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Operator/Owner Materials-ControLinks Software

1. 25 TROUBLESHOOTING n coi Eb a omui eet oe uude 24 R7999 OUTPUTS AND INPUTS 2 lt 28 65 0242 2 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL R7999 FAULT CODES AND ACTIONS 29 3 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL INTRODUCTION The ZM7999 ControLinks Software Configuration Tool reduces burner boiler setup time by letting you create a burner boiler modulation curve profile for the burner boiler that allows for safe and efficient operation at all points along the modulation curve The software uses a wizard like process to assist you through the commissioning process It also lets you save curves in standard PC files so that you can commission similar systems rapidly and safely Once the burner boiler is commissioned real time monitoring of the system can be done via the monitoring tool The software can be used on systems with one or two fuels and on systems with or without flue gas re circulation FGR The information in this user guide is also available on line see Getting Help below REQUIREMENTS The minimum system requirements for using the ZM7999 ControLinks Software Configuration Tool are as follows a PCorlaptop with a Pentium processor running Windows 95 Windows 98 Windows ME or Windows 2000 b 16 MB of R
2. refers r Firing Rate Modulation An Purge Psion 135 uM Modulation Move to Higher Position Start Lightoft Cycle Sequence 2 15 Load Save Frafile to File Save Profile lal 7 T Lis hiore est Lower Postion Demand present Profile Incomplete Minimum Modulation Position E 1 Degree Help Exit Prev Config Info Analyzer Fig 18 Create Modify Profile Curves 65 0242 2 16 Fuel Air Profile Graph Fuel FGR Firing Rate mA Open 100 Air Position 2 Open Fig 19 Fuel Air Profile Graph Fuel Air F GR e Open Close Press one of these buttons to manually open or close the actuator the number of degrees indicated in the slide bar from 0 1 to 10 You can also use the function keys indicated next to the buttons F1 F2 F5 F6 F9 or F10 to perform the same actions When you are positioning actuators while any actuators are below 20 you can only move the actuator 1 degree at time This is a safety constraint 2 Outputs Inputs e The 47999 outputs and inputs are displayed on the screen and their current state is noted See Outputs and Inputs for a description 3 Firing Rate This window displays the current value of input firing rate from the pressure or temperature controller Once the minimum and maximum modulation positions are entered
3. E 8 Intro 0 8 Connect to Fuel Air Controller Screen 8 Select Base Configuration 5 9 Set Air Fuel Actuator Endpoints Screen 9 System 0 13 Default System 13 Create Fuel Ratio Curve 5 15 Create Modify Profile Curve for Fuel 16 ret c 20 SETTING THE FIRING RATE HYSTERESIS AND ACTUATOR DEADBAND 4 480 20 Fring IV SCCTOSIS Et 20 Actuator MERE 20 one E A A 20 COMIN OMS s 22 OPERATING PROCEDURES 24 How to Change the System 24 How to Connect to the PC Comm 2 24 How Set the Actuator Maximum Open Closed Positions 24 How to Verify the Profile Walking the 24 How to Delete a Position on the 25 How to Load an Existing 25 CREATING AN AIR FUEL RATIO PROFILE
4. Degree Auto Seck pen 1 Lock Position em Degrees 1 Degree Auto Seek Eosed 5 2 Lock Position Prey gt gt Fig 8 Set Air Actuator Endpoint 11 Set Actuator Endpoints Actuator Configuration Direction of Closed Travel Actuator Type Clockwise Fixed Stops CounterClack wise Continuous Rotatian Serial Number 0006031 9 D Set Configuration cet Maximum Air Open Position F2 Dir Degrees Relative to potentiometer span Set Maximum Air Closed Position FB den Degrees F5 Cloze Relative to potentiometer span 1 Degree Auto seek Closed Lock Position Help Prev gt gt Fig 9 Set Direction of Travel Set An Actuator Endpoints Actuator Confiquration Direction of Closed Travel Actuator Type Clockwise Fixed Stops f CounterClackwise t Continuous Rotation Serial Number 00080319 Set Configuration cet Maximum Air Open Position F2 Open 109 3 Degrees 1 FA Relative to potentiometer span Lock Position z _ beck Postion Upen Degrees set Maximum Air Closed Position F5 Close Relative to potentiometer span FB 5 1 Degree Auto Seek closed Lack Position Prev lt lt gt gt Fig 10 Set Configuration 1 Degree 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL
5. Move to Next Save Higher Position Move to Hert Lower Postion e mE m nee Fig 31 Fuel 1 Configured Fuel 2 Not Configured Fig 29 Verifying the Minimum Modulation Point Monitor Screen The Monitor screen Fig 32 is used to Monitor the burner controlled by an R7999 Fuel FGR Firing Rate mA a Review alarms that were generated during run cycles 2 Open You can perform the following action from this screen 100 j e View various parameters of the system including the current positions of the Air Fuel and FGR actuators the 90 status of the system on modulating lockout alarm etc an historical list of alarms 1 Fuel Selection 70 e Identifies which fuel is currently in use Fuel 1 or Fuel 2 60 2 Fuel 50 Displays the current position of the fuel actuator 3 Air 40 Displays the current position of the air actuator 30 4 FGR Displays the current position of the FGR actuator if 20 present 5 Firing Rate a Displays the current firing rate position in milliamps 6 Aux Temperature Input 0 10 20 30 40 50 50 70 80 90 100 e Displays the actual interpreted temperature reading from the auxiliary input If the function is disabled Air Position Open the value indicates disabled 7 Status ndicates system status for example manual Fig 30 Verifying the Minimum Modulation
6. 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Create Modify Profile Curve for Fuel Screen The Create Modify Profile Curve for Fuel 1 or Fuel 2 screens Fig 18 are used to Create modulation curves for the burner Identify whether fuel air ratio curves are configured You can perform the following actions from this screen Enter points on the graph to indicate the Air Purge position Light Off position Maximum and Minimum modulation positions and intermediate positions for the actuators for the specified fuel Fuel 1 or Fuel 2 See Fig 19 Create a curve that provides safe and efficient operation of the burner from minimum to maximum modulation Verify the profile that was created Load a file from your PC that contains a curve profile to use as a starting point for constructing a profile for this burner Save the profile you created to a file on your PC or disc for reference or future use Fig 20 through 31 illustrate creating the profile curve Create Modify Profile Curve For Fuel 1 Fiye Alt PEN Inputs pen F2 pen Open LCI rn EI EN 1 1 HF OFF 15 3 2 15 8 76 Open Open T T Mv dinge F1 es F5 ON 1 1 1 Degee Outputs LEO OFF OFF DER Easton Postion LFP DFF intermediate Light mhi Delete Position ALM
7. Check wiring of actuator verify correct ID is being used Use online move counterclockwise and move clockwise Actuator LED to verify that the actuator that is being brought commands Furthermore all potentiometer tests online A fast flash in the actuator equates to off line state must successfully passed to bring an actuator while a 1 second flash equates to an online state online Internal memory fault Reset Control Internal check sum error Reset Control Aractstornonsespensve neck actuator wring and stuck damperivae _ _ 85 FoR actuator nonresponse Check actuator wring and stuck dampenabe _ 31 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Table 7 Fault Codes and Corrective Actions Continued Fault Blink Code The 4 to 20 mA firing rate input is below 3 mA Out of Range Low Actuators return to or remain at the minimum modulation point with the alarm on the control remains operational only to the extent that Minimum Modulation firing operation is allowed Not supported on Version 1 2 controllers 92 The manual potentiometer rate input is higher than an allowable range i e Out of Range High The actuators move to the maximum modulation point with alarm on control will remain operable yet when MANUAL MODE is selected maximum modulation and alarm output shall occur Auto mode operation is not affected Not supported on Version 1 2 controllers 9
8. FGR Endpoints Mot Contiqured System Parameters Help e Frew z gt gt Her Fig 7 Base Configuration for Dual Fuel with FGR Set Air Fuel Actuator Endpoints Screen Fig 8 The Set Air Fuel Actuator Endpoints screens there is one screen for each actuator are used to Identify the configuration of each actuator in the system This prevents actuator and or controller replacement without recommissioning the system and verifying safe operation Set the maximum open and closed positions for each actuator You can perform the following actions from these screens Enter the actuator configuration information including direction of travel actuator type and KEY serial number Set the maximum open and closed position for each actuator N CAUTION Operating condition hazard Wrong actuator information can cause an unsafe operating condition Use caution when selecting this setting If you enter the wrong direction of travel you may create an unsafe condition later in the commissioning process ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Actuator Configuration a Direction of Closed Travel Select the direction that the actuator travels to close either Clockwise or Counterclockwise See Fig 9 Actuator Type Select the type of actuator either Fixed Stops or Continuous rotation Serial Number Enter the serial number of the actuator you are configuring The serial number can be found on the
9. MV lel 3 Degrees E OFF LFF ALM E LED eem scc hie Delete All 1 Positions Air Purge Move to Next Lower Position Profile Incomplete Segments not verified Prev Contig Info Analyzer Finish Fig 25 Setting Maximum Modulation Point Fuel Air Profle Graph Fuel FGR Firing Rate m Open 4 B 12 16 20 100 at at Bl al all 20 10 0 10 20 30 40 50 70 50 90 100 Air Position Open Fig 26 Establishing Maximum Modulation Point for the Curve 19 75 9 8034 299 OFF Close F5 Close F3 F51 ON Outputs Firing Rate 50 1 4 4 AAA A A A A A 4 A 4 4 A A I ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Create Modify Profile Curve For Fuel 1 Fuel ODER etree jr Ar E NP RE ER jj Inputs 1 Open Open re Open m ON aaa H OFF 1 383 41976 246 H OFF Open Open Open 277 ON Close F Close Close E a 4 3Degrees 3 De
