BC 7700 Chassis Module Boiler Control System 7700
CONTENTS
Specifications ... 2
Ordering Information ... 2
Installation ... 3
Checkout ... 5
The BCS 7700 is a microprocessor based inte-
grated control system for gas, oil, or combination fuel single burner applications. The BCS 7700 consists of a Chassis Module, Program Module, Keyboard Display Module, Flame Signal Ampli- fier, Solid State Sensors (Fuel Oil and Water Temperature, Steam Pressure, Gas Pressure, Oil Pressure), and a Firing Rate Motor. The BC7700 Chassis Module is a component of the BCS 7700.
The BCS 7700 provides levels of safety, func- tional capability and features beyond the capac- ity of conventional controls. Functions of the BCS 7700 include automatic burner sequencing, flame supervision, system status indication, and system diagnostics.
The Chassis Module provides mounting means for the Program Module and Flame Signal Am- plifier, line voltage input and output electrical connections, and panel mounting.
■ Field replacable 10 A fuse.
■ BCS 7700 Boiler Controller mount.
■ 2 Status LEDs.
■ Digital input monitoring and output load control.
SPECIFICATIONS • ORDERING INFORMATION
Specifications
Ordering Information
When purchasing replacement and modernization products from your BCS 7700 distributor, refer to the TRADELINE Catalog for complete ordering number.
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Honeywell Residential and Building Controls Division Sales Office (check white pages of your phone directory).
2. Residential and Building Controls Division Customer Satisfaction Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 (612) 542-7500
(In Canada—Honeywell Limited/Honeywell Limitee, 740 Ellesmere Road, Scarborough, Ontario M1P 2V9) International Sales Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
ELECTRICAL RATINGS:
Voltage and Frequency: 120 Vac (+10/-15%), 50 or 60 Hz (+/-10%).
Fusing:
Chassis Module: 10A, field replaceable.
System: 15A, (type FRN or equivalent) maximum.
ENVIRONMENTAL RATINGS:
Ambient Temperature:
Operating 32° F to 130° F.
Storage -30° F to 150° F.
Humidity:
Operating 85% RH continuous, noncondensing.
Vibration:
Continuous 0.5G environment.
Dimensions:
See Fig. 1.
Weight:
3 pounds, 2 oz. (unpacked without Flame Signal Amplifier and Program Module).
ACCESSORIES:
4074EPZ Bag Assembly includes:
Electrical Connector [Terminals 2-8]
Electrical Connector [Terminals 23-31]
Electrical Connector [Terminals 16-22]
Electrical Connector [Terminals a-c]
Electrical Connector [Terminals 9-15]
200857 Field Replaceable 10A Fuse APPROVAL BODIES:
Underwriters Laboratories Inc. Component Recog- nized: File No. MP268, Guide No. MCCZ2.
Canadian Standards Association Certified, LR80141.
Factory Mutual Approved.
Federal Communications Commission, Part 15, Class A emissions.
Fig. 1—Approximate dimensions of BC7700 in in. [mm shown in brackets].
7-27/32 (199.1) (22.4)
9-19/32 (243.8)
7/8 (8.1)
11/16
M1122C 3 ALARM READY
1
2
3
1
2
MOUNT DEVICE WITH (4) #8 SCREWS.
ALLOW ADDITIONAL 1.5 INCHES EACH SIDE FOR FIELD CONNECTIONS.
ALLOW ADDITIONAL 2 INCHES BELOW FOR PROGRAM MODULE MOUNTING.
7-3/16 (182.9) 5/16 (8.1)
3-11/32 (85.1)
8-13/32 (213.4) 7-7/8 (200.4)
7-7/16 (189.7)
SPECIFICATIONS
TERMINAL RATINGS:
Terminal No. Description Rating
L2 Line Voltage Common 120 Vac +10/-15%
E Earth Ground 50 or 60 Hz +/- 10%1,2
L1 Line Voltage Supply 2000 VA Maximum
4 Burner Motor Starter 120 Vac, 9.8AFL/58.8 ALR, 1/3 H.P.
5 Preignition Interlock 120 Vac, 4mA Maximum (Input)
6 Recycle Limits 120 Vac, 4mA Maximum(Input)
7 Burner Switch 120 Vac, 4mA Maximum (Input)
8 Lockout Interlocks 120 Vac, 7A Maximum (Input)
9 Unused
10 Pilot Valve/Ignition 120 Vac, 4.5A Ignition and 50 VA Transformer Pilot Duty or 120 Vac 2.5A Ignition and 75 VA Pilot Duty
11 Oil Main Valve 120 Vac, 250 VA Pilot Duty3
12 Gas Main Valve/ 120 Vac, 250 VA Pilot Duty3
Gas Pressure Sensor Test Valve
13 Alarm Normally
Open, N.O.
