Honeywell P7810C1000 User Guide

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P7810C PressureTrol® Controller

FEATURES

• Use only with steam, air or noncombustible gases that do not corrode the pressure sensing element.

• Models available in 15, 150 and 300 psi (103, 1034 and 2069 kPa) maximum setpoints.

• Light Emitting Diode (LED) indicators show power, call for heat function and lockout status.

• Clear cover allows setpoint and differential to be read, but not adjusted without opening the cover.

• Manual reset possible without opening the cover.

• Electronic maximum fixed stop limit.

PRODUCT DATA

APPLICATION

The P7810C PressureTrol® Controller is a line voltage pressure controller for pressure systems up to 300 psi (2069 kPa). The P7810C provides On/Off Control, High Limit and 4 to 20 mA modulation.

Contents

Application 1 Features 1 Specifications 2 Installation 3 Wiring 4 Operation 6 Checkout 10 Troubleshooting 11 Service Information 11

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P7810C PRESSURETROL® CONTROLLER

SPECIFICATIONS

Model:

P7810C PressureTrol® Controller with On/Off control,

modulate and safety high limit.

Electrical Ratings:

Power Input: 120 Vac (+10% /-15%), 50/60 Hz (±10%). Power Consumption: See Table 1. Output Impedance: 300 ohm maximum.

Table 1. Power consumption.

120 Vac

Rating 50 Hz 60 Hz

Watts 21.8 2.8

VA 7.0 7.0

Switch Contact Ratings: See Table 2.

Table 2. Switch contact ratings.

Relay Load Type 120 Vac

Control Amps Full Load (FLA) 9.8A

Amps Locked Rotor (ALR) 58.8A

Non-Inductive 10.0A

Alarm Pilot Duty 1.0A

Sensor Material: 304 stainless steel.

Pressure Connector: 1/2 in. NPT.

Case Material: Plastic.

Electrical Terminations: Screw terminals.

Accuracy: ±4.0 percent full scale output operating range,

over operating temperature.

Environmental Ratings:

Operating Temperature Range: 32°F to 140°F (0°C to 60°C). Storage Temperature Range: -20°F to +150°F (-29°C to

+66°C). Humidity: 5% to 95% relative humidity, noncondensing. Vibration: 0.5G continuous maximum vibration.

Dimensions: See Fig. 1.

Mounting Position: Upright, see Fig. 2.

Device Weight: 2.0 lb, 8 oz (1.15 kg).

Approvals:

Underwriters Laboratories Inc.: Listed; MP446-30-1. Canadian Standards Association Certified; 158158-1355621. Factory Mutual Approved: Approved; 3018936. CSD-1 AFB (Control Safety Devices, Automatic Fired Boilers): Acceptable. FCC Class B, computing devices, part 15.

Accessories:

205860 Minimum Position Potentiometer for Series 70

Motors. 209731A Siphon Loop with 1/2 in. NPT threads. 4074EWD Mounting Bracket with six screws. 4074EDC or EED Bag Assembly to interface 4 to 20 mA with

Series 90 Firing Rate Motor.

Replacement Parts:

4074EWC Door Assembly with captive screw and adjusting

wrench (replacement part for P7810C). 4074EVP Door Wrench.

Pressure Ratings: See Table 3.

Table 3. Pressure ratings (psig).

Pressure Range Maximum Setpoint Differential Overpressure Burst Pressure

0 to 15 15 2 to 10 22.5 60

0 to 150 150 5 to 20 225 600

0 to 300 300 15 to 50 450 1200

ORDERING INFORMATION

When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the TRADELINE® Catalog or price sheets for complete ordering number.

If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:

1. Your local Honeywell Automation and Control Products Sales Office (check white pages of your phone directory).

2. Honeywell Customer Care

1885 Douglas Drive North

Minneapolis, Minnesota 55422-4386 In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Toronto, Ontario M1V 4Z9. International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.

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P7810C PRESSURETROL® CONTROLLER

WARNING

1/4 (6) 2x1-5/8 (41)

5-1/4

(133)

3-3/16

(81)

1-5/8 (41) 2-5/8 (67)

3-7/32 (82)

DIMENSIONS WITH DOOR IN OPEN POSITION.

22PIPE THREAD IS 1/4 INCH NATIONAL PIPE THREAD FOR P7810A,B; 1/2 INCH NATIONAL PIPE THREAD FOR P7810C,D.