10. the window also provides a visual indication if over firing the current load demand of the system occurs during the commissioning process When the color of the mA value is blue it indicates an under firing condition exists When the color of the mA value is red it indicates your commanded firing rate exceeds the present input demand needs over firing 4 Save Position e After positioning the actuator s press the appropriate button to save the point on the graph a Intermediate Press to save positions on the curve that are between the max and min modulation points A point is displayed on the graph each time ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL you press this button You need at least 6 intermediate points between the max and min modulation points on a curve for a valid profile b Light Off Press to save the light off position on the graph An L is displayed on the graph to indicate the lightoff point Only one light off point is allowed per curve c Max Modulation Press to save the maximum modulation position on the graph An M is displayed on the graph to indicate the maximum modulation point Only one maximum modulation point is allowed per curve d Min Modulation Press to save the minimum modulation position on the graph An m is displayed in the graph to indicate the minimum modulation point Only one minimum modulation point is allowed per curve e Air Purge Press to sav
11. 4 c Enter the KEY serial number of the Actuator Manually move the actuator to a midspan position to allow the ID unlocking algorithm to function properly Please ensure all eight digits are entered correctly You may confirm that an actuator has been successfully brought on line by noting its flash rate has changed from a rapid flash to a slow flash i e one blink a second 4d PrssSelComgwalon 0 77 77 At Ifnecessary press Open or Close to adjust the actuator position Mg the other actuators in your system 4 PressNex 2 c Next E Csi Ft Rao ER passe Far Tor FURT If you selected DONIS Wis se Fuel in the base configuration 2 button step ony one only Fuel button appears 8 On the Create Profile screen perform the following steps the external burner demam switch power LCI terminal E and then hit the start lightoff sequence button Press Open and or Close for Fuel and Air and the FGR if present System Parameters and configured to follow purge to move the cursor to the Air The 47999 will automatically move the Air actuator to Purge point of the burner a 6296 open position 6 c Press Air Purge A P will be displayed on the profile The R7999 will energize its output terminal 10 which in turn allows the burner control to start the purge time Press the Open and Close buttons for Fuel and Air and the FGR Th
12. Corrective Actions Fault Blink Code Description Corrective Action peres is operano propery MV input energized at improper time Reset control Check Burner Control Interface wiring and correct error This error causes the device to remain in initiate state at power up The R7999 incorporates two methods to retrieve fault information HF and LF are energized at the same time Reset control Check Burner Control Interface wiring and correct error This error causes the device to remain in initiate state at power up Transition to the requested Burner Control input Check wiring to burner control and or burner control operation state is not allowed from the current state E g Standby to Modulate is not allowed NOTE Moving a RM78XX Run Test switch to Test will Induce this fault during commissioning mode E PME Internal Error Time base Reset Control E Internal Error KEY decode Reset Control Internal Error Rdow Error Rdlow Reset Reset Control es peace Lm emt mes ae er 1 _ 29 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Table 7 Fault Codes and Corrective Actions Continued Fault Blink Code Description Corrective Action 34 Internal Fault LCO I Feedback 1 Reset Control Check actuator wiring See Channel LED for actuator 2 Terminal 14 has voltage present from an external source correct wiring probl
13. Fragram Non Selected Fuel Position C 1 Help Finish Fig 16 System parameters Screen 2 15 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Create Fuel Ratio Curve Screen The Create Fuel Ratio screens are used to e Select which fuel is to be configured If your base configuration has only one fuel the Fuel 1 button is all that is available dentify whether fuel air ratio curves are configured You can perform the following actions from these screens see Fig 17 Create Fuel Ratio Curve Not Configured Fuel Not Configured Prey lt lt Fig 17 Create Fuel Ratio Curve e Select which Fuel Air curves to configure Fuel 1 or Fuel 2 If your base configuration has only one fuel the Fuel 1 button is the only one available 1 Fuel 1 Fuel 2 Press the appropriate button to indicate the fuel for which you want to create a fuel ratio curve If you have only one fuel only a Fuel 1 button is displayed Configured means a curve already exists Not Configured means the profile must be created changed or validated 2 Help Press this button to display the help system 3 Exit Press this button to exit the program Valid changes will be saved 4 Prev Press this button to return to the previous Select Base Configuration screen 5 Next This button is not available on this screen Press the Fuel 1 or Fuel 2 button to proceed to the Create Profile screen 65 0242
14. ML7999 actuator body in two places under the label KEY The key is made up of eight numbers the first four numbers represent the date code of manufacture for the actuator When you attempt to set the configuration the software writes the serial number to the actuator to verify your entry If you enter the wrong number you will receive an error message If you change an actuator in a commissioned system you cannot run the system until you have entered the new KEY serial number of the actuator set the maximum open and closed positions and re verify the existing curve or set and verify a new curve for the system Set Configuration Fig 10 e Set Actuator Endpoints Actuator Configuration Direction of Closed Travel Actuator Type e Clockwise Fixed Stops 4 CounterClackwise Continuous Rotation SerialNumber FFFFFFFF Set Configuration posset Position Fe F1 Clase Relative to potentiometer span Set At closed Ere Ttt 1622 Relative to potentiometer span Press this button after you have selected the direction of closed travel actuator type and entered the KEY serial number The software verifies the serial number and stores the configuration information If the serial number you entered and the device serial number do not match you will receive an error message Degrees P
15. NOTE You must resend the KEY serial number any time you revise the closed direction setting or change the type of end stop selection 3 Set Maximum Closed Position Set Maximum Open Position Fig 11 and 12 Press one of these buttons to manually open or close the actuator the number of degrees indicated in the slide bar from 1 to 10 You can also use the function keys indicated next to the buttons F1 F2 F5 or F6 to perform the same actions Each time you press the Open or Close key the R7999 receives a command to execute the move command the interface is essentially locked out until the command has been completed 4 Auto Seek Open Closed Press one of these buttons to let the software automatically locate the maximum open or maximum closed position of the actuator The actuators are moving in a limited torque mode Therefore the time required to move from one end of travel to the other is extended by approximately a factor of three You can speed up this activity by opening the actuator cover and pressing the CW or CCW buttons 5 Itis not recommended that you let the actuators hit the damper or valve system endpoints when using the actuator CW or CCW buttons Set Air Actuator Endpoints 65 0242 2 Help Actuator Configuration Direction of Closed Travel Actuator Type Clockwise Fixed Stops CounterClockwise Continuous Rotation Serial Number 00060319 Configuration c
16. Or you may want to save the current profile so that you have a copy of it in case an actuator or another part of the system needs to be changed out You may still have to modify points and you WILL have to walk the curve to verify operation but it will save you time To load an existing profile from your PC 1 Press Load Profile on the Create Profile screen 2 Navigate to the directory where you saved the profile 3 Highlight the file and press the OK button on the File Open window The curve will be displayed on the graph in the color that indicates it must be verified WHEN HIGHLIGHTED INDICATES THE FGR ACTUATOR IS ABOVE A FLAT LINE CONDITION WITH RESPECT TO THE NEAREST POINT TO THE LEFT OF CURRENT FGR POSITION A AT A FLAT LINE CONDITION WITH RESPECT TO THE NEAREST POINT TO THE LEFT OF CURRENT FGR POSITION CREATING AN AIR FUEL RATIO PROFILE EXAMPLE The steps required to commission a burner depends on the complexity of the system A single fuel system without an FGR will require fewer steps than a system with an FGR or a dual fuel system with an FGR that you understand the basic steps required to commission a system you should review the following example before you attempt to commission a live system During commissioning you must monitor the combustion process with an oxygen meter to verify save operation as you commission the system Flat Line FGR Wizard The Flat Line FGR Wizard is supported
17. Rev 1 3 B 161 Prev lt lt gt gt Fig 4 Changing the password Connect to Fuel Ar Controller Commissioning Password Connect Conne cted New Password verify Password Change Password Fuel ir Ratio Controller Firmware Rev 1 3 B161 o Help Prey lt lt Fig 5 Connected 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Select Base Configuration Screen The Select Base Configuration screen Fig 6 is used to Identify the configuration of the system you want to commission for example dual fuel system with a FGR or a single fuel system etc Begin configuration of the actuators Allow the user to set System Parameters Select Base Configuration and Set Actuator Endpoints Jess Configuration Single Fuel Single Fuel with Dual Fuel Dual Fuel with FGA estem Ee Brameters Help Prev lt lt gt gt Fig 6 Select Base Configuration You must perform the following actions from this screen Select base configuration for the system Select and configure all actuators within the base configuration Go to the System Parameters screens to set system parameters or view the default system parameters NOTE Depending on the number of actuators physically connected to the 47999 some of the selections on this screen may be grayed out For example if you have a single fuel
