Installation Manual
Installation Manual
Installation Manual
RM7890A1056
MV1 MV2
RM7890B1048
RM7890A2056
RM7890B2048 VP
SW.
RM7890A/B Relay Modules offer the following additional
features: INLET OUTLET
SIL3
Capable 32-00205-01
RM7890A/B 7800 SERIES RELAY MODULES
SIL 3 Capable:
MV1—Wired to terminal 9. It is located at the most SIL 3 Capable in a properly designed Safety Instrumented
upstream position of the main gas valve train. System. See form number 65-0312 for Certificate
VPS—Valve Proving Switch (Rated 1/2 of main valve inlet Agreement.
pressure.
Approvals:
MV2—Wired to terminal 17. It is the main valve located
RM7890A,B:
closest to the burner.
Underwriters Laboratories Inc. Listed: File No. MP268,
The Proof of Closure Switch (or PII—Preignition Interlock)
Guide No. MCCZ.
for terminal 20 can be installed on MV1, MV2, or both
Factory Mutual Approved: Report No. J.I.1V9A0.AF.
valves.
Swiss RE (Formerly IR) : Acceptable.
Explosion Hazard.
Federal Communications Commission: Part 15, Class
Can cause severe injury, death or property damage.
B, Emissions.
Be sure to select adequate testing times when the Valve
EAC: TC N RU д-US.Aи3O.B.04013.
Proving feature is enabled. A shorter time can result in
inadequate leak testing of the valves.
This document provides installation and static checkout
instructions. Other applicable publications are: INSTALLATION
Form
Number Description When Installing this Product...
32-0110 S7800A2142 4-line LCD Keyboard Display 1. Read these instructions carefully. Failure to follow
Module Product Data them could damage the product or cause a
32-0166 204729A/C KDM NEMA4 Covers for 4-line LCD hazardous condition.
KDM 2. Check the ratings given in the instructions and
marked on the product to make sure the product is
65-0084 Q7800A,B 22-Terminal Wiring Subbase suitable for the application.
Product Data
3. Installer must be a trained, experienced, flame
65-0091 S7810A Data ControlBus Module™ Product safeguard service technician.
Data 4. After installation is complete, check out the product
65-0095 S7820 Remote Reset Module Product Data operation as provided in these instructions.
65-0097 221729C Dust Cover Packing Sheet
65-0109 R7824, R7847, R7848, R7849, R7851, R7861,
R7886 Flame Amplifiers for the 7800 SERIES WARNING
Product Data Fire or Explosion Hazard.
Can cause property damage, serious injury, or
65-0131 221818A Extension Cable Assembly Product death.
Data To prevent possible hazardous burner operation,
65-0288 S7800A1142 Keyboard Display Module verify safety requirements each time a control is
Product Data installed on a burner.
65-0229 7800 SERIES Relay Modules Checkout and
Troubleshooting
65-0249 S7810M ModBus Module WARNING
Electrical Shock Hazard.
65-0295 50023821-001/2 NEMA4 Covers for 2-line Can cause personal injury, death or equipment
Keyboard Display Module damage.
Disconnect the power supply before beginning
installation.
SPECIFICATIONS
IMPORTANT
Electrical Ratings (See Table 3): 1. Wiring connections for the relay modules are
Voltage and Frequency: unique; refer to Fig. 3 or the appropriate Specifica-
RM7890: 120 Vac (+10/-15%), 50/60 Hz (±10%). tions for individual subbase wiring.
Power Dissipation: 10W maximum. 2. Wiring must comply with all applicable codes,
Maximum Total Connected Load: 2000 VA. ordinances and regulations.
Fusing Total Connected Load: 15A maximum, type SC 3. Wiring must comply with NEC Class 1 (Line Volt-
or equivalent, fast blow. age) wiring.
4. Loads connected to the RM7890 must not exceed
Environmental Ratings: those listed on the RM7890 label or the
Ambient Temperature: Specifications; see Tables 3, 4, and 5.
Operating: -40°F to +140°F (-40°C to +60°C). 5. Limits and interlocks must be rated to simultane-
Storage: -40°F to +150°F (-40°C to +66°C). ously carry and break current to the ignition trans-
Humidity: 85% relative humidity continuous, noncon- former, pilot valve, and main fuel valve(s).
densing. 6. All external timers must be listed or component-
Vibration: 0.5G environment. recognized by authorities who have proper
jurisdiction.
32-00205—01 2
RM7890A/B 7800 SERIES RELAY MODULES
7. For on-off gas-fired systems, some authorities 3. For surface mounting, use the back of the subbase
who have jurisdiction prohibit the wiring of any as a template to mark the four screw locations. Drill
limit or operating contacts in series between the the pilot holes.
flame safeguard control and the main fuel valve(s). 4. Securely mount the subbase using four no. 6 screws
8. Two flame detectors can be connected in parallel (not provided).
with the exception of Infrared Flame Detectors
(C7915) and solid state models C7927, C7952,
and C7961.
Relay Module and Subbase
9. This equipment generates, uses and can radiate Compatibility
radio frequency energy and, if not installed and
used in accordance with the instructions, can NOTE: There are several different subbase models that
cause interference with radio communications. It can be purchased. It is important to note which
has been tested and found to comply with the subbase is compatible with the relay module
limits for a Class B computing device of Part 15 of when purchasing new, repair or replacement
FCC rules which are designed to provide parts.
reasonable protection against such interference
when operated in a commercial environment. Series 1000 Relay Modules
Operation of this equipment in a residential area
can cause interference, in which case, the users, at All relay product codes that start with a 1 (example:
their own expense, may be required to take RM7840G1014/U) can be used with existing subbase
whatever measures are required to correct this Q7800A1003/U and Q7800A1005/U.
interference.