WIRING COMPARTMENT ACCESS COVER.

2-17/32

(82)

3-3/8 (86)

2x27/32 (22) DIAMETER

2-1/8 (55)

4-23/32

(120)

4-21/32 (119)

PRESSURETROL

RESET

2x5-1/4 (133)

5-29/32 (150)

2-5/8

(67)

(102)

4-3/4 (120)

3/8

(10)

7/8

(22)

M11893B

Fig. 1. Approximate dimensions of P7810C PressureTrol® Controller in in. (mm).

INSTALLATION

When Installing This Product…

1. Read the instructions carefully. Failure to follow them

could damage the product or cause a hazardous condition.

2. Check ratings (pressure and voltage, for example) and

description given in the specifications to make sure the product is suitable for your application.

3. Installer must be a trained, experienced technician.

4. After installation is complete, check out product

operation as provided in these instructions.

Electrical Shock Hazard and Explosion Hazard. Can cause severe injury, death or property damage.

1. Disconnect power supply before installation. More than one disconnect may be involved.

2. Allow pressure to decrease to atmosphere from the pressure vessel before removing old control.

3. Follow all installation and checkout procedures for safe installation.

IMPORTANT

Do not remove the overpressure inlet seal until ready to connect piping, to prevent contamination of inlet.

Location

Install the P7810C PressureTrol® Controller above the boiler water line when used with steam boilers. Connect the siphon loop (part number 209731A or equivalent) between the P7810C Controller and the boiler to prevent scale and corrosive vapors from attacking the controller sensor element. Mount the P7810C Controller next to the pressure gauge in the manufacturer-provided fitting on the boiler. See Fig. 2 and 3. Mount at a remote location to avoid excessive vibration, or mount in a special mounting on a low water cutoff.

IMPORTANT

1. Locate the P7810C PressureTrol® Controller where ambient temperature does not exceed 140°F (60°C).

2. Use pipe compound sparingly to avoid clogging the hole in the pipe or the sensor element fitting.

3. Do not hand tighten the controller connection by holding the case. Use a wrench on the flats of the sensor fitting to avoid leaks and damage to the case.

4. Level the controller for appearance.

5. Install the P7810C where the relative humidity never reaches the saturation point. The P7810C is designed to operate in a maximum 85 percent relative humidity, continuous, noncondensing moisture environment. Condensing moisture can cause a shutdown.

6. Do not install the P7810C where it could be subjected to vibration in excess of 0.5G continuous maximum vibration.

7. The P7810C is not designed to be weather-tight. If installed outdoors, protect the P7810C with an approved weather-tight enclosure.

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P7810C PRESSURETROL® CONTROLLER

WARNING

4-1/2 TO 5-1/2

(114.3 TO 139.7)

BOILER

14026 STEAM TRAP (SIPHON LOOP)

TEE

PRESSURE GAUGE

PRESSURE CONTROLLER

M8934A

1/4 IN. BLACK IRON PIPE WITH 1/4 - 18 NPT EXTERNAL TRHEADS ON BOTH ENDS. BEND THE STEAM TRAP (SIPHON LOOP) TO LEVEL THE CONTROLLER.

CORRECT

BOILER

2-1/4 (57.2) DIA.

INCORRECT

P7810C

GAUGE

BOILER

M11891A

Fig. 2. Right and wrong mounting of steam trap (siphon

loop) for the P7810C, with approximate dimensions in in.

(mm).

4. If not convenient to mount the P7810C Controller next to

the pressure gauge, install a siphon loop in the manufacturer-provided fitting.

5. If there is no fitting, mount the siphon loop at the boiler

manufacturer recommended location.

6. Attach the P7810C Controller directly to the siphon loop.

7. Level the P7810C Controller after the installation.

NOTE: The P7810C model requires 1/2 in. (13 mm)

mounting, either directly or on a siphon loop.

Remote Location Mounting

Excessive vibration at the boiler can damage the P7810C Controller electronics.

1. Mount the P7810C Controller at a remote location to

eliminate vibration problems.

2. Make sure that all piping from the boiler is suitable to the

application and is solidly mounted.

3. Pitch the piping properly to drain the condensate back to

the boiler.

4. Mount the siphon loop between the remote piping and

the P7810C Controller.

