Honeywell RA116A User manual

Honeywell
PROTECTORELAY
OIL BURNER
CONTROLS
THESE ONE-PIECE, STACK-MOUNTED OIL BURNER
PRIMARY CONTROLS CYCLE THE BURNER ON
THERMOSTAT DEMAND AND SHUT DOWN THE
BURNER ON FLAME LOSS OR SYSTEM MALFUNC¬
TION.
□ Combine a Protectorelay unit for cycling the burner
and a Pyrostat flame detector for sensing temperature
changes of flue gases up to 1000° F [556° C],
□ RA116A is used with intermittent ignition burners
(formerly called constant ignition burners).
□ RA117A and RA817A are used with interrupted
ignition burners (formerly called intermittent ignition
burners).
□ Used with line voltage or 24V controllers.
□ Safety switch may be manually tripped on all models.
□ On RA116A, lockout occurs if flame is not re-es¬
tablished during safety switch timing.
□ On RA117A and RA817A, flame or power failure is
followed by a one minute (approximate) scavenging
period and one attempt to re-establish flame. Lockout
occurs if flame is not re-established.
□ Manual reset of safety switch is required after ignition
failure completely shuts off main burner.
D.T.
3-91
Form Number 68-0119
©Honeywell Inc. 1991
RA116A
RA117A
RA817A

SPEgmiCM»ONS|Ml : W ; -'1
-IMPORTANT-----
THE SPECIFICATIONS GIVEN IN THIS PUBLICATION DO NOT INCLUDE NORMAL MANUFACTURING
TOLERANCES. THEREFORE, UNITS MAY NOT MATCH THE LISTED SPECIFICATIONS EXACTLY. ALSO,
PRODUCTS ARE TESTED AND CALIBRATED UNDER CLOSELY CONTROLLED CONDITIONS, AND SOME
MINOR DIFFERENCES IN PERFORMANCE CAN BE EXPECTED IF THOSE CONDITIONS ARE CHANGED.
SUPER TRADELINE MODELS -
SUPER TRADELINE controls offer features not
available on TRADELINE or standard models, and
are designed to replace a wide range of Honeywell
and competitive controls.
TRADELINE MODELS -
TRADELINE controls offer features not available TRADELINE MODELS:
on standard models and are designed to replace a wide rai 16A Stack Mounted Protectorelay
range of Honeywell and competitive controls. Special TRADELINE packaging with cross refer¬
ence label and TRADELINE instruction sheet.
SUPER TRADELINE MODELS AVAILABLE:
RA117A Stack Mounted Protectorelay
Special SUPER TRADELINE packaging with
cross reference label and SUPER TRADELINE in¬
struction sheet.
STANDARD MODELS
MODEL
NUMBER
TYPE OF IGNITION
24V
THERMOSTAT
IGNITION
RATING
INPUT
VOLTAGE
RA116A
Intermittent ignition 3
(formerly called
constant ignition)
2- wire
3- wire
series 10
360 VA
120V/60HZ
RA117A
Interrupted ignition 6
(formerly called
intermittent ignition)
2- wire
3- wire
series 10
550 VA
120V/60 Hz
RA817A
Interrupted ignition 6
(formerly called
intermittent ignition)
2-wire
550 VA
110V/50 Hz
120V/60 Hz
220V/50 Hz
240V/60 Hz
« Lockout occurs if flame is not re-established during the safety switch timing.
b Flame or power failure is followed by a one minute (approximate) scavenging period and one attempt to re-establish the
flame. Lockout occurs if flame is not re-established.
