Delphi

General
Installation
Tips

1
 Literature
• Unit ships with full manual
- Installation Instructions 66-1190
- Quick Start Guide, 66-1191
- RM7840L
- S7800
- Q7800
- Tachometer
- Hall-effect sensor
- Oxygen sensor
- Spec sheets for other components
- Wiring diagram
- Installer & Manager access cards
• Technical Brochure
2
 Pre Installation Considerations
• Boiler make / model / size
• Combustion motor make / model / size / nameplate
• Is boiler currently operational and up to code?
- Review the maintenance log
- Fuel delivery system and feedwater system operational?
- Pressure vessel integrity
- Burner turndown
- Emissions
- Other operation critical items
• Layout/operation of current system
• Layout/operation of Delphi system
- Where/How to mount: Delphi panel, VFD, Hall-Effect sensor
- Actuator coupling, Wiring, Transmitters, etc…
3
 Panel Mounting
• Overall panel size: 30 in high x 24 in wide x 10.5 in deep
(includes emergency stop button, panel is 8 in deep)

• Panel weight: 80 pounds

• Mounting holes are 0.44 inches typical diameter, 22.5

inches on center

• Available floor stand:

- Through Hubbell-Weigmann®
- Floor stand kit FKxx08 or SSFKxx08
Š xx” high x 8 “ deep

- Paint color RAL5102 to match Delphi

4
 Field Wiring
• For detailed information, reference document 66-1190-03,
Delphi Installation Instructions
• There are 3 field wiring terminal blocks; TB0/1, TB2, TB3
TB0: VFD
Modbus
connection

TB1:
T1-T38 TB2:
Low T40-T101
Voltage Line
Voltage

TB3: 120Vac
Power Input
Grounding bar

5
 Field Wiring
• Low Voltage Wiring
- Everything wired to TB0 and TB1
- Includes VFD modbus, transmitters, actuator command/feedback
and Hall-effect speed sensor wiring
- Route in separate grounded conduit or route in conduit with
shielded cable and ground one end only at the Delphi ground
bar.

• Line Voltage Wiring

- Everything wired to TB2 and TB3
- Includes incoming power, flame detector, valves, ignition,
actuator power wires, limits, interlocks…
- Route in separate grounded conduit
- EXCEPTION: Flame detector F and G leads require their own
conduit – refer to flame detector documentation
6
 Field Wiring
• VFD Wiring
- Power Wiring
Š Isolate power wiring and properly ground – DO NOT share a ground.

- VFD to Motor
Š Run wiring in separate conduit due to the EMF potential
Š Use shielded cable
Š Ground 1 end of shielded cable at VFD or motor

- VFD Modbus Wiring

Š Run wiring in separate conduit with all other low voltage wires.
Ground 1 end only at the Delphi ground bar.
Š MUST be shielded from electrical noise on bus - wiring is routed
DIRECTLY into ABC900 CPU
• Failure to do so may cause CPU to lose its programming due to electrical
noise
7
 Field Wiring
• TB0: VFD Modbus Wiring
- +, -, S

NOTE:
• Delphi can control VFD and/or Air Damper
• If VFD is Disabled, Channel 3 is automatically assigned as the air actuator
• If VFD is Enabled, Channel 3 can be used for another purpose
(Not Air Actuator)
• If using O2 trim, VFD and/or Air Damper is trimmed (if enabled)

8
 Field Wiring
• TB1: T1-T38 Low Voltage Input
- T1-T14 Sensor wiring

• Delphi trims/opens air damper and/or VFD

(dependent on user setup)

9
 Field Wiring
• TB1: T1-T38 Low Voltage Input
- T15-T19 Air Actuator Low Voltage

● Can mix & match actuator types (ML7999B / HercuLine) on a panel

● Wiring is different for ML7999B and HercuLine

10
 Field Wiring
• TB1: T1-T38 Low Voltage Input
- T20-T24 Fuel 1 Actuator Low Voltage

• If using VPS, Fuel 1 must be gas

11
 Field Wiring
• TB1: T1-T38 Low Voltage Input
- T25-T34 Fuel 2 and 4th Channel Actuator Low Voltage

12
 Field Wiring
• TB1: T1-T38 Low Voltage Input
- T35-T38 Hall-Effect Sensor Wiring

13
 Field Wiring
• TB2: T40-T101 Line Voltage Input
- T40-T58 Detector, Valves, Blower

● Flame detector F and G leads require their own conduit

• To motor contactor/starter
• If using VFD, motor contactor not needed

• 2 separate connections for double block valves

• Important if using VPS
• If using VPS, Fuel 1 must be gas
• DO NOT jumper if not using MV2

