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Honeywell 7800 Series Installation Instructions Manual

Valve proving primary relay modules
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RM7898A
7800 SERIES Valve Proving
Primary Relay Modules
APPLICATION
The RM7898 is a microprocessor-based integrated burner
control for automatically fired gas, oil or combination fuel
single burner applications. The RM7898 system consist of a
relay module, subbase, amplifier, and purge card. Options
include Keyboard Display Module (KDM), Personal Computer
Interface, Data ControlBus™ Module, remote display
mounting, Expanded Annunciator and Combustion System
Manager® Software.
Functions provided by the RM7898 include automatic
burner sequencing, flame supervision, system status
indication, system or self-diagnostics and
troubleshooting.
This document covers the following 7800 Series Relay
Modules:
RM7898A1000
RM7898A1018
RM7898A2000
RM7898A2018
The RM7898 provides unique functions to a standard
primary control.
As received, the RM7898 offers the following features:
• Interrupted pilot with 10 second pilot flame establishing
period.
• Main valve operation with 10 second MFEP.
• Pre-Ignition Interlock (POC) input.
• Shutter-driven output when appropriate amplifier is
selected (R7861A, R7886A, R7851C).
• Blinking Fault Code Power LED on safety shutdown.
RM7898A1018 offers early spark shutoff when flame is
sensed.
Available features when appropriate terminals are
energized:
• Intermittent pilot T8 (Terminal 19).
• Direct spark feature for Valve Proving System (VPS)
(Terminal 18).
• Valve Proving System function (Terminal 17).
• See "Appendix b - ignition options" on page 25 for
examples of 24 single or dual fuel system combinations
with or without using the Valve Proving feature.
Programmable features using the S7800A1142 Keyboard
Display Module (KDM) (not included):
• Postpurge time—(up to 60 minutes).
• Valve Prove System features, including:
NOTE:
At commissioning time, the Valve Proving System may be
scheduled to occur at one of five different times:
1. Never—Device default as received; valve proving
does not occur. (Demand wired to Terminal 6.)
2. Before—Valve proving after standby and safe start
check, prior to ignition trials, concurrent with Pre-
Purge.
3. After—Valve proving occurs after the Run state
before the device goes to Standby, concurrent with
postpurge.
4. Both—Valve proving occurs at both times Before and
After noted above.
5. 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.
To perform Valve Proving, it must be commissioned and
Demand Input (Terminal 17) must be used.
The following assumptions apply when using the RM7898
Valve Proving testing.
INLET
1 CAUTION: VALVE ENERGIZING TIMING IS BASED ON HONEYWELL VALVE
Fig. 1. Valve Proving System—simplified diagram.
SIL
3
Capable
INSTALLATION INSTRUCTIONS
VPS test time
When in burner sequence to conduct VPS time
(Never, Before, After, Both or Split):
The S7800A1142 Series 5 or higher can be pro-
grammed for ModBus Communication. (See 65-0288
Spec Sheet.)
MV1
MV2
VP
SW.
1
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).
OUTLET
M24161
32-00209-03

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  Summary of Contents for Honeywell 7800 Series

  • Page 1 • Intermittent pilot T8 (Terminal 19). • Direct spark feature for Valve Proving System (VPS) (Terminal 18). 1 CAUTION: VALVE ENERGIZING TIMING IS BASED ON HONEYWELL VALVE OPENING TIMES OF 13 SECONDS MAXIMUM. • Valve Proving System function (Terminal 17).
  • Page 2: Specifications

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES MV1—Wired to terminal 9. It is located at the most upstream position of the main gas valve train. VPS—Valve Proving Switch (Rated 1/2 of main valve inlet SPECIFICATIONS pressure). MV2—Wired to terminal 21. It is the main valve located Electrical Ratings (See Table 4): closest to the burner.
  • Page 3: Mounting Wiring Subbase

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Vibration WARNING Do not install the relay module where it can be subjected Electrical Shock Hazard. to vibration in excess of 0.5G continuous maximum Can cause serious injury, death or equipment vibration.
  • Page 4: Wiring Subbase