ORDERING ^NFORMAT^O^^—
FOR ORDERING INFORMATION WHEN PURCHASING REPLACEMENT AND MODERNIZATION PRODUCTS FROM YOUR
TRADEUNE WHOLESALER OR YOUR DISTRIBUTOR, REFER TO THE TRADEUNE CATALOG OR PRICE SHEETS FOR
COMPLETE ORDERING NUMBER, OR SPECIFY:
1. Order number. TRADELINE or SUPER TRADELINE.
2. Input voltage and frequency.
IF YOU HAVE ADDITIONAL QUESTIONS, NEED FURTHER INFORMATION, OR WANT TO COMMENT ON OUR PRODUCTS
OR SERVICES, PLEASE WRITE OR PHONE:
1. YOUR LOCAL HONEYWELL RESIDENTIAL AND BUILDING CONTROLS DIVISION SALES OFFICE (CHECK
WHITE PAGES OF PHONE DIRECTORY).
2. RESIDENTIAL AND BUILDING CONTROLS CUSTOMER SATISFACTION
HONEYWELL INC., 1885 DOUGLAS DRIVE NORTH
MINNEAPOUS, MINNESOTA 55422-4386
[phone]
IN CANADA: HONEYWELL CONTROLS LIMITED
740 ELLESMERE ROAD
SCARBOROUGH, ONTARIO M1P 2V9
INTERNATIONAL SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES OF THE WORLD.

AMBIENT TEMPERATURE:
Operating: 0° F to 104° F [-18° C to 40° C].
Shipping: -40° F to 150° F [-40° C to 66° C],
DIMENSIONS: Refer to Fig. 1.
ELECTRICAL RATINGS (amperes):
Motor Ratings
110V/50 Hz
220V/50 Hz
120V/60 Hz
240V/60 Hz
Full Load
7.4
3.7
Locked Rotor
44.4
22.2
ELEMENT INSERTION LENGTH:
Adjustable from 3-1/2 to 5-1/2 inches [89 to 140 millime-
MOUNTING FLANGE:
Available for 6 inch [152 millimeter] diameter pipe (refer
to Fig. 2). Can also be flattened for flat-mounting applica¬
tions.
24V THERMOSTAT HEAT ANTICIPATOR CURRENT:
0.4A.
LINE VOLTAGE THERMOSTAT OR CONTROLLER
(RA116A, RA117A): 2 wire, 8A. Requires jumper across
W and B terminals. Refer to Fig. 5 or 7.
SAFETY SWITCH TIMING: 75 Seconds (nominal).
APPROVALS:
UNDERWRITERS LABORATORIES INCORPORATED
LISTED (RA116A, RA117A ONLY): File Number
MP268, Guide Number MCCZ.
ters].
The RA116A replaces the following competitive devices:
HONEYWELL
WHITE RODGERS
GENERAL ELECTRIC
GENERAL PERFEX
R116A.B
603
A101B2
5200
R124A.B
611-1
CR7865
5300
R134A
611-31
R168A
611-33
R494A
615
RA116A.B
6L18
RA416A
RA816A,D b
PENN
ITT GENERAL
MERCOID
DETROIT
664
5200
JM
CA701 a
670
R96A102A
CA702 8
680
R96G102DC
a A Detroit 3-wire thermostat must be replaced by a 2-wire thermostat with a suitable heat anticipator.
b When replacing a model having an F or O terminal to power a clogged filter indicator light, provide a separate transformer
for the light.
The RA117A replaces the following competitive devices:
HONEYWELL
WHITE RODGERS
GENERAL ELECTRIC
GENERAL PERFEX
R116A,B
602
A101A2
5200
R117A
603
A101B2
5230
R123A,B
610-2
CR7856
5520
R124A.B
610-32
5525 c
R134A
611-1
R168A
611-31
R494A
615
RA116A.B
6L18
RA117A
RA416A
RA816A
RA817A.C
RA817A,C b » c
DELCO PENN
ITT GENERAL
MERCOID
DETROIT
COA
664 5200
JM
CA701 a
COA-1 670
R96A102A
JM1
CA702 3
672
R96G102DC
680
682
a A Detroit 3-wire thermostat must be replaced by a 2-wire thermostat with a suitable heat anticipator.
b When replacing a model having an F or O terminal to power a clogged filter indicator light, provide a separate transformer
for the light.
c Do not use RA117A to replace this control where timed ignition is required for a wall-flame burner.
