PANEL SENSOR CONNECTOR OXYGEN SENSOR TOUCHSCREEN INDUSTRIAL PC s RESET BUTTON SPEED SENSOR EMERGENCY SENOR SYSTEM STOP BUTTON MOUNTING ON OFF FITTING SWITCH N Tuis SWITCH WILL DISABLE THE BURNER CONTROL WHEN IN OFF POSITION THIS EMERGENCY STOP BUTTON WILL SHUTDOWN THE BOILER WHEN DEPRESSED ON RELEASE RESET OF THE RM7840 IS REQUIRED AA BURNER ALARM RESET BUTTON WILL RESET THE RM7840 M31104A Fig 2 YP900A Combustion Efficiency Panel Oxygen Sensor hardware and Hall effect sensor RM7840L1075 INDUSTRIAL PANEL PC TOU COOLING FAN ABC900A1000 WITH 57800 1142 RELAYS TB2 T40 T100 i E E E LOE g n E p n TITS S 120VAC POWER INPUT TB3 ETHERNET 1 SWITCH T1 T37 TACHOMETER GROUNDING BAR 24 VDC POWER POWER CONDITIONER SUPPLIES M31103A Fig 3 YP900A Combustion Efficiency Panel internal components 66 1190 03 YP900A DELPHI COMBUSTION EFFICIENCY PANEL Location Humidity Install the panel where the relative humidity never reaches the saturation point The relay module inside the panel is designed to operate in a maximum 85 perce
13. YP900A Delphi Combustion APPLICATION The Honeywell Delphi YP900A Combustion Efficiency Panel integrates loop and logic based fuel air ratio control with O2 trim capability flame safeguard control with VPS capability VFD control with feedback capability and a touchscreen interface for burner and boiler applications Commissioning control and monitoring is all accomplished through the touchscreen interface The Delphi Combustion Efficiency Panel is a completed panel assembly which consists of a RM7840L 1075 burner safety controller with wiring subbase S7800A1142 Keyboard Display Module Built in industrial panel PC with touchscreen display ABCO900A loop and logic controller for load and O trim control Also included in the YP900A Combustion Efficiency Panel assembly are O gt Sensor mounting accessories and Hall effect speed sensor with tachometer Functions provided by the Delphi Combustion Efficiency Panel assembly include automatic burner sequencing with VPS Valve Proving System flame supervision status and system diagnostic indications fuel air ratio control with O gt trim to provide complete combustion PID modulating load control for firing rate plus low fire hold capability The panel PC ABC900A controller and RM7840L burner safety controller all communicate to provide accurate control and time in commissioning and runtime modes During runtime mode the display is used for monitoring shutdown manual control and
14. ation Please see Quick Start Guide Form 66 1191 for Software or Hardware Alarms and Lockouts details 66 1190 03 YP900A DELPHI COMBUSTION EFFICIENCY PANEL Automation and Control Solutions Honeywell International Inc 1985 Douglas Drive North Golden Valley MN 55422 Honeywell Limited Honeywell Limit e 35 Dynamic Drive Toronto Ontario M1V 4Z9 customer honeywell com U S Registered Trademark 2010 Honeywell International Inc 66 1190 03 Rev 02 10 Printed in U S A Honeywell
15. back signal Fuel 2 Actuator feedback common ML 7999 common When ML7999 is used jumper 4 20mA and FB terminals 29 Feedback high ref Fuel 2 Actuator feedback pot high reference voltage ML7999 black wire When HercuLine actuator is used no connection to PH is needed 30 4 4 20mA FGR Channel 4 FGR Channel 4 Actuator command 4 20mA command 4 20 mA _ 20mA 4 command common When ML7999 is used jumper 4 20mA and FB terminals 32 FB Feedback signal FGR Channel 4 position feedback ML7999 red wire 20 lt 5 Vdc ML7999B 0 5Vdc HercuLine Feedback signal FGR Channel 4 feedback common ML7999 common When ML7999 is used jumper 4 20mA and FB terminals md Feedback high ref FGR Channel 4 feedback pot high reference voltage ML7999 black wire When HercuLine actuator is used no connection to PH is needed R Power supply 5 White Signal output Hall Effect Blower Speed sensor 0 3000 RPM loop powered 4 20 mA E Black Common Required for blower motor position feedback when using VFD 7 66 1190 03 YP900A DELPHI COMBUSTION EFFICIENCY PANEL TB2 Table 4 Terminal block TB2 To Connecting Device Flame Detector 42 fH Required for certain detector types only See RM7840L and applicable EX Shutter flame detector specification sheets for wiring details Pilot Valve Pil