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Subbase Compatibility Wiring Subbase Any Relay Module in the 1000 Series with a Software Revision level number starting with a "5" or greater will be WARNING compatible with all subbase models both installed and newly purchased.
  • Page 5 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES INTERNAL ELECTRONICS AIRFLOW DEMAND LIMITS CONTROLLER SWITCH ALARM DEMAND BLOWER PILOT VALVE VALVE PROVING SWITCH MAIN VALVE 1 PILOT SELECT IGNITION DSI SELECT FOR VP MODE MAIN VALVE 2 PREIGNITION PLUG IN...
  • Page 6 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES BEFORE 4 SEC. 3 SEC. TEST TIME 3 SEC. TEST TIME PURGE 4 SEC. L1-17 L17-7 MV2 (21) MV1 (9) VPS (16) VPS (16) PII (20) PII (20) PII (20) AFTER 4 SEC.
  • Page 7 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Q7800 SUBBASE LINE VOLTAGE ALARM BURNER MOTOR (BLOWER) BURNER LIMITS CONTROL AIRFLOW INTERLOCK INTERRUPTED PILOT/ IGNITION PRE-IGNITION MAIN FUEL VALVE #1 INTERLOCK (POC) IGNITION FLAME DETECTOR MASTER SWITCH PFEP INITIATE PFEP 10 SEC.
  • Page 8 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Q7800 SUBBASE LINE VOLTAGE ALARM BURNER MOTOR (BLOWER) VALVE PROVING (L1) SWITCH BURNER LIMITS CONTROL AIRFLOW INTERLOCKS INTERMITTENT/ INTERRUPTED PILOT/ IGNITION PREIGNITION MAIN FUEL VALVE 1 INTERLOCK (POC) MAIN FUEL IGNITION VALVE #2...
  • Page 9: Final Wiring Check

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES 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, type SC, fast blow fuse (or breaker) in the event of an internal short circuit.
  • Page 10 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 3. Terminal Ratings. Ratings Terminal Number Description RM7898 Flame Sensor Ground — Earth G — Earth Ground L2(N) Line Voltage Common — Alarm 120 Vac, 1A pilot duty. Burner Motor 120 Vac, 9.8A AFL, 58.8 ALR (inrush).
  • Page 11: Static Checkout

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES STATIC CHECKOUT 3. Replace all limits and interlocks that are not operat- ing properly. Do not bypass limits and interlocks. After checking all wiring, perform this checkout before Equipment Recommended installing the RM7898 on the subbase. These tests verify the Q7800 Wiring Subbase is wired correctly, and the 1.
  • Page 12: Valve Proving System

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 6. Static Checkout. Test Relay Test Numbe Module Jumper Voltmete If Operation is Abnormal, Model Normal Operation Check Items Listed Below None 5-L2 Line voltage at terminal 5. 1. Master switch.
  • Page 13: Typical Valve Proving System Function

    4 seconds, MV2 is commanded closed again. b. This is followed by a three second delay during which the Valve Proving pressure switch (VPS) is ignored. Table 7. Honeywell Pressure Switch Selection for Valve Proving System. Maximum Maximum Operating Differential...
  • Page 14 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Setup of Valve Proving and Post 7. To get to the next screen, press the down arrow. “Get- ting Data” will be displayed, then the following Purge Functions screen. Prior to setup of the Valve Proving and Post Purge...
  • Page 15: Install Postpurge

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Press ENTER when correct time is displayed. Edit: M22665B Edit: Fig. 16. Save Changes screen. M22665B 15. Use the down arrow to save changes. “Getting Data” Fig. 13. Save Changes screen. is displayed momentarily.
  • Page 16 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES The Release Reset screen will appear on the KDM. Edit: M22671B Edit: M22765B Fig. 20. Confirm Correct screen. Fig. 24. Release Reset screen. 19. Use the down arrow to confirm correct. “Getting Data” will be displayed.
  • Page 17: Principal Technical Features

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES PRINCIPAL TECHNICAL h. Purge card is removed. Purge card is bad. FEATURES 6. RUN PERIOD a. No flame present (JR2 removed). b. Airflow lockout feature is enabled and the airflow The RM7898 provides all customary flame safeguard switch opens.
  • Page 18: Ignition Trials