3
68-0119

| % ■ IS r j INSTALLATION ,
WHEN INSTALLING THIS PRODUCT...
1. R e a d these instructions carefully. Failure to follow
them could damage the product or cause hazardous
condition.
2. Check the ratings given in these instructions and on
the product to ensure the product is suitable for your
application.
3. Ensure the installer is a trained, experienced service
technician.
4. After completing installation, use these instructions
to check product operation.
MOUNTING (Refer to Fig. 2)
Followthe mounting instructions supplied bythefurnace,
boiler, or burner manufacturer, if available. Otherwise, use
the instructions provided below.
When replacing one of the controls listed on page 3,
identify each leadwire as it is removed from the old control
by marking the wire with the number of the RA116A or
RA117A terminal to which it will be connected. Refer to
Table 1 and 2 to translate the old terminal identifications to
the new RA116A or RA117A terminal identifications.
TABLE 1—IDENTIFYING TERMINALS FOR RA116A
REPLACEMENT.
TERMINAL
TERMINAL
IDENTIFICATION
IDENTIFICATION ON
ON OLD CONTROL
NEW RA116A
1, LH, or HOTLINE
1
2, LG, or LINE
2
3, 4, M, or MOTOR
3
TABLE 2—IDENTIFYING TERMINALS FOR RA11 7 A
REPLACEMENT. _
TERMINAL
TERMINAL
IDENTIFICATION
IDENTIFICATION ON
ON OLD CONTROL
NEW RA117A
1, LH, or HOTLINE
! i
2, LG, or LINE
2
3, M, or MOTOR
3
4, 1, or IGNITION
4
If the position of the old control was satisfactory, install
the new RA116A or RA11 7 A in the same location as the old
one, making sure to insert the bimetal element the same
distance into the stack as the old element. If the old
element was inserted more than 5-1 /2 inches [140 millime¬
ters], insert the new control 5-1/2 inches [140 millimeters]
into the stack.
If the position of the old control was not satisfactory,
close the old holes tightly with a metal plate and follow
these instructions.
1. F ollow these location considerations.
CAUTION
1. Do not bend contact arms or stops on the Py rostat
detector mechanism or make any adjustments
other than those given in the instructions.
2. Remove the cardboard packing behind the drive
shaft lever by pushing the packing up and pulling
it straight, out over the top of the lever. Do not
remove packing by pulling sideways.
3. Ensure all wiring complies with applicable codes
and ordinances.
4

A DO NOT FORCE THE COLLAR OF THE MOUNTING FLANGE PAST THE STOP. M15 a 6A
FIG. 2—MOUNTING AND LOCATION CONSIDERATIONS.
• Locate the control between the boiler or furnace and
draft regulator.
• Locate the control as near as possible to the boiler
or furnace.
• If mounting in an elbow, locate the element near the
outer curve where the hottest gases flow.
• Do not locate the element where the temperature
may exceed 1000° C [556° C],
2. Cut a 1 -3/8 inch [35 millimeter] hole in the stack at the
location desired.
3. Drill two holes and fasten the mounting flange using
the screws provided. The flange should fit the mounting
surface snugly, but it may be bent to fit a different radius
stacker flattened to fit aflat surface. Do not force the collar
or mounting flange past the stop.
4. Insert the bimetal element at the center of the stack
in direct path of the hottest flue gasses.
5. Tighten the lockscrew.
WIRING
Follow the appliance manufacturer’s instructions, if
available. Otherwise, follow the wiring diagrams shown in
Fig. 3 through 7.
WIRING DIAGRAMS
L2A
RA116A
SERIES 10
THERMO¬
STAT A
LI
A ( H ° T )
H
IGNITION
1 * 1 1
r
j
OIL VALVE
1
0
&
.© 0
1K1
: 1K2
ISLI
.SAFETY
.SWITCH
•HEATER
1K3
|_I PYROSTAT
CONTACTS
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
A IF USING A TWO-WIRE THERMOSTAT. TAPE LOOSE END OF RED
WIRE (IF NECESSARY).
