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Honeywell 2RM7800L1087 Installation Instructions Manual

Relay modules with valve proving.
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RM7800L1087; RM7840G1022,L1075;
EC7840L1014 Relay Modules
with Valve Proving
APPLICATION
The Honeywell RM7800L/40L and EC7840L Relay Modules
are microprocessor-based integrated burner controls for
automatically fired gas, oil, or combination fuel single burner
applications. The RM7800L/40L and EC7840L Relay Modules
are used for UL/CSA Modulating and FM/IRI Modulating
burner applications. The RM7800L/40L, 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 Personal Computer Interface, DATA CONTROLBUS
MODULE™, Remote Display Mounting, First-Out Expanded
Annunciator and Combustion System Manager™ Software.
Functions provided by the RM7800L/40L, EC7840L include
automatic burner sequencing, flame supervision, system
status indication, system or self-diagnostics and
troubleshooting.
RM7800L1087/RM7840G1022,L1075; EC7840L1014 offer
the Valve Proving test feature.
Using the S7800A1142 Keyboard Display (standard on
RM7800L1087) the following features can be set up:
• Post Purge time—Up to 66 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) for its features.
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.)
• 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.
INSTALLATION INSTRUCTIONS
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
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.
SPECIFICATIONS
Electrical Ratings, see Table 3:
Voltage and Frequency:
RM78xx—120 Vac (+10/-15%), 50 or 60 Hz (±10%).
EC78xx—220–240 Vac (+10/-15%), 50 or 60 Hz (±10%).
Power Dissipation: RM7800/RM7840/EC7840L: 10W
maximum in the Run mode.
MV2
OUTLET
M24161
66-1162-2

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   Summary of Contents for Honeywell 2RM7800L1087

  • Page 1

    Personal Computer Interface, DATA CONTROLBUS MODULE™, Remote Display Mounting, First-Out Expanded Annunciator and Combustion System Manager™ Software. 1 CAUTION: VALVE ENERGIZING TIMING IS BASED ON HONEYWELL VALVE OPENING TIMES OF 13 SECONDS MAXIMUM. Functions provided by the RM7800L/40L, EC7840L include −...

  • Page 2

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Maximum Total Connected Load: 2000 VA. 3. Installer must be a trained, experienced, flame safeguard service technician. Fusing: 15A maximum, Type SC or equivalent Fast Blow. 4. After installation is complete, check out the product operation as provided in these instructions.

  • Page 3

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Location 5. Recommended wire size and type: see Table 1. 6. Recommended grounding practices: see Table 2. Humidity The Keyboard Display Module, Data ControlBus Module™ Install the relay module where the relative humidity never (for remote mounting or communications), through a 203541 reaches the saturation point.

  • Page 4

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING L1 (HOT) INTERNAL ELECTRONICS ALARM BLOWER DEMAND LOW FIRE CONTROLLER LIMITS 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 5

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 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 6

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Table 4. Combinations for Terminals 8, 9, 10 and 21. Combination No. 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...

  • Page 7

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 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) 2ND STAGE FUEL VALVE (OPTIONAL) BURNER MOTOR (BLOWER) BURNER...

  • Page 8

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 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 MAIN VALVE 1 MODULATE (L1) MAIN VALVE 2 BURNER MOTOR VALVE PROVING (BLOWER)

  • Page 9

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING BEFORE FINISH HF T19 PURGE CLOSED 4 SEC. TEST TIME 4 SEC. 3 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)

  • Page 10

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 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...

  • Page 11

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 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...

  • Page 12

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING WIRING SUBBASE RUN/TEST SWITCH H O N E Y W E LL RELAY MODULE CONFIGURATION JUMPERS PURGE TIMER SEQUENCE STATUS LED PANEL POWE R RESET PILOT BUTTON FLAM E MAIN ALAR M KEYBOARD CAPTIVE RESE T...

  • Page 13

    The Valve Proving System requires a pressure switch to be installed to monitor the pressure in the internal space between the two shutoff valves. Recommended pressure switches are the following Honeywell non-manual reset models: Table 6. Honeywell Pressure Switch Selection for Valve Proving System. Maximum Maximum Operating...