18. help system b Exit Press this button to exit the program Valid changes will be saved c Prev Press this button to return to the previous Select Base Configuration screen without completing this screen d Next Press this button to move to the Select Base Configuration screen You cannot move to the next screen until you have completed the actions required on this screen See Fig 13 and 14 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Select Base Configuration and Set Actuator Endpoints Base Configuration C Uneonfigured Single Fuel C Single Fuel with FGR Dual Fuel 8 Dual Fuel with FGA Configured Fuell Endpoints Not Configured Fuel Endpoints Mot Configurer FGR Endpoints Not Configured Ea Siete i meters Prev gt gt Nex Fig 13 Air Configured Select Base Configuration and Set Actuator Endpoints Base Configuration Uncanfigured Single Fuel C Single Fuel with FGF C Dual Fuel Dual Fuel with FGA nfigured Fuel Configured Fuel Configured med Eu FGR Configured System Parameters Help Prev gt gt Next Fig 14 Base Configuration Set Actuators Configured System Parameters Screens Selectable 13 System Parameters Screen SYSTEM PARAMETERS 1 Press to set system parameters System pa
19. in the Commissioning Password field The factory default password is password 4 Press the appropriate radio button COM 1 COM2 etc on the Connect to Fuel Air Controller screen 5 Press Connect f you selected the correct communications port and the R7999 is properly connected you will see the word Connected displayed next to the Connect button If you get an error while connecting refer to Troubleshooting How To Set the Actuator Maximum Open Closed Positions To set the maximum open and closed positions for the actuator proceed as follows 65 0242 2 24 1 Lookat the open and closed positions displayed on the screen lf no number is displayed press Open or Close so that a number is displayed Typically the position of one maximum is closer to its end point than the other For example the open position reading might be 85 3 Degrees and the closed position reading might be 40 2 Degrees Since the actuator will be fully open at approximately 100 degrees it will take less time to move it to its maximum open position than its maximum closed position You will note that the readings are initially in percentage of potentiometer travel NOTE The system must exhibit at least 15 degrees of travel from open to closed 2 Press Auto Seek Open or Auto Seek Closed based on your observation in Step 1 The controller automatically opens or closes the actuator to its maximum open or closed value 3 When the ac
20. on what the particular fault is and when the fault is introduced relative to the R7999 operating state Automation and Control Solutions Honeywell International Inc Honeywell Limited Honeywell Limit e 1985 Douglas Drive North 35 Dynamic Drive Golden Valley MN 55422 Scarborough Ontario M1V 4Z9 65 0242 2 Rev 12 04 9 Honeywell Printed in U S A on recycled paper containing at least 1096 post consumer paper fibers www honeywell com
21. only with version 1 3 or greater of R7999 ControLinks controllers The Create Modify Profile screen includes a Flat Line Wizard to help you set points for the FGR that are precisely flat line with respect to an existing point to the right or left of the current position As you position the cursor on the profile the discrete segments of the Wizard are highlighted to indicate what condition exists and inform you of the steps required to create an FGR actuator flat line segment Refer to the following description and examples See Fig 33 and Table 3 WHEN HIGHLIGHTED INDICATES THE FGR ACTUATOR IS ABOVE A FLAT LINE CONDITION WITH RESPECT TO THE NEAREST POINT TO THE RIGHT OF CURRENT FGR POSITION AT A FLAT LINE CONDITION WITH RESPECT TO THE NEAREST POINT TO THE RIGHT OF CURRENT FGR POSITION WHEN HIGHLIGHTED INDICATES THE FGR ACTUATOR IS 0 A WHEN HIGHLIGHTED INDICATES THE FGR ACTUATOR IS WHEN HIGHLIGHTED INDICATES THE FGR ACTUATOR IS BELOW A FLAT LINE CONDITION WITH RESPECT TO THE NEAREST POINT TO THE LEFT OF CURRENT FGR POSITION WHEN HIGHLIGHTED INDICATES THE FGR ACTUATOR IS BELOW A FLAT LINE CONDITION WITH RESPECT TO THE NEAREST POINT TO THE RIGHT OF CURRENT FGR POSITION M17928 Fig 39 FGR Flat Line Wizard symbols and meanings 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Table 3 Examples of Flat Line Wizard displays symbol Mang oooO The FGR actuator is above Flat Line with respect
22. understand the purpose of each and view the selections parameters and information that is available or required on each The Zh7888 Commissioning Software is ta be used only by Experienced and or Licensed Boiler Operators and Mechanics Screen Descriptions The ZM7999 ControLinks Software Configuration Tool screens include the following Operators of this Software may move Fuel and or Air Actuators to positions that can create Hazardous burner conditions improper user operation may result in PROPERTY LOSS FHYSICAL INJURY ar DEATH Monitor a Honeywell Fuel Air Ratio Controller Commissioner ZM7998 referred to as the Intro screen b Connect to Fuel Air Controller c Select Base Configuration d Set XXXX Actuator Endpoints where XXXX is either Air or Fuel or FGR Serial Number e Create Fuel Air Ratio Curve Create Modify Curve for Fuel X where X is either 1 2 g Monitor This screen is not part of the commissioning process but allows you to monitor a system after it has been commissioned Th Fig 1 Intro Screen Intro Screen Connect to Fuel Air Controller s Intro screen Fig 1 is used to select one of the following Commissioning Password actions Commission the system Connect Not Connected Monitor the system You can perform the following actions from this screen 1 Begin to commission a new system 2 Modify the commissioning of a
23. 0 Mew Husteresis Val Percent af 4 20 173 E Firing Hate Required Change 1117 ma In Opposite Direction ma Previous Hysteresis Val Percent af 4 20ma 73 E Firing Rate Required Change 1 ma In Opposite Direction ma Digital Value Digital value Actuator Deadband n rl Honeywell Default Value is 0 1 Previous Deadband New Deadband Val Value 07 Value 07 Download Status and Control Download New Hysteresis and Deadband Values Exit Program Fig 35 Firing Rate Hysteresis and Actuator Deadband Successfully read data from 7333 New Values to downloaded Hysteresis 30 0 117 ma Actuator Deadband 1 Download Status and Control Downloading Deadband 1 Deadband written amp verified Downloading Hysteresis 30 Hysteresis written amp verified Downloading CAL written amp verified Download New Hysteresis and Deadband Values Fig 36 Successful download NOTE Ifthe ControLinks stops responding after writing the new values and is in Factory Test mode all LED s are on attempt to re write the values using the procedure above If Commissioning or Monitoring are attempted and a message asking if you want to reset the ControLinks to the Factory Default Values appears Fig 37 select No then attempt to re write the values using the procedure above If this does not cause the ControLinks to operate properly
24. 14 Next e This button is not available on this screen It is grayed out 15 Finish 65 0242 2 18 Press to save the profile you have created The Finish button is grayed out until you complete the profile After you press this button the Monitor screen is displayed You can exit the program from there Fuel Alf FGR Open F2 Oper Open Fig 15334 16 7 96 17 d Open Open Open Tr Close Close F5 Close Fi p 1 D egree 1 LCO OFF OFF ADM OFF Firing Rate 13 5 mA WEES kastia Delete Position Delete Positions I Save Position Intermediate Light Off Modulation Modulation vla ram Eure bove to Next Postion Mowe to ext Lower Position Set lightoff position 1 Degree Profile Incomplete Ma Minimum Modulation Position Help E xit Prev Config Info Analyzer Emish Fig 23 Setting Lightoff point FGR Firing Rate m Open FuelZAi Profile Graph 100 at al BU al all 20 10 10 20 30 40 50 70 60 90 100 Alr Position gt Open Fig 24 Establishing Lightoff Point for the Curve Create Modify Profile Curve For Fuel 1 ir EE ip FGR r Inputs Open FIO LE ON Open Open TT
25. 3 The auxiliary 4 to 20 mA input must be below 3 mA when configured for use The actuators return or remain at the minimum modulation point with alarm on the control will remain operable only to the extent that Minimum Modulation firing operation is allowed Not supported on Version 1 2 controllers 94 After is set by the 47999 the Burner Control must provide a Lightoff or Purge request within 20 seconds Controller remains in a processing demand condition indefinitely waiting for valid inputs on the LF MV and HF inputs the alarm sounds after the 20 second period expires Not supported on Version 1 2 controllers Check CmA input Terminals 39 and 40 for proper operation polarity and range The input must be within 3 0 mA to 21 0 mA The voltage at this terminal must be within 0 7 to 5 0 Vdc respectively Conditional Alarm Alarm output is energized controller continues to 2 The manual potentiometer is out of range high Make sure a 5000 ohm x1096 potentiometer is being used and wiring to it is correct Shielded cable is recommended Conditional Alarm Alarm output is energized controller continues to 2 Check XmA input Terminals 37 and 38 for proper operation polarity and range The input must be within 3 0 mA to 21 0 mA The voltage at this terminal must be within 0 7 to 5 0 Vdc respectively Conditional Alarm Alarm output is energized controller continues to Check burne
26. AM c 1G hard drive with 100 MB of free memory d RS232 Serial Port DB9 Before commissioning a burner boiler with the ZM7999 you will also need the following equipment a Acalibrated stack gas analyzer b An RS232 to 45485 converter QM4520A1008 32005354 001 Self Powered SAFETY FEATURES This software incorporates many features that are designed to guide you safely through the commissioning process Safety however is your responsibility This software should only be used by experienced and or licensed burner boiler operators and mechanics Read all documentation carefully and respond appropriately to all error messages Be aware that as you command the software to open and close actuators the software is designed to prevent you from opening or closing them too rapidly When any of the system actuators is below 20 of its full open position the R7999 effectively limits any actuator from traveling more than three degrees without moving the other actuators in the system When all the actuators are over 30 of their full open position the limit increases to 10 degrees 65 0242 2 4 A WARNING Explosion Hazard Improper configuration can cause fuel buildup and explosion Operators of this software may move fuel and or air actuators to positions that can create Hazardous burner conditions Improper user operation may result in PROPERTY LOSS PHYSICAL INJURY or DEATH The ZM7999 ControLinks Software Commissio