A USE GREEN TERMINAL TO CONNECT CASE TO GROUND.
FIG. 3—RA116A WIRING DIAGRAM WITH A 24V, 3-
WIRE THERMOSTAT.
5
68-0119

LINE VOLTAGE
THERMOSTATOR I
CONTROLLER
BURNER .
MOTOR (
I
I 1K2
IK
— LT^J—
.SAFETY
.SWITCH
■ H E ATER
|_| PYROSTAT
CONTACTS
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
A USE GREEN TERMINAL TO CONNECT CASE TO GROUND. M1&83
FIG. 4—RA116A WIRING DIAGRAM WITH A LINE
VOLTAGE THERMOSTAT OR CONTROLLER.
LI
L2 A A ( H OT)
I LINE VOLTAGE JL.
CONTROLLER OR I 6 I
- THERMOSTAT I
A (HOT)
SERIES 10
THERMO¬
STAT a
(HOT) Ip 1K3
LX J [PYROSTAT
-j CONTACTS
(COLD) A
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
A USE GREEN TERMINAL TO CONNECT CONTROL CASE TO GROUND.
A IP USING A TWO-WIRE THERMOSTAT, TAPE LOOSE ENDS OF RED
WIRE (IF NECESSARY).
A CONTACTS BREAK IN SEQUENCE ON TERMPERATURE RISE.
A TO REPLACE AN INTERMITTENT IGNITION DEVICE (FORMERLY
CALLED CONSTANT IGNITION), CONNECT IGNITION LEADWIRE TO
TERMINAL 3, INSTEAD OF TERMINAL4. M15a2
FIG. 5—RA117A WIRING DIAGRAM WITH A 24V, 3-
WIRE THERMOSTAT.
BURNER.
MOTOR (
y (J) 2K1 :
(HOT)
fni
SAFETY
► SWITCH
► HEATER
LXJ [PYROSTAT
-J CONTACTS
(COLD) A
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
A USE GREEN TERMINAL TO CONNECT CONTROL CASE TO GROUND.
A CONTACTS BREAK IN SEQUENCE ON TERMPERATURE RISE.
Ml 584
FIG. 6—RA117A WIRING DIAGRAM WITH A LINE VOLTAGE THERMOSTAT OR CONTROLLER.
6

LI
A POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
^ USE GREEN TERMINAL TO CONNECT CASE TO GROUND.
^ CONTACTS BREAK IN SEQUENCE ON TERMPERATURE RISE.
Ml 581
FIG. 7—RA817A WIRING DIAGRAM.
OPERATION
The schematic diagrams show all systems in the idle
condition:
• Burner off, no call for heat.
• Pyrostat contacts closed (RA116A).
• “Cold”contactsclosed, "hot”contacts open (RA117A,
RA817A).
• Safety switches closed.
• All relays de-energized.
NORMAL OPERATING SEQUENCE
On a thermostat (or line voltage controller) call for heat,
the ignition, oil valve, and burner motor start. The safety
switch begins heating. Afterthe burner flame is established,
the stack temperature rises and expands the bimetal
detector element. The Pyrostat contacts open (RA116A) or
the "hot” contacts close and the “cold” contacts open
(RA117A, RA817A), de- energizing the safety switch heater.
The ignition circuit de-energizes (RA117A, RA817A only).
When the call for heat is satisfied, the system returns to
the idle condition.
IGNITION FAILURE
Iftheburnerflameis not established within approximately
75 seconds (nominal) of a thermostat (or line voltage
controller) call for heat, the Pyrostat contacts (RA116A) or
"cold” contacts (RA117A, RA817A) remain closed. During
that time, the safety switch is heated. If the burner flame is
not established after 75 seconds (nominal), the system
locks out and cannot be started again until the safety switch
is manually reset.
