Table of Contents
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RM7800L1087, RM7840G1022, RM7840L1075, EC7840L1014
RM7800L2087, RM7840G2022, RM7840GL2075, EC7840L2014
Relay Modules with Valve Proving
APPLICATION
The Honeywell RM7800L/40G,L and EC7840L Relay
Modules are microprocessor-based integrated burner
controls for automatically fired gas, oil, or combination fuel
single burner applications. The RM7800L/40G,L and
EC7840L Relay Modules are used for UL/CSA Modulating
and FM/IRI Modulating burner applications. The
RM7800L/40G,L, EC7840L system consists of a Relay
Module. Keyboard Display Modules (standard with
RM7800), Dust Cover (standard with RM7840/EC7840L),
Subbase, Amplifier, and Purge Card. Options include DATA
CONTROLBUS MODULE™, Remote Display Mounting,
First-Out Expanded Annunciator and Modbus™
communications capable.
Functions provided by the RM7800L/40G,L, EC7840L
include automatic burner sequencing, flame supervision,
system status indication, system or self-diagnostics and
troubleshooting.
Using the S7800A2142 Keyboard Display (standard on
RM7800L2087) the following features can be set up:
• Post Purge time—Up to 60 minutes—Device shipped
with 15 seconds Post purge.
• Valve Proving features including:
—
VPS test time
—
When (Never, Before, After, Split or Both)
• See S7800A1142 Instructions (65-0288), also see
S7800A2142 Instructions. Series 5 can be
programmed for Modbus communication.
At commissioning time, the Valve Proving System may be
scheduled to occur at one of five different times:
• Never—Device default as received—Valve proving
does not occur.
• Before—Valve proving before run concurrent with Pre-
Purge.
• After—Valve proving occurs after the Run state,
before the device goes to Standby (Concurrent with
Post-Purge, if selected.)
honeyvell.energy
SIL
Capable
INSTALLATION INSTRUCTIONS
• Both—Valve proving occurs at both times Before and
After, noted above.
• Split—The main valve 2 (MV2) (high pressure) seat
test is performed at the Before time and the main
valve 1 (MV1) (low pressure) seat test is performed
during the After time.
The following assumptions apply when using the
RM7840G,L, RM7800L, EC7840L:
MV1
VP
SW.
INLET
1
1 CAUTION: VALVE ENERGIZING TIMING IS BASED ON HONEYWELL VALVE
OPENING TIMES OF 13 SECONDS MAXIMUM.
− FOR VALVES WITH TIMINGS GREATER THAN 13
SECONDS OR THOSE THAT DO NOT OPEN THE ACTIVE
VALVE WITHIN THE ENERGIZED TIME, A BYPASS SSOV
RATED SOLENOID VALVE (1/4", 120 VAC) IS REQUIRED TO
OBTAIN THE PROPER TEST PRESSURES.
− THE BYPASS VALVE WILL BE WIRED IN PARALLEL TO THE
VALVE IT IS BYPASSING (TERMINAL 9 FOR MV1 OR
TERMINAL 21 FOR MV2).
Fig. 1. The valve proving system.
MV1—Wired to terminal 9. It is located in the most
upstream position of the main gas valve train.
VPS—Valve Proving Switch: Setpoint at 1/2 of Main Valve
inlet pressure.
MV2—Wired to terminal 21. It is the main valve located
closest to the burner.
The PII—Pre-Ignition Interlock (or Proof of Closure Switch)
for terminal 20 can be installed on MV1, MV2, or as a
series connection through both valves.
Appendix B lists many wiring options for single and dual
fuel along with the Valve Proving options.
3
MV2
OUTLET
M24161A
32-00142-01
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Table of Contents
Related Manuals for Honeywell RM7800L1087
Summary of Contents for Honeywell RM7800L1087
- Page 1 1 CAUTION: VALVE ENERGIZING TIMING IS BASED ON HONEYWELL VALVE Using the S7800A2142 Keyboard Display (standard on OPENING TIMES OF 13 SECONDS MAXIMUM. RM7800L2087) the following features can be set up: −...
