Honeywell RA116A User's Manual
Contents
1. hot contacts and shuts the system down by de energizing the 2K burner motor relay After a one minute approximate scavenging period the cold con tacts close and energize the safety switch heater If the thermostat or line voltage controller is still calling for heat the Protectorelay control makes one attempt to restart the system If the burner flame is not re established in 75 seconds nominal the system locks out and cannot be started again until the safety switch is manually reset POWER FAILURE DURING THE RUNNING CYCLE A power failure shuts off the ignition and burner motor lf the thermostat is still calling for heat when power is restored the stack temperature must cool and return the system to the idle position Once the system returns to the idle condition it begins the normal operating sequence 68 0119 FIRE HAZARD CAN CAUSE SEVERE BURNS Ensure the combustion chamber is free of oil or oil vapor before starting system STEP THE PYROSTAT DETECTOR CONTACTS The detector contacts are actuated by a friction clutch that is mounted on a rod connected directly to the heat actuated element Occasionally this clutch gets out of step after along period of idleness To place the clutch and the contacts in step 1 Remove the cover 2 Pull the lever forward 1 4 inch Fig 8 3 Slowly release the lever 4 Replace the cover PULL LEVER FORWARD 1 4 INCH THEN RELEASE SLOWLY FIG 82. Honeywell THESE ONE PIECE STACK MOUNTED OIL BURNER PRIMARY CONTROLS CYCLE THE BURNER ON THERMOSTAT DEMAND AND SHUT DOWN THE BURNER ON FLAME LOSS OR SYSTEM MALFUNC TION J Combine a Protectorelay unit for cycling the burner and a Pyrostat flame detector for sensing temperature changes of flue gases up to 1000 F 556 C RA116A is used with intermittent ignition burners formerly called constant ignition burners C RA117A and RA817A are used with interrupted ignition burners formerly called intermittent ignition burners O Used with line voltage or 24V controllers C Safety switch may be manually tripped on all models On RA116A lockout occurs if flame is not re es tablished during safety switch timing C On RA117A and RA817A flame or power failure is followed by a one minute approximate scavenging period and one attempt to re establish flame Lockout occurs if flame is not re established J Manualresetofsafety switch is required after ignition failure completely shuts off main burner D T Form Number 68 0119 3 91 Honeywell Inc 1991 PROTECTORELAY OIL BURNER CONTROLS RA116A A117A RA817A IMPORTANT THE SPECIFICATIONS GIVEN IN THIS PUBLICATION DO NOT INCLUDE NORMAL MANUFACTURING TOLERANCES THEREFORE UNITS MAY NOT MATCH THE LISTED SPECIFICATIONS EXACTLY ALSO PRODUCTS ARE TESTED AND CALIBRATED UNDER CLOSELY CONTROLLED CONDITIONS AND SOME MINOR DIFFERENCES IN PERFORMANCE CAN BE
3. Offices in all principal cities of the world Manufacturing in Australia Canada Finland France Germany Japan Mexico Netherlands the detector and clean bimetal element Replace the detector Check the detector location If the stack temperature is below 300 F 149 C replace the bimetal detector Replace the oil primary and perform Startup and Checkout procedures Q r QUALITY IS KEY Golden Valley MN 55422 4386 Spain Taiwan United Kingdom U S A CANADA 740 Ellesmere Road Scarborough Ontario M1P 2V9 PRINTED IN U S A
4. RA116A replaces the following competitive devices HONEYWELL WHITE RODGERS GENERAL ELECTRIC GENERAL PERFEX R116A B A101B2 5200 H124A B CR7865 5300 R134A R168A R494A RA116A B RA416A RA816A D PENN ITT GENERAL DETROIT 664 5200 CA7014 670 R96A102A CA702 680 R96G102DC a A Detroit 3 wire thermostat must be replaced by a 2 wire thermostat with a suitable heat anticipator b When replacing a model having an F or O terminal to power aclogged filter indicator light provide a separate transformer for the light The RA117A replaces the following competitive devices HONEYWELL WHITE RODGERS GENERAL ELECTRIC GENERAL