  • Page 14

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING 1. Scroll down until the “Setup” is displayed in the second 8. Use the up/down arrows to select from Never, Before, line. (Setup is only available when the control is in After, Both, or Split, then press ENTER. Standby or Lockout state.) NOTE: Use Never (as shipped) on initial startup so gas line purging and System Checkout can be performed.

  • Page 15

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Edit: Edit: M22764B M22670B Fig. 16. Select/Restart screen. Fig. 19. Confirmation Acknowledgement screen. (The Valve Proving Test location is shown.) 11. Press down arrow to select. 12. “Getting Data” will be momentarily displayed, followed 16.

  • Page 16

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Once the system is in operation, the settings of the Valve Proving and Postpurge can be viewed in Diagnostics, using your S7800 Keyboard Display Module (KDM). Future changes to the Valve Proving and Postpurge features are still possible.

  • Page 17

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Standby 5. PILOT FLAME ESTABLISHING Period (PFEP): a. Low Fire Switch opens. The RM7800L/40L, EC7840L is ready to start an operating b. Lockout Interlock opens (RM7800L/40L, EC7840L). sequence when the operating control determines a call for c.

  • Page 18

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Proving, Terminal 21 is Main Valve 2 only. During PFEP, the Low Fire Switch must remain 1. A ten-second stabilization period occurs at the closed. If it opens, a safety shutdown occurs. beginning of the RUN period.

  • Page 19

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Keyboard Display Module (VFD) The Keyboard Display Module (see Fig. 9) is provided with the the High Fire (RM7800L/40L, EC7840L) position (Run/ RM7800 Relay Module (but is not required for operation) and Test Switch is ignored while the Valve Proving test is is an option for the RM7840/EC7840 Relay Module.

  • Page 20

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Table 8. Site Configurable Jumper Options. RM7800L/40L, Jumper Number Description Intact Clipped EC7840L Type 10 seconds 4 seconds G, L Pilot Flame Establishing Period Enabled Disabled DSI with Valve Proving Intermittent Interrupted Pilot Valve /Main Flame Establishing Period (MFEP)

  • Page 21

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Table 9. Static Checkout. RM7800/ RM7840/ Test EC7840 Test If Operation is Abnormal, Models Jumpers Voltmeter Normal Operation Check the Items Listed Below None 4-L2 Line voltage at Terminal 4. 1. Master Switch. 2.

  • Page 22

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Table 9. Static Checkout. (Continued) RM7800/ RM7840/ Test EC7840 Test If Operation is Abnormal, Models Jumpers Voltmeter Normal Operation Check the Items Listed Below RM7800L; 19-L2 Firing rate motor drives open; line 1.

  • Page 23

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING TROUBLESHOOTING 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 LED.

  • Page 24

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Table 10. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code System Failure Recommended Troubleshooting Code 3-2 Lockout Interlock 1. Check wiring to make sure that the Lockout Interlocks are connected properly *Running/ powered at improper between terminals 6 and 7.

  • Page 25

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING Table 10. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code System Failure Recommended Troubleshooting Code 5-3 Man-Open Switch, Start 1. Check wiring and correct any errors. *Man-Open Switch or Control On in 2.

  • Page 26

    2. Go to the Lookup Tables noted (13, 14 or 15) to get the results for your system. Pipe Size—used to define A IMPORTANT Pipe Cross Section Area (from Table 15) The Tables show information on Honeywell Valves Test Seconds Minimum VPS test period. only. Contact other valve manufacturers to obtain Time data on their specific valves.

  • Page 27

    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...

  • Page 28

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 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...

  • Page 29

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 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 30

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING APPENDIX B: 7800L 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 31

    RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING LIMITS CONTROL LIMITS CONTROL IF EA IS USED THEN IF EA IS USED THEN INTERLOCKS GAS/OIL SWITCHING IS 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 32

    T. VALVE PROVING/DUAL FUEL: DSI FOR GAS AND OIL M24136A Honeywell International Inc. Honeywell Limited-Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley, MN 55422 Toronto, Ontario M1V 4Z9 customer.honeywell.com ® U.S. Registered Trademark © 2007 Honeywell International Inc. 66-1162—2 M.S. Rev. 03-07...

This manual also for:

Rm7840g1022,l1075, Ec7840l1014

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