27. Honeywell 2 7999 ControLinks Software Configuration Tool USER S MANUAL Software License Advisory This document supports software that is proprietary to Honeywell International and or to third party software vendors Before software delivery the end user must execute a software license agreement that governs software use Software license agreement provisions include limiting use of the software to equipment furnished limited copying preserving confidentiality and prohibiting transfer to a third party Disclosure use or reproduction beyond that permitted in the license agreement is prohibited U S Registered Trademark 2004 Honeywell International Inc 65 0242 2 All Rights Reserved ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL TABLE OF CONTENTS 2 INTRODUCTION 4 REQUIREMENTS 0 LEE 4 SAFETYFEATURES SuSE ES eeu a ELE LS dE i LA ep EET 4 GETING HELP dam oett eR E m UEM e LED UIS 4 INSTALLING THE HARDWARE unii eec eva eden eva el Co Eu D edo ee ene 3 INSTALLING THE SOFTWARE aub 4 BEFORE VOWBEGIN a a 5 STARTING THE PROGRAM tee e 5 THE COMMISSIONING PROCESS 5 2 8
28. To verify the transition lines between points or points themselves you should allow sufficient time for the combustion system to stabilize before accepting the fuel air and FGR ratios After each point move carefully monitor the oxygen sensor for unsafe conditions or inefficient combustion Make adjustments to the curve shape or add points as necessary When you have completely walked the curve the entire profile is one color and the Finish button is operational ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL How to Delete a Position on the Profile Points on the curve can be deleted individually For example if you want a new fuel FGR mixture at a predefined air point simply position the actuators near the point of interest until the Delete Point button is highlighted and pressing Delete Point Pressing this button removes all data relative to the point of interest If you want to add a new point between two existing points and it is not on the existing curve move the cursor to the appropriate stop and add the new point by pressing the ntermediate button If you decide the entire curve you created is not usable press Delete All Positions button This will clear the display and let you start over How to Load an Existing Profile If you are responsible for commissioning a number of burner systems with similar characteristics you may want to create and save one profile and then load it when you commission another system
29. ally negative slope of 1 to 5 anywhere within the modulation band 65 0242 2 6 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Table 1 Commissioning Overview Sep Acin Nees Press Intermediate A dot will be displayed on the profile and a line will connect the minimum modulation point and the first intermediate point Or press Maximum Modulation With Rev 1 4 controllers or greater the user may alternatively Entering a new Maximum Modulation point causes an place a maximum modulation point in place of an intermediate as pre existing Maximum Modulation point to change to long as a span of at least 17 degrees exist between the minimum an intermediate point This technique of entering each and maximum modulation points new intermediate point as the new temporary Maximum Modulation point has an advantage which is apparent under light boiler load conditions the user will be able to use the Move Along Curve commands during the next light off sequence and hence will be able to more quickly reach the firing rate point where the system was at prior to going out because of low demand For gas systems of which the gas pressure has not been adjusted to match the burner rated btu capability the use should use the maximum Modulation replacement technique to rough in a curve until maximal airflow is obtained The gas flow may then be adjusted to set the maximum firing rate The user may then delete all poin
30. assword Change the password as described in How to Change the System Password Enter your new password and press change password b Connect Press after you have entered a valid password and selected the PC Comm Port Fig 5 See How to Connect to the PC Comm Port c New Password Enter your new password in this field See How to Change the System Password d Change Password Press to change your password e PC Comm Port Select the communications port that the R7999 is connected to See How to Connect the R7999 in the specification sheet Fig 5 Help Press to display the help system Exit Press to exit the program Valid changes will be saved Prev Press to return to the previous screen Next Press to move to the next screen Select Base Configuration You cannot move to this screen until you have properly connected to the R7999 o Connect to Fuel Am Controller Connect Connected Please change the Default password verity Password Change Password FC Comm COMI C DDM2 COM3 C COM4 Fuel Ar Ratio Controller Firmware Rev 1 3 B 16 Help Prev lt lt gt Fig 3 Connected ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Connect to Fuel Ar Controller Commissioning Password Connect Conne cted Please chan ge the Default New Password F verify Password Change Password Fuel ir Ratio Controller Firmware
31. at is not currently being used Select Closed Lightoff or Open If you select Open you must enter a value in the appropriate field to indicate how wide the actuator should be opened percentage of maximum open value 9 FGR Behavior During Purge Lets you set the position of the FGR actuator during the purge cycle The options are Remain Closed or Follow FGR Curve to Purge Position Default System Parameters The default values settings for each system parameter are shown in Table 2 See also Fig 15 and 16 Table 2 Default Values Settings for System Parameters Parameter Xma Operation Disabled NA Operation Max 20 mA Automanual Switch 5 5 Fuel Selection 1 Fuel Selection 2 Fuel Selection 2 Fuel Selection 1 FGR Behavior During Purge FGR Behavior During Purge Remains Closed System Parameters Page 1 of 2 ma Operation Uperation Disabled Ranges in T emp Degrees Max 20ma 7 Degrees 40 to 1400 Min mal o Degrees Threshold 40 Differential 0 Degrees Controller Timings Postpurge Timeout 30 Cecond 0 Auta hilanual Switch f C Maximum Firing Rate Limit Help Prev lt lt gt gt Fig 15 System parameters Screen 1 System Parameters Page 2 of 2 Frogram standby Position Fuel Selection 1 Fuel Closed Lightaff C Open x 14 Closed Lightoff C pen x Cy m v C EG v oy v 6 73
32. ation Point Afinished profile requires the purge position to be lower than the maximum modulation If you encounter a condition where you are required to place the maximum modulation point below the current purge setting you must first move the purge point to a lower position The purge position can be moved at any time by reselecting the Air Purge button in the Save Position command window Cannot Establish Communications Beyond the difficulties associated with communications polarity wiring errors RS232 to RS485 converter problems and lack of power to the devices RS232 converter or R7999 there are several subtle system errors that preclude communications All of the errors are indicated by the green LED and red Lockout LED being continuously on Fuel select problems after power up are indicated with all LED s being on continuously a f no fuel select inputs on or both fuel selects are made you cannot establish communications with the controller The corrective action is to select one of the fuels or remove one of the fuel select inputs R7999 is in a locked out state The corrective action is to first reset the control If that does not work you must remove the fault c Ifthe Fuel Air Commissioning Tool was aborted due to a PC operating system fault or ZM operating system fault the ZM7999 software may have been improperly shut down and the program may still be running even though there is no ind
33. centration CO Concentration Concentration Air Temp Stack Temp S status OFF LINE vat vu i Fig 43 Off Line Low Battery Fig 38 The A7999 is indicating the battery power is low Replace the batteries Combustion Analyzer Information Concentration CO Concentration CO Concentration MO Concentration Air Temp Status LOWY BATT stack Temp Fig 44 Low Battery TROUBLESHOOTING Burner Control Locks Out Due to Loss of Air Flow Switch The R7999 ControLinks Controller has a preset of 25 air position O fuel for the initial lightoff point Depending on the air damper topology this may not provide enough airflow to maintain the air flow switch and cause the burner control to lock out The R7999 is still functional at this time even though the burner control is locked out Therefore before resetting the burner control and restarting the light off process you should first set a new temporary light off point to a higher airflow value to prevent the air flow switch from dropping out The next time through the sequence the new higher light off point may allow the air flow switch to be maintained or you will have to repeat the process i e move the light off point air value to a more open value such that the new point can maintain the air flow switch 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Purge Setting Beyond Maximum Modul
34. d not sampling CO Concentration PPM carbon monoxide reading referenced to O2 NO Concentration PPM Nitric Oxide reading that is referenced to O2 Stack Temperature Stack temperature The following screens will be displayed during the commissioning process Warming Up Hold Fig 34 The A7999 is going through self diagnostic startup which takes 60 seconds This is a normal screen Combustion Analyzer Information Concentration Concentration CO Concentration MO Concentration 000 Air Temp Stack Temp status WARMING LIP HOLD Fig 40 Warming up hold Warming Up Hold Fig 35 The 7999 is in a hold mode and waiting for data to be transmitted This is a normal screen Combustion Analyzer Information Q2 Concentration CO Concentration CO Concentration NO Concentration ETT Air Temp Es status HOLD stack Temp Ee Um i Fig 41 Hold Run Fig 36 The A7999 is processing data In the lower lefthand corner is a rotating bar This means that the A7999 is active 27 O Concentration 20 9 25 m CO Concentration 0 0 PPM c E CO Concentration 0 0 25 Concentration OOPPM O stack Temp Status RUM Air Temp Fig 42 Run Off Line Fig 37 The A7999 is not communicating with the ZM7999 Configuration Tool Check for proper wiring connections Combustion Analyzer Information Q2 Concentration CO Con