PERFEX R116A B A101A2 5200 R117A A101B2 5230 R123A B CR7856 5520 R124A B 5525 R134A R168A R494A RA116A B RA117A RA416A RA816A RA817A C RA817A Cb c DELCO PENN ITT GENERAL uc DETROIT COA 5200 CA7014 COA 1 R96A102A je CA7028 R96G102DC a A Detroit 3 wire thermostat must be replaced by a 2 wire thermostat with a suitable heat anticipator b When replacing a model having an F or O terminal to power a clogged filter indicator light provide a separata transformer for the light c Do not use RA117A to replace this control where timed ignition is required for a wall flame burner 3 68 0119 lt 3 76 RADIUS 4 1 4 32 DIA 5 1 4 133 MAX STANDARD INSERTION LENGTH 3 745 183 EM 32 80 3 KNOCKOUTS FOR 1 2 INCH 13 mm CONDUIT O000900000 MENS ns v
5. STEPPING THE PYROSTAT DETECTOR CON TACTS START THE SYSTEM 1 Ensure the Pyrostat detectors are in step 2 Push in and release the safety switch reset button 3 Open the hand valve in the oil supply line 4 Set the limit control and thermostat to call for heat 5 Close the line switch The burner should start CHECK THE SAFETY FEATURES Simulate Flame Failure 1 Follow the starting procedure to turn on the burner 2 Close the hand valve in the oil supply line 3 The RA116A locks out after 75 second nominal safety switch timing The RA117A and RA817A lock out after one minute approximate scavenging period and 75 second nominal safety switch timing 4 Reset the safety switch and open the hand valve in the oil supply line Simulate Ignition Failure 1 Follow the starting procedure to turn on the burner except do not open the oil supply hand valve 2 Safety switch locks out after 75 second nominal safety switch timing Ignition and burner motor stops and oil valve closes 3 Reset the safety switch and open the hand valve in the oil supply line Simulate Power Failure 1 Follow the starting procedure to turn on the burner 2 With the burner running trip the circuit breaker or remove the fuse to turn off power to the system The burner should stop 3 Restore power The burner should restart Check the Scavenger Timing 1 Follow the starting procedure to turn on the burner 2 With the burner
6. qp nen arua a Tan WHEN INSTALLING THIS PRODUCT 1 Read these instructions carefully Failure to follow them could damage the product or cause hazardous condition 2 Check the ratings given in these instructions and on the product to ensure the product is suitable for your application 3 Ensure the installer is a trained experienced service technician 4 After completing installation use these instructions to check product operation CAUTION 1 Donotbend contact arms or stops onthe Pyrostat detector mechanism or make any adjustments other than those given in the instructions Remove the cardboard packing behind the drive shaft lever by pushing the packing up and pulling it straight out over the top of the lever Do not remove packing by pulling sideways Ensure all wiring complies with applicable codes and ordinances MOUNTING Refer to Fig 2 Followthe mounting instructions supplied by the furnace boiler or burner manufacturer if available Otherwise use the instructions provided below When replacing one of the controls listed on page 3 identify each leadwire as it is removed from the old control by marking the wire with the number of the RA116A or RA117A terminal to which it will be connected Refer to Table 1 and 2 to translate the old terminal identifications to the new RA116A or RA117A terminal identifications aa ata a a a a n n a RRC NC NRE a a a e an 17 1075 267 ete OOO OEE TET C