14
 Field Wiring
• TB2: T40-T101 Line Voltage Input
- T59-T70 VPS, Alarm, POC, Limits

• VPS pressure switch

15
 Field Wiring
• TB2: T40-T101 Line Voltage Input
- T71 -T90 Lockout Interlocks

16
 Field Wiring
• TB2: T40-T101 Line Voltage Input
- T91-T101 Reset and Actuator power wiring
Resets external
device + RM7840L
with blue reset button

• If using VPS, Fuel 1 must be gas

17
 Field Wiring
• TB3: 120Vac Power Input
- L1, L2, G

18
 ML7999B1002 Actuators
• Overview
- Looks like ML7999A externally
- Direct couple 100 in-Lb
- Programmed manually off-line
(not through Delphi)

- 4-20mA input
- >0Vdc to <5Vdc feedback for Delphi
- Potentiometer high fire reference voltage for Delphi
- Ships with mounting bracket, shaft adapter & drive stem
for V5197A firing rate valve

19
 ML7999B1002 Actuators
• ML7999B1002 Differences
- Added wires
Š Red
• >0Vdc to <5Vdc feedback for
Delphi

Š Black
• Proving high potentiometer
position reference voltage for
Delphi

- Fault & Mode LEDs

- Erase & Program buttons
- 4-20mA connections

20
 ML7999B1002 Actuators
• ML7999B1002 Interface
Manual drive buttons

Program status LED

Fast – Unconfigured
Slow – Configured
Solid – Failed

Erase/Program buttons

Program sequence
flash LED
5, 4, 3, 2, 1-Flash

4-20mA Current
Source Input
21
 ML7999B1002 Actuators
• Need to complete ML7999B programming of span off-line
before connection to Delphi – Differs from ControLinks™
- A separate 4-20mA current source is required
(Class 2 power supply)

- Actuator is manually driven to 5 points and manually

programmed via interface buttons under the cover

- After completion, actuator is connected to Delphi panel;

actuator is driven low and high, so Delphi can learn the span
and feedback of the pre-programmed actuator
Š Feedback value is dependent on user-programmed rotation

Š Feedback between 0Vdc and 5Vdc (or 5Vdc and 0Vdc)

22
 ML7999B1002 Actuators
• ML7999B Programming Sequence
- A-A: Fixed CW/CCW mechanical stops of actuator
- 5-Flash & 4-Flash: Fixed closed/open positions of mod device
- 3-Flash & 2-Flash: Min/max modulation positions

23
 ML7999B1002 Actuators
• ML7999B Programming Sequence
- A–A nominal actuator stroke of 95±3°
Š Including CW / CCW mechanical fixed stops

- 5-Flash:
Š Actuator powered & un-configured

Š Move actuator to one of its physical

endpoints, using CCW/CW buttons
Š Move actuator at least 5° off its mechanical
fixed stop (A)
Š Attached to valve/damper and adjust/verify
it is at its closed position. Mechanically
lock to shaft to ML7999B/tighten set
screws.
Š Press Program button until acknowledged
24
 ML7999B1002 Actuators
• ML7999B Programming Sequence
- 4-Flash:
Š Move actuator to other endpoint, using CCW/CW buttons

Š Setting must be at least 5° off mechanical fixed stop of the actuator (A)

Š Verify that the valve/damper is at its open position

Š Press Program button until acknowledged

25
 ML7999B1002 Actuators
• ML7999B Programming Sequence
- 3-Flash:
Š Move actuator to the Min or Max mod position, with CCW/CW buttons
Š Setting must be at least 2-5° off the 5-flash setting
• Make sure this position DOES NOT hit against the modulating device endpoint
Š Once there, send the current source (4mA or 20mA)
Š Press Program button until
acknowledged

26
 ML7999B1002 Actuators
• ML7999B Programming Sequence
- 2-Flash:
Š Move actuator to the other Max or Min mod position, with CCW/CW buttons
Š Setting must be at least 2-5° off the 4-flash setting
• Make sure this position DOES NOT hit against the modulating device endpoint
Š Once there, send the current source (20mA or 4mA)
Š Press Program button until
acknowledged

- 1-Flash:
Š Signifies the actuator firing rate
band is fully configured.
Š LED by CCW/CW buttons
changes from a fast to a slow
flash rate.