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Page 2: Specifications
RELAY MODULES WITH VALVE PROVING SPECIFICATIONS This document provides installation and static checkout instructions. Other applicable publications are: Electrical Ratings, see Table 3: Publication Voltage and Frequency: Product RM78xx—120 Vac (+10/-15%), 50 or 60 Hz (±10%). 65-0084 Q7800A,B 22-Terminal Wiring Subbase EC78xx—220–240 Vac (+10/-15%), 50 or 60 Hz Product Data (±10%). -
Page 3: Mounting Wiring Subbase
RELAY MODULES WITH VALVE PROVING IMPORTANT Mounting Wiring Subbase 1. Wiring connections for the relay modules are 1. Mount the subbase in any position except horizontally unique; therefore, refer to Figs. 3, 4, 6, 7, or with the bifurcated contacts pointing down. The Appendix B for proper subbase wiring. -
Page 4: Final Wiring Check
RELAY MODULES WITH VALVE PROVING 1. For proper subbase wiring, refer to Figs. 3, 4, 6, 7, or c. Enclose flame detector leadwires without armor Appendix B. cable in metal cable or conduit. 2. For proper remote wiring of the Keyboard Display d. - Page 5 RELAY MODULES WITH VALVE PROVING 120 Vac 50/60 Hz L1 (HOT) INTERNAL ELECTRONICS ALARM BLOWER DEMAND LOW FIRE LIMITS CONTROLLER SWITCH HIGH FIRE DEMAND (VALVE SWITCH PROVING) AIR FLOW SWITCH PILOT VALVE VALVE PROVING SWITCH MAIN VALVE 1 IGNITION PRE-IGNITION INTERLOCK FLAME PLUG IN FLAME DETECTOR...
- Page 6 RELAY MODULES WITH VALVE PROVING Table 2. Recommended Grounding Practices. Ground Type Recommended Practice Earth ground (subbase and relay 1. Use to provide a connection between the subbase and the control panel of the module). equipment. Earth ground must be capable of conducting enough current to blow the 15A fuse (or breaker) in the event of an internal short circuit.
- Page 7 RELAY MODULES WITH VALVE PROVING Table 4. Combinations for Terminals 8, 9, 10 and 21. Pilot Fuel 8 Main 9 Ignition 10 Valve 21 No Load No Load No Load No Load No Load No Load No Load No Load No Load No Load No Load...
- Page 8 RELAY MODULES WITH VALVE PROVING SERIES 90 FIRING RATE SERIES 90 Q7800 MOTOR CONTROLLER HIGH FIRE FOR DIRECT SPARK IGNITION (OIL OR GAS) COMMON IGNITION TRANSFORMER LOW FIRE LINE VOLTAGE ALARM MODULATE (L1) 2ND STAGE FUEL VALVE BURNER MOTOR (OPTIONAL) (BLOWER) BURNER CONTROLLER/LIMITS...
- Page 9 RELAY MODULES WITH VALVE PROVING SERIES 90 FIRING RATE SERIES 90 Q7800 MOTOR CONTROLLER HIGH FIRE FOR DIRECT SPARK IGNITION (OIL OR GAS) COMMON IGNITION TRANSFORMER LOW FIRE LINE VOLTAGE ALARM MAIN VALVE 1 MODULATE (L1) MAIN VALVE 2 BURNER MOTOR VALVE PROVING (BLOWER) SWITCH...
- Page 10 RELAY MODULES WITH VALVE PROVING BEFORE FINISH HF T19 PURGE CLOSED TEST TIME 4 SEC. 3 SEC. 4 SEC. 3 SEC. TEST TIME IGNITION TRIALS CONTROLLER L1-17 AIRFLOW 17-7 MV2 (21) MV1 (9) VPS (16) VPS (16) PII (20) PII (20) PII (20) POST FINISH POST...
- Page 11 RELAY MODULES WITH VALVE PROVING SERIES 90 FIRING RATE SERIES 90 Q7800 MOTOR CONTROLLER HIGH FIRE COMMON LOW FIRE 120V ALARM MODULATE (L1) FOR DIRECT SPARK IGNITION BURNER MOTOR (OIL OR GAS) (BLOWER) IGNITION TRANSFORMER BURNER CONTROLLER/LIMITS 1ST STAGE FUEL VALVE RUNNING INTERLOCKS LOW FIRE (INC.
- Page 12 RELAY MODULES WITH VALVE PROVING SERIES 90 FIRING RATE SERIES 90 Q7800 MOTOR CONTROLLER HIGH FIRE FOR DIRECT SPARK IGNITION (OIL OR GAS) COMMON IGNITION TRANSFORMER LOW FIRE 120V ALARM MODULATE (L1) BURNER MOTOR VALVE PROVING (BLOWER) SWITCH RECYCLE LIMITS BURNER CONTROLLER RUNNING INTERLOCKS LOW FIRE...