14 Alarm Common 120 Vac, 5A Resistive
15 Alarm Normally Isolated spdt
Closed, N.C.
16 Atomizing 120 Vac, 4 mA Maximum (Input)
Proving Switch
17 Unused
18 Load Demand
Normally Open, N.O.
19 Load Demand Common 120 Vac, 5A Resistive
20 Load Demand Normally Isolated spdt
Closed, N.C.
21
22 Unused
23
24 Firing Rate Motor Close 24 Vac, 1A Maximum,
25 Firing Rate Motor Common common to open or
26 Firing Rate Motor Open common to close (triac output for energizing motor)
27 Flame Sensor Shutter 120 Vac
28 Power Flame Sensor 60 to 220 Vac, Current Limited
29 Ground Flame Sensor
30 F2 Flame Sensor
31 F1 Flame Sensor
1 The earth ground provides for a connection between the Chassis Module and the control panel or boiler. The Chassis Module needs a low impedance ground connection to the boiler frame which, in turn, needs a low impedance connection to earth ground. (For a ground path to be low impedance at RF frequencies, connections must be made with minimum length conductors having maximum surface areas. Wide straps or brackets are preferred over leadwires.) Care should be taken to insure that the mechanically tightened joints along the ground path, such as pipe or conduit threads or surface held together with fasteners, are free of nonconductive coatings and are protected against corrosion on mating surfaces.
The earth ground wire must be capable of conducting the current required to blow the 15A fuse (or breaker) in case of an internal short circuit.
2 2000 VA maximum connected load to Chassis and Program Module Assembly.
3 Can also be 65 VA pilot duty with:
a) motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold.
b) motorized valve, 1500 VA inrush, 600 VA open, 250 VA hold.
INSTALLATION
Installation
WHEN INSTALLING THIS PRODUCT…
1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.
2. Check the ratings given in the instructions and on the product to make sure the product is suitable for your application.
3. Installer must be a trained, experienced flame safe- guard technician.
4. After installation, check out the product as provided in these instructions.
CAUTION
1. Disconnect power supply before beginning installation to prevent electrical shock and equipment damage. MORE THAN ONE dis- connect may be involved.
2. Wiring must comply with all applicable codes, ordinances and regulations.
3. Wiring must comply with NEC Class 1 (Line Voltage).
4. Refer to Fig. 2 and 3 for proper system wiring.
IMPORTANT: This equipment generates, uses and can radiate radio frequency energy. If not installed and used in accordance with the instructions, it may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device, part 15 of FCC rules, which are designed to provide reasonable protec- tion against such interference when operated in a commercial environment. Operation of this equip- ment in a residential area may cause interference; in which case, users at their own expense may be required to take whatever measures are required to correct this interference.
HUMIDITY
Install the Chassis Module where the relative humidity never reaches the saturation point. The Chassis Module is designed to operate in an 85% RH continuous, noncondensing moisture environment. Condensing mois- ture may cause a safety shutdown.
VIBRATION
Do not install the Chassis Module where it could be subjected to excessive vibration, 0.5G continuous maxi- mum.
WEATHER
The Chassis Module is not designed to be weather tight;
if installed outdoors, the Chassis Module must be pro- tected.
MOUNTING THE CHASSIS MODULE NOTE: For installation dimensions see Fig. 1.
1. The Chassis Module can be mounted vertically as shown in Fig. 1; it may also be mounted horizontally. The Chassis Module must be mounted in an electrical enclo- sure.
2. Select the location in the electrical enclosure; be sure to allow clearances for servicing, installation, and removal of the Program Module and electrical field con- nectors, see Fig. 1:
a. Allow for an additional 2 inches minimum below the Chassis Module for Program Module mounting.
b. Allow for an additional 1.5 inches minimum on each side for electrical field connectors.
c. Allow 3 inches above for access to flame signal jacks.
3. Using the Chassis Module as a template, mark the four screw locations. Drill the pilot holes.
4. Insert the mounting screws using four no. 8 screws.
5. Mount the Chassis Module by placing the foot mounts over the screws and tightening the screws se- curely.
REPLACING THE CHASSIS MODULE FUSE 1. Disconnect power supply, more than one disconnect may be involved.
2. Remove the Program Module.
3. Remove the fuse cap.
4. Remove and replace the 10A fuse.
5. Reposition the fuse cap and Program Module and reconfigure the BCS 7700.
WIRING
1. Refer to Fig. 2 and 3 for proper operation.
2. Before beginning wiring to the electrical connec- tors, be sure power is removed from the control panel by opening the main disconnect, more than one disconnect may be involved.