16. by Delphi which is the final actuator setup step O gt Trim and VFD Control If the O5 Transmitter is installed and enabled the system will monitor the O gt Transmitter and will shut the boiler down if the level drops below 1 or has a sensor fault as determined by the ABC900A controller If used the sensor is wired for fault proof operation and is monitored by Delphi If the sensor should fail Delphi will shut down the boiler and provide notification The alarm must be acknowledged by the user in order to reset the burner At that point the O5 sensor can be disabled and the burner restarted The control will follow the curve and not trim When the Trim is enabled the output to the air actuator and or the Variable Frequency Drive will be adjusted depending on the setup as established in the Software Settings pages to add or subtract Air to satisfy the Setpoint If a and an Air actuator are used both will be trimmed The system can be configured to run without the VFD If Os trim is selected without the VFD enabled the system will only trim the Air Damper Channel 3 must be selected and used for the Air damper when a VFD is not used If a VFD is used Channel 3 can be used for another purpose and the VFD is the only channel trimmed during O gt Trim If VFD bypass is desired the user must buy a VFD with that feature built in When using a VFD with bypass an air damper actuator should be used to ensure air con
17. ckouts are required for the wiring WARNING Electrical Shock Hazard Can cause serious injury death or equipment damage Disconnect the power supply before beginning installation to prevent electrical shock equipment and control damage More than one power supply disconnect may be required Field Wiring and Terminal Designation There are three terminal blocks for field wiring please refer to Fig 3 for their locations Table 2 Terminal block TBO Terminal To Connecting Device Description VFD Modbus RTU see O2 Trim and VFD Control on page 11 for Data setting details TB1 Table 3 Terminal block TB1 To Connecting Device FR Signal for details 24Vdc power 0Vdc common 4 ours Ground 11 66 1190 03 6 Process Variable Firing Rate Temperature or Pressure 24Vdc loop Transmitter powered 4 20mA see Firing Rate on page 11 for details FR Signal BMS SCADA Firing Rate Control 4 20 mA see Firing Rate on page 11 i E O gt Sensor Transmitter 4 20 mA it mitt 24Vdc d 20m Transmitter onitor Transmi er 4 C lOO owere 4 A Te E ransmitter i YP900A DELPHI COMBUSTION EFFICIENCY PANEL Table 3 Terminal block TB1 Continued Stack Temperature Transmitter 24Vdc loop powered 4 20 mA p 5 20 Air Actuator Channel 3 command 4 20 16 4 20mA Air Actuator Channel 3 command common
18. connect means and overload protection as required Final Wiring Check and Static Checkout All wiring shall be in accordance with the National A WARN Electrical Codes NEC and local electrical codes Explosion and Electrical Shock Hazard 1 Check the power supply circuit The voltage and fre Can cause serious injury death or equipment quency must match the specification listed damage 2 Check wiring terminations and routings to ensure proper 1 Close all manual fuel shutoff valves before starting connections these tests 3 Restore power to the panel 2 Use extreme care while testing the system Line 4 Refer to the RM7840L Product Instruction sheet for voltage is present on most terminal connections Checkout procedures when power is on 3 Replace all limits and interlocks that are not A CAU TION operating properly Do not bypass limits and Test each limit and interlock to ensure system interlocks operates correctly as defined in the 7800 Series Checkout and Test document Form 65 0229 OPERATION Theory and Sequence of Operation The Delphi Combustion Efficiency Panel is designed to keep the fuel to air ratio to a minimum to provide complete combustion While each boiler will have specific limitations the algorithm is designed to maintain repeatability regardless of the boiler design once the commissioning is complete To minimize fuel consumption the installer may choose to enable Oxygen Trim to allo
19. ler will not operate if the module is removed or the node address has been changed NOTE the S7800A1142 modbus address setting should be 21 The ABC900A receives important information from the burner controller and the connection must remain intact at all times System Operator Interface Display The Delphi Combustion Efficiency Panel includes an Industrial Panel PC on the front panel to provide system commissioning monitoring and status display functions The display uses a wizard like process to assist you through the commissioning process Please refer to the Quick Start Guide Form 66 1191 for commissioning and burner setup instructions The display screen goes blank after 15 minutes of inactivity To re activate the screen simply touch it Oxygen Sensor MF020 Life Expectancy Shelf life of Honeywell oxygen sensor Ziconium dioxide technology is theoretically infinite because there are no components inside which can be used up or degrade Other sensors based on an electromechanical principal produce current and will degrade over time Application Life Typical life for a sensor used in clean air is approximately 10 years If the combustion environment is polluted life can be shortened In a very polluted or dirty environment the porous sensor cap which acts as a filter may block the exchange from measured gas to the sensing element Temperature Range at Probe Tip The temperature specifications for the oxygen se