7. CONNECT CONTROL CASE TO GROUND N IF USING A TWO WIRE THERMOSTAT TAPE LOOSE ENDS OF RED N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD WIRE IF NECESSARY PROTECTION AS REQUIRED A CONTACTS BREAK IN SEQUENCE ON TERMPERATURE RISE USE GREEN TERMINAL TO CONNECT CASE TO GROUND A TO REPLACE AN INTERMITTENT IGNITION DEVICE FORMERLY CALLED CONSTANT IGNITION CONNECT IGNITION LEADWIRE TO TERMINAL 3 INSTEAD OF TERMINAL 4 M1582 FIG 5 RA117A WIRING DIAGRAM WITH A 24V 3 FIG 4 RA116A WIRING DIAGRAM WITH A LINE WIRE THERMOSTAT VOLTAGE THERMOSTAT OR CONTROLLER LINE VOLTAGE CONTROLLER OR THERMOSTAT BURNER RA117A N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED AX USE GREEN TERMINAL TO CONNECT CONTROL CASE TO GROUND PYROSTAT J CONTACTS A J CONTACTS BREAK IN SEQUENCE ON TERMPERATURE RISE M1584 e THERMO STAT PYROSTAT 3 CONTACTS COLD A A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED J USE GREEN TERMINAL TO CONNECT CASE TO GROUND A CONTACTS BREAK IN SEQUENCE ON TERMPERATURE RISE M1581 FIG 7 RA817A WIRING DIAGRAM The schematic diagrams show all systems in the idle condition Burner off no call for heat e Pyrostat contacts closed RA116A e Cold contacts closed hot contacts open RA117A RA817A e Safety switches closed All relays de energiz
8. EXPECTED IF THOSE CONDITIONS ARE CHANGED SUPER TRADELINE MODELS SUPER TRADELINE controls offer features not SUPER TRADELINE MODELS AVAILABLE available on TRADELINE or standard models and RA117A Stack Mounted Protectorelay are designed to replace a wide range of Honeywell Special SUPER TRADELINE packaging with and competitive controls cross reference label and SUPER TRADELINE in struction sheet TRADELINE MODELS TRADELINE controls offer features not available TRADELINE MODELS on standard models and are designed to replace a wide RA116A Stack Mounted Protectorelay range of Honeywell and competitive controls Special TRADELINE packaging with cross refer ence label and TRADELINE instruction sheet STANDARD MODELS MODEL 24V IGNITION INPUT NUMBER TYPE OF IGNITION THERMOSTAT RATING VOLTAGE RA116A Intermittent ignition 2 wire 360 VA 120V 60Hz formerly called 3 wire constant ignition series 10 RA117A Interrupted ignition 2 wire 550 VA 120V 60 Hz formerly called 3 wire intermittent ignition series 10 RA817A Interrupted ignition 550 VA 110V 50 Hz formerly called 120V 60 Hz intermittent ignition 220V 50 Hz 240V 60 Hz a Lockout occurs if flame is not re established during the safety switch timing b Flame or power failure is followed by a one minute approximate scavenging period and one attempt to re establish the COMPLETE ORDERING NUMBER OR SPECIFY 1 Order number TRADELINE or SUPER
9. SN I Ee ET u aa u aqa u u aae erate eres 5 TABLE 1 IDENTIFYING TERMINALS FOR RA116A REPLACEMENT TERMINAL TERMINAL IDENTIFICATION IDENTIFICATION ON ON OLD CONTROL NEW RA116A 1 LH or HOT LINE 1 2 LG or LINE 2 3 4 M or MOTOR 3 TABLE 2 IDENTIFYING TERMINALS FOR RA117A REPLACEMENT TERMINAL TERMINAL IDENTIFICATION IDENTIFICATION ON ON OLD CONTROL NEW RA117A 1 LH or HOT LINE 1 2 LG or LINE 2 3 M or MOTOR 3 4 1 or IGNITION 4 lf the position of the old control was satisfactory install the new RA116A or RA117A inthe same location as the old one making sure to insert the bimetal element the same distance into the stack as the old element If the old element was inserted more than 5 1 2 inches 140 millime ters insert the new control 5 1 2 inches 140 millimeters into the stack If the position of the old control was not satisfactory close the old holes tightly with a metal plate and follow these instructions 1 Follow these location considerations DRILL HOLES AND FASTEN FLANGE WITH SCREWS FURNISHED C4 cur A 1 3 8 INCH 35 MM HOLE IN STACK 4 TIGHTEN LOCK SCREW INSERT BIMETAL ELEMENT TO THE CENTER OF THE STACK IN THE DIRECT PATH OF THE HOT FLUE GASES A DO NOT FORCE THE COLLAR OF THE MOUNTING FLANGE PAST THE STOP FIG 2 MOUNTING AND LOCATION CONSIDERATIONS Locate the control between the boiler or furnace and WIRING DIAGRAMS draft regulator Locate the control as near as possibl