27
 ML7999B1002 Actuators

• Reference document 65-0264-05, ML7999B Product Data sheet

28
 ML7999B1002 Actuators
• Accessories
- Ships with mounting bracket, shaft adapter & drive stem
for V5197A firing rate valve
- 32003396-001/-002: V51E mounting kits, 1 ½ - 2” and 2 ½ -4”
- 32002935-001: Weatherproofing kit for actuator (NEMA 3/IP54)
- 32003167-001: Shaft adapter for 5/16” round or square shaft
- 201391: Shaft adapter for 3/8” round or square shaft
- 32003168-001: Shaft adapter for 3/4” diameter round shaft
- 32003168-002: Shaft adapter for 5/8” diameter round shaft
- 32003168-003: Shaft adapter for 9/16” diameter round shaft
- 201052B*: Double aux switch kit - for high/low outputs
- 50036542-001*: Aux switch adapter plate bag assembly
Š*For local codes where an external end switch for proven high/low fire
is required
29
 RM7840L
• Model
- RM7840L1075
- Programmable post purge
- VPS (Valve Proving System) capable
Š 13 second opening main valve(s) preferred for VPS
- Program enhanced features via included S7800A1142
- Refer to 66-1162-03 Installation Instructions

• Wiring
- Add 120 Ohm, 1/4 Watt termination resistor on S7800A
keyboard display terminals 1 and 2 for signal balance
- Will need to add to VFD as well

DATA +

DATA -
30
 Hall-Effect Sensor
• Purpose
- Provide blower motor speed feedback to Delphi when a VFD is
used to control the blower motor
- Provides REAL blower speed feedback, not CALCULATED
feedback
• Operation
- Sensor is designed to detect a passing ferro-magnetic (such as
iron) material (NOT stainless steel)
- Set-up to count a SINGLE pulse per revolution of a rotating
presence or absence (such as a keyed motor shaft)

31
 Hall-Effect Sensor
• Installation
- Installation is critical for proper motor speed feedback
- Sensor body is threaded 5/8-18UNF-2A
- Gap between sensor & object up to 0.07 in (1.78mm) maximum

32
 Hall-Effect Sensor
• Incorrect Installation Example
Š Bolt too close to fan
housing, which is also
ferrous material

Š Sensor picking up the

fan housing material.
Tachometer clicking
and rpm signal
bouncing from 0 to
2300.

Š Sensor too far away

from bolt – Must be
0.07 inches (1.78mm)
or less away.

33
 Hall-Effect Sensor
• Correct Installation Example
- Gap between sensor & object up to 0.07 in (1.78mm) maximum
- May need to modify motor to mount Hall effect sensor
Š Example: Drill & tap the fan
hub to install a bolt of
FERROUS MATERIAL for
pulse counting

Š May need to raise bolt ½” to

¾” from fan housing so it
does not sense the fan
housing. If tachometer picks
that up, it will click & the rpm
signal will bounce. MUST
have a stable rpm reading
before commissioning.

Š Create bracket

34
 Hall-Effect Sensor
• Mounting
- Mounting position is critical to VFD feedback
- May need to adjust sensor mounting and/or gap
Š If rpm not stable as shown in the Commissioning screen (standby & purge)

1798 RPM

35
 Hall-Effect Sensor
Š If get feedback fault at low fire position after purge
• Sensor may not be close enough to measuring object to pick up low end rpm
• Will likely get a Lockout Interlock fault on RM7840L as Delphi will drop power to AFS,
which supplies power to the Interlocks

36
 Hall-Effect Sensor

• Mounting bracket example

• Wiring:
- Wires to Delphi TB1: T35-T38
- 18 gauge wire should be sufficient
- IMPORTANT: Run low voltage wiring in separate conduit.
DO NOT run low voltage wiring with any current carrying wires.