35. e damper will automatically move to a 25 open if present to move the cursor to the Light Off point of the burner position while the fuel actuator will remain at the closed position plus 1 degree When used with Honeywell burner controls the user has 240 seconds to perform this action otherwise the burner control will lock out Press Light Off An L will be displayed on the profile and the R7999 will energize the LFP output terminal 8 which will allow the burner control to light off the system The burner should light Press here for troubleshooting information Open and Close for Fuel Air and the FGR if present to Press here for information on using the flat line the cursor to the Minimum Modulation point for the burner Wizard for the FGR Press Min Modulation An will be displayed on the profile NOTE The min modulation point may be higher or lower than the Light Off point 6 h Press Open and Close for Fuel Air and the FGR if present to The R7999 enforces slope limitations of 1 to 8 and 8 move the cursor to the next desired fuel air mixture point to 1 in degrees with the exception of Flat Line or Negative FGR capability The cursor changes from a cursor to a diamond when you have moved out of the range of allowable slopes You are not allowed to enter points when a diamond shape is present With controller release 1 4 or greater the FGR actuator may have negative slopes maxim
36. e the air purge position on the graph A P is displayed on the graph to indicate the air purge point Only one air purge point is allowed per curve 5 Delete Positions a Delete Position Press to delete a point on the curve To delete the point you must position the cursor on the point b Delete All Positions Press to delete ALL positions on the curve including the light off air purge max and min modulation points Use this button ONLY when you want to start creating the curve from the beginning 6 Start Lightoff Sequence e Stop Modulation This button serves a dual purpose Press this button after you have positioned the actuators as shown by the cursor to the light off position Pressing this button activates the burner controller lightoff sequence If the lightoff sequence is successful this button then displays Stop Modulation If the lightoff sequence fails the Status window indicates the problem f you want to stop the system at any time during the commissioning process use the Stop Modulation button 7 Move Along Curve Move to Next Higher Position Move to Next Lower Position Press these buttons to move the cursor along the curve to a previously set position Use these buttons to reposition the cursor or to walk the curve and verify system operation As the curve is verified the color of the curve changes NOTE The ZM7999 requires you to enter at least 3 points inclusive of the m
37. earest point to the right You would need to close the l FGR actuator to react the Flat Line condition No programmed point exists to the left M17934 The FGR actuator is below Flat Line with respect to the nearest point to the right You would need to open the FGR actuator to reach the Flat Line condition No programmed point exists to the left M17935 7999 Portable Combustion Analyzer commission process the A7999 can be used to monitor the burner combustion parameters By using the 32004354 001 The Honeywell A7999 Portable Combustion Analyzer can be used with the R7999 ControLinks System During the Port Expander the A7999 combustion parameters can be displayed during the commissioning process as the fuel air 65 0242 2 26 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL curve is being built To access the A7999 parameters click on the Analyzer button and a screen will open Combustion Analyzer Information The screen is similar to the screen that is displayed on the analyzer This screen is only active during the commissioning process Table 4 A7999 Combustion Analyzer Information Screen Description Screen Display Definition O2 Concentration Oxygen reading multiplied by a factor of ten CO2 Concentration Carbon Dioxide reading multiplied by a factor of ten Air Temperature Room Primary Air temperature Rotating bar indicates A7999 is active and sampling Static bar indicates 7999 is inactive an
38. em 3 9 Internal Fault Commanded State Reset Controls 36 Fuel Selection Problem Check wiring through fuel select switch at least one fuel must be selected at any given time not zero not two 37 Fault HFP or LFP output Verify correct wiring to burner control Specifically check wiring at LFP and HFP 39 Internal Fault AC sampling Reset control Feedback potentiometer Interface circuit fault Air verify correct wiring of Potentiometer uel 1 uel 2 Ir uel 1 uel 2 Ir uel 1 uel 2 58 Stuck Reset button Turn off remote reset switch Check operation of controller button Actuators not reaching light off point Check for actuator wiring problems or stuck valves dampers Place controller in standby and use actuator manual keys to verify actuator travel Internal Memory fault Reset control Internal Initialization Error Reset control Check the wiring and range capability for both the CmA input and XmA input if configured Fuel Actuator off curve selected fuel type Check for stuck fuel actuator and or proper shielding on actuator interface 65 0242 2 30 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Table 7 Fault Codes and Corrective Actions Continued Fault Blink Code Description Corrective Action FGR Actuator off curve Check for stuck FGR actuator and or proper shielding on actuator interface Bol Air Actuator off curve Check for stuck Air actuator and or prope
39. er at least deleted in 6 k three points inclusive of the min and max modulation points in order to use the Move Along the Curve buttons 6 n Repeat step 6 m until you have moved along the curve from top The profile is now complete and operational to bottom The R7999 requires reverification of any line segment after the maximum modulation point has been altered If you wish to save the profile you have just created to your PC or The user must insure that the purge point is within the disc press Save Profile minimum and maximum modulation points before finishing the profile The purge point can be moved while the burner is firing by simply using the Move Along the Curve commands and pressing the PURGE button at the desired level or at the purge point definition period during the next start up sequence 7 When you are through with the profile press Finish The Monitor screen appears You have successfully commissioned the R7999 7 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL PROGRAM OPERATION Honeywell Fueli Ratio Controller Commissioner M7999 Because the ZM7999 ControLinks Software Configuration Honeywell Fuel Air Ratio Controller wersian 1 1 B4 Tool operates like a wizard you cannot open screens randomly You must step through them one at a time and provide the information necessary for one before you can move on to another The screen descriptions are provided below so that you can
40. et Maximum Air Open Position 7 4 109 4 Degrees Fi Close Relative to potentiometer span 1 Degree Auta Seek Wpen Y Set Maximum Air Closed Position FB duet Degrees Close Relative to potentiometer span 5 1 Degree Auto seek Closed Lack Position Prev lt lt gt gt Fig 11 Set Maximum Air Open Position 12 Set Actuator Endpoints Actuator Configuration Direction of Closed Travel Actuator Type Clockwise f Fixed Stops CounterClockwise Continuous Rotation Serial Number 0008031 G 581 Configuration cet Maximum Air Open Position 109 4 Degrees FI Close Belate to potentiometer span Seek Unlock Position Set TEES Air Closed Position FB Open 19 4 Degrees FS pisse Relative to potentiometer span 5 1 Degrees ulta seek d Help Prey lt lt gt gt Next Fig 12 Set Maximum Air Closed Position Lock Unlock Position e After you have set the maximum open or closed positions for the actuator lock the settings by pressing the Lock Position button Once you press the Lock Position button the degrees position will change from red to blue and the button redisplays as Unlock Position To change the position settings once the Lock Position button has been pressed you must press the Unlock Position button a Help Press this button to display the
41. figuration screen If you make changes to the system parameters they are not saved until you press Finish on the second system parameters screen System parameters you can set include Stack or boiler water temperature sensor operating parameters Controller timing postpurge time e Auto manual maximum firing rate option via the manual potentiometer input Program standby positions and nonselected fuel position FGR behavior during purge e XmA Operation Auxiliary mA input Select an operation from the dropdown list 1 2 Disabled means the input is ignored Low Fire Hold Selecting this option field enables an algorithm that protects the boiler from thermal shock Upon successful progression to modulation the R7999 holds the burner at the light off point until the auxiliary temperature input exceeds the programmed threshold The Low Fire Hold function re enables once the tempeature input falls below the threshold minus the differential Use of this function requires an auxiliary linearized 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL temperature transducer You must match the programmed high and low temperature range points to that of the transducer all other values are determined in a linear interpolated manner ranging from 4 0 mA to 20 0 mA the maximum temperature range is 40 F to 1400 F respectively The minimum span is 100 F 3 FGR Hold Selecting this option field enables a
42. grees o4 Degrees Outputs HET M 7 I LEO ON E ESENE EEE EE A Save Position Se ee eens eee 7 J LFP OFF t t Delete Position ALM Delete All Im Firing Rate I Positions 19 4 1 MovetoNext Higher Position Moveto Next Lower Position 5 Degrees Profile Incomplete 4 Segments not verified Prev gt gt Fig 27 Verifying an Intermediate Point FuelV Air Profile Graph Fuel FGR Firing Rate mA s Open 4 5 12 16 20 100 at atl al atl 20 10 0 10 20 30 40 50 70 90 100 Alr Position Open Fig 28 Verifying an Intermediate Point on the Curve 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Create Modify Profile Curve For Fuel 1 Create Fuel Ratio Curve 1 975 5 Open Open TT Close F5 Clase pe Delete Position Configured 3 Degrees 0 1 Degrees B 3 Degrees Nat Configured 5 OFF LFF OFF ALM OFF Save Position Intermediate Light mt Delete Position Modulation Air Purge opi i i 15 cle Min Stop Modulation P Move Along Cure Load Save Profile ta File
43. ication on the screen Press CTRL ALT DEL This brings up the Task Manager Select End Task for any occurrence of the Fuel Air Commissioning Tool before you start another session of Fuel Air Commissioning Tool d If the communications port settings at the low setting you can experience connect disconnection problems To check the communications port settings the following steps get you to the proper screen s Double click on My Computer Double click on Control Panel Double click on System Click on Device Manager Double click on Ports COM amp LPT1 Double click on comm port could be COM 1 4 Double click on port settings Click on advanced settings This screen displays the Receive Buffer and Transmit Buffer settings Move the slide bars up to the high settings Click OK to verify the new settings Unable to Land on a Predefined Point Under unique actuator loading conditions it may be difficult to land on an existing programmed point This can occur while using the Move Along the Curve command it can also occur when you are completing the curve verification process on extremely flat or steep line segments as you reach the end of the curve If you ar experiencing problems back up from the problem point at least 5 degrees then move back to the point using a 3 degree 1 degree or 0 1 degree movement This should allow you to complete your curve verification or land on a problem point for deletion Password n