3. Wiring must comply with all applicable electrical codes, ordinances, and regulations.
4. Recommended wire size and type:
Line voltage terminals and terminal identification num- bers are noted within brackets [ ]:
• Demand [7]
• Atomizing air proving [16]
• Preignition Interlocks [5]
• Line voltage common [L2]
• Line voltage supply [L1]
• Recycle limits [6]
• Lockout interlocks [8]
• Pilot valve/ignition transformer [10]
• Oil main valve [11]
• Gas main valve/gas sensor valve [12]
• Alarm [13, 14, and 15
• Load demand [18, 19, and 20]
• Burner motor starter [4]
• Earth ground [E]
• Alarm [13, 14, 15]
No. 14 Copper conductors TW[60C] or THW[75C] or THNN[90C].
!
INSTALLATION
Fig. 2—BCS 7700 Internal block diagram.
3
2 8
8 2
5
2
2
2
1
2
3
9
4
5
7 6
8
9
1 7
2 OIL
GAS
OIL SELECT
GAS SELECT 11K1
120 VAC L1 (HOT) L2
OIL LINE PURGE VALVE
10K1 DIGITAL MONITOR DIGITAL MONITOR
10K
11K 24VDC
24VDC RESET
PUSHBUTTON RELAY DRIVE CIRCUIT
OPTOISOLATOR INPUTS
24 25 26 27 28 29 30 31 32 33 34 35
36 37 38 39 40 41
42 43 44 45 46 47 50
51
52
53
55 54
56 ATOMIZING AIR
COMPRESSOR MOTOR STARTER
TEMPERATURE SENSOR AMPLIFIER
SENSOR POWER SUPPLY
ANALOG TO DIGITAL CONVERTOR
SIGNAL COMMON SIGNAL
SIGNAL SIGNAL (BLUE)
SIGNAL (BLUE)
SIGNAL (BLUE) COMMON
COMMON COMMON (BLACK)
COMMON (BLACK)
COMMON (BLACK) POWER (RED)
POWER (RED)
POWER (RED)
WATER TEMP.
SENSOR / CON- FIG. ANALOG
OIL TEMP.
SENSOR
STEAM PRESSURE SENSOR / CONFIG.
ANALOG POWER
OIL PRESSURE SENSOR
GAS PRESSURE SENSOR MICROCOMPUTER
PROGRAM MODULE AND CHASSIS MODULE INTERFACE
SAFETY RELAY CIRCUIT OPTOISOLATOR 1K
INPUTS RUN-TEST SWITCH
RELAY DRIVE CIRCUIT
2K 3K 4K 6K 7K 8K
ALARM
RELAY 9K PLUG IN FLAME AMPLIFIER RS485
BURNER MOTOR STARTER 4
5
6 10
L2
8 L1
11
12 16 7
6K1
PREINGINTION INTERLOCKS
BURNER SWITCH
RECYCLE
LIMITS LOCKOUT INTERLOCKS
F1, 10A
1K1 4K1
3K1
2K1 ATOMZING AIR PROVING SWITCH
PILOT VALVE
IGNITION TRANSFORMER
OIL MAIN VALVE
GAS PRESSURE SENSOR TEST VALVE
GAS MAIN VALVE
KEYBOARD AND DISPLAY
LIQUID CRYSTAL DISPLAY
MICROCOMPUTER A
B C A B C
KEYBOARD
120VAC
24VAC
40VA
INDICATES FEEDBACK SENSING TO OPTOISOLATORS
WIRING SHOWN FOR INFRED FLAME DETECTOR FOR C7027 ULTRA VIOLET FLAME DETECTOR WIRE AS NOTED BELOW – ULTRA VIOLETDECTECTOR BLUE LEAD - TERMINAL 31 – ULTRA VIOLET DETECTOR WHOTE LEAD - TERMINAL 30
THE ULTRA VIOLET FLAME DETECTOR WIRING IS POLARITY SENSITIVE, REVERSING THE LEDS WIRES MAY DAMAGE THE SENSOR.
FOR ULTRA VIOLET C7012E,F WIRE AS NOTED BELOW:
– BLUE LEAD - TERMINAL 31 – YELLOW LEAD - TERMINAL 29 – WHITE LEAD - TERMINAL 27 – WHITE LEAD - L2 – BLACK LEAD - L1 – BLACK LEAD - L2
WIRE THESE TERMINALS WITH SHIEDLED CABLE PER SPECIFICATION.