37
 Honeywell VFDs
• Compatible VFDs
- Honeywell NXS with modbus card (32006630-002) or NXL
- Newest SMART HVAC models to be determined
- Due to scaling factors and modbus polling settings
• Drive Information
- NXS - PREFERRED
Š Embedded keypad
Š Requires purchase of 32006630-002 RS-485 Multi-protocol card
• Has status/troubleshooting LEDs
Š Menus full language
Š Selectable languages (English, French, Spanish, Portuguese)
- NXL
Š Embedded keypad
Š Embedded modbus card
Š Menus alpha-numerical
38
 Honeywell VFDs
• Affinity Laws
- Pumps & Fans Flow Rate Rotational Speed
- Centrifugal & Axial System Friction Rotational Speed2
Horsepower* Rotational Speed3
*Motor effective HP reduced by an X3 relationship if reduce speed

Percent Frequency Percent

Speed (Hertz) Savings
100% 60 0%
90% 54 27%
80% 48 49%
70% 42 66%
60% 36 78%
50% 30 88%
40% 24 94%
30% 18 97%
20% 12 99%
10% 6 100%
0% 0 100%
39
 Honeywell VFDs
• If reduce blower speed by 10%,

• Motor effective HP is reduced to (0.9 x 0.9 x 0.9) or 73%,

• Which reduces electrical demand by 27% (100% – 73%)

Percent Frequency Percent
Speed (Hertz) Savings
100% 60 0%
90% 54 27%
80% 48 49%
70% 42 66%
60% 36 78%
50% 30 88%
40% 24 94%
30% 18 97%
20% 12 99%
10% 6 100%
0% 0 100%

40
 Honeywell VFDs
Variable
VariableFrequency Electricity Savings
Frequency Drive Electricity Savings

100%

90%
27%

80%
(%))
Demand (%

70% 66%
Power Demand

60% 88%

50% Percent Savings 97%

Pump Power

40%
Blower
Blower

30%

20%

10%

0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Blower
Pump Speed
Blower (%)
Speed (%)

VFD
VFD&&Blower
Pump CV Pump
Blower
41
 Honeywell VFDs
• Set-up Tips
- NXS Modbus card in slot E ONLY
- NCDrive software with Delphi NX*.par file uses a wizard process
Š installer only changes M2 parameter set (motor nameplate)

• Considerations
- NOTE: Honeywell VFDs do have line reactors embedded
- Make sure motor can be used with VFD
Š Inverter duty rated motor to NEMA MG1 part 31
(Insulation Class F or H or KVA Code)
- Consider burner design before removing air damper
Š With VFD only, may not have good control at low fire
- Adjust motor min speed through Delphi
Š So motor does not stall
Š So motor does not overheat (may get feedback error)

42
Š Typical minimum around 20-30Hz
 Honeywell VFDs
• Wiring
- Modbus
Š NXS modbus card: T4 (Data+), T3(Data -), T5 (Ground)
• X4 jumpers ON (down) to activate termination resistor
• Will need to add to RM7840L/S7800 also

Š NXL modbus connection: B (Data+), A (Data-), T3, T7 or T11 (Ground)

• 120 Ohm, 1/4 Watt for termination resistor – Larger drives may have X9
jumper instead
• Will need to add to RM7840L/S7800 also

Š Add (2)1.8KOhm bias resistors at the VFD for signal boost as needed
(longer wires runs)

Š Delphi modbus connection TB0: +, -, S

Š IMPORTANT: Run low voltage wiring in separate conduit.

DO NOT run low voltage wiring with any current carrying wires.
Ground cable shield to Delphi ground bar.
43
 Honeywell VFDs
• Wiring
- Modbus
Š NXS modbus card
Š Bias resistors
(1.8KOhm)
• Add as needed for
signal boost (longer
wires runs)
• Per VFD literature, bias
resistors typically give
better communication
between RS-485 bus
devices & puts bus at
proper potential when
no device is transmitting

44
 Honeywell VFDs
• Wiring
- Modbus
Š NXS modbus card
Š RS485 board LEDs

• NOTE: This light is likely

to blink even if the
modbus parameters are
setup wrong
• If VFD does not respond
to Delphi start command:
- Check all wiring
(integrity, interference)
- Verify modbus
parameters
45
 Honeywell VFDs
• Wiring
- Power
Š IMPORTANT: Isolate power wiring and
properly ground
Š DO NOT share a ground

- Motor
Š IMPORTANT: Run wiring in separate
conduit due to the EMF potential
Š Use shielded cable
Š Ground 1 end of shielded cable at VFD
or motor

46
 Honeywell VFDs
• Wiring
- VFD Modbus Wiring
Š Run wiring in separate conduit with
all other low voltage wires. Ground 1
end only at the Delphi ground bar.