10.This digital apparatus does not exceed the Class B Series 2000 Relay Modules
limits for radio noise for digital apparatus set out All relay product codes that start with a 2 (example:
in the Radio Interference Regulations of the Cana- RM7840G2014/U) must be used with subbase
dian Department of Communications. Q7800A2003/U and Q7800A2005/U.
3 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
5. If you attempt to place a 2000 series relay on a non- 6. For KDM: Because the KDM is powered from a low
compatible 1000 series subbase, you will receive an voltage, energy limited source, it can be mounted
error code of 101. This indicates that you must a) outside of a control panel if it is protected from
change out the subbase to a Q7800A2003/U or mechanical damage.
Q7800A2005/U or b) choose a compatible 1000
series relay module. NOTE: Use 13 Vdc power supply any time more than two
KDM or Data ControlBus Modules™ are used or
are placed more than 100 feet (31 meters) from
Wiring the relay module.
32-00205—01 4
RM7890A/B 7800 SERIES RELAY MODULES
5 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
A B C D F
4.5A ignition 50 VA Pilot Duty 180 VA ignition plus 2A Pilot Duty. 65 VA Pilot Duty plus
plus 4.5A motor valves with: 660 motor valves with: 3850 VA
ignition. VA inrush, 360 VA open, inrush, 700 VA Open, 250
250 VA hold. VA hold.
General Instructions
WARNING 1. Perform all applicable tests listed in the Static
Explosion Hazard. Checkout, Table 6, in the order listed.
Can cause serious injury, death or equipment 2. Make sure all manual fuel shutoff valves are closed.
damage. 3. For each test, open the master switch and install the
1. Close all manual fuel shutoff valve(s) before jumper wires between the subbase wiring terminals
starting these tests. listed in the Test Jumpers column.
2. Use extreme care while testing the system. Line 4. Close the master switch before observing the opera-
voltage is present on most terminal connections tion.
when power is on. 5. Read the voltage between the subbase wiring termi-
3. Open the master switch before installing or nals listed in the Voltmeter column.
removing a jumper on the subbase. 6. If there is no voltage or the operation is abnormal,
4. Before continuing to the next test, be sure to check the circuits and external devices as described
remove test jumper(s) used in the previous test. in the last column.
5. Replace all limits and interlocks that are not 7. Check all wiring for proper connections, tight termi-
operating properly. Do not bypass limits and nal screws, and appropriate wire and wiring tech-
interlocks. niques.
8. Replace all damaged or incorrectly sized wires.
32-00205—01 6
RM7890A/B 7800 SERIES RELAY MODULES
7 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
L1 L2
(HOT) 2
3 L2
1 CONFIGURATION TEST
JUMPERS FLAME SIGNAL JACK
F
PLUG-IN
MICROCOMPUTER FLAME G
RESET TEST AMPLIFIER
PUSH-
BUTTON 22
RELAY 2K
DRIVE
CIRCUIT 3K RELAY
STATUS
4K FEEDBACK
AND LINE
VOLTAGE
SAFETY RELAY 1K INPUTS
CIRCUIT
STATUS LEDs
POWER SUPPLY CONTROL
POWER
LIMITS CONTROLLER
1K1 2K2 5K1
6 10 IGNITION
3 4K1
7 8 PILOT
2K2
LIMIT 9 MAIN
3K1 INPUT VALVE 1
4 ALARM
7K
OPTIONAL KEYBOARD 17 MAIN
DISPLAY MODULE VALVE 2
RS485
DDL
1 INDICATES FEEDBACK SENSING
DDL 2 TO RELAY STATUS FEEDBACK
COMMUNICATIONS 3 REMOTE
AND LINE VOLT INPUTS
RESET
VALVE FIELD WIRING
PROVING SWITCH INTERNAL WIRING
16
M23030A
Mounting RM7890 Relay Module 3. Make sure no subbase wiring is projecting beyond
the terminal blocks. Tuck in wiring against the back
1. Mount the RM7890 vertically on the Q7800 of the subbase so it does not interfere with the knife
Subbase, or mount horizontally with the knife blade blade terminals or bifurcated contacts.
terminals pointing down. When mounted on the
Q7800A, the RM7890 must be in an electrical NOTE:
enclosure.
2. When mounting in an electrical enclosure, provide IMPORTANT
adequate clearance for servicing, installation and Install the RM7890 with a plug-in motion rather
removal of the RM7890, KDM, flame amplifier, flame than a hinge action.
amplifier signal voltage probes, electrical signal
4. Mount the RM7890 by aligning the four L-shaped
voltage probes, and electrical connections.
corner guides and knife blade terminals with the
a. Allow an additional two inches (51 mm) below
bifurcated contacts on the wiring subbase and
the RM7890 for flame amplifier mounting.
securely tightening the two screws without
b. Allow an optional three-inch (76 mm) minimum
deforming the plastic.
to both sides of the RM7890 for electrical signal
5. Mount the RM7890 by aligning the four L-shaped
voltage probes.
corner guides and knife blade terminals with the
bifurcated contacts on the wiring subbase and
securely tightening the two screws without deform-
ing the plastic.