20. neywell ML7999B or HercuLine actuators are used with the Delphi panel Actuators can be mixed or matched on a panel For instance on a panel a ML7999 could be used for the fuel valve and a HercuLine for the air damper YP900A DELPHI COMBUSTION EFFICIENCY PANEL Delphi will continuously monitor the actuator positions relative to the baseline curve setup during commissioning Should any portion of the curve not match the baseline curve the burner will shut down and will require manual reset Each actuator must be setup according to the manufacturer s guidelines see ML7999B Herculine actuator product sheets for details prior to completing setup through the Delphi Combustion Efficiency Panel When performing the preliminary actuator setup the actuator must be connected to the modulating device it controls and the contractor must ensure the actuator command endpoints don t run up against the mechanical fixed stops of the device Note that tolerances may shift after burner warm up and adjustments may be necessary to the modulation endpoints If an actuator feedback error occurs at or near the modulation endpoints check the modulating device s physical endpoint s versus the commanded endpoint s to verify they do not overlap The ML7999B preliminary actuator setup requires a 4 20mA signal The 4 20mA signal must come from a separate current source other than Delphi Preliminary setup occurs before the actuator span and direction is learned
21. not match the baseline curve the burner will shut down and will require and manual reset A lockout will be annunciated on the display and the alarm contact will be energized When the oxygen transmitter is enabled and functioning properly the Os level will continuously be compared against the baseline curve If the excess air oxygen level deviates from the baseline more than 20 of the measured value the O gt Trim functionality will be disabled and the burner will be shut down An alert will be generated and must be cleared before the O gt Trim function will be re enabled At that time the O2 trim sensor and O2 trim function can be disabled if desired and the burner can be started again The Display ABC900A loop and logic controller and RM7840L Burner Controller all communicate to provide accurate control and time in commissioning and runtime modes During runtime mode the display is used for monitoring shutdown manual control and setpoint changes The ABC900A and RM7840 are responsible for the runtime operation NOTE If panel power has been shut off and there is a call for heat present upon power up there may be a delay in the start command to the burner control while the system updates itself Profile Curve The Delphi Combustion Efficiency Panel provides 11 curve steps with a separate light off point Light off and minimum modulation are separate points however light off is not shown on the profile curve During curve c
22. nsor tip are 148F to 752F 100C to 400C Do not exceed these temperature limits Sensor Self Testing The system conducts a O gt sensor self test automatically at the start of each burner cycle Fresh atmospheric air on the O gt sensor is required Therefore it is important to select plug in purge timer used on the RM7840L for 30 seconds or longer Use with other fuels Methane Methane will cause some O2 to be burned inside the sensor leading to a small drop in the measured levels of O2 It should be small Hydrogen The sensor can not be used for oxygen measurement in a vacuum or at very low Oxygen pressures concentrations YP900A DELPHI COMBUSTION EFFICIENCY PANEL lt 1 The sensor is not suitable to operate in an H gt environment Even at small percentages of i e 2 Oxygen will recombine with and there will be errors in the readings At 50 of H gt sensor will not work any more Heavy Oil 6 In general burning of heavy oil produces soot which would clog the porous sensor cap This has not been tested or confirmed but in general it is not suited for heavy oil applications For more information on testing with other fuels please contact Honeywell 66 1190 03 YP900A DELPHI COMBUSTION EFFICIENCY PANEL VFD Hall Effect Speed Sensor Fig 4 and Fig 5 Application The LCZ Hall effect zero speed sensor is used for blower motor speed feedback to Delphi when a VFD Variable Frequenc