5. Level the P7810C Controller after the installation.

WIRING

Mounting

Make all pipe connections in accordance with applicable local standards. Use parallel jaw wrench to tighten P7810C Controller hexagonal fitting to avoid leaks and damage to the case.

Mounting P7810C Controller next to pressure gauge

To mount the P7810C PressureTrol® Controller next to the pressure gauge:

1. Remove the pressure gauge.

2. Replace the gauge with a siphon loop with tee connector

on top.

Fig. 3. Connecting P7810C PressureTrol® Controller to

3. Mount the P7810C Controller and pressure gauge on the

end of the tee.

steam boiler.

Electrical Shock Hazard. Can cause severe injury, death or property damage.

Disconnect the power supply before wiring. More than one disconnect may be involved.

All wiring must comply with applicable electrical codes, ordinances and regulations. Use NEC Class 1 line voltage wiring.

For nominal installation, use moisture-resistant No. 14 wire (maximum size allowed) suitable for at least 167°F (75°C) or 194°F (90°C) for Flame Safeguard Primary Controls.

Use shielded wire for 4 to 20 mA modulating output and terminate the shield to earth ground. Do not run these wires in the same conduit as high voltage ignition wires.

All P7810C PressureTrol® Controllers have terminal screws and 27/32 in. (22 mm) holes in both sides for conduit, cables and wiring. Remove the top cover by loosening the screw at the top of the P7810C Controller case.

Follow the burner or boiler manufacturer wiring diagram, if provided. Make sure the loads do not exceed the contact ratings in the Specifications section. See Fig. 4 for terminal locations and Fig. 5 through 9 for typical wiring hookups.

Table 4 provides conversion wiring information for upgrading older P7810 devices to newer series.

Replace the front cover after completing the wiring.

IMPORTANT

LIne voltage wiring terminals have changed between Series 2 and Series 3 models.

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P7810C PRESSURETROL® CONTROLLER

PROGRAMMER WIRING

HIGH FIRE

COMMON

MODULATE

LOW FIRE

–

MODUTROL® MOTOR

P7810 CONTROLLER

M17130A

+mA -mA

(MODULATE)

1/2 IN. NPT

1 USE COPPER CONDUCTORS ONLY

OUT

NPT

Fig. 4. P7810C (Series 3 or greater)

PressureTrol® Controller.

LINE VOLTAGE

ALARM

7800 SERIES PROGRAMMER

GND

1/4 IN. NPT

STEAM PRESSURE CONTROL SENSOR

1/4 IN. NPT

STEAM PRESSURE HIGH LIMIT CONTROL SENSOR

M22024A

8K1

8K2

MODULATION

9K1

9K2

FIELD WIRING

7800 SERIES SHOWN. REFER TO SPECIFICATIONS PACKED WITH THE PROGRAMMER FOR WIRING OF OTHER PRIMARY SAFETY CONTROLLERS.

MODUTROL® MOTOR MUST BE MODUTROL III OR MODUTROL IV, SERIES 90, ELECTRONIC BALANCE RELAY TO OPERATE AS SHOWN.

PART OF 4074EDC OR 4074EED BAG ASSEMBLY ORDERED SEPARATELY.

LINE VOLTAGE TO PROGRAMMER AND CONTROLLER SHOULD BE IN PHASE.

SEE CONVERSION WIRING TABLE FOR CONVERTING OLDER SERIES

DEVICES.

HIGH

COMMON

LOW

237

OHM

66.5

OHM

120 VAC LINE VOLTAGE

MODUTROL® MOTOR

DEVICE WIRING

OTHER LIMITS

P7810 PRESSURETROL®

CONTROLLER

–

4 TO 20mA

2K1

OUT

3K1

ALARM

1K1

120 VAC LINE VOLTAGE

M13698

4 to 20 mA signal output (-) - - -

4 to 20 mA signal output (+) + + +

Limit string output to programmer

L1 (Hot) COM

120 Vac Power Supply (L2) L2 L2 L2

120 Vac Power Supply (L1) L1

External Alarm Device — ALARM ALARM

If any additional/external limits are used, make sure they are inserted between the P7810C PressureTrol® Controller and the Pro-

grammer in the Limit string.

b When converting to a newer series from Series 1, L1 (120 Vac Power Supply) lead wire is not used, remove or wire-nut and tuck

away.