32-00205—01 8
RM7890A/B 7800 SERIES RELAY MODULES
Q7800
3
G 12
L2 13
L1
(HOT)
L2 3 (L1) 14
1
MASTER
SWITCH LINE VOLTAGE 4 15
ALARM
VALVE PROVING
5 16 SWITCH
2
BURNER MAIN FUEL
6 17 VALVE 2
CONTROLLER/LIMITS
7 18
INTERMITTENT
PILOT/IGNITION 8 19
IGNITION 10 21
4
FLAME DETECTOR F 5 22
00 00 4/10 20
LED SAFE- PFEP
INITIATE STANDBY START 4 OR 10 SEC MFEP RUN STANDBY
DISPLAY
POWER POWER POWER POWER POWER POWER POWER
PILOT PILOT PILOT
FLAME FLAME FLAME
MAIN MAIN MAIN
ALARM ALARM ALARM
BURNER IGNITION 10
START 6
INTERMITTENT PILOT 8
MAIN VALVE 9
OPERATING
CONTROLLER
AND LIMITS LIMITS AND BURNER CONTROL CLOSED 3 TO 6
FLAME
SIGNAL SAFE START CHECK FLAME PROVING SSC
PREIGNITION INTERLOCK (PII) 20 PII
1 120V, 50/60 HZ POWER SUPPLY. 3 DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
AS REQUIRED. 4 TERMINAL 22 IS ONLY ON THE RM7890B.
2 TERMINAL 7 MUST BE POWERED. IF VALVE PROVING OPTION IS 5 SEE FLAME DETECTOR SPECIFICATION FOR CORRECT WIRING.
“NEVER” OR “BEFORE”, A JUMPER BETWEEN SUBBASE TERMINALS
6 AND 7 MAY BE INSTALLED. IF SPLIT, BOTH OR AFTER OPTION IS 6 TERMINAL 8 TURNS OFF IF JR3 IS CLIPPED.
USED, TERMINAL 7 SHOULD GET POWER FROM L1, CHECK LOCAL
CODES REGARDING PLACEMENT OF LIMITS IN SERIES WITH THIS
CONNECTION. M23031B
9 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
Q7800A1005
(plastic panel mount
subbase version)
HONEYWELL
RELAY
MODULE
CONFIGURATION
JUMPERS
SEQUENCE
STATUS
LED PANEL
POWER
RESET PILOT
BUTTON MAIN
FLAME
ALARM
CAPTIVE
RESET
MOUNTING
DUST SCREW
COVER
BURNER CONTRO
L FLAME
AMPLIFIER
M11588B
VALVE PROVING SYSTEM After—Valve Proving occurs after the Run state before
the internal Safety Relay dropout state.
The Valve Proving System feature provides a systematic Both—Valve proving occurs at both times Before and
way of testing the valve seat integrity to assure the valves After noted above.
are in the closed state whenever the sequence of
operation required them to be closed. It is designed to Split—The downstream (high pressure) seat test is
detect a leak greater than 0.1% of the burner input performed at the Before time and the upstream (low
capacity. For example, a 10 million Btu/hr natural gas pressure) seat test is performed during the After time.
fueled burner would have a fuel capacity of approximately
1000 ft3/hr. A leak rate greater than 0.1% of 1000 ft3/hr The Valve Proving items programmed:
or 1 ft3/hr in either valve will be detected with the Valve
Proving System. Smaller leaks will not be detected. 1. Enable Valve proving and when to perform it.
2. Define the time duration of the test is calculated
At commissioning time, the Valve Proving System may be using Appendix A.
scheduled to occur at one of five different times: Never,
Before, After, Both, and Split.
Valve Proving Function
Never—Device Fault as received: in this case Valve
Proving does not occur. Valve proving consists of monitoring the pressure in the
space between two shutoff valves, MV1 (upstream) and
Before—Valve Proving occurs after Standby and Safe MV2 (downstream). The valve proving function, identified
Start Check, but before Run. by letters A through G, operates as follows:
32-00205—01 10
RM7890A/B 7800 SERIES RELAY MODULES
The following are steps performed during valve proving E. MV1 is commanded to be open, while MV2 remains
tests. This section is for background information and does closed, to pressurize the space. After four seconds, MV1
not define the exact behavioral requirements. is commanded closed again.
A. The RM7890 must have an input on terminal 7 (to F. This is followed by a three second delay, during which
power the valves for testing). If the Valve Proving Test is the valve proving pressure switch (VPS) is ignored.
conducted After, Both or Split, terminal 7 must be
powered from the L1 source. G. Thereafter, the VPS is monitored for the duration of
the valve proving test time and, if it turns off, a lockout
B. MV2 is commanded to be open while MV1 remains occurs. (Because the gas pressure has decreased due
closed; to depressurize the space. After four seconds, to a leaky downstream valve [high pressure test].)
MV2 is commanded closed again.
Pressure Switches for Valve Proving
C. This is followed by a three second delay during which
the valve proving pressure switch (VPS) is ignored. System
The Valve Proving System requires a pressure switch to be
D. Thereafter, the VPS is monitored for the duration of installed to monitor the pressure in the internal space
the valve proving test time and, if it turns on, a lockout between the two shutoff valves. Recommended pressure
occurs. (Because the gas pressure has increased due to switches are the following Honeywell non-manual reset
a leaky upstream valve [low pressure test].) models:
11 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
1. Scroll down until the “Setup” is displayed in the sec- NOTE: This screen sets up when to do the Valve Proving
ond line. (Setup is only available when the control is Test.
in Standby or Lockout state.)
8. Use the up/down arrows to select from Never,
Before, After, Both, or Split, then press ENTER.
M22662B
M22665B
STANDBY SU
Fig. 10. Save Changes screen.
± BC Password: 00
9. Use the down arrow to save changes. After pressing
BACK
the down arrow, “Getting Data” is displayed.
Edit: - + ENTER
M22663B
SETUP: ValveProve SU
Fig. 7. Password screen. ±VP Time: 00:00
3. Use the up/down arrows to enter the first number—7.
4. Use the far right key to shift over one space. BACK
5. Use the up/down arrows to enter the second number Edit: - + ENTER
8.
M22666B
6. Press ENTER (left/right arrow simultaneously).
Fig. 11. Valve Prove time screen.
