HEATEC TEC-NOTE

Troubleshooting modulation motors

Purpose
This document provides a guide for troubleshooting burner modulation motors (Figure 1), which are commonly called mod motors. They are also known as modulation actuators.

Publication No. 1-07-184 Revised 4-24-07

motor operates the linkage as it rotates within an arc of 90 degrees.

Key components of concern

Low-fire cam and low-fire proof switch. High-fire cam and high-fire proof switch. Resistor board or resistor harness. Transformer. NOTICE: For clarity some photos of mod motor are shown not installed on the heater. It is not necessary to remove it to perform the checks and adjustments described.

Scope
This document applies to Honeywell mod motors M7284C-000, M974C-025, and M984F-034 used on Heatec HC and HCS heaters.

What the mod motor does

The mod motor is connected to mechanical linkage that opens and closes fuel valves and air dampers of the burner (Figure 1). It provides proportional control of its firing rate. The shaft of the mod

SHAFT MOD MOTOR LINKAGE

LINKAGE

Figure1. Honeywell mod motor M7284C-1000 installed on heater. Page 

TRANSFORMER 120 VAC TO 24 VAC

HIGH-FIRE PROOF SWITCH

HIGH-FIRE CAM (BLUE)

LOW-FIRE CAM (RED)

LOW-FIRE PROOF SWITCH

TERMINAL BOARD

Figure 2. Top view of Honeywell mod motor M7284C-1000.

Model differences
The following table identifies the models of mod motors used on Heatec HC and HCS heaters that

have modulating burners. There are important differences in the way the switches and cams are configured. Figure 2 shows the motor now used.

Key differences
Heatec heaters used on Color of low-fire cam Wiring of low-fire proof switch Wires used, low-fire proof switch Color of high-fire cam Wiring of high-fire proof switch Wires used, high-fire proof switch Resistor board or resistor harness
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Honeywell mod motors M7284C-1000

HC & HCS 12-06 & after
Red Normally closed Red=common Yellow=Normally closed Blue Normally open Black/red=common Black/blue=Normally open (Not used) Page 2

M9174C-1025
HC & HCS prior to 12-06
Blue Normally open (held closed) Red=common Yellow=Normally open Blue Normally open Black/red=common Black/blue=Normally open Yes

M9184F-1034
HC & HCS early units with modulating burners
Red Normally closed Red=common Yellow=Normally closed Blue Normally open Black/red=common Black/blue=Normally open Yes

On mod motors with a blue low-fire cam the cam holds the low-fire proof switch in its closed position while the damper is fully closed. After the damper begins to open, the cam opens the switch. On all mod motors, the high-fire cam closes the high-fire proof switch when the damper reaches a preset open position. After the damper begins to close, the cam opens the switch.

SHOCK HAZARD. High voltage is present on certain terminals and wires inside the main control panel, inside the mod motor and inside the burner panel. Touching them will cause death or serious injury. Do not work on these components unless you are a qualified technician familar with the hazards of electricity. Some circuits in the main control panel may receive power from remote sources. Thus, the breaker operator on the door may not deenergize all exposed live parts. Always use a voltage tester to make sure there is no voltage on the terminals or bare wires you may touch.

40 AUTO FLAME SIGNAL

SCRL RESET MODE

FLAME-MONITOR

Figure 3. Fireye flame monitor.

Interaction with Honeywell modulation controller (Figure 4)

The modulation controller controls the mod motor using a circuit that provides an output of 4 to 20 mA. With a 4 mA signal the mod motor should be in the low-fire position with the damper fully closed. With a 20 mA signal the mod motor should open the damper to the high-fire position.

Interaction with Fireye flame monitor (Figure 3)

The Fireye flame monitor monitors the open/ closed status of the low-fire and high-fire proof switches in the mod motor while the burner is being purged. The low-fire proof switch is wired between terminals m and d. The high-fire proof switch is wired between terminals d and 8. Thus, the flame monitor shows either m-d limit or d-8 limit when indicating the status of these switches. Each switch is activated and de-deactivated by its own rotating cam in the mod motor. On mod motors with a red low-fire cam the low-fire proof switch remains in its normally closed position while the damper is fully closed. After the damper begins to open, the cam opens the switch.

Figure 4. Honeywell modulation controller.