23. nt relative humidity continuous non condensing moisture environment Condensing moisture may cause a safety shutdown Vibration Do not install the panel where it could be subjected to vibration in excess of 0 5G continuous maximum vibration Weather The panel is not designed to be weather tight When installed outdoors protect the panel from the weather WARNING Fire or Explosion Hazard Can cause property damage severe injury or death To prevent possible hazardous burner operation verify safety requirements each time a control is installed on a burner Panel Wiring All wiring shall be in accordance with the National Electrical Codes NEC and local electrical codes The Delphi Combustion Efficiency Panel arrives as a completed panel assembly and has been tested for accuracy and compliance DO re wire the control panel without TBO prior factory consent in writing unless the wiring modifications are documented on the control drawing No other modifications are authorized For reference and troubleshooting a complete wiring schematic diagram can be found in the Delphi literature package IMPORTANT Run line voltage and low voltage wiring in separate conduit to avoid signal interference Terminate ML7999B actuator wire shield at the Delphi ground bar Power the variable frequency drive VFD from a different circuit breaker than the Delphi panel to avoid electrical noise interference Field kno
24. ommissioning light off is shown as a separate point After light off the panel goes to Step 1 Firing Rate 0 which is the minimum modulation point Light off can be different lower or higher than Step 1 Minimum Modulation See Table 6 For further information refer to the Quick Start Guide form 2266 1191 Table 6 Profile Curve P Meee 3 UNE ZWEIEN me mmm Rate Purge Light off Min Max Mod Mod Monitor Points There are two extra points that can be used for monitoring purposes Proper transmitters sensors must be used and connected to the system These monitor points include Stack Temperature 66 1190 03 10 e Montior Value F C GPM LPM PSI kPa PPM RH Lbs Hr in w c CFH When enabled these points will be displayed on the monitor screens A history will also be enabled and will be displayed on the Transmitter Chart in the Touch Screen Interface These monitor points can be named as appropriate in the set up screen page Firing Rate The process variable of the boiler is user selectable to control leaving water temperature or leaving steam pressure via a Loop Powered 24Vdc 4 20ma transmitter connecting to TB1 terminals 1 amp 2 see Table 3 The default selection is Temperature The Firing Rate is set using an ABC900A PID control algorithm to determine the appropriate firing rate to satisfy the process setpoint The setpoint is user adjustable via the to
25. ot valve L2 Blower motor L1 Blower Motor Remote Oil Pump DO NOT jumper if not used Oil pump L2 Ignition Transformer Fuel 1 MV L1 Fuel 1 MV L1 Fuel 1 Main Valve 2 Fuel 1 MV L2 Fuel 2 Main Valve s i L1 OUT Dry contacts Valve Proving Switch VPS L1IN Dry contacts Alarm L1 120Vac Alarm Output Alarm L2 L1IN Dry contacts Main Valve Proof of Closure Pre ignition Interlock 1 OUT Dry contacts 65 L1IN Dry contacts Limit 1 If not used place jumper between terminals 66 L1 OUT Dry contacts L1IN Dry contacts Limit 2 If not used place jumper between terminals 68 L1 OUT Dry contacts contacts 69 L1 IN contacts Limit 3 If not used place jumper between terminals L1 OUT Dry contacts L1 IN Dry contacts L1 OUT Dry contacts 730 L1IN Dry contacts Fuel 1 Lockout Interlock 1 If not used place jumper between terminals L1 OUT Dry contacts contacts Ca L1 IN contacts Fuel 1 Lockout Interlock 2 If not used place jumper between terminals gos L1 OUT Dry contacts L1IN Dry contacts Fuel 1 Lockout Interlock 3 If not used place jumper between terminals 78 L1 OUT Dry contacts 9 L1IN Dry contacts Fuel 2 Lockout Interlock 1 If not used place jumper between terminals 80 L1 OUT Dry contacts contacts Bh 1 L1 IN HM contacts Fuel 2 Lockout Interlock 2 If not