This screen sets up how long the RM7890 will conduct the
=Select Valve Proving Test for a given time. VP Time: 00:30 is
=Restart shown.
SETUP: ValveProve SU
± VP When: BEFORE
=Save changes
BACK =Restart
Edit: - + ENTER
BACK
M22664B
Edit: - + ENTER
32-00205—01 12
RM7890A/B 7800 SERIES RELAY MODULES
11. Use the down arrow to save changes. After pressing 15. Press ENTER.
the down arrow, “Getting Data” is displayed.
12. Use down arrow to save changes.
“Getting Data” is displayed.
=Confirm correct
The following steps are to confirm your selections. =Incorrect
BACK
Edit: - + ENTER
CONFIRM:ValvProve SC
M22671B
±VP When: BEFORE ?
Fig. 16. Confirm Correct screen.
BACK
Edit: - + ENTER
16. Use the down arrow to confirm correct.
“Getting Data” will be displayed.
M22670B
13. Press ENTER. The Valve Proving test location is SETUP DONE: Press
shown. Reset for 5 sec . . .
BACK
Edit: - + ENTER
=Confirm correct
=Incorrect M22676B
M22765B
13 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
BEFORE
4 SEC. 3 SEC. TEST TIME 4 SEC. 3 SEC. TEST TIME IGNITION TRIALS
CONTROLLER
L1-6
L1-7
MV2 (17)
MV1 (9)
VPS (16) 1 VPS (16) 2
PII (20) PII (20) PII (20)
AFTER
RUN 4 SEC. 3 SEC. TEST TIME 4 SEC. 3 SEC. TEST TIME STANDBY
CONTROLLER
L1-6
L1-7
MV2 (17) MV1 (9)
VPS (16) 1 VPS (16) 2
PII (20) PII (20)
SPLIT
STANDBY 4 SEC. 3 SEC. TEST TIME BURNER RUN TIME 4 SEC. 3 SEC. TEST TIME STANDBY
CONTROLLER
L1-6
L1-7
MV1 (9) MV2 (17)
VPS (16) 2 VPS (16) 1
PII (20) PII (20)
32-00205—01 14
RM7890A/B 7800 SERIES RELAY MODULES
SERVICE NOTE
Standby Clipping and removing a site-configurable jumper
The RM7890 is ready to start an operating sequence when enhances the level of safety. If using three-second
the operating control input (terminal 6) recognizes a call amplifier,
for heat. The burner switch, limits, operating limit control site-configurable jumper JR2 must be clipped and
and all microcomputer monitored circuits must be in the removed. If not removed, an F46 Lockout occurs.
correct state for the RM7890 to continue into the Safe
Start Check. The RM7890 must also have an input on
terminal 7.
SELECTABLE CONFIGURATION JUMPERS
Ignition Trials
a. Pilot Flame Establishing Period (PFEP):
(1) The pilot valve and ignition transformer,
terminals 8 and 10, are energized. The
RM7890 has an intermittent pilot valve,
M22777A
terminal 8. (Interrupted if JR3 is removed).
(2) Flame must be proven by the end of the four-
or ten-second PFEP or a safety shutdown Fig. 20. Selectable site-configurable jumpers.
occurs.
Table 8. Site-Configurable Jumper Options.
(3) Once flame is proven:
(a)Intermittent—the ignition, terminal 10, is Jumper
de-energized and the main valves, terminal Number Description Intact Clippedb
9 and 17, are energized.
JR1 Pilot Flame 10 4 seconds
(b)Interrupted—at the end of the timed PFEP, Establishing Period seconds
terminal 10 is de-energized and the main (PFEP)
Valve 1 (terminal 9) and main valve 2
(terminal 17) are energized. After a 10- JR2 Flame Failure Action Relighta Lockout
second Main Flame Establishing time, the JR3 Pilot Valve (T8) Intermitte Interrupted
Pilot Valve (terminal 8) is de-energized. nt
a The Relight feature (JR2 intact) requires a 0.8 second
Run
FFRT Flame Amplifier. The RM7890 locks out and indi-
The RM7890 is now in RUN and remains in RUN until the cates a Fault 46 if a 3 second FFRT is used and jumper
controller input, terminal 6, opens, indicating that the JR2 is not clipped and removed.
demand is satisfied or a limit has opened. bClipping and removing a site-configurable jumper after
The Pre-Ignition Interlock must close five seconds after 200 hours of operation results in a hard lockout, code
terminal 6 opens. (It is ignored during Valve-On time in the 110.
Valve Proving Sequence if After, Split, or Both option is
chosen for Valve Proving tests.) Pre-Ignition Interlock
input is required five seconds after the valve output is de-
energized.
15 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
SYSTEM CHECKOUT 1. Make sure all manual fuel shutoff valve(s) are closed
before starting initial lightoff check and Pilot Turn-
down tests.
IMPORTANT 2. Do not put the system into service until you have
Perform Static Checkout Procedures before start- satisfactorily completed all applicable tests in this
ing these procedures. section and any others recommended by the original
equipment manufacturer.
3. Limit trial for pilot to ten seconds. Limit the attempt
WARNING to light main burner to two seconds after fuel
Explosion Hazard. reaches the burner nozzle. Do not exceed manufac-
Can cause severe injury, death or property turer nominal lightoff time.
damage.
1. Do not allow fuel to accumulate in the IMPORTANT
combustion chamber for longer than a few 1. If the system fails to perform properly, note the
seconds without igniting to prevent danger of fault code, fault message, equipment status, and
forming an explosive mixture. sequence time on the display. Then refer to the
2. Close manual fuel shutoff valve(s) if flame is not Troubleshooting section.
burning at the end of the specified time. 2. Repeat all required Checkout tests after all
adjustments are made. All tests must be satisfied
with the flame detector(s) in their final positions.