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Page 13: Valve Proving System
RELAY MODULES WITH VALVE PROVING WIRING SUBBASE RUN/TEST DIN RAIL MOUNT BASE: SWITCH SHOWN Q7800XX CONFIGURATION JUMPERS PURGE TIMER BASE SECURITY PIN RESET BUTTON CAPTIVE MOUNTING SCREW SCR OLL MO DE - SAV E - 2-LINE VFD KEYBOARD DISPLAY MODULE FLAME (STANDARD ON AMPLIFIER... -
Page 14: Typical Valve Proving System Function
(Because the gas pressure has increased due to a leaky upstream valve.) (Low pressure test.) Table 6. Honeywell Pressure Switch Selection for Valve Proving System. Maximum Maximum Operating... - Page 15 RELAY MODULES WITH VALVE PROVING System operation requires the Valve Proving function setup and demand input must be connected to terminal NOTE: The S7800A1142 and/or S7800A2142 Keyboard Display is NOT supplied on RM7840G,L or EC7840L device. Edit: When the RM7800L/40G,L, EC7840L is installed and powered, “STANDBY”...
- Page 16 RELAY MODULES WITH VALVE PROVING Edit: Edit: M22665B M22665B Fig. 15. Save Changes screen. Fig. 18. Save Changes screen. 15. Use the down arrow to save changes. “Getting Data” is displayed momentarily. The following steps are to confirm your selections. Edit: M22764B Fig.
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Page 17: Safety Shutdown
RELAY MODULES WITH VALVE PROVING 18. Press Enter. 23. Press and hold the relay module RESET button for five seconds to program the Valve Proving setup into the relay module. The Release Reset screen will appear on the KDM. Edit: M22671B Fig. -
Page 18: Sequence Of Operation
RELAY MODULES WITH VALVE PROVING 4. PREPURGE Period: OPERATION a. Pre-Ignition Interlock opens anytime during PREPURGE period (except during VP test). (L model only) Sequence of Operation b. Flame signal is detected after first ten seconds The RM7800L/40G,L, EC7840L has the following during PREPURGE (RM7800L/40L, EC7840L). - Page 19 RELAY MODULES WITH VALVE PROVING c. If Before, Split or Both Valve Proving tests are c. Terminal 21 action: selected (and demand input T17 is used), the (1) RM7800/40L, EC7840L - turned off15-sec- RM7800L/40G,L, EC7840L will sequence the onds after Terminal 9 is energized. main valves to conduct the VP tests concurrently (2) The RM7840G: with Pre-Purge (beginning at 10 seconds into the...
- Page 20 RELAY MODULES WITH VALVE PROVING Ignition Trials—Valve Proving with DSI Postpurge System The RM7800L/40G,L, EC7840L provides a programmable (default is 15 seconds) POSTPURGE following the 1. Demand connected to Terminal 17: completion of the RUN period. The blower motor output is —...
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Page 21: Run/Test Switch
RELAY MODULES WITH VALVE PROVING Keyboard Display Module Options actions. The scroll bar adjusts to give a relative position of the current view with respect to all lines that the page can display. Vacuum Fluorescent Display (VFD) When a line has a right arrow symbol positioned on the The Keyboard Display Module (see Fig. -
Page 22: Settings And Adjustments
RELAY MODULES WITH VALVE PROVING SETTINGS AND ADJUSTMENTS Selectable Site-Configurable Jumpers The RM7800L/40G,L, EC7840L has three site-configurable jumper options, see Fig. 29 and Table 8. If necessary, clip the site-configurable jumpers with side cutters and remove the resistors from the Relay Module. SELECTABLE CONFIGURATION JUMPERS RUN/TEST SWITCH NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G. -
Page 23: Static Checkout
RELAY MODULES WITH VALVE PROVING STATIC CHECKOUT 3. Ammeter can be used to verify valve loads con- nected to the wiring subbase. After checking all wiring, perform this checkout before General Instructions installing the RM7800L/40G,L, EC7840L on the subbase. These tests verify the Q7800 Wiring Subbase is wired 1. - Page 24 RELAY MODULES WITH VALVE PROVING Table 9. Static Checkout. (Continued) RM7800/RM Test 7840/EC784 Test If Operation is Abnormal, 0 Models Jumpers Voltmeter Normal Operation Check the Items Listed Below 7-L2 1. Burner motor (fan or blower) 1. Burner motor circuit. starts.