Š MUST be shielded from electrical

noise on bus - wiring is routed
DIRECTLY into ABC900 CPU
• Failure to do so may cause CPU to
lose its programming due to electrical
noise

Š Refer to appropriate NX spec sheet

for wiring details

47
 Honeywell VFDs
• Install Software
- Get free NCDrive software from customer.honeywell.com/vfd -
software downloads page

- Download Delphi specific parameter file:

Š Delphi NXS.par or Delphi NXL.par
Š Contains modbus setup & speed settings

- Obtain 32006629-011, Honeywell M to F serial interface cable

(remove keypad to plug in-VFD is female)

- Get 32006629-004, RS-232 adapter for NXL drives

- Obtain a protocol converter as needed

Š USB to RS-232 if your PC does not have a serial port
Š Suggested USB to RS-232 converter TBD
48
 Honeywell VFDs
• VFD Setup Tips
- Keypad Control Menu
Š Control place = 3 (Fieldbus) – in file

- Fieldbus parameters – in file

Š NXL System Menu S6 or NXS Expander Board Menu M7
Š Fieldbus protocol = 1 (modbus protocol)
Š Slave address = 10
Š Baud rate = 6 (19200 baud)
Š Stop bits = 0 (1 stop bit)
Š Parity type = 0 (None)**
• **NOTE: Current Installation Instruction (66-1190-03) is incorrect

- Basic parameters (motor nameplate) – Manual Entry

Š Nominal motor voltage, frequency, speed, current
Š Motor COSφ (power factor) IF AVAILABLE or DEFAULT
Š Min Speed = 0 Hz – in file (allows Delphi to control min/max)
Š Max Speed = 60 Hz – in file (allows Delphi to control min/max)
49
 Honeywell VFDs
• Motor Nameplate Example

NOTE: This is
NOT the power
factor
50
 Honeywell VFDs
• VFD Commissioning Tips
- Start up the drive, preferably without the motor connected
- Open Delphi NX*.par with NCDrive software
Š Walk through the start-up wizard

- Set motor nominal information

Š Motor current, voltage speed and COSφ

- Load to the drive

Š Can save and rename files

- Connect to motor
Š If motor does not run, may need to switch motor phase wires

51
 Honeywell VFDs
• For detailed set-up information, reference the following:
- NX Series User Manual and Application Manual, 63-2600
- NXL User Guide, 63-2599
- NX Series Selection Guide, 63-9251
- VFD Application Guide, 63-7062
- http://customer.honeywell.com
- Vacon OPT-C2/C8 Modbus/N2 Option card manual, UD00972C
Š NOTE: This manual is not shipped with the RS-485 protocol card

- www.vacon.com
- Honeywell VFD technical assistance line
Š 888-516-9347 (option 4) -OR- 763-954-6464 (option 4)

52
 MF020 Oxygen Sensor
• Overview
- MF020-1-LC3
- Zirconium dioxide
- Measures 0.1 to 25 vol%O2
- 15.7 in (400mm) probe length (other sizes available)
- High accuracy sensor; ± 2% full scale
- Quick response; approximately 3 seconds
- No replacement filters; no moving parts to wear out
- Auto-calibration feature
- Calibrates in air; no sample gas
- Separate O2 setpoints for each 10% of firing rate
53
 MF020 Oxygen Sensor
• Calibration
- Sensor is set-up to automatically calibrate during the burner purge
sequence if the purge time is 30 seconds or longer.
- If the sensor does not read 20.7% O2 in air, manual calibration
may be required.
Š METHOD 1:
• Jumper SENSOR pin 2 / 0Vdc to pin 6 / Cal for 10 seconds.
(DELPHI TB1: T6 to T9)

Š METHOD 2:
• Ventilate the probe tip
• Remove sensor housing &
locate internal
potentiometer
• Turn pot with slotted
screwdriver until the output
shown on the panel PC
equals 20.7% O2
54
 MF020 Oxygen Sensor
• Wiring
- Panel comes with cable connector
- 22-16 gauge wire
- 6 pins are used: 1, 2, 4, 5, 6, 7
- Part number 99-4218-14-07
- Follow low voltage wire route
recommendations

• Mounting
- Panel comes with Swagelok
compression tube fitting, ½ inch
bore through with ¾ inch male
connection, stainless steel
construction
- Part SS-810-1-12BT
55
 MF020 Oxygen Sensor
• Mounting