WARNING Equipment Recommended
Electrical Shock Hazard.
Can cause severe injury, death or property
1. S7800 Keyboard Display Module
damage.
2. Volt-ohmmeter (1 Megohm/volt minimum sensitiv-
1. Use extreme care when testing system. Line
ity) with:
voltage is present on most terminal connections
a. 0-300 Vac capability.
when power is on.
b. 0-6000 ohm capability.
2. Open the master switch before removing or
c. 0-10 Vdc capability.
installing the 7800 SERIES Relay Module or
Keyboard Display Module connector.
Checkout Summary
Table 8 provides an overview of checkout steps performed
for each applicable system.
32-00205—01 16
RM7890A/B 7800 SERIES RELAY MODULES
1. Wiring connections are correct and all terminal a. Open the master switch and remove the 7800
screws are tight. SERIES Relay Module from the subbase.
2. Flame detector(s) is (are) clean, installed and b. On the subbase, jumper L1 to the ignition termi-
positioned properly. Consult the applicable nal; refer to the appropriate wiring diagram to
instructions. determine the proper terminal. Disconnect the
3. Combination of amplifier and flame detector(s) is leadwire to the pilot valve if it is connected to the
correctly used. See the amplifier specifications. same terminal.
4. Burner is completely installed and ready to fire; con- c. Close the master switch to energize only the igni-
sult equipment manufacturer instructions. tion transformer.
5. Fuel lines are purged of air. d. If the ignition spark is not strong and continuous,
6. Combustion chamber and flues are clear of fuel and open the master switch and adjust the ignition
fuel vapor. electrode spark gap setting to the manufacturer
7. Power is connected to the system disconnect switch recommendation. \
(master switch). e. Make sure the ignition electrodes are clean.
8. Lockout is reset (reset button) only if the Relay Mod- f. Close the master switch and observe the spark.
ule is powered. g. After a continuous spark is obtained, open the
9. Run/Test Switch (if present) is in the RUN position. master switch and add a jumper on the subbase
10. System is in STANDBY condition. STANDBY message from terminal L1 power to the pilot terminal 8.
is displayed in the S7800 Keyboard Display Module. Reconnect the leadwire from the pilot valve if it
11. All limits and interlocks are reset. was disconnected in step b.
h. Close the master switch to energize both the
ignition transformer and the pilot valve.
Flame Signal Measurement i. If the pilot does not ignite and if the ignition
See instructions provided with the amplifier. spark is still continuous, adjust the pressure reg-
ulator until a pilot is established.
j. When the pilot ignites properly and stays ignited,
INITIAL LIGHTOFF CHECKS open the master switch and remove the
jumper(s) from the terminals of the subbase.
k. Check for adequate bleeding of the fuel line.
Proved Pilot Systems l. Reinstall the 7800 SERIES Relay Module on the
subbase, close the master switch and return to
Perform this check on all installations that use a pilot. It step 4.
should immediately follow the preliminary inspection. 7. When the pilot ignites, measure the flame signal. If
Low fuel pressure limits, if used, could be open. If so, the pilot flame signal is unsteady or approaching the
bypass them with jumpers during this check. 1.25 Vdc minimum value, adjust the pilot flame size
or detector sighting to provide a maximum and
1. Open the master switch. steady flame signal.
2. Make sure the manual main fuel shutoff valve(s) 8. Recycle the system to recheck lightoff and pilot
is(are) closed. Open the manual pilot shutoff valve. If flame signal.
the pilot takeoff is downstream from the manual 9. When the MAIN LED turns on, make sure the
main fuel valve(s), slightly open the main valve to automatic main fuel valve is open; then smoothly
supply pilot gas flow. Make sure the main fuel is shut open the manual main fuel shutoff valve(s) and
off just upstream from the burner inlet, or discon- watch for main burner flame ignition. When the main
nect power from the automatic main fuel valve(s). burner flame is established, go to step 16.
3. Close the master switch and start the system with a 10. If the main burner flame is not established within
call for heat by raising the setpoint of the operating five seconds or the normal lightoff time as specified
controller; see the relay module sequence. The 7800 by the equipment manufacturer, close the manual
SERIES Relay Module should start the INITIATE main fuel shutoff valve(s).
sequence. 11. Recycle the system to recheck the lightoff and pilot
4. Let the sequence advance to PILOT IGN (status is flame signal.
displayed on the Keyboard Display Module, if used). 12. Smoothly open the manual fuel shutoff valve(s) and
PILOT LED turns on, ignition spark should occur and try lightoff again. (The first re-attempt may have
the pilot should light. If the pilot ignites, the FLAME been required to purge the lines and bring sufficient
LED is energized. Go to step 7. fuel to the burner.)
5. If the pilot flame is not established in ten seconds 13. If the main burner flame is not established within
(four seconds if configuration jumper JR1 is five seconds or the normal lightoff time specified by
clipped), safety shutdown occurs. Let the sequence the equipment manufacturer, close the manual main
complete its cycle. fuel shutoff valve(s). Check all burner adjustments.
6. Push the reset pushbutton, and let the system recy- 14. If the main burner flame is not established after two
cle once. If the pilot still does not ignite, make the attempts:
following ignition/pilot adjustments: a. Check for improper pilot flame size.
b. Check for excess combustion air at low fire.
c. Check for adequate low fire fuel flow.
d. Check for proper gas supply pressure.
e. Check for proper valve operation.
f. Check for proper pilot flame positioning.
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RM7890A/B 7800 SERIES RELAY MODULES
15. Repeat steps 8 and 9 to establish the main burner NOTE: If the sequence does not stop, reset the system
flame; then go to step 16. and make sure you set the Run/Test Switch to
16. With the sequence in RUN, make burner adjust- TEST within the first eight seconds of the PILOT
ments for flame stability and Btu input rating. IGN sequence.