BURNER FLAME FAILURE DURING THE RUNNING
CYCLE
RA116A
The loss of burnerflame reduces the stacktemperature,
closes the Pyrostat contacts, and energizes the safety
switch. If the burner flame is not re-established within the
75 second (nominal) safety switch timing, the system locks
out and cannot be started again until the safety switch is
manually reset.
RA117A, RA817A
The loss of burnerflame reduces the stacktemperature,
opens the "hot” contacts, and shuts the system down by
de-energizing the 2K burner motor relay. After a one
minute (approximate) scavenging period, the "cold” con¬
tacts close and energize the safety switch heater. If the
thermostat (or line voltage controller) is still calling for heat,
the Protectorelay control makes one attempt to restart the
system. If the burner flame is not re-established in 75
seconds (nominal), the system locks out and cannot be
started again until the safety switch is manually reset.
POWER FAILURE DURING THE RUNNING CYCLE
A power failure shuts off the ignition and burner motor.
If the thermostat is still calling for heat when power is
restored, the stack temperature must cool and return the
system to the idle position. Once the system returns to the
idle condition, it begins the normal operating sequence.
7
68-0119

STARTUP AND CHECKOUT
WARNING
FIRE HAZARD
CAN CAUSE SEVERE BURNS
Ensure the combustion chamber is free of oil or
oil vapor before starting system.
STEP THE PYROSTAT DETECTOR CONTACTS
The detector contacts are actuated by a friction clutch
that is mounted on a rod connected directly to the heat-
actuated element. Occasionally, this clutch gets “out of
step” after a long period of idleness. To place the clutch and
the contacts “in step,”
1. Remove the cover.
2. Pull the lever forward 1/4 inch (Fig. 8).
3. Slowly release the lever.
4. Replace the cover.
TACTS.
START THE SYSTEM
1. Ensure the Pyrostat detectors are in step.
2. Push in and release the safety switch reset button.
3. Open the hand valve in the oil supply line.
4. Set the limit control and thermostat to call for heat.
5. Close the line switch. The burner should start.
CHECK THE SAFETY FEATURES
Simulate Flame Failure:
1. Follow the starting procedure to turn on the burner.
2. Close the hand valve in the oil supply line.
3. The RA116A locks out after 75 second (nominal)
safety switch timing. The RA117A and RA817A lock out
after one minute (approximate) scavenging period and 75
second (nominal) safety switch timing.
4. Reset the safety switch and open the hand valve in
the oil supply line.
Simulate Ignition Failure:
1. Follow the starting procedure to turn on the burner,
except do not open the oil supply hand valve.
2. Safety switch locks out after 75 second (nominal)
safety switch timing. Ignition and burner motor stops and
oil valve closes.
3. Reset the safety switch and open the hand valve in
the oil supply line.
Simulate Power Failure:
1. Follow the starting procedure to turn on the burner.
2. With the burner running, trip the circuit breaker or
remove the fuse to turn off power to the system. The burner
should stop.
3. Restore power. The burner should restart.
Check the Scavenger Timing:
1. Follow the starting procedure to turn on the burner.
2. With the burner operating normally, open and im¬
mediately close the line switch. The burner should stop
immediately.
3. After recycle timing (one minute approximately), the
burner should restart automatically.
ff the system does not operate as described, proceed to
Troubleshooting.

To completely troubleshoot an oil burner installation,
check the burner, ignition transformer, and oil primary
control for proper operation and condition.
To trifi the safety switch, move the safety switch lever
down until the red reset button pops out. Refer to Fig. 9.
The burner will not operate until the safety switch is reset
by pushing the red reset button.
TRIP SAFETY SWITCH BEFORE OPERATING BURNER
MAINTENANCE
Tripping the safety switch shuts down the burner but
does not disconnect the power supply. Turn off the
power at the system switch or the circuit breaker
before servicing the control system, burner motor, oil
valve, or ignition to avoid electrical shock.