Fig. 6. Wiring diagram for typical P7810 installation,

Series 3 and greater, using Series 90 Modutrol® Motor.

Fig. 5. Firing rate wiring diagram using 4 to 20 mA

controller and series 70 Modutrol® Motor.

Table 4. Conversion wiring information for upgrading older P7810 devices to newer series.

Signal/Input Series 1 Terminals Series 2 Terminals

N.O. OUTPUT OUT

Series 3 or Greater

Terminals

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P7810C PRESSURETROL® CONTROLLER

LOW FIRE

MODULATE

COMMON

8K1

8K2

9K2

9K1

AUTO

MAN

66.5

OHM

237

OHM

HIGH FIRE

7800 SERIES

PROGRAMMER

M20568C

–

MODUTROL IV

MOTOR

CONTROLLER

P7810

(4-2O mA)

SERIES 90

1K OHM

7800 SERIES SHOWN. REFER TO SPECIFICATIONS PACKED WITH THE PROGRAMMER FOR WIRING OF OTHER PRIMARY SAFETY CONTROLLERS.

LOW FIRE

MODULATE

COMMON

8K1

8K2

9K2

9K1

AUTO

MAN

HIGH FIRE

7800 SERIES

PROGRAMMER

M20569C

205860

24V AC

MOD MOTOR

–

MODUTROL IV

MOTOR

CONTROLLER

P7810

(4-2O mA)

REMOTE MINIMUM POSITION

POTENTIONMETER

SERIES 70

(M7284)

7800 SERIES SHOWN. REFER TO SPECIFICATIONS PACKED WITH THE PROGRAMMER FOR WIRING OF OTHER PRIMARY SAFETY CONTROLLERS.

ONLY 50% MOTOR AUTHORITY IS AVAILABLE WHEN USING THE 205860 POTENTIOMETER WITH THE SWITCH IN THE MANUAL POSITION.

Fig. 7. Firing rate wiring diagram using P7810C

PressureTrol® Controller and Series 90 Modutrol® Motor

with manual position potentiometer and auto-manual

switch.

7800 SERIES

PROGRAMMER

HIGH FIRE

8K1

COMMON

8K2

MODULATE

9K1

9K2

LOW FIRE

7800 SERIES SHOWN. REFER TO SPECIFICATIONS PACKED WITH THE PROGRAMMER FOR WIRING OF OTHER PRIMARY SAFETY CONTROLLERS.

SERIES 70

(M7284)

MODUTROL IV

MOTOR

–

OHM

CONTROLLER

(4-2O mA)

AUTO

–

MAN

–

Fig. 9. Series 70 Motor with auto/manual switch

and 12 Vdc source.

OPERATION

P7810

12V DC

M20570C

Fig. 8. Series 70 Motor with auto/manual switch, using

205860 Minimum Position Potentiometer.

65-0285—02 6

The P7810 uses integral electronic pressure sensors to sense pressure at the inlet through an internal manifold. The control sensor connects to the internal manifold with 1/4 inch NPT threads and provides the pressure signal to control a relay for the on/off control function. The same sensor provides the information for the 4 to 20 mA firing rate modulation output.

A separate integral electronic pressure sensor is required to provide the high limit function. This sensor also connects to the internal manifold with 1/4 inch NPT threads P7810C devices contain two internal sensors and require a 1/2 inch NPT mounting to the steam pressure header. Devices with high limits lock out at setpoint and require manual reset when pressure returns below the setpoint. Devices will not reset with power interruption.

The P7810C has on/off function, 4 to 20 mA modulation control output, and safety high limit function in one control. A 1/2 inch NPT mounting is required to the steam pressure header.

Pressure On/Off Control Function

When pressure increases to the control setpoint, the control relay contacts open. The relay contacts close when the pressure decreases to a level at or below (differential) the control range differential setting. This cycle continues until power is removed, opening the relay. See Fig. 10.

Page 7

Fig. 10. P7810 on/off control function versus pressure.

CAUTION

OFF

CONTROL

RELAY

(K)

CONTROL

RANGE

PRESSURE

CONTROL SETPOINT

M4881B

DIFFERENTIAL SETTING

Modulate Control Function

When the pressure decreases to or below the modulation setpoint, the current is 20 mA. The current remains constant at all pressures below the modulation setpoint.

The modulation range is an additive value to the modulation setpoint value.