17. Shut down the system by opening the burner switch
or by; lowering the setpoint of the operating control- IMPORTANT
ler. You have 0.8 second or three seconds, depending
18. Restart the system by closing the burner switch on the PFEP selected, to position the Run/Test
and/or raising the setpoint of the operating control- Switch to the TEST position to stop the sequence
ler. Observe that the pilot is established during after the start of the PILOT IGN period.
PILOT IGN and the main burner flame is established
during MAIN IGN within the normal lightoff time. 7. Turn down the pilot pressure very slowly, reading the
19. Measure the flame signal. Continue to check for the manometer (or pressure gauge) as it drops. Stop
proper signal through the RUN period. Check the instantly when the FLAME LED goes out. Note the
signal at both High and Low Firing Rate positions pressure. The pilot is at the minimum turndown
and while modulating, if applicable. position. Immediately turn up the pilot pressure until
20. Run the burner through another sequence, observ- the FLAME LED comes on again or the flame signal
ing the flame signal for: increases to 1.25 Vdc.
a. Pilot flame alone. NOTE: If there is no flame for 15 seconds, with the
b. Pilot and main flame together. RUN/TEST Switch in the TEST position, the relay
c. Main flame alone (unless monitoring an inter- module locks out.
mittent pilot). Also, observe the time it takes to
light the main flame. Ignition of main flame 8. Repeat step 7 to verify the pilot gas pressure reading
should be smooth. at the exact point the FLAME LED goes out.
21. Make sure all readings are in the required ranges 9. Increase the pilot pressure immediately until the
before proceeding. FLAME LED comes on, and then turn it down slowly
22. Return the system to normal operation. to obtain a pressure reading just above the dropout
point or until the flame signal increases to 1.25 Vdc.
NOTE: After completing these tests, open the master 10. Set the Run/Test Switch in the RUN position (if used)
switch and remove all test jumpers from the and let the sequence proceed. When the MAIN LED
subbase terminals, limits/controls or switches. turns on, make sure the automatic main fuel valve(s)
opens; then smoothly open the manual main fuel
shutoff valve(s) (or any other manually-opened
PILOT TURNDOWN TEST (ALL safety shutoff valve(s), if used) and watch for main
INSTALLATIONS USING A burner ignition. If the main burner flame is estab-
lished, go to step 18.
PILOT) NOTE: This step requires two people, one to open the
manual valve(s) and one to watch for ignition.
Perform this test on all installations that use a pilot. The
purpose of this test is to verify that the main burner can be 11. If the main burner flame is not established within
lit by the smallest pilot flame that can hold in the flame five seconds, or within the normal lightoff time spec-
amplifier and energize the FLAME LED. Clean the flame ified by the equipment manufacturer, close the man-
detector(s) to make sure that it detects the smallest ual main fuel shutoff valve(s) and open the master
acceptable pilot flame. switch. If the lightoff is rough, the pilot flame size is
too small.
If using AMPLI-CHECK™ or self-checking amplifier and 12. Close the master switch to recycle the burner and
1M ohm/volt meter, the flame signal fluctuates every time stop the sequence in the PILOT period by using the
the amplifier does a self-check or a shutter check. Run/Test Switch.
NOTE: Low fuel pressure limits, if used, could be open. If 13. Increase the pilot flame size by increasing its fuel
so, bypass them with jumpers during this test. flow until a smooth main flame is accomplished.
14. Reposition the flame scanner sight tube or use ori-
1. Open the master switch. fices until the pilot flame signal voltage is in the
2. Close the manual main fuel shutoff valve(s). range of 1.25 to 1.50 Vdc.
3. Connect a manometer (or pressure gauge) to mea- 15. When the main burner lights reliable with the pilot at
sure pilot gas pressure during the turndown test. turndown, disconnect the manometer (or pressure
4. Open the manual pilot shutoff valve(s). gauge) and turn up the pilot gas flow to that
5. Close the master switch and start the system with a recommended by the equipment manufacturer.
call for heat. Raise the setpoint of the operating con- 16. If used, remove the bypass jumpers from the sub-
troller. The 7800 SERIES sequence should start, and base terminals, limits/controls, or switches.
PREPURGE, if applicable, should begin. 17. Run the system through another cycle to check for
6. After the PILOT LED turns on interrupted pilot normal operation.
applications, set the Run/Test Switch to the TEST 18. Return the system to normal operation.
position to stop the sequence. The FLAME LED
comes on when the pilot ignites.
32-00205—01 18
RM7890A/B 7800 SERIES RELAY MODULES
Detectors, Ultraviolet Detectors) 1. Close the pilot and main burner manual fuel shutoff
valve(s).
This condition can delay response to flame failure and 2. Start the burner and use the Run/Test Switch (if
also can prevent a system restart if hot refractory is available) to stop the sequence in the PILOT IGN
detected. period. Ignition spark should occur, but the flame
signal should not be more than 0.5 Vdc.
Infrared (lead sulfide) detectors can respond to infrared
3. If the flame signal is higher than 0.5 Vdc and the
rays emitted by a hot refractory, even when the refractory
FLAME LED does come on, consult the equipment
has visibly ceased to glow. Infrared radiation from a hot
operating manual and resight the detector farther
refractory is steady, but radiation from a flame has a
out from the spark, or away from possible refection.
flickering characteristic. The infrared detection system
It may be necessary to construct a barrier to block
responds only to flickering infrared radiation; it can reject
a steady signal from hot refractory. The refractory steady
19 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
the ignition spark from the detector view. Continue 1. Opening a Preignition Interlock during STANDBY.
adjustments until the flame signal due to ignition a. *Preignition ILK* fault is displayed on the
spark is less than 0.5 Vdc. Keyboard Display Module (KDM). Fault code 10
or 33 is displayed to denote the fault.