26. rve allows the user to ignore changes made to the existing curve and restore the saved default curve The restored curve must be re verified by going into the commissioning mode and walking through all 11 curve steps The Burner Controller is in alarm RM7840 The O gt Sensor has failed or the circuit is open PLC The level dropped below 1 PLC Burner Controller Sensor Failure O gt Sensor Lockout YP900A DELPHI COMBUSTION EFFICIENCY PANEL The curve save and restore features can be found in the Curve Setup screen which is reached by selecting the following buttons in order from the Home page Settings Utilities Commission Commissioning Save Backup and Restore of the Delphi Database Delphi has database save backup and restore features in the panel PC The database consists of the user selected settings and the fuel air ratio curve The Save feature saves the database directly in the panel PC memory It may then be backed up onto a USB drive and copied into another Delphi panel PC or used to restore a system Upon restore copy any existing settings will be overwritten and the system will default to an uncommissioned state The user must complete the commissioning process including verification of all 11 fuel air ratio curve steps to make the system operable The Backup and Restore features require a specific case sensitive file format on the USB drive Do not use a USB smart drive with the Delphi panel
27. to low load as measured by the process variable transmitter the burner will cycle off when the Process Variable Max Value setpoint is reached It will restart once the measured process variable drops below the value of the Process Variable Max Value minus the Offset differential value provided the external mechanical limits and operating control are made The mechanical limits are also in place and will also cause the burner to cycle off in the event the limit s are opened for any reason Delphi will continuously monitor the actual speed of the blower motor to ensure the motor is running at the expected speed by monitoring the actual RPM feedback of the blower motor This is achieved via a separate input from a tachometer which receives a signal from a Hall effect zero speed sensor mounted within 2mm of the keyed shaft If the shaft is not keyed a suitable replacement location shall be determined by the installer The expected speed is stored in the curve during the commissioning process If the blower motor is running lower than the expected speed for an extended period of time the burner will shut down and will require manual reset A lockout will be annunciated on the display and the Delphi alarm contact will be energized The Delphi Combustion Efficiency Panel will continuously monitor the acturator VFD feedback on the curve and will compare them to the baseline curve setup during commissioning Should any portion of the curve
28. trol is maintained 66 1190 03 YP900A DELPHI COMBUSTION EFFICIENCY PANEL Due to the scaling factors and Modbus polling address settings the VFD Variable Frequency Drive must be the Honeywell NXS Series with add on 32006630 002 Modbus connection card or the NXL Series with internal modbus card Please refer to NXS NXL product sheet for setup details Modbus RTU settings e 19 2K Baud Rate 8 Start Bits e 9 Stop Bits Parity 1 e Modbus Address 10 Speed settings OHz minimum e 60 Hz maximum Complete Delphi specific parameters for the Honeywell NXS NXL series VFD can be downloaded from Honeywell s website http customer honeywell com vfd Click the Software Downloads link and download the file named Delphi NXS par To install the downloaded file onto the VFD drive the NCDrive software is needed it can be downloaded from the same web site After installing the NCDrive program connect a laptop to the VFD drive with a cable part number 32006629 011 Details can be found in the NCDrive software Help file To upload the Delphi specific parameters for the NXS NXL Series VFD 1 Download and save Delphi application to folder on PC 2 Download and install NCDrive 3 Connect the PC to the VFD using cable 32006629 011 4 Run NCDrive and load Delphi application 5 Upload the application to the VFD The oxygen sensor is automatically calibrated during each purge cycle if a ST78xx plug in purge timer of 30
29. uch screen interface with the installer level password Default PID rate settings P 15 1 46 D 0 Delphi also allows users to control firing rate via a remote BMS or SCADA system instead of the Process Variable transmitter If remote control is selected the BMS or SCADA system must be connected to TB1 terminal 3 amp 4 see Table 3 The process variable set up is found on page 6 of the Software Settings pages When the Remote Process Variable option is selected the Firing Rate is calculated by the BMS and delivered to the Delphi system via the BMS When Remote is selected the scaling is automatically set as 0 to 100 and the PV value equals the Firing Rate The PV Max Value must be set to a value over 100 and the Low Fire Hold Setpoint must be set at 0 when Remote is selected The PV Max Value and the Low Fire Hold Setpoint can be found on Software Settings Page 1 The PID can be set to Auto Tune mode in the Settings section of the Touch Screen Interface This mode will allow the loop to learn the best parameters to control the PID loop You should only use this mode if the default settings are not acceptable The Auto Tune algorithm will automatically shut off after two hours Manual Mode can be enabled from the touch screen interface This mode allows the operator to control the firing rate independent of the temperature or pressure If this mode is selected the high limit is still active Actuators The Ho