When the pressure increases above the modulation setpoint, the current decreases linearly until the modulation range point is reached. The output current is 4 mA at and above this pressure. See Fig. 11.

20 mA

MODULATION

CURRENT

4 mA

P7810C PRESSURETROL® CONTROLLER

Equipment Damage Hazard. Exceeding pressure vessel limits can damage equipment.

The Maximum Fixed Stop Limit pressure setting must not exceed the maximum working pressure rating of the pressure vessel. Adjust the Maximum Fixed Stop Limit setting to the maximum working pressure rating that is stamped on the pressure vessel by the manufacturer.

b. To set the High Limit Setpoint. This is the desired

pressure value to which the P7810C control is adjusted at at which it performs its intended function

(i.e., safety shutdown). The High Limit Setpoint can be set lower than the internal stored Maximum Fixed Stop Limit Value and will provide system lockout at the knob setting. For example, the internal stored Maximum Fixed Stop Limit Value is 12 psi and the knob is set at 10 psi. System lockout is at 10 psi. The LED pattern will be green on and yellow blinking slowly.

The High Limit Setpoint can be set above the internal stored Maximum Fixed Stop Limit Value but it will have no functional effect. For example, the internal stored Maximum Fixed Stop Limit Value is 12 psi and knob is set at 14 psi. Lockout will occur at 12 psi. The LED pattern will be green on and yellow blinking fast.

When pressure increases to the high limit setpoint, the relay contacts (1K1, 2K1) open and the P7810C indicates a safety lockout by alternately flashing the yellow and green LED. The P7810C remains in this condition until the manual reset button (see Fig. 1) is pressed. The Alarm relay contacts (3K1) will close, providing a 120 Vac output on the Alarm terminal.

Reset Switch Functions

The Reset Switch has the functions listed in Table 5.

MODULATION

SETPOINT

PRESSURE

Fig. 11. P7810C modulation current versus pressure.

Limit Function

The Limit potentiometer has two functions:

a. To set the Maximum Fixed Stop Limit. This is the

maximum pressure setting that the P7810C control can be adjusted to and still perform its intended function (i.e., safety shutdown).

MODULATION

RANGE

M4882

P7810C PressureTrol® Controller Setup

For the P7810C PressureTrol® Controllers with more than one function (control, modulate and high limit), adjust setpoints and differentials separately for each function.

Equipment Damage Hazard. Improper setting of control setpoint and control range knob errors can damage the P7810C.

Adjust setpoints and differentials using the knobs on the front of the P7810C PressureTrol® Controller.

Set the knobs to the desired points by aligning the center of the knob arrow with the desired mark on the scale plate. See Fig.

12.

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P7810C PRESSURETROL® CONTROLLER

CAUTION

DIAL ARROW

SCALE PLATE

M4880A

Table 5. Reset switch function, P7810C.

Reset Switch

Action Lockout Unconfigured

Press and Continuously Hold.

Press and release. Clear the fault code

Blink existing fault code until the reset switch is released.

and reset the P7810C.

Both LED turn on after three seconds, indicating the Maximum Fixed Stop Limit Value has been stored. Wait for up to 30 seconds for a release. Enter lockout after 30 seconds.

Press and release of the Reset Switch within three seconds is ignored. If the Reset Switch is pressed for more than three seconds, both LED turn on and the Maximum Fixed Stop Limit Value is stored into non-volatile (NV) memory. Upon release, the device will recycle and enter normal operation.

P7810C Modes of Operation

(Run) Normal

Operation

The green LED turns off and the yellow LED turns on, waiting until the reset switch is released.

Resets the control. Enter normal

Both LED turn on. Wait for up to 30 seconds for a release. Lockout after 30 seconds. If released within 30 seconds, enter normal operation.

operation.

Power-up

(Configuration

Time Expired)

Power-up

(Configuration

Time Not Expired)

Enter unconfigured mode of operation.

Fig. 12. Setting control setpoint and control range knobs.

IMPORTANT

P7810C devices must set Maximum Fixed Stop Limit Value function first.

Setting Maximum Fixed Stop Limit Value

Equipment Damage Hazard. Exceeding pressure vessel limits can damage equipment. The Maximum Fixed Stop Limit pressure setting must not rating of the pressure vessel. Adjust the Maximum Fixed Stop Limit setting to maximum working

pressure rating that is stamped on the pressure vessel by the manufacturer.