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A common problem
Faulty electrical connections are common causes of mod motor malfunctions. Faulty connections can be caused from loose connections, dust, or corrosion from moisture. Connection problems may occur at the following locations: Terminals in mod motor. (Figure 5) Terminals on Temperature controller (Figure 6). Terminal strip on back plate of heater panel (Figure 7). Terminal strip in burner junction box (Figure 8). Failure of resistor board or resistor harness (Figures 11 and 12). Slippage of cams (Figure 2). Failure of transformer (Figure 2).

Symptoms of problems
Mod motor fails to move when burner is first turned on. Flame monitor (Figure 3) indicates abnormal status of either m-d limit or d-8 limit. Mod motor fails to operate the linkage. Modulation controller (Figure 4) fails to modulate the mod motor.

Remedy for faulty electrical connections

All wire connections that pertain to the mod motor have either screw terminals or cageclamp spring terminals. (See Figures 5, 6, 7 and 8) On connections with screw terminals use a screwdriver to slightly loosen the screws and retighten them. On connections with cage clamps, push on the wire, wiggle it and then pull on it to make sure it is held tightly.

Other problems

Figure 5. Terminal connections in mod motor.

Figure 7. Terminal connections on back plate of heater panel.

Figure 6. Terminal connections on Honeywell modulation controller.

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Figure 8. Terminal connections in burner junction box. Page 4

Checking and resetting cams

. Remove the top cover so that you can gain access to the tops of the cams (Figure 2). 2. Make sure the shaft of the mod motor is rotated to its position for a fully closed damper. 3. Check positions of the target lobes of the cams. The cams have click stops that hold them in position. Repositioning a cam does not turn the drive shaft of the mod motor. 4. You may be able to rotate the cams with your fingers. Otherwise insert the blade of a screwdriver in the slots of the cam (Figure 9) and rotate them.

5. In order to make sure the cams are positioned properly you may need to rotate them until you can see their target lobes (indicated by yellow dots in Figure 10) and then reset them to their proper positions. NOTE: The yellow dots are only shown in Figure 0. There are no dots on the actual lobes. 6. You can also use the blade of a small screwdriver to press on the actuating arms of the switches to determine whether they are actuated. All switches except the blue low-fire switch should not be actuated while the damper is closed. Thus you should hear a distinct click if you press on their actuating arms. 7. Because the blue low-fire switch should be actuated or held closed by the cam when the damper is closed, you should not be able to move its actuating arm. Note that it is shown with its arm in the actuated position in Figure 10. 8. Make sure the target lobes of the two cams are rotated to the positions shown relative to the actuating arms of the two switches as shown in Figure 10. The U-shaped ends of the switch arms should rest on the cams as shown in 12 Figure 10.

Figure 9. Using screwdriver to position cams.

1

MODULATING MOTOR M7284C-1000

Thermocouple Type J Duplex + 26 +
Jum per

Honeywell Controller UDC2500 27 25 19 + 21 White Shielded Pair #1 12 12 Shielded Pair #2 10 LOW FIRE HOLD HOLD NORMAL Red 9 S-1 11 11 X 13 Black F 10 Red T1 24 vac T2 White + 120 vac

Figure 9A. Wiring diagram for mod motor currently used.

Circuit Breaker CB-4 1A 8

5 Alarm-2

Honeywell Modulating Motor

420 mA Signal Modulation Circuit Gnd Shld

L1

GND

L2 Burner Control Relay (13) (14) BC 1

8 Alarm-1

9 + 12 13

Set at 20 degrees above setpoint. White White

14

15

LEGEND
Optional Auxiliary Output To Chatterbox 420mA Signal Denotes terminal on Fireye Flame Monitor. Denotes terminal on Modulating Controller. Denotes terminal on terminal strip in control panel.

Red Gnd

16 Shield

Red

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HONEYWELL MODELS M7284C-1000 AND MF9184F-1034

BLUE (NO) YELLOW (NC) TOP VIEW RED (COMMON) LOW-FIRE PROOF SWITCH (NORMALLY CLOSED BLK/YELLOW (NC) HIGH-FIRE CAM BLK/BLUE (NO)

BLK/RED (COMMON)

HIGH-FIRE PROOF SWITCH (NORMALLY OPEN)

LOW-FIRE CAM 90

SHAFT

90

YELLOW DOTS INDICATE TARGET LOBES. CAMS ROTATE CLOCKWISE AS DAMPER OPENS.