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Pre-Purge a. When this main flame establishing period begins: The RM7898 Relay Module provides PREPURGE timing, (1) Ignition, Main Valve 1, and Main Valve 2 ter- selectable with ST7800 Purge Timer cards, from two...
  • Page 19: Settings And Adjustments

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Q7800A1005 (plastic panel mount version) 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...
  • Page 20: Troubleshooting

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 8. Site-configurable jumper options. RUN/TEST SELECTABLE Jumper SWITCH CONFIGURATION JUMPERS Number Description Intact Clipped Pilot Flame Establishing Period (PFEP) seconds seconds Flame Fail Recycle Lockout Interlock Recycle Lockout TROUBLESHOOTING The POWER LED provides fault identification when the Relay Module locks out on an alarm.
  • Page 21 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 9. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code System Failure Recommended Troubleshooting Code 2-3 Flame signal value is 1. Make sure the flame detector and flame amplifier are compatible.
  • Page 22 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 9. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code System Failure Recommended Troubleshooting Code 4-3 Flame not sensed, or 1. Check wiring; correct any errors. *Flame sensed when it should 2.
  • Page 23: Appendix A: Valve Proving Test

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES APPENDIX A: VALVE PROVING The following steps are to determine the test time for the Relay Module to verify the valve seats are not leaking at a TEST rate of greater than/equal to 0.1% of the burner capacity.
  • Page 24 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES NOTE: 10 seconds is the minimum test time allowed. If your We have a 2.5 MBTU burner with 2 psi valve train inlet calculations are less than 10 seconds, enter 10 pressure. The upstream valve is a proof-of-closure V5044 seconds.
  • Page 25: Appendix B - Ignition Options

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 14. Schedule 40 Pipe Internal Cross-Sectional Area. Cross-Sectional Area (Sq. In.) Pipe Size NPT (Inches) “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 15. VPS Worksheet.
  • Page 26 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 16. Ignition options. (Continued) DRAWING I.D. FUEL CHANGEOVER POLES IGNITION OPTIONS CODE REQUIRED NO VALVE PROVING Direct Spark Ignition Intermittent Pilot Direct Spark Ignition Direct Spark Ignition VALVE PROVING Single Fuel 10 Sec.
  • Page 27 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES T18 DSI-VP SEL. NO VP LIMITS CONTROL T19 (IP SEL.) CONTROL LIMITS (IP SEL.) INTERLOCKS INTERLOCKS IF EA IS USED THEN A. SINGLE FUEL: 10 SECOND INTERRUPTED PILOT INTERLOCKS GAS/OIL SWITCHING IS ALSO NEEDED HERE.
  • Page 28 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES LIMITS CONTROL LIMITS CONTROL (IP SEL.) (IP SEL.) T18 DSI- VP SEL. INTERLOCKS INTERLOCKS IF EA IS USED THEN GAS/OIL SWITCHING IS INTERLOCKS IF EA IS USED THEN ALSO NEEDED HERE. INTERLOCKS...
  • Page 29 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES LIMITS CONTROL (IP SEL.) T18 DSI- CONTROL LIMITS VP SEL. (IP SEL.) DSI-VP SEL. INTERLOCKS INTERLOCKS IF EA IS USED THEN INTERLOCKS REQUIRED WIRING IF VALVE PROVING GAS/OIL SWITCHING IS BOTH, SPLIT, OR AFTER IS SELECTED ALSO NEEDED HERE.
  • Page 30 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES LIMITS CONTROL LIMITS CONTROL (IP SEL.) (IP SEL.) DSI-VP SEL. DSI-VP SEL. INTERLOCKS INTERLOCKS IF EA IS USED THEN IF EA IS USED THEN INTERLOCKS INTERLOCKS GAS/OIL SWITCHING IS GAS/OIL SWITCHING IS ALSO NEEDED HERE.
  • Page 31: Safety And Security

    RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES SAFETY AND SECURITY LIMITS CONTROL Physical device protection T18 DSI- Device shall be accessible to authorized personnel only – VP SEL. Installation on publicly accessible places is not (IP SEL.) recommended as this could lead to unwanted and...
  • Page 32 RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES 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.