- Mount in the boiler stack as close to the boiler breeching

(flue gas outlet) as physically possible
- Provides quick response to combustion changes in the boiler
combustion chamber, optimizing the overall combustion efficiency

• Commissioning
- Still need to use a stack gas analyzer
- Need real values, not correlated values
56
 MF020 Oxygen Sensor
• Maximum Temperatures
- Housing: Ambient -14°F to 122°F (-10°C to 50°C)
- Bar probe: Ambient -148°F to 752°F (-100°C to 400°C)

• For detailed information, reference documents

- 66-1190-03 (Delphi Installation Instructions)
- 50030542-2-EN (Oxygen sensor Installation Instructions)

• Burner Shutdown / Alarm

- If O2 level drops below 1% (not adjustable)
- Sensor fault; ABC900 has 4-20mA input monitor algorithm to
indicate when a sensor is bad

57
 MF020 Oxygen Sensor
• Shelf Life –
- Shelf life is theoretically infinite (Ziconium dioxide technology)
- There are no components inside which can be “used up” or
degrade.
- Other sensors based on an electromechanical principal
produce current and will degrade over time

• Application Life –
- Typical sensor life used in clean air is approximately 10 years
- If combustion environment is polluted, life can be shortened.
- In a very polluted or dirty environment, the porous sensor cap
(which acts as a filter) may block the exchange from
measured gas to the sensing element

58
 MF020 Oxygen Sensor
• Oxygen Sensor Fuel Compatibility
- Methane
Š Methane will cause some O2 to be burned inside the sensor, leading to
a small drop in the measured levels of O2. It should be small.

- Hydrogen, Propane, Butane

Š The sensor cannot be used for oxygen measurement in a vacuum, or
at very low Oxygen pressures (concentrations) < 1%. The sensor is
not suitable to operate in an H2 environment. Even at small
percentages of H2 (i.e. 2%), Oxygen will recombine with H2 and there
will be errors in the readings. At 50% of H2 the sensor will not work
any more.

- Light Oil, Distillates, Diesel, Jet Fuel, Kerosene

Š The MF020 oxygen sensor can be used for these fuels, with a slightly
reduced life expectancy. In such applications, a life span of 3-5 years
has been typical.

59
 MF020 Oxygen Sensor
• Use with Other Fuels
- Heavy Oil (#6)
Š In general, burning of heavy oil produces soot, which would clog the
porous sensor cap. This has not been tested or confirmed, but in
general it is not suited for heavy oil applications.

- For more information on testing with other fuels, please contact

Honeywell.

- NOTE:
Š MF020 Oxygen sensors are also available for non-Delphi applications

60
 HercuLine 2001 Actuators
• HercuLine 2001 Actuators Available through ECC
- 100-130Vac, 60Hz, 4-20mA input, 0-5Vdc output, 2 limit switches
- 2001-100-090-EC: 100 in-Lb, 12 sec speed / 90° travel
- 2001-200-090-EC: 200 in-Lb, 25 sec speed / 90° travel
- 2001-400-090-EC: 400 in-Lb, 50 sec speed / 90° travel
- NOTE:
Š As of 7/16/2010, the above actuators have the embedded keypad for
programming purposes.

61
 HercuLine 2001 Actuators
• Accessories for HercuLine 2001 actuators
- Actuator ships with crank arm
- 2 End-of-travel limit switches are standard*
Š*For local codes where an external end switch for proven high/low fire
is required
- 51452354-501EC: Mounting plate adapter for Barber Coleman
MP495
- 51452354-502EC: Mounting plate adapter for Landis&Staefa
SQM53/56
- 51452354-503EC: Direct Coupled Valve hardware
- 51452354-504EC: Linkage assbly ball joint for 5/16” dia. push rod
- 51452354-505EC: Pushrod 12 in. long, 5/16” diameter
- 51452354-506EC: Pushrod 18 in. long, 5/16” diameter
62
 HercuLine 2001 Actuators
• Accessories for HercuLine 2001 actuators (continued)
- 51452354-507EC: Pushrod 24 in. long, 5/16” diameter
- 51452354-508EC: Pushrod 48 in. long, 5/16” diameter
- 51452354-511EC: North American valve retrofit kit
- 51452354-513EC: V51E 2.5”-3” valve mounting kit
- 51452354-514EC: V51E 4” valve mounting kit

63
 HercuLine 2001 Actuators
• Accessories for HercuLine 2001 actuators
- 51452354-501EC: Mounting plate adapter for Barber Coleman MP495
actuator