LOW-FIRE CAM (RED) DAMPER CLOSED

HIGH-FIRE CAM (BLUE) DAMPER CLOSED

HONEYWELL MODEL M9174C-1025

BLUE (NC) YELLOW (NO) BLK/YELLOW (NC) BLK/BLUE (NO)

RED (COMMON) LOW-FIRE PROOF SWITCH (NORMALLY OPEN BUT HELD CLOSED)

TOP VIEW

HIGH-FIRE CAM

BLK/RED (COMMON)

HIGH-FIRE PROOF SWITCH (NORMALLY OPEN) 90

LOW-FIRE CAM 90

SHAFT

YELLOW DOTS INDICATE TARGET LOBES. CAMS ROTATE CLOCKWISE AS DAMPER OPENS.

LOW-FIRE CAM (BLUE) DAMPER CLOSED

Figure10. Configuration of cams and switches.
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HIGH-FIRE CAM (BLUE) DAMPER CLOSED

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Checking transformer in the mod motor

. Make sure heater control switch is set to off. 2. Make sure there is 20 Vac on the primary winding of the transformer using an ac voltmeter. Check for 24 Vac on its secondary winding. The transformer is defective if there is no voltage on its secondary winding.

4. Disconnect wires from terminals r, w and b of the resistor board. 5. Temporarily connect a short jumper wire from terminals r to b. The motor of the actuator should go to high-fire, which indicates that the motor is okay and its particular circuit on the resistor board is okay. Otherwise, either the motor or the resistor board is bad. 6. Temporarily connect a short jumper wire from terminals w to r. The motor of the actuator should go to low-fire (if it is not already there), which indicates that the motor is okay and its particular circuit on the resistor board is okay. Otherwise, either the motor or the resistor board is defective and should be replaced. 7. Remove the resistor board. 8. Connect the two wires from the secondary side of the transformer to terminals t1 and t2 of the circuit board where the resistor board was removed.

Checking resistor board and motor (Fig. 11)

. Make sure heater control switch is set to off. 2. Make sure that the dipswitch settings are correct as indicated in Figure 11. Use a ballpoint pen to make sure that switches are fully depressed. (Partially depressed switches have been a problem in the past.) 3. Make sure its transformer is not defective. Refer to instructions above.

1 OPEN

2 OPEN

3 OPEN

DIP SWITCH SETTINGS 4 5 6 7 OPEN CLOSED CLOSED OPEN

8 CLOSED

9 OPEN

10 OPEN

SWITCH IS OPEN WHEN BLUE BAR APPEARS NEXT TO SWITCH NUMBER

DIP SWITCHES

Figure11. Resistor board, Heatec PN 5004718, Honeywell PN 221508A. Page 7

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9. Using a short jumper wire, temporarily connect from terminal r to b on the circuit board. If the motor works, the resistor board is defective and should be replaced.

Replacing mod motor

The Model M7284C-000 Honeywell motor replaces all inoperable mod motors used on past and present Heatec HC and HCS heaters with modulating burner. Do not use a resistor harness or resistor board (Figures 11 and 12) with this motor. Be sure to use the new wires that come with the new mod motor (Figure 13) and connect directly to the low-fire and high-fire switches. Do not use the old wires. Although the old wire colors may be the same as the new wires they may not be connected to the same terminals on the low-fire and high-fire switches. See wiring diagram (Figure 9A) and cover of mod motor (Figure 14) for wiring information. Note differences in terminal markings indicated below: TERMINAL MARKINGS IN MOD MOTORS M7284C-1000 + F M9174C-1025 M9184F-1034 W R B
Figure 13. Wires furnished with Model M7284C-1000 Honeywell mod motor.

66.5 OHM RESISTOR 237 OHM RESISTOR

NOTE: Special precision resistors are used. Do not use substitutes

Figure 12. Resistor kit (harness), Heatec PN 5018099, Honeywell PN 4074EDC.

Figure 14. Information in cover of mod motor.

Heatec, Inc. 5200 Wilson Road Chattanooga, Tennessee 37410 www.heatec.com (423) 821-5200 (800) 235-5200 Fax (423) 821-7673

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2007 Heatec, Inc.