IMPORTANT

The Maximum Fixed Stop LImit Value must be programmed first for the P7810C to operate.

1. Initial Startup—Maximum Fixed Stop Limit Value is

unprogrammed. a. Green LED (Control LED)—Blinking rapidly (1/2 sec-

b. Yellow LED (Power LED)—On steady and bright.

2. Setting the Maximum Fixed Stop Limit Value.

a. Monitor the 4 to 20 mA output. Long filtering delays

b. Turn the Limit Setpoint knob to the desired setting

exceed the maximum working pressure

ond on, 1/2 second off).

cause a lag between the 4 to 20 mA output and the limit setting, i.e., 20 to 25 seconds for a full-scale change.

and confirm by comparing the current noted to the corresponding reading in Table 6. Ensure that the mA output is stable before using the value.

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Page 9

P7810C PRESSURETROL® CONTROLLER

c. Press and hold the Reset Switch. d. Release the Reset Switch when both LED turn on. e. The Maximum Fixed Stop Limit Value is set and the

device will recycle and attempt to enter the Run mode.

f. After an accumulated run time (Call for Heat) of one

hour (Series 1 and 2) or eight hours (Series 3 or greater), the Maximum Fixed Stop Limit Value setting will be permanently stored in the P7810C memory. Changing the Maximum Fixed Stop Limit Value setting after this time will then be ineffective.

Table 6. Setting maximum fixed stop limit value—

current readings.

15 psi 150 psi 300 psi 4 to 20 mA Output

00 04.00

110205.07

220406.13

330607.20

440808.27

550 1009.33

6 60 120 10.40

77014011.47

8 80 160 12.53

9 90 180 13.60

10 100 200 14.67

11 11 0 22 0 15 .73

12 120 240 16.80

13 130 260 17.87

14 140 280 18.93

15 150 300 20.00

Changing the Maximum Fixed Stop Limit Value Setting (if Run Time is less than one hour [For Series 1 and 2] or less than eight hours [For Series 3 or greater])

1. Remove power from the P7810C.

2. Press and hold the Reset Switch, then apply power to

the P7810C.

3. When the green LED blinks rapidly, release the Reset

Switch.

4. Follow the steps in Setting the Maximum Fixed Stop

Limit Value, above.

NOTE: If both LED turn on, the configuration timer (one hour)

has expired. Release the Reset Switch and continue normal operation. Changing the Maximum Fixed Stop Limit Value Setting is no longer allowed.

Checking the Maximum Fixed Stop Limit Value (Stored in Memory)

1. Record the original location of the Limit setpoint knob.

Make sure that the Limit setpoint knob is set (moved to) a lower value than the Maximum Fixed Stop Limit Value setpoint. The green LED will be reflective of the call for heat status and the yellow LED will blink slowly.

IMPORTANT

Do not decrease the Limit Setpoint knob far enough to cause a lockout.

2. Very slowly increase the Limit setpoint knob until the yel-

low LED begins to blink fast. The current position of the Limit setpoint now represents the Maximum Fixed Stop Limit Value setpoint stored in memory.

3. Return the Limit setpoint knob to the original location

(step 1).

Setting High Limit Setpoint

After the Maximum Fixed Stop Limit Value has been stored into memory, adjust the Limit setpoint knob to the desired pressure value at which safety shutdown (lockout) will occur when the vessel pressure exceeds this setpoint value.

NOTE: The High Limit setpoint value can be less than or

equal to the Maximum Fixed Stop Limit Value but cannot be set to a value higher than the Maximum Fixed Stop Limit Value.

Pressure On/Off Control

Adjust the setpoint and differential using the potentiometer knobs on the front of the controller. The differential is a subtractive value from the setpoint adjustment. The upper operating point is determined by the control setpoint, while the lower operating point is determined by the control range setting (control setpoint minus the differential setting).

Set the potentiometer knobs to the desired point by aligning the center of the arrow on the potentiometer knob with the desired mark on the scale plate. See Fig. 12.

Yellow LED ON constantly indicates power applied; green LED On indicates closed contact or call for heat.

Modulate Control

The P7810C adds 4 to 20 mA modulation output and uses two additional potentiometers. The pressure sensor output is fed to an error and gain amplifier to perform the modulation determined by the control potentiometer settings.

The potentiometer knobs mounted on the P7810C face adjust the current output for a given set of pressures.