44. in and max modulation points to use the Move Along the Curve buttons 17 8 Load Save Profile to File Load Profile Press this button to load an existing profile curve from a file saved on your PC or disc When you press the button a File Search window opens and you can navigate to the directory and filename of the file you want to load Press Okay to load the profile in the file The profile will be displayed in red You must walk the curve to verify system operation with the curve e Save Profile Press this button to save the curve you have created to a file on your PC or disc When you press the button a File search window opens and you can navigate to the directory you want to save the file in Fig 20 Use a descriptive filename for the file The extension prf is automatically added when you press Save to save the profile Save Profile Save In 3 Fuel Air Wizard ZM 7999 g File name prf Save as type pit z Cancel Open as read only Fig 20 Save Profile Screen 9 Configuration Information e Config Info Press this button to view the system configuration information e Save to file Press this button txt e Save Press this button to save the system configuration you have created to a file on your PC or disc When you press the button a File search window opens and you can navigate to the directory you want to save the file in Use a descripti
45. in to commission a system 1 Read this guide to understand how the program operates 2 Review the Commissioning Process and Creating an Air Fuel Ratio Profile Example sections so that you have a clear understanding of the commissioning process STARTING THE PROGRAM To start the program proceed as follows Double click the FuelAir ZM7999 icon on your desktop OR 1 Press the Windows Start button 2 Select Fuel Air Wizard ZM7999 3 Select FuelAir ZM7999 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL THE COMMISSIONING PROCESS Commissioning a burner using the ZM7999 ControLinks Software Configuration Tool requires the following general steps 1 Connecting the R7999 to the communications port of your PC and logging onto the software with a password This prevents unauthorized users from modifying the modulation curve 2 Specifying the base configuration one or two fuels with or without FGR 3 Selecting system parameters such as Low Fire Hold 4 Specifying the characteristics of the actuators and setting the valve damper end points for those actuators 5 Creating a modulation curve profile for each fuel and verifying it from maximum to minimum modulation While you are commissioning the system you must monitor the burner operation with appropriate safety instrumentation to verify the modulation curve Refer to Creating an Air Fuel Ratio Curve Example fora detailed example of how a sys
46. ks software builds 178 and lower and will be disabled Firing Rate Hysteresis The Firing Rate Hysteresis value controls the amount of hysteresis for the 4 to 20 mA firing rate CmA input signal Adjusting the Firing Rate Hysteresis value determines when the R7999 will react to a firing rate change in the opposite 21 direction The ControLinks only reacts to a firing rate change in the opposite direction when it has increased or decreased more than the user selected Hysteresis value However the ControLinks always follows the firing rate signal as it changes in the same direction For example When a hysteresis value of 0 5 mA has been selected and the firing rate dropped from 12 mA to 10 mA the ControLinks will not begin to follow an increased firing rate until it increases to a value of 10 5 mA or higher All firing rate values between 10 mA and 10 5 mA are interpreted as a value of 10 mA The configured actuators will remain at their corresponding 10 mA firing rate position until the firing rate has increased higher than 10 5 mA Increasing the hysteresis value may reduce the amount of actuator dither and hunting and premature wear out due to noisy environment or an intelligent firing rate controller continuously attempting to satisfy a very precise setpoint Actuator Deadband The Actuator Deadband setting controls how closely the actuators will follow the profile curve configured in a ControLinks and defines the all
47. modulation air purge lightoff sequence etc Point on the Curve 8 Cycle Indicates the current cycle of the system with one being the first call for heat cycle since the system was commissioned 65 0242 2 20 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL M7999 Monitor Fuel Selection Fuel 1 Fuel 11 8 Ar 16 8 2 76 Firing Rate 5 9 mA Aux Temp Input Disabled Status Auta Modulation Cycle 2 Active Alarm Mone Alarm History History Log 5 Inputs 4 Outputs ON LCO ON HF OFF OFF LF j LEP OFF Mv ON ALM OFF FS1 ON FE OFF Contig Into Finish Fig 32 Monitor Screen 9 Active Alarm Indicates if the system is in an Alarm state 10 Alarm History Displays all alarms that have been generated The dropdown box displays the cycle the alarm occurred in and the alarm type 11 Inputs Outputs All Outputs and Inputs are displayed and their current state is noted See Outputs and Inputs for a description 12 Help Press this button to display the help system 13 Finish Press this button after you are through monitoring the system to return to the ntro screen SETTING THE FIRING RATE HYSTERESIS AND ACTUATOR DEADBAND The Firing Rate Hysteresis feature is available for all R7999 controller ControLinks software builds except 176 The Actuator Deadband feature is not available for ControLin
48. n algorithm that holds the FGR damper closed until the stack temperature has reached a programmed threshold After successful progression to modulation the R7999 holds the FGR closed until the auxiliary temperature input exceeds the programmed threshold The FGR function re enables once the temperature input falls below the threshold minus the differential use of this function requires an auxiliary linearized temperature transducer You must match the programmed high and low temperature range points to that of the transducer all other values are determined in a linear interpolated manner ranging from 4 0 mA to 20 0 mA The maximum temperature range is 40 F to 1400 F respectively the minimum span is 100 F 4 FGR and Low Fire Hold Selecting this option enforces both of the above actions a Max 20 mA This field lets you set the maximum sensing range of the transducer The maximum value must be between 40 F and 1400 F b Min 4 mA This field lets you set the minimum sensing range of the transducer The minimum must be less than the maximum by at least 100 F c Threshold This field lets you set the threshold temperature at which you want the low fire hold or FGR hold or Low Fire and FGR hold to be released The threshold temperature must be less than the maximum d Differential This field lets you set the differential temperature at which the system will revert to a hold condition The threshold must be set lower tha
49. n existing system Password 3 Monitor the status of a commissioned system Verify Password 4 Verify the version number of the ZM7999 software Change Password a Commission Press to start commissioning a new system or modify review the commissioning settings PUO Ego PEN of an existing system 4 COMI b Monitor Press to monitor the status of a commissioned system C 3 c Help Press to display the help system d Exit Press to exit the program Connect to Fuel Air Controller Screen The Connect to Fuel Air Controller screen Fig 2 is used to gt gt Prev lt lt Help Protect the system from unauthorized users ns murice i e Connect the R7999 to the software Refer to the R7999A B ControLinks Controller specification sheet Fig 2 Fuel Air Controller Screen Form No 65 0238 NOTE The password has to have a minimum of four and a You can perform the following actions from this screen maximum of 15 characters 1 Enter your password to access the commissioning a Commissioning Password Before you can function of the program connect to the system you must enter a valid 2 Select the PC communications port the R7999 is password here See Fig 3 and 4 connected to 3 Change the password 65 0242 2 8 NOTE The first time you use the system enter the password password and then press Connect A message will display that you must change the default p
50. n the threshold but greater than the minimum 5 Controller timing a Postpurge Timeout Use the dropdown list to select how long the system should wait at the postpurge position once the postpurge state has been detected It is important that the postpurge timeout time be at least as long as the burner control time especially when the air damper is configured to close while in standby 6 Auto Manual Switch a Select either Normal or Maximum Firing Rate Limit b When the Maximum Firing Rate Limit is selected the R7999 when in auto mode reads the value of the manual potentiometer input and does not allow modulation beyond its interpreted value The manual potentiometer input equates 0 to 500 ohms as a 4 mA firing rate input and 4500 ohm or greater as a 20 mA input all other values are determined by linear interpolation The behavior during manual switch setting is not affected i e the firing rate input is derived directly from the potentiometer value and the controller mA input is ignored 7 Program Standby Position Lets you set the position of the actuators when the controller is in the standby position For each actuator select Closed Lightoff or Open If you select Open you must enter a value in the appropriate field to indicate how wide the actuator should be opened percentage of maximum open value 65 0242 2 14 8 Program Non Selected Fuel Position Lets you set the position of the fuel actuator of the fuel th