64
 HercuLine 2001 Actuators
• Accessories for HercuLine 2001 actuators
- 51452354-502EC: Mounting plate adapter for Landis&Staefa SQM53/56
actuator

65
 HercuLine 2001 Actuators
• Accessories for HercuLine 2001 actuators
- 51452354-503EC: Direct Coupled Valve hardware
Š Valve adapter, valve coupling, hardware

66
 HercuLine 2001 Actuators
• Accessories for HercuLine 2001 actuators
- 51452354-504EC: Linkage assbly ball joint for 5/16” diameter push rod
- 51452354-505EC: Pushrod 12 in. long, 5/16” diameter
- 51452354-506EC: Pushrod 18 in. long, 5/16” diameter
- 51452354-507EC: Pushrod 24 in. long, 5/16” diameter
- 51452354-508EC: Pushrod 48 in. long, 5/16” diameter

Pushrod

Ball Joint

67
 HercuLine 2001 Actuators
• Accessories for HercuLine 2001 actuators
- 51452354-511EC: North American valve retrofit kit
Š Replace Honeywell Actionator actuator with HercuLine 2001

- 51452354-513EC: V51E 2.5”-3” valve mounting kit

- 51452354-514EC: V51E 4” valve mounting kit
Š Adapter plate, linkage, hardware

Adapter Plate

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 HercuLine 2001 Actuators
• Accessories for HercuLine 2001 actuators
- 51452354-513EC and -514: V51E vale mounting kits (continued)
Š Adapter plate, linkage, hardware

Assembly

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 HercuLine 2001 Actuators
• Accessories for HercuLine 2001 actuators
- 51452354-513EC and -514: V51E vale mounting kits (continued)
Š Adapter plate, linkage, hardware

Linkage
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 HercuLine 2001 Actuators
• For detailed set-up information, reference the following
- Installation Manual, 62-86-25-10
- Quick Start Guide, 62-86-25-14
- Technical Assistance Center, 1-800-423-9883
- http://hpsweb.honeywell.com: Products, then Instrumentation

• Set-up of HercuLine 2001 actuators

- Wiring: Line voltage
- Wiring: Low voltage
250 ohm resistor
required for
0-5 Vdc output/
feedback to
Delphi

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 Mod IV Actuator Notes
• CANNOT use Mod IV Actuators
- Versions with 4-20mA / 2-10Vdc input do not have feedback,
which is required for the Delphi application.

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 Replacement Parts
• Delphi Parts Currently Setup
- S900A1000 PC touchscreen, pre-programmed
- MF020-1-LC3 Oxygen sensor
- 99-4218-14-07 Oxygen sensor cable connector
- SS-810-1-12BT Oxygen sensor compression tube fitting
- LCZ460-30-ECC Hall-effect sensor
- RM7840L and associated parts

• Delphi Parts Being Setup

- 50050785-001 Fuel transfer delay circuit board
- SNDJ-CNT-G02-ECC Tachometer, pre-programmed
- 900C32-YP, ABC900 CPU, pre-programmed
- ABC900 Individual I/O modules
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 Replacement Parts
• Field Available Parts
- Line conditioner
- Ethernet switch
- 24Vdc Power supplies
- Relays
- Circuit breakers
- System on/off switch
- Emergency off switch
- Reset switch
- Muffin fan/filter
- Refer to Installation Instructions, 66-1190-03 for information

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 Compatible Components
• High Limits and Low Limits:
- Pressure: L404, L408, L4079, P7810C*
- Temperature: L4008, L6008, T675, T678

• Operating Controls:
- Pressure: L404, L408, P7810C*
- Temperature: L4008, L6008, T675, T678

• Ignition Transformers: Q624, Q652

• Fuel Pressure Limits: C6097, C437

* NOTE: P7810C High-Limit and Operating controls functions CAN be used with
Delphi. The 4-20mA Firing Rate output CANNOT be used with Delphi - 24Vdc loop
powered, 4-20mA transmitter is required for that purpose.
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 Compatible Components
• Valves:
- V5197A Firing Rate Valve (Gas)
Š Flow adjustment screw controls maximum flow

Š ML7999 actuators ship with mounting bracket for

V5197A valve + shaft adapter + drive stem
Š Accepts direct mount of C6097 pressure switch

Š Not rated for safety shut-off

Š NPT and BSP pipe adapters sold separately

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