The modulation range is an additive value to the modulation setpoint value.

LED Display (Tables 7 and 8)

The yellow LED is always lit with power applied to the P7810C PressureTrol® Controller. The microprocessor changes the brightness of the yellow LED to indicate normal operation, turns the green LED on and off to indicate call for heat status and flashes both LED to indicate a fault.

NOTE: The P7810C must be powered and in the Run mode.

NOTE: The term “flashing” means on/off/on/off for the green

LED and bright/dim/bright/dim for the yellow LED.

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P7810C PRESSURETROL® CONTROLLER

WARNING

Press and hold the Reset Switch to access internal diagnostics. The green (right) LED will flash a series of long followed by a series of short flashes. Count the long and short flashes and check the fault code table (Table 8) for information.

Table 7. P7810 blink bodes.

Yellow Green Control State

Off Off Device off.

No LED blinking Device on, Central Processing Unit (CPU) malfunction.

Slow Blink Off Run mode, output off, Limit potentiometer setpoint used.

Slow Blink On Run mode, output on, Limit potentiometer setpoint used.

Fast Blink Off Run mode, output off, Internal Maximum Fixed Stop Value setting used.

Fast Blink On Run mode, output on, Internal Maximum Fixed Stop Value setting used.

Alternating Fast Blinks Lockout, output off, high limit exceeded, Alarm output engaged.

Simultaneous Fast Blinks Lockout, output off, internal fault, Alarm output engaged.

On, Bright Fast Blink Output off, internal Maximum Fixed Stop Value setting not set.

Table 8. LED fault codes and recommended troubleshooting.

Fault Code System Failure Recommended Troubleshooting

11 High Limit Setpoint Exceeded. When pressure in vessel returns to normal, P7810C can be reset.

12-32, 71-90, 92 Internal fault. Reset P7810C; if same fault occurs again, replace P7810C.

51, 54, 61 Internal fault—internal relays

welded.

52-69, 91 Relay fault. Verify that no voltage potential exists on Output terminal. If code repeats after

Verify loads do not exceed rating of P7810C contacts, then replace P7810C.

normal operation, look for back feed of voltage greater than 50V (ac or dc) any time during boiler sequence. Replacing P7810C will only result in same lockout on new control.

For example: four long and three short flashes is code 43. If you miss the code the first time, keep holding the Reset Switch down and the code will repeat. Letting go of the Reset Switch clears the fault information and resets the P7810.

CHECKOUT

Electrical Shock Hazard and Explosion Hazard. Can cause severe injury, death or property damage.

1. Line voltage is present at the P7810C and all

controller circuits. Use extreme care during checkout.

2. This checkout procedure disables the Safety High

Limit function.

IMPORTANT

1. Do not put the system into service until all applicable tests described in the Checkout section of the instructions for the primary safety control and any additional tests required by the burner or boiler manufacturer are satisfactorily completed.

2. Close all manual fuel shutoff valves when trouble occurs.

After installation and wiring, check out the P7810C PressureTrol® Controller with the system in operation.

Checkout

1. Allow the system to stabilize.

2. Observe the operation of the P7810C while raising and

lowering the setpoint. Pressure increases when the setpoint is increased and decreases when the setpoint is decreased.

3. Check the make and break points of the P7810C. If they

do not agree with a separate, accurately calibrated pressure gauge, make a slight adjustment according to the scale. Use accurate pressure testing equipment when checking out the P7810C. Do not rely on inexpensive gauges. The P7810C is carefully calibrated at the factory.

Test the P7810C PressureTrol® Controller as follows:

NOTE: Make sure the P7810C is operating properly by

checking the LED indicators. If the P7810C LED indicate a lockout condition, press the manual Reset Switch.

NOTE: This procedure simulates pressure changes using

knob setpoint adjustments. Make knob adjustments very slowly because of filtering delays within the P7810C (20 to 25 seconds for full scale changes). Inaccuracy can result if knob adjustments are not made very slowly. To observe actual P7810C control accuracy, set the knobs to normal operating values. Compare the knob settings to the boiler pressure readings where P7810C actions occur.

To check the control setpoint of the P7810C:

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P7810C PRESSURETROL® CONTROLLER

WARNING

CAUTION

WARNING

1. Note the boiler pressure by checking the boiler pressure

gauge. To properly perform these tests, the boiler pressure should be near the middle of the P7810C pressure range.