51. ning Tool is to be used only by experienced and or licensed burner boiler operators and mechanics GETTING HELP In addition to referring to this manual you can get on line help when using the software by pressing the HELP button on any of the screens You can then use the table of contents of the help system to open topics or use the search function to find information INSTALLING THE HARDWARE Use the following ControLinks instructions to install the system hardware 65 0238 R7999A B ControLinks Controller 65 0239 ML7999A ControLinks Actuator 65 0240 Q7999A Wiring Subbase INSTALLING THE SOFTWARE To install the software follow the directions provided in the CD ROM booklet If those instructions are not available proceed as follows Start Windows Insert the CD ROM in your CD ROM drive Press the Windows Start button Enter D setup assuming your CD ROM drive is your D drive and press OK Follow the installation directions as they are displayed An on line help file will be installed along with the configuration software A printed copy of this User Guide form number 65 0242 can be ordered from Honeywell Inc by calling 1 800 468 1502 6 When updating or removing ZM7999 software perform an uninstall of the old software Once installed the ZM7999 software can be used to configure and monitor the R7999A B ControLinks Controller A OM BEFORE YOU BEGIN Before you beg
52. o Longer Valid Bringing a system to an unconfigured state utilizing the ZM7999 tool wipes out your custom password and returns the system password to password Enter a new password Fault Code Retrieval The R7999 incorporates two methods to retrieve fault information Press and hold the reset button The fault code is indicated by the blinks and flashes of the LED All codes are two digits The 10 s digit is indicated by a series of slow blinks while the 1 s digit is indicated by a series of short flashes after the slow 10 s digit For example 64 is made up of six slow blinks followed by four fast flashes The cadence is repeated as long as the user holds the reset button The device will not reset by the action of the reset switch once it enters the flash mode To reset the R7999 push and release the reset button within one second Readthe code directly from the Monitor screen of the ZM7999 Click here for a list of Fault Codes and Actions Click here for LED Status Panel Blink Patterns R7999 OUTPUTS AND INPUTS The current state of the R7999 outputs and inputs are displayed on both the Create Modify Profile Curve screen and the Monitor screen for convenience and diagnostics purposes The inputs and outputs are defined as follows Table 5 Outputs Abbreviation Meaning when ON Limit Control Output Limits are satisfied and demand exits The R7999 is operational and able to move all actuators High Fire Pr
53. oved The R7999 has moved the actuators to the Purge position 65 0242 2 28 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Table 5 Outputs Continued Abbreviation Meaning when ON Low Fire Proved The R7999 has moved the actuators to the Light Off position Fuel Select Channel 1 Fuel 1 is selected Fuel Select Channel 2 Fuel 2 is selected Table 6 Inputs Abbreviation Meaning when ON Limit Control Input Limits are satisfied and demand is present High Fire Input R7999 is being commanded to drive actuators to the Purge position Low Fire Input R7999 is being commanded to drive actuators to the Light Off position Main Valve Input The main valve input is active Normally only active during and transitional with LF during light off R7999 FAULT CODES AND the 1 s digit is indicated by a series of short blinks following the slow ten s digit For example 64 is made up of six slow CORRECTIVE ACTIONS blinks followed by four fast blinks The cadence is repeated as long as you hold the reset button The device will not reset by the action of the reset switch once it enters the flash mode To reset the R7999 push and release the reset button within one second Press and hold the reset button The fault code is code directly from theMonitor screen of the indicated by the blinks of the LED All codes are two digits The 10 s digit is indicated by a series of slow blinks while Table 7 Fault Codes and
54. owable tolerance for achieving each commanded position The ControLinks will normally drive the actuators to within 0 1 degree default value of the programmed curve Applications that do not require 0 1 degree of accuracy can benefit from increasing the Actuator Deadband value which will reduce the amount of actuator dither hunting and premature wear out due to a noisy environment Downloading the new Actuator Deadband and Hysteresis values will cause the controller to reset and the new values will be written into nonvolatile memory Note Setting the Actuator Deadband to a value other than 0 1 degree will disable 0 1 degree positioning commands when commissioning the curve To maintain accuracy during commissioning it is recommended to change the actuator deadband to 0 1 degrees then back to the previous setting when finished Procedure See Fig 33 to 36 1 Savethe profile curve and Config Info if not already saved 2 Onthe Home page click the Modify Factory Default Values button Read the Warning screen then click the OK button Reset the ControLinks Click the Connect button and wait for the ControLinks to connect with ZM7999 Select the Modify Factory Default Values button Wait for the current values to be read from the Con troLinks Note that the current values are displayed on the left half of the screen and the new values to be downloaded are displayed on the right half of the screen 9 Use the drop d
55. own combo boxes to select the desired Firing Rate Hysteresis and Actuator Deadband values 10 Click the Download New Hysteresis and Deadband Values button 11 Verify that the download was successful See figure 4 for an example 12 Click the Exit Program button to reset the ControLinks and exit ZM7999 13 The ControLinks will start operating using the new values MAp 0 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Honeywell 2447999 Fuel Commissioner Honeywell Fuel Air Ratio Controller Version 4 5 The 2999 Commissioning Software is ta be used only by Experienced and or Licensed Boller Operators and Mechanics Operators of this Software may move Fuel and or Air Actuators to positions that can create Hazardous burner conditions improper user operation may result in PROPERTY LOSS PAY SICAL INJURY or DEATH This feature of the 247999 requires multiple RF 999 resets The experienced burner boiler commissioner is solely responsible far safety at all times Prior ta using this feature please save all configuration information and profile curve files A communication interruption while downloading modified data may require ALL factory default settings ta be restored Fig 34 Warning 65 0242 2 22 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Modify Parameters Firing Rate Husteresis Control and Actuator Deadband 30 Honeywell Default Salue 10
56. r control interface wiring and burner control operation Terminals 10 11 12 The R7999 is waiting for a command via these terminals Conditional Alarm Alarm output is energized controller continues to Itis possible that a random external electrical noise event has caused a fault checking algorithm to be detected Resetting the control will allow recalculation of the fault and provided it is not a hard failure the device will continue to operate If the condition will not clear the control must be replaced 5 Check AC waveform severe noise on AC lines can corrupt the sampling of AC signals Verify actuator total resistance and wiper measurements check the ability of the actuator to travel full stroke using the Manual override buttons within the actuator Verify input power to the actuator If actuator is not functioning replace the actuator d Verify a short does not exist at terminal 14 The control will need replacement if a sustained fault code 34 exists after the noted items 1 and 2 have been performed Fuse line voltage power to control system with type SC15 fuse or fuse Limit input terminal 13 with type SC5 fuse Conditional Alarm Causes the alarm output to be energized The system may still be operating but requires attention in order to modulate or to proceed with the light off sequence The actuators would be positioned at light off point minimum modulation point or maximum modulation point dependent
57. r shielding on actuator interface Verifies that the Air actuator accepted the off line Check wiring of actuator verify correct ID is being used Use on line move counterclockwise and move Actuator LED to verify that the actuator that is being brought clockwise commands Furthermore all online A fast flash in the actuator equates to off line state potentiometer tests must successfully passed to while 1 second flash equates to an online state bring an actuator online Verifies that the Fuel 1 actuator accepted the Check wiring of actuator verify correct ID is being used Use off line on line move counterclockwise and move Actuator LED to verify that the actuator that is being brought clockwise commands Furthermore all online A fast flash in the actuator equates to off line state potentiometer tests must successfully passed to while 1 second flash equates to an online state bring an actuator online Verifies that the Fuel 2 actuator accepted the Check wiring of actuator verify correct ID is being used Use 76 83 off line on line move counterclockwise and move Actuator LED to verify that the actuator that is being brought clockwise commands Furthermore all online A fast flash in the actuator equates to off line state potentiometer tests must successfully passed to while 1 second flash equates to an online state bring an actuator online Verifies that the FGR actuator accepted the off line
58. rameters let you choose advanced features that use the auxiliary 4 20mA input such as low fire hold and or FGR holds configure actuator positions during standby configure the position of the non selected fuel actuator configure action of the FGR actuator during purge adjust the postpurge timing parameter and select a maximum firing rate limit via the manual potentiometer input See System Parameters Screen below Setting these parameters is optional If you do not set system parameters the default values will be used See Default System Parameters for the default value setting for each parameter NOTE The selection of Xma auxiliary mA operation system parameters result in a common attribute between the operation of both fuel selections For example selecting low fire hold will apply to both fuels a Help Press to display the help system b Exit Press to exit the program Valid changes will be be saved Prev Press to return to the Connect to Fuel Air Prev Press to return to the Connect to Fuel Air Controller Controller screen e Next Press to move to the next screen Create Fuel Ratio Curve NOTE You cannot move to Create Fuel Ratio Curve screen until all of the actuators have been configured NOTE You do not have to set any of these system parameters Default values positions are defined If you want to review system parameter settings or add modify them Press System Parameters on the Select Base Con