PUSH LEVER DOWN TO
TRIP SAFETY SWITCH
D
FIG. 9—TRIPPING AND RESETTING THE SAFETY
SWITCH.
PRELIMINARY STEPS
Before checking the oil primary and cad cell, check out
the following parts of the burner and ignition systems.
Repair or replace controls as indicated.
1. Wiring connections, power supply, and burner motor
fuse. Ensure power is on to the controls, burner motor, and
ignition transformer.
2. Limit switch.
3. Ignition transformer.
4. Electrode gap and position.
5. Contacts between ignitiontransformer and electrode.
6. Oil pump pressure.
7. Oil tubing to tank.
8. Oil nozzle.
9. Oil supply.
10. Oil filter.
If the system is still not operating properly, check the oil
primary control as instructed below.
CHECK THE OIL PRIMARY CONTROL
CAUTION
Since troubleshooting is done with the system pow¬
ered, observe all necessary precautions to prevent
electrical shock or equipment damage.
Equipment Required:
1. Screwdriver
2.0 to 300 Vac Voltmeter
3. Insulated Jumper Wires
4. Hard Surface Card (such as a business card) for
cleaning contacts
68-0119

Burner Does Not Start When Thermostat Calls For Heat
PRELIMINARY CHECKS
1. Ensure all limit switches are closed.
2. Ensure safety switch is reset.
3. Check for the proper line voltage at the oil primary.
Proceed as follows after completing the preliminary checks.
CORRECTIVE ACTION
PROCEDURE
BURNER STARTS
BURNER DOES NOT START
1. Jumper the thermostat
terminals:
• Low voltage thermostat
at oil primary
• Line voltage thermostat
at thermostat
Trouble in the thermostat circuit.
Check the thermostat and
wiring connections.
!
Trouble is in the bimetal detector or
the oil primary. Put contacts in step
by pulling drive shaft lever out 1/4
inch and releasing. Refer to Fig. 8.
'
2. Jumper thermostat terminals
to start burner.
Bimetal detector and oil primary
are OK.
Clean the bimetal detector contacts
and timer contacts (if provided).
Go to step 3.
3. Jumper thermostat terminals
to start burner.
Bimetal detector and oil primary
are OK.
Go to step 4.
4. Jumper the thermostat
terminals and jumper the
normally closed contacts.
Reclean the bimetal detector
contacts again and recheck
by jumpering the thermostat
terminals. If the burner starts,
bimetal detector and oil primary
are OK.
Go to step 5.
5. Jumper the thermostat
terminals and jumper the
R and B terminals on the
oil primary.
Check for broken wires, loose
connections between the bimetal
detector and the control.
Repair and recheck by jumpering
the thermostat terminals. Replace
the bimetal detector if necessary.
Replace the oil primary and perform
Startup and Checkout procedures.
Burner Starts, Flame is Established. Then Safety Switch Locks Out on Safety.
PRELIMINARY STEPS:
1. Reset the safety switch.
2. Clean bimetal detector contacts.
Proceed as follows after completing the preliminary checks.
CORRECTIVE ACTION
PROCEDURE
BURNER KEEPS RUNNING
BURNER LOCKS OUT
1. Jumper thermostat
terminals to start burner.
• Low voltage thermostat
at oil primary
• Line voltage thermostat
at thermostat
Bimetal detector and oil primary
are OK.
• Clean the drive shaft, remove
the detector and clean bimetal
element. Replace the detector.
• Check the detector location. If
the stack temperature is below
300° F [149° C], replace the bimetal
detector.
2. Reset the safety switch
and jumper the thermostat
terminals to start the burner.
Bimetal detector and oil primary
are OK.
Replace the oil primary and perform
Startup and Checkout procedures.
Honeywell Inc.
U.S.A.: 1885 Douglas Drive N.
Golden Valley, MN 55422-4386
CANADA: 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.
PRINTED IN U.S.A.
QUALITY IS KEY