NOTE: The Honeywell Q624A and Q652A,B Solid State b. Safety shutdown occurs.
Spark Generators prevent detection of ignition 2. Detection of flame 40 seconds after entry to
spark when properly applied with C7027, STANDBY from RUN, fault code 9. Detection of flame
C7035,C7044 or C7061 Ultraviolet Flame Detec- from 10 seconds up to 30 seconds into PREPURGE
tors. The Q624A and Q652B are only for use with time.
gas pilots; the Q652A is only for oil applications. a. Simulate a flame to cause the flame signal volt-
age level to be at least 1.25 Vdc for 40 seconds
Response to Other Ultraviolet after entry to STANDBY from RUN.
b. *Flame Detected* fault is displayed on the
Sources Keyboard Display Module. Fault code 9 or 15 or
18 is displayed to denote the fault.
Some sources of artificial light (such as incandescent or
c. Safety shutdown occurs.
fluorescent bulbs, mercury sodium vapor lamps and
3. Failure to ignite pilot.
daylight) produce small amounts of ultraviolet radiation.
a. Close pilot and main fuel manual shutoff
Under certain conditions, an ultraviolet detector responds
valve(s).
to these sources as if sensing a flame. To check for proper
b. Cycle burner on.
detector operation, check the Flame Failure Response
c. Automatic pilot valve(s) should be energized but
Time (FFRT) and conduct Safety Shutdown Tests under all
the pilot cannot ignite.
operating conditions.
d. *Pilot Flame Fail* fault is displayed on the Key-
board Display Module. Fault code 28 is displayed
Flame Signal With Hot Combustion four or ten seconds, depending on the jumper
configuration selection for Pilot Flame Estab-
Chamber (All Installations) lishing Period (PFEP) after the pilot valve(s) is
1. With all initial start-up tests and burner adjustments energized to denote the fault.
completed, operate the burner until the combustion e. Safety shutdown occurs.
chamber is at the maximum expected temperature. 4. Failure to ignite main (only interrupted pilot applica-
2. Observe the equipment manufacturer warm-up tion).
instructions. a. Open the manual pilot valve(s); leave the main
3. Recycle the burner under these hot conditions and fuel manual shutoff valve(s) closed.
measure the flame signal. Check the pilot alone, the b. Depress the RESET button.
main burner flame alone, and both together (unless c. Start the system.
monitoring only the pilot flame when using an d. The pilot should ignite and the flame signal
intermittent pilot). Check the signal at both High should be at least 1.25 Vdc but the main burner
and Low Firing Rate positions and while modulating, cannot light.
if applicable. e. The flame signal should drop below 1.25 Vdc
4. Check the FFRT of the flame amplifier and relay within the FFRT of the amplifier and the relay
module. module after the interrupted pilot goes out.
5. Lower the setpoint of the operating controller and f. *Main Flame Ign.* fault is displayed on the
observe the time it takes for the burner flame to go Keyboard Display Module. Fault code 19 is
out. This should be within the maximum FFRT. displayed to denote the fault.
6. If the flame signal is too low or unsteady, check the g. Safety shutdown occurs.
flame detector temperature. Relocate the detector if 5. Loss of flame during RUN.
the temperature is too high. a. Open the main fuel manual shutoff valve(s) and
7. If necessary, realign the sighting to obtain the open manual pilot shutoff valve(s).
proper signal and response time. b. Depress the RESET button.
8. If the response time is still too slow, replace the c. Start the system. Start-up should be normal and
Plug-in Flame Signal Amplifier. the main burner should light normally.
9. If the detector is relocated or resighted, or the d. After the sequence is in the normal RUN period
amplifier is replaced, repeat all required Checkout for at least 10 seconds with the main burner
tests. firing, close the manual main shutoff valve(s) to
extinguish the main burner flame. (On
intermittent pilot applications, also, close the
SAFETY SHUTDOWN TESTS pilot manual shutoff valve[s].)
e. The flame signal should drop below 1.25 Vdc
(ALL INSTALLATIONS) within the FFRT of the amplifier and the relay
module after the main flame and/or pilot goes
Perform these tests at the end of Checkout, after all other out.
tests are completed. If used, the external alarm should f. *Main Flame Fail* fault is displayed on the Key-
turn on. Press the RESET push button on the relay module board Display Module. Fault code 17 is displayed
to restart the system. to denote the fault.
g. Safety shutdown occurs. (RM7890 Relay Mod-
ules will recycle if jumper JR2 is intact, then lock
out on failure to light the pilot.)
32-00205—01 20
RM7890A/B 7800 SERIES RELAY MODULES
6. Opening a Preignition Interlock after the first five Amplifier Type, Flame Failure Response Time, Selectable
seconds of STANDBY. Jumper Configuration Status, Run/Test Switch Status and
a. Open the main fuel manual shutoff valve(s) and Terminal Status.
open manual pilot shutoff valve(s).
b. Depress the RESET button.
c. *Preignition ILK* fault is displayed on the Key-
Diagnostic Information Index
board Display Module. Fault code 33 is displayed The relay module monitors input/output terminals and
to denote the fault. can display the status of the terminal at the KDM
d. Safety shutdown occurs. (example: Pilot Valve T8 1). See the applicable relay
module installation instructions for a complete terminal
IMPORTANT description and number. The display shows the actual
1. If the relay module fails to shut down on any of status of the terminal. If voltage is detected at the
these tests, take corrective action; refer to Trouble- terminal, 1 is displayed, but if no voltage is detected at the
shooting and the relay module diagnostic and terminal, 0 is displayed.
return to the beginning of all Checkout tests.