59. s you will have to perform when using the ZM7999 ControLinks Software Configuration Tool to commission a burner The ZM7999 works like a wizard As you progress through the screens use this section to answer specific questions as to how to perform required actions The process of commissioning a system is described in detail in Creating an Air Fuel Ratio Profile Example How to Change the System Password To change the system password proceed as follows 1 Enter the current password in the Commissioning Password field The factory default password is password 2 Press Connect The system must be connected in order to change the password 3 Enter a new password in the New Password field NOTE Your new password requires a minimum of four 4 characters and a maximum of 15 characters 4 Press Change Password 5 Return to the Commissioning Password field and enter your new password to proceed NOTE The password is not case sensitive Make sure you write down your new password before you press Change Password Once you have pressed this button you cannot enter the system without the password How to Connect to the PC Comm Port To connect to the PC communications port proceed as follows 1 Refer to your PC manual to determine the location of your communications ports 2 Connect the RS232 to 45485 conversion cable from the R7999 to the appropriate communications port of your PC 3 Enter your password
60. system and only two actuators you can only select Unconfigured or Single Fuel a Base Configuration 1 Unconfigured This is the initial default option You can select this option to erase the current configuration and reset to factory configuration 2 Single Fuel Select if you want to configure only one fuel actuator and one air actuator 3 Single Fuel with FGR Select if you want to configure a fuel actuator an air actuator and an FGR actuator 4 Dual Fuel Select if you want to configure two fuel actuators and one air actuator 5 Dual Fuel with FGR Select if you want to configure two fuel actuators one air actuator and an FGR actuator 65 0242 2 10 b Air Fuel1 Fuel 2 FGR 1 Press a button to configure the actuator If you selected Single Fuel or Single Fuel with FGR in the Base Configuration the Fuel 2 button is not displayed If you selected Single Fuel or Dual Fuel in the Base Configuration the button is not displayed When you press a button the Set Actuator Endpoints screen is displayed When the actuator has been configured the word Configured is displayed next to the appropriate button See Fig 7 Select Base Configuration and Set Actuator Endpoints Base Configuration Uncanfiqured Single Fuel Single Fuel with FGA Dual Fuel Endpoints Mot Configurer Fuel 1 Endpoints Not Configured Fuel 2 Endpoints Mot Configured
61. tem should be commissioned Commissioning Overview The following table provides a step by step overview of how a system is commissioned A detailed example of how to commission a system is described in Creating an Air Fuel Ratio Curve Example The Notes column in the table provide references to detailed information when completing the more complex operations Table 1 Commissioning Overview Step Action PCN On the Tiro screen press Commission The ZM7999 requires you to enter your own password The factory default password is password Select or verify the communications port to which the R7999 is connected 2 PressNextbutton Next button E On the Select Base Configuration screen perform the following steps 2 lr the Connect to Fuel Air Controller screen perform the following steps Enter your password Select the base configuration The choices are Unconfigured selecting this option takes the device back to a factory state Single Fuel Single Fuel with FGR Dual Fuel Dual Fuel with FGR 3 0 5 an actuator to configure Air Fuel 1 Fuel 2 or FGR There may not be a button for each actuator a OntheSetAcuatorEndpomtssoen perform the folowing Steps PS Counteriocnse Counterclockwise C Continuous Rotation 5 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Table 1 Commissioning Overview Sep
62. then it is necessary to completely re commission the ControLinks Select Yes to the Reset to Factory Default Values message All factory default values will be loaded and all old data will be cleared Commission the actuators then load your saved profile curve 23 ooo Factory Reset Reset the RM 999 to factory settings WARNING ALL DATA WILL BE LOST Fig 37 Factory Test Mode Comm Ports Some computers do not have comm ports or the comm ports are being used by other devices so a USB to Comm Port adapter needs to be installed Follow the manufacturer instructions then write down the Comm Port number it was installed as It should get installed in the first available comm port but may not be if several attempts were made to install a USB to Comm Port adapter To find out which comm port the adapter is use the Device Manager which is a Windows Hardware utility typically located in the Control Panel System Properties Hardware tab Ports The Comm Port number may be changed manually in the Advanced Properties of the Comm Port Connect ta Fuel Air Controller Commissioning Password Connect Not Connected New Password Verify Password henge Password PC Comm Port Modify Factory Fig 38 PC Comm Port Selection 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL OPERATING PROCEDURES This section describes procedures for the various operation
63. to the nearest point to the left You would need to close the 1 FGR actuator to reach the Flat Line condition shown next No programmed point exists to the right M17929 The FGR actuator is at a Flat Line position with respect to the nearest programmed point to the left No programmed exist to the right M17930 The FGR actuator is below Flat Line with respect to the nearest programmed point to the left and above Flat Line l with respect to the nearest programmed point to the right You would need to close the FGR actuator to achieve Flat Line with respect to the left point and open the FGR actuator to achieve Flat Line with respect to the nearest M17931 programmed point to the right The FGR actuator is at Flat line position with respect to the nearest programmed point to the left and to the nearest programmed point to the right No further adjustment open or closed is necessary to enter a Flat Line gt point with respect to the closest programmed points to the left and right of the current position M17932 The FGR actuator is above Flat Line with respect to the nearest programmed point to the left and above Flat Line l l with respect to the nearest point to the right You would need to close the FGR actuator to achieve Flat Line with respect to the right point and or close the FGR actuator to achieve Flat Line with respect to the nearest programmed point to the left M17933 The FGR actuator is above Flat Line with respect to the n
64. ts and immediately re enter another maximum modulation point 6 j Repeat steps 6 h and 6 i until you have created at least six intermediate points along the profile 6 k Press Open and Close for Fuel Air and the FGR if present to For gas systems of which the gas pressure has not move the cursor to the Maximum Modulation point for the burner been adjusted to match the burner rated btu capability the use should use the maximum until maximal airflow is obtained The gas flow may Modulation replacement technique to rough in a curve then be adjusted to set the maximum firing rate The user may then delete all points and immediately re enter another maximum modulation point This may save the user some time by not having to successively delete invalid intermediate points due to the gas pressure change R7999 requires re verification of any verified curve segments after setting the maximum modulation point Move to Next Lower Next Higher position until the cursor The line segment turns color red to blue to indicate reaches the next lower point on the profile Alternatively the user the curve has been walked verified Press Max Modulation An M will be displayed on the profile and a line will connect it to the previous intermediate points The may add intermediate points as the effective firing rate is lowered Jump back to 6 h if the temporary intermediate points were NOTE The ZM7999 requires you to ent
65. tuator has been driven to is maximum position visually verify its position and use the Open or Close buttons to manually adjust the maximum position necessary Press the Lock Position button for the endpoint once the appropriate position has been achieved and verified 4 Repeat Steps 2 and 3 for the other maximum position 5 When the maximum open and closed values are set where you want them and you have pressed Lock Position buttons for both positions the Next button will be available 6 Pressthe Next button This will return you to the Se ect Base Configuration screen to configure another actuator After all actuators are configured press the Next button again to display the Create Fuel Ratio Curve screen How to Verify the Profile Walking the Curve Walking the Curve means to verify the profile you have just completed You can walk a partial curve however you must have successfully entered minimum and maximum modulation points and one additional point such as light off or an intermediate point If you modify a point on a profile you must walk the section of the curve connecting the new point to points that have already been verified walked To walk the curve 1 Position the cursor at one end of the profile that needs to be verified 2 Press either the Move to Next Higher Position button or the Move to Next Lower Position button As you reach a new point the line changes color red to blue
66. ve filename for the file The extension prf is automatically added when you press Save to save the system configuration NOTE The curve is saved in the R7999 as you create it Saving the profile to a file is only necessary to provide a backup copy of the profile or to use it as a base for creating a curve for a similar system in another location 65 0242 2 ZM7999 CONTROLINKS SOFTWARE CONFIGURATION TOOL Configuration Information Base Configuration Dual Fuel with FGR Fuel Selection Fuel 2 Configurations Actuator degrees are relative to the actuator potentiometer span FUEL 1 ACTUATOR Serial Number 99370113 Direction Counter Clockwise Type Continuous Rotation Open Position 185 Degrees Closed Position 15 1 Degrees span 89 9 Degrees FUEL 2 ACTUATOR Serial Number 99346082 Direction Counter Clockwise Save to File Close Fig 21 Configuration Information Save Configuration Information Savein al Fuel Air Wizard 2 7999 ex Gave bet Cancel Open as read only Fig 22 Save Configuration Information 10 Status This window displays status and error information as you create the profile It cannot be edited 11 Help Press to display the help system 12 Exit Press to exit the program Valid changes will be saved 13 Prev Press return to the Create Fuel Ratio Curve screen

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