30. used place jumper between terminals 82 L1 OUT Dry contacts L1 IN Dry contacts s Fuel 2 Lockout Interlock 3 If not used place jumper between terminals 84 L1 OUT Dry contacts 66 1190 03 8 Fuel 1 Main Valve 1 Air Flow Switch YP900A DELPHI COMBUSTION EFFICIENCY PANEL Table 4 Terminal block TB2 Continued L1 IN Dry contacts Lockout Interlock 4 If not used place jumper between terminals L1 OUT Dry contacts L1 IN Dry contacts l Lockout Interlock 5 If not used place jumper between terminals L1 OUT Dry contacts L1 IN Dry contacts Lockout Interlock 6 If not used place jumper between terminals L1 OUT contacts Device Load Push button provides reset for an external device Device Load Ground G 1 L Fue actuator ground L L1 87 88 Fuel 1 Actuator Power Fuel 2 actuator neutral Fuel 2 Actuator Power Ground Fuel 2 actuator ground 7 Er Air actuator power 2 L Air actuator neutral Channel 3 Actuator Power i e Air depending on installer setup Ground Air actuator ground L Actuator power 1 L2 Actuator neutral Channel 4 Actuator Power i e FGR depending on installer setup Ground Actuator ground B3 cO cO cO CO Co Q N gt NES e O Table 5 Terminal block TB3 120 Vac Power Input Terminal To Connecting Device Descilon 120VAC Power Supply 20A Max PANE DEUNA Provide dis
31. w the Delphi Combustion Efficiency Panel 9 66 1190 03 YP900A DELPHI COMBUSTION EFFICIENCY PANEL to trim the air in order to achieve the setpoint This is accomplished by adding to or subtracting from the output to the Air Damper and or VFD Each Honeywell actuator servo is equipped with a 4 20mA input for accurate positioning and a 0 5 Vdc output to indicate position feedback Each actuator must be set up according to manufacturer s guidelines see ML7999B Herculine actuator product sheets for details prior to completing setup through the Delphi Combustion Efficiency Panel Actuator setup is completed though the display where the Delphi learns the span and direction of the actuators There is no need to set the direction of the actuator since Delphi will learn this during the actuator commissioning On a call for heat the Delphi Combustion Efficiency Panel will close the ABC Limit relay and the ABC Interlock circuit This will allow the RM7840 to initiate a safe start and start the burner Please refer to the RM7840 amp Sheet for a detailed sequence Once the burner is released to Modulate by the RM7840 controller the ABC900 will sequence the actuators and VFD to maintain the process variable Firing Rate Loop Setpoint or will respond to the remote firing rate control signal depending on the setup Once the Firing Rate Loop Setpoint is met the burner will remain in low fire If the process variable continues to rise due
32. y Drive is used to control the blower motor The sensor is designed to detect the passing of a ferro magnetic material near the sensing tip of the sensor such as keyed motor shaft It is typically used to detect the speed of rotating device having such a metal discontinuity The sensing is accomplished via the interruption of a magnetic field providing non contact speed sensing capability down to zero speed Q G For proper application only a single ferro magnetic mass or discontinuity should be sensed with the YP900 panel Refer to Fig 4 Mounting and Setup The sensor is designed to mount in a threaded hole 5 8 18UNF 2A or via a suitable bracket The gap between the sensor and detecting object should be adjusted to have a gap up to 0 07 in 1 78 mm If the shaft is not keyed or readily available a suitable replacement location or motion detection point shall be determined by the installer The tachometer is fully programmed from the factory The installer need only connect the Hall effect sensor to TB1 refer to Table 3 For further information on the SNDJ CNT G02 ECC tachometer refer to its documentation TARGET MOTION M31106A Fig 4 Target motion examples EQUIVALENT ELECTRICAL SCHEMATIC RED POWER SUPPLY WHITE SIGNAL OUTPUT SHIELD NC COMMON SENSOR r M31107 Fig 5 Equivalent Electrical Schematic 66 1190 03 14 Startup and Login Procedures
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