10. TRADELINE 2 Input voltage and frequency IF YOU HAVE ADDITIONAL QUESTIONS NEED FURTHER INFORMATION OR WANT TO COMMENT ON OUR PRODUCTS OR SERVICES PLEASE WRITE OR PHONE 1 YOUR LOCAL HONEYWELL RESIDENTIAL AND BUILDING CONTROLS DIVISION SALES OFFICE CHECK WHITE PAGES OF PHONE DIRECTORY 2 RESIDENTIAL AND BUILDING CONTROLS CUSTOMER SATISFACTION HONEYWELL INC 1885 DOUGLAS DRIVE NORTH MINNEAPOLIS MINNESOTA 55422 4386 612 542 7500 IN CANADA HONEYWELL CONTROLS LIMITED 740 ELLESMERE ROAD SCARBOROUGH ONTARIO M1P 2V9 INTERNATIONAL SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES OF THE WORLD AMBIENT TEMPERATURE MOUNTING FLANGE Operating 0 F to 104 F 18 C to 40 C Available for 6 inch 152 millimeter diameter pipe refer Shipping 40 F to 150 F 40 C to 66 C to Fig 2 Can also be flattened for flat mounting applica DIMENSIONS Refer to Fig 1 tions ELECTRICAL RATINGS amperes 24V THERMOSTAT HEAT ANTICIPATOR CURRENT 0 4A Notor naling LINE VOLTAGE THERMOSTAT OR CONTROLLER 110V 50 Hz 220V 50 Hz RA116A RA117A 2 wire 8A Requires jumper across 120V 60 Hz 240V 60 Hz W and B terminals Refer to Fig 5 or 7 Full Load 3 7 SAFETY SWITCH TIMING 75 Seconds nominal Locked Rotor 44 4 22 2 A RONS UNDERWRITERS LABORATORIES INCORPORATED A ONLY File Numb ELEMENT INSERTION LENGTH ee ee a NLY File Number Adjustable from 3 1 2 to 5 1 2 inches 89 to 140 millime ters The
11. e to the boiler or furnace f mounting in an elbow locate the element near the outer curve where the hottest gases flow BURNER e Do not locate the element where the temperature may exceed 1000 C 556 C 2 Cut a 1 3 8 inch 35 millimeter hole in the stack at the L location desired RA116A 3 Drill two holes and fasten the mounting flange using the screws provided The flange should fit the mounting surface snugly but it may be bent to fit a different radius stack or flattened to fit a flat surface Do not force the collar or mounting flange past the stop SERIES 10 4 Insert the bimetal element at the center of the stack in direct path of the hottest flue gasses 5 Tighten the lockscrew Du L 1 PYROSTAT CONTACTS WIRING Follow the appliance manufacturer s instructions i N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD available Otherwise follow the wiring diagrams shown in PROTECTION AS REQUIRED Fig 3 through 7 IF USING A TWO WIRE THERMOSTAT TAPE LOOSE END OF RED WIRE IF NECESSARY N USE GREEN TERMINAL TO CONNECT CASE TO GROUND M1585 FIG 3 RA116A WIRING DIAGRAM WITH A 24V 3 WIRE THERMOSTAT 5 68 0119 SURNER LINE VOLTAGE THERMOSTAT OR CONTROLLER RA117A SERIES 10 PYROSTAT 3 CONTACTS COLD A A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED O L IPYROSTAT CONTACTS N USE GREEN TERMINAL TO
12. ed NORMAL OPERATING SEQUENCE On athermostat or line voltage controller call for heat the ignition oil valve and burner motor start The safety switch begins heating Afterthe burnerflame is established the stack temperature rises and expands the bimetal detector element The Pyrostat contacts open RA116A or the hot contacts close and the cold contacts open RA117A RA817A de energizing the safety switch heater The ignition circuit de energizes RA117A RA817A only When the call for heat is satisfied the system returns to the idle condition IGNITION FAILURE ifthe burner flame is not established within approximately 75 seconds nominal of a thermostat or line voltage controller call for heat the Pyrostat contacts RA1164A or cold contacts RA117A RA817A remain closed During that time the safety switch is heated If the burner flame is not established after 75 seconds nominal the system locks out and cannot be started again until the safety switch is manually reset BURNER FLAME FAILURE DURING THE RUNNING CYCLE RA116A The loss of burner flame reduces the stack temperature closes the Pyrostat contacts and energizes the safety switch If the burner flame is not re established within the 75 second nominal safety switch timing the system locks out and cannot be started again until the safety switch is manually reset RA117A RA817A The loss of burner flame reduces the stack temperature opens the