THE CABLE SHIELD SHOULD NOT BE CONNECTED AT THE SENSOR END AND SHOULD BE TAPED TO AVOID UNINTENTIONAL CONTACT. AT THE BOILER CONTROLLER END, THE SHIELD WIRES MUST BE GROUNDED TO THE CONTROL PANEL WITH AS SHORT AS POSSIBLE A LEAD LENGTH.
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
DO NOT CONNECT WIRES TO ANY UNUSED TERMINALS.
TERMINALS 9, 17, 21, 22, 23, 28, 48 ARE NOT USED.
POWER SUPPLY FOR SYSTEM SENSORS.
FIELD WIRING INTERNAL CIRCUITRY.
SEE FLAME DETECTOR WIRING FIGURE IN FORM NO 63-2991.
SEE TYPICAL STACK TEMPERATURE SETUP FIGURE IN FORM 63-2991.
USE 120 OHM TERMINATING RESISTOR ON DEVICE FURTHEREST FROM BC7700 CHASSIS MODULE (120 OHM TERMINIATING RESISTOR INSTALLED BETWEEN TERMINALS A AND B.)
3
2
1 G
T Y FIRING RATE MOTOR
OPEN
CLOSE RS485
FLAME DETECTOR FIRING
RATE
M602C 49
E
15
14
13 9K2
9K1 ALARM
UNUSED LOAD DEMAND 20
19
18 8K2
8K1
23
22
21 7K2
7K1 EARTH GROUND
INSTALLATION
Fig. 3—BCS 7700 field wiring diagram.
22 2
2 2 3 4 5 6 7
1
2626
1 7 3
5 WIRE THESE TERMINALS WITH SHIEDLED CABLE PER SPECIFICATION SHEET. THE CABLE SHIELD SHOULD NOT BE CONNECTED AT THE SENSOR END AND SHOULD BE TAPED TO AVOID UNINTENTIONAL CONTACT. AT THE BOILER CONTROLLER END, THE SHIELD MUST BE GROUNDED TO THE CONTROL PANEL WITH AS SHORT A LEAD LENGTH AS POSSIBLE. POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. DO NOT CONNECT WIRES TO ANY UNUSED TERMINALS. TERMINALS 9, 17, 21, 22, 23, 28, 48 ARE NOT USED. SEE FLAME DETECTOR WIRING FIGURE. SEE TYPICAL STACK TEMPERATURE SETUP FIGURE. USE 120 OHM TERMINATING RESISTOR ON DEVICE FURTHEST FROM BC7700 CHASSIS MODULE (120 OHM RESISTOR INSTALLED BETWEEN TERMINALS A AND B).
PLUG-IN FLAME AMPLIFIER L2 EARTH GROUND L1 BURNER MOTOR STARTER PREIGNITION INTERLOCKS RECYCLE LIMITS DEMAND LOCKOUT INTERLOCKS
FIRING RATE MOTOR
F1 F2 G UNUSED SHTR OPEN COM CLOSE N / C N / C N / C
UNUSED UNUSED
UNUSED
COM COM COM
N / O N / O N / OLOAD DEMAND
PILOT VALVE IGNITION OIL MAIN VALVE GAS MAIN VALVE
ALARMAAPS AAPS
LINE COMMON LINE HOT
120V24V M741B
1 1
2 2 33 4 5 6 7 8 9101112131415 J2
J1
J4 J3
J9 BMSI
CAPS
LMTS
LWCO
MOVBS
MGV
BURNER MOTOR STARTER
120V LINE (HOT) LINE COMMON
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
GT
YCHASSIS MODULE IGNITORGAS PILOT VALVE
OIL MAIN VALVE GAS MAIN VALVE
A B C OIL GAS PURGE VALVE ATOMI- ZING AIR COMP.