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Page 25: Troubleshooting
RELAY MODULES WITH VALVE PROVING TROUBLESHOOTING portion of the fault code (two slow blinks is 2). Three fast blinks followed by two slow blinks would be fault code 32. (See Table 10 for Blink Fault Code list.) Troubleshooting can be accomplished by using the S7800 Keyboard Display Module (KDM) or a blinking POWER The LED code repeats as long as the fault exists. - Page 26 RELAY MODULES WITH VALVE PROVING Table 10. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code System Failure Recommended Troubleshooting Code 3-1 Running or Lockout 1. Check wiring; correct any errors. *Running/ Interlock fault during 2. Inspect the fan; make sure there is no air intake blockage and that it is Interlock Pre-Purge.
- Page 27 RELAY MODULES WITH VALVE PROVING Table 10. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code System Failure Recommended Troubleshooting Code 5-1 Pre-Ignition Interlock 1. Check wiring and correct any errors. *Pre-Ignition fault. 2. Check Pre-Ignition Interlock switches to assure proper functioning. Interlock* 3.
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Page 28: Valve Proving Test
Length of pipe between valves. the results for your system. Pipe Size—used to define A IMPORTANT Pipe Cross Section Area (from Table The Tables show information on Honeywell Valves only. Contact other valve manufacturers to obtain Test Second Minimum VPS test period. - Page 29 X = 0.0218 + 0.0267 + (3.356 x 1.75 ÷ 144) = 0.0893. Round up to 14 seconds; enter 14 seconds into the VPS Calculation of Valve Proving Test Time: Setup. Table 13. V1 Upstream Volumes for Honeywell Valves. Pipe Size NPT (inches) V4295...
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Page 30: Safety And Security
RELAY MODULES WITH VALVE PROVING Table 15. Schedule 40 Pipe Internal Cross-Sectional Area. Pipe Size NPT (Inches) Cross-Sectional Area (Sq. In.) “A” 0.191 0.304 0.533 0.864 1-1/4 1.498 1-1/2 2.036 3.356 2-1/2 4.788 7.393 12.730 Table 16. VPS Worksheet. Item Description Information Lookup Table... - Page 31 RELAY MODULES WITH VALVE PROVING APPENDIX B: RM7800L/40G,L, EC7840L IGNITION OPTIONS Column 1 lists the ignition option. Column 2 lists the figure letter that shows the connections for that option. The figure letters refer to the figures on pages 30–32. Column 3 refers to the fuel changeover switch and how many connections or poles that would be required.
- Page 32 RELAY MODULES WITH VALVE PROVING APPENDIX B: 7800 IGNITION OPTIONS LIMITS CONTROL LIMITS CONTROL IF EA IS USED THEN GAS/OIL SWITCHING IS INTERLOCKS INTERLOCKS ALSO NEEDED HERE. A. NO VP/SINGLE FUEL: M24098A LIMITS CONTROL INTERLOCKS INTERLOCKS GAS MV RM7840G - CLIP JR2 B.
- Page 33 RELAY MODULES WITH VALVE PROVING LIMITS CONTROL LIMITS CONTROL IF EA IS USED THEN IF EA IS USED THEN GAS/OIL SWITCHING IS INTERLOCKS GAS/OIL SWITCHING IS INTERLOCKS ALSO NEEDED HERE. ALSO NEEDED HERE. INTERLOCKS INTERLOCKS GAS MV OIL MV GAS MV RM7840: NO JUMPER - SWITCH FUEL OFF TERMINAL 21.
- Page 34 RELAY MODULES WITH VALVE PROVING LIMITS CONTROL LIMITS CONTROL IF EA IS USED THEN IF EA IS USED THEN GAS/OIL SWITCHING IS INTERLOCKS GAS/OIL SWITCHING IS ALSO NEEDED HERE. INTERLOCKS ALSO NEEDED HERE. INTERLOCKS INTERLOCKS THE SOFTWARE DOES NOT ENERGIZE T8 WHEN GAS IS SELECTED AND JUMPER 2 (JUMPER 3...
- Page 35 RELAY MODULES WITH VALVE PROVING 32-00142—01...
- Page 36 RELAY MODULES WITH VALVE PROVING For More Information The Honeywell Thermal Solutions family of products includes Honeywell Combustion Safety, Eclipse, Exothermics, Hauck, Kromschröder and Maxon. To learn more about our products, visit ThermalSolutions.honeywell.com or contact your Honeywell Sales Engineer. Honeywell Process Solutions...