2. Turn the P7810C Limit setpoint knob fully clockwise to

make sure this limit does not interfere during steps 4 and

5. This setting must be returned to the proper operating position when return the system to normal operation.

3. Check the control setpoint and control differential.

4. Set the control differential knob to the center of its range.

5. Turn the control setpoint knob fully counterclockwise and

make sure the P7810C control circuit is open and the green LED is off (no call for heat).

6. Read the boiler pressure gauge and add this number to

the control differential setting.

7. Turn the control setpoint knob slowly clockwise and

make sure the control circuit closes and the P7810C indicates a call for heat (green LED on) when the P7810C control setpoint passes through the value determined in step 6.

8. Turn the control setpoint knob slowly counterclockwise

and make sure the control circuit opens and the P7810C no longer indicates a call for heat (green LED off) when the control setpoint passes through the boiler pressure

gauge value. Check the modulation setpoint and modulation range of the P7810C as follows:

1. Set the P7810C modulation range knob to the center of

the range.

2. Turn the modulation setpoint knob fully clockwise and

make sure the firing rate motor travels to the fully open

position (boiler is firing).

3. Turn the modulation knob slowly counterclockwise and

make sure the firing rate motor starts moving toward the

closed position when the modulation setpoint passes

through the boiler pressure gauge value. (Alternately,

make sure the current starts decreasing toward 4 mA.)

4. Determine the pressure point at which minimum

modulation output will occur by checking the boiler

pressure gauge and subtracting the modulation range

knob setting (at midpoint).

5. Turn the modulation setpoint knob slowly

counterclockwise and make sure the firing rate motor

continues to move to the closed position. Make sure the

firing rate motor reaches the lowfire position when the

modulation setpoint reaches the pressure point identified

in step 4 above. (Alternately, make sure the measured

current decreases gradually toward 4 mA.) Check the limit setpoint as follows (boiler pressure required):

1. Turn the control setpoint knob clockwise until the control

circuit closes. Make sure the yellow LED is flashing and

the green LED is on, indicating normal operation with a

call for heat.

2. Turn the limit setpoint knob slowly counterclockwise and

make sure that the P7810C opens the circuit and

indicates a safety lockout by alternately flashing the

yellow and green LED (see LED Display section) when

the limit setpoint passes through the boiler pressure

gauge value.

3. Make sure that the Alarm output is energized.

Check for normal system operation as follows:

1. Set all knobs to the required operating position.

2. Press the Reset Switch to clear the safety lockout

condition.

3. Start the system and observe the operation through at

least one complete cycle to make sure the P7810C functions properly as described in the Operation section.

TROUBLESHOOTING

Electrical Shock Hazard. Can cause severe injury, death or property damage.

Line voltage is present in the P7810C and in all controller circuits. Use extreme care when troubleshooting.

To determine control malfunctions, use checkout procedures as listed in the Checkout section.

Equipment Damage Hazard. Can cause equipment damage or improper operation.

Do not put the system into service until you have satisfactorily completed all applicable tests described in this checkout section, and also all tests in the Checkout section of the applicable instructions for the primary safety control and any other tests the burner and boiler manufacturer require.

SERVICE INFORMATION

Electrical Shock Hazard. Can cause severe injury, death or property damage.

1. Only qualified Flame Safeguard technicians should

attempt to service Flame Safeguard controls and burners.

2. Line voltage is present in the electrical circuits to the

P7810C PressureTrol® Controller. Open the master electrical switch before replacing the device. More than one power supply disconnect may be involved.

Scheduled Inspection and Maintenance

Calibration

The P7810C PressureTrol® Controller was carefully calibrated during manufacturing and does not require field calibration.

Maintenance

Keep the cover of the P7810C PressureTrol® Controller in place at all times to protect the internal components from dust, dirt and physical damage. Routine maintenance consists of occasional inspection and removal of accumulated dirt and dust. Make sure the P7810C PressureTrol® Controller is functioning properly by performing an operation check of the entire system during routine maintenance checks.

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P7810C PRESSURETROL® CONTROLLER

Automation and Control Solutions

Honeywell International Inc.

1985 Douglas Drive North

Golden Valley, MN 55422

Honeywell Limited-Honeywell Limitée

35 Dynamic Drive

Toronto, Ontario M1V 4Z9

customer.honeywell.com