13. erminals Bimetal detector and oil primary Go to step 4 to start burner are OK 4 Jumper the thermostat Reclean the bimetal detector Go to step 5 terminals and jumper the normally closed contacts Jumper the thermostat terminals and jumper the R and B terminals on the oil primary contacts again and recheck by jumpering the thermostat terminals If the burner starts bimetal detector and oil primary are OK Check for broken wires loose connections between the bimetal detector and the control Repair and recheck by jumpering the thermostat terminals Replace the bimetal detector if necessary Replace the oil primary and perform Startup and Checkout procedures Burner Starts Flame is Established Then Safety Switch Locks Out on Safety PRELIMINARY STEPS 1 Reset the safety switch 2 Clean bimetal detector contacts Proceed as follows after completing the preliminary checks CORRECTIVE ACTION PROCEDURE BURNER KEEPS RUNNING BURNER LOCKS OUT 1 Jumper thermostat Bimetal detector and oil primary Clean the drive shaft remove U S A 1885 Douglas Drive N terminals to start burner Low voltage thermostat at oil primary Line voltage thermostat at thermostat Reset the safety switch and jumper the thermostat terminals to start the burner Honeywell Inc are OK Bimetal detector and oil primary are OK International Sales
14. operating normally open and im mediately close the line switch The burner should stop immediately 3 After recycle timing one minute approximately the burner should restart automatically If the system does not operate as described proceed to Troubleshooting To completely troubleshoot an oil burner installation check the burner ignition transformer and oil primary control for proper operation and condition TRIP SAFETY SWITCH BEFORE OPERATING BURNER MAINTENANCE CAUTION Tripping the safety switch shuts down the burner but does not disconnect the power supply Turn off the power at the system switch or the circuit breaker before servicing the control system burner motor oil valve or ignition to avoid electrical shock PUSH LEVER DOWN TO TRIP SAFETY SWITCH WHEN SAFETY SWITCH TRIPS RESET BUTTON POPS OUT FIG 9 TRIPPING AND RESETTING THE SAFETY SWITCH The burner will not operate until the safety switch is reset by pushing the red reset button PRELIMINARY STEPS Before checking the oil primary and cad cell check out the following parts of the burner and ignition systems Repair or replace controls as indicated 1 Wiring connections power supply and burner motor fuse Ensure power is onto the controls burner motor and ignition transformer 2 Limit switch 3 Ignition transformer 4 Electrode gap and position 5 Contacts between ignition transformer and electrode 6 Oil pump
15. pressure 7 Oil tubing to tank 8 Oil nozzle 9 Oil supply 10 Oil filter If the system is still not operating properly check the oil primary control as instructed below CHECK THE OIL PRIMARY CONTROL CAUTION Since troubleshooting is done with the system pow ered observe all necessary precautions to prevent electrical shock or equipment damage Equipment Required 1 Screwdriver 2 0 to 300 Vac Voltmeter 3 Insulated Jumper Wires 4 Hard Surface Card such as a business card for cleaning contacts 68 0119 Burner Does Not Start When Thermostat Calls For Heat PRELIMINARY CHECKS 1 Ensure all limit switches are closed 2 Ensure safety switch is reset 3 Check for the proper line voltage at the oil primary Proceed as follows after completing the preliminary checks CORRECTIVE ACTION PROCEDURE BURNER STARTS BURNER DOES NOT START 1 Jumper the thermostat Trouble in the thermostat circuit Trouble is in the bimetal detector or terminals Low voltage thermostat at oil primary e Line voltage thermostat at thermostat Jumper thermostat terminals to start burner Check the thermostat and wiring connections Bimetal detector and oil primary are OK the oil primary Put contacts in step by pulling drive shaft lever out 1 4 inch and releasing Refer to Fig 8 Clean the bimetal detector contacts and timer contacts if provided Go to step 3 3 Jumper thermostat t
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