5655
5453
5251
50
49
48UNUSED L2 TERMINAL 50 TERMINAL 51 OIL SELECT GAS SELECT OIL LINE PURGE VALVE L1 ATOMIZING AIR COMPRESSOR MOTOR STARTERUPPER PROGRAM MODULE CONNECTOR LOWER PROGRAM MODULE CONNECTOR SIGNAL SIGNAL COMMON COMMON SIGNAL COMMON
POWER SIGNAL COMMON
POWER SIGNAL COMMON
POWER SIGNAL COMMON
POWER
WATER TEMP.OIL TEMP.STEAM PRESSUREMOTOR POSITIONOIL PRESSURE
GAS PRESSURE GAS PRESSURE SENSOR
OIL PRESSURE SENSOR
STEAM PRESSURE SENSOR
OIL TEMP. SENSOR
WATER TEMP. SENSOR 32333435363738394041424344454647 J8
J10 J7
PROGRAM MODULE M1924A
KEYBOARD / DISPLAY MODULE WIRING SHOWN FOR C7015 INFRARED FLAME DETECTOR, FOR C7027 ULTRA VIOLET FLAME DETECTOR WIRE AS NOTED BELOW: – ULTRA VIOLET DETECTOR BLUE LEAD - TERMINAL 31 – ULTRA VIOLET DETECTOR WHITE LEAD - TERMINAL 30. THE ULTRA VIOLET FLAME DETECTOR WIRING IS POLARITY SENSITIVE, REVERSING THE LEDS WIRES MAY DAMAGE THE SENSOR. FOR ULTRA VIOLET C7012E,F WIRE AS NOTED BELOW: – BLUE LEAD - TERMINAL 31 – YELLOW LEAD - TERMINAL 29 – WHITE LEAD - TERMINAL 27 – WHITE LEAD - L2 – BLACK LEAD - L1 – BLACK LEAD - L2
INSTALLATION • CHECKOUT Energy limited terminals, terminal identifications are
noted within brackets [ ]:
• Firing Rate motor [24, 25, and 26]
• Flame sensor power [28].
• Flame sensor ground [29]
• Flame signal input [30 and 31].
No.18 Copper conductors TW[60C] or THW[75C] or THNN[90C].
Keyboard and Display Module ControlBus, terminals a, b, and c.
• Belden’s 8723 cable or equivalent. The shield is to be connected to ground at both ends.
5. Recommended grounding practices—The earth ground provides for a connection between the Chassis Module and the control panel or boiler. The Chassis Module needs a low impedance ground connection to the boiler frame which, in turn, needs a low impedance con- nection to earth ground. (For a ground path to be low impedance at RF frequencies, connections must be made with minimum length conductors having maximum sur- face areas. Wide straps or brackets are preferred over leadwires.) Care should be taken to ensure that the me- chanically tightened joints along the ground path such as pipe or conduit threads or surface held together with fasteners, are free of nonconductive coatings and have protection against corrosion on mating surfaces. The earth ground wire must be capable of conducting the current required to blow the 15A fuse (or breaker) in case of an internal short circuit.
6. Recommended wire routing—flame detector leadwires; do not run high voltage ignition transformer wires in the same conduit with the flame detection wiring.
For Keyboard and Display Module ControlBus:
a. Do not route the ControlBus shielded cable in con- duits that carry line voltage circuits.
b. Avoid routing the ControlBus shielded cable close to the ignition transformer leadwires.
c. Route the ControlBus shielded cable outside of conduit if properly supported and protected from damage.
d. The ControlBus requires a termination resistor on the module farthest from the Chassis Module. This is accomplished by connecting a 120Ω 1/4 watt resistor across the a and b terminals of the ControlBus connector on the farthest module from the Chassis Module.
7. Maximum wire lengths:
• Flame detector leadwires—The maximum flame sensor leadwire length varies with the type of flame sensor used. Consult the applicable sensor and ampli- fier instructions to determine application requirements.
• Keyboard and Display Module ControlBus—The maximum ControlBus leadwire length, under ideal conditions, is 1000 feet.
8. Fusing—The Chassis Module has a field replace- able 10A fuse in series with the fuel valves, and ignition transformer.
The total connected BCS 7700 load and its power consumption must be less than 2000 VA. The System fuse must NOT exceed 15A.
9. Make sure that loads do not exceed the terminal ratings. Refer to the Chassis Module label or ratings in SPECIFICATION.
10. Check all wiring with Fig. 2 and 3 before installing electrical connectors in their mating Chassis receptacles.
11. Install all electrical connectors; be sure power is removed before installing or removing connectors to the Chassis Module.
12. Restore power to the panel.
Fig. 4—BC7700 chassis module.
Checkout
After the Chassis Module is installed, return the BCS 7700 to normal operation by restoring power to the burner system, reprogramming, and operating the system through at least one complete automatic cycle. For complete Troubleshooting and System Checkout information, refer to form 63-2291.
READY AND ALARM LED
PROGRAM MODULE ELECTRICAL CONNECTOR
ELECTRICAL CONNECTORS
FOOT MOUNTS FIELD
REPLACEABLE FUSE
M15590
Building Controls Division Building Controls Division
Honeywell Inc. Honeywell Limited—Honeywell Limitée 1985 Douglas Drive North 740 Ellesmere Road
Golden Valley, MN 55422 Scarborough, Ontario QUALITY IS