2. When all Checkout tests are completed, reset all
switches to the original status. Historical Information Index
The relay module has nonvolatile memory that allows the
relay module to retain historical information for the six
TROUBLESHOOTING most recent lockouts. Each of the six lockout files retains
the cycle when the fault occurred, the hour of operation
The POWER LED provides fault identification when the when the fault occurred, a fault code, a fault message and
Relay Module locks out on an alarm. Fault identification is burner status when the fault occurred.
a series of fast- and slow-blinking LED lights. The fast
blinks identify the tens portion of the fault code (three fast IMPORTANT
blinks is 30), while the slow blinks identify the units Some older relay modules cannot operate without
portion of the fault code (two slow blinks is 2). Three fast a KDM, extension cable assembly with KDM, or a
blinks followed by two slow blinks would be fault code 32. Data ControlBus™ Module installed.
(See Table 9 for Blinking Fault Code List.)
SERVICE NOTES:
The LED code repeats as long as the fault exists. To clear
the fault, press the RESET button. 1. If the KDM is scrambled, remove and reinstall the
KDM, and reset the 7800 SERIES Relay Module.
The S7800 KDM displays a sequence status message 2. Reset the 7800 SERIES Relay Module by pressing
indicating: STADBY, PURGE, PILOT IGN, MAIN IGN, RUN the RESET pushbutton on the 7800 SERIES Relay
and POSTPURGE. The selectable messages also provide Module, or by pressing a remote reset pushbutton
visual indication of current status and historical status of wired through the KDM, Data ControlBus™ Module,
the equipment, such as: Flame Signal, Total Cycles, Total or Remote Reset Module. A power-up reset causes
Hours, Fault History, Diagnostic Information, and an electrical reset of the relay module but does not
Expanded Annunciator terminal status (if used). With this reset a lockout condition.
information, most problems can be diagnosed without 3. Use the access slots in the sides of the Q7800A,B
extensive trial and error testing. Wiring Subbase to check terminal voltage.
4. Maximum ambient temperature of a
Diagnostic Information and History Data are available to C7012E,F;Series 1 through 6, is reduced to 125°F
assist in troubleshooting the relay module. because of the duty cycle operation of the relay
module.
The relay module provides diagnostic information to aid
the service mechanic in obtaining information when
troubleshooting the system. Information available in the
Diagnostic Information includes Device Type, Device
Suffix, Software Revision, Manufacturing Code, Flame
21 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
Code 2-3 Flame signal value is 1. Make sure the flame detector and flame amplifier are compatible.
*Flame Signal too high to be valid. 2. Remove the flame amplifier and inspect its connections. Reset the flame
Overrange* amplifier.
3. Reset and sequence the relay module.
4. Check the flame detector sighting position; reset and recycle. Measure
flame strength. Verify that it meets specifications. If not, refer to the flame
detector and/or flame amplifier checkout procedures in the installation
instructions.
5. If the code reappears, replace the flame amplifier and/or the flame detec-
tor.
6. If the fault persists, replace the relay module.
Code 3-1 Running or Lockout 1. Check wiring; correct any errors.
*Running/Inte Interlock fault during 2. Inspect the fan; make sure there is no air intake blockage and that it is
rlock Switch Prepurge. supplying air.
Problem* 3. Make sure the Lockout Interlock switches are functioning properly and
the contacts are free from contaminants.
4. Reset and sequence the relay module to Prepurge (place the TEST/RUN
Switch in the TEST position, if available). Measure the voltage between
terminal 7 and G (ground); 120 Vac should be present. Switch TEST/RUN
back to RUN.
5. If steps 1 through 4 are correct and the fault persists, replace the relay
module.
32-00205—01 22
RM7890A/B 7800 SERIES RELAY MODULES
23 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
32-00205—01 24
RM7890A/B 7800 SERIES RELAY MODULES
APPENDIX A
Valve Proving Test
The Valve Proving System feature offers a systematic
way of testing the valve seat integrity to assure the valves
are in the closed position when the system is off-line, in
WARNING
Explosion Hazard.
STANDBY. Can cause severe injury, death or property
The following steps are to determine the test time for the damage.
relay module to verify the valve seats are not leaking at a Be sure to select adequate testing times when the
rate of greater than/equal to 0.1% of the burner capacity. Valve Proving feature is selected. A shorter time
can result in inadequate leak testing of the valves.
The following diagram shows a typical valve train. The
legend identifies information that will be used to fill out
the worksheet that appears at the end of this appendix.
V1 V2
VP
D SW.
P
INLET OUTLET
L
C
X
LEGEND
V1 UPSTREAM VALVE
V2 DOWNSTREAM VALVE
D PIPE DIAMETER (IN INCHES.) USED TO DETERMINE A;
ARE FOUND IN TABLE III
L PIPE LENGTH (IN FEET)
P VALVE INLET PRESSURE (PSIG)
C BURNER MAX. FIRING (CFH)
X CALCULATED TEST VALVE TRAIN VOLUME M22778
1. Identify items of your system and fill in the “Informa- Table 11. Valve Proving Test Time Symbols
tion” portion of the worksheet. and Descriptions.
2. Go to the Lookup Tables noted (13, 14, or 15) to get
the results for your system. Symbol Unit Description
X ft3 Volume between the two valves to be
IMPORTANT tested.
The tables show information on Honeywell Valves
V1 ft3 Volume of upstream valve outlet
only. Contact other valve manufacturers to obtain cavity.
data on their specific valves.
V2 ft3 Volume of downstream valve inlet
3. Use appropriate Results column items to fill in the cavity.
Valve Train Volume Formula and the Calculation of L ft Length of pipe between valves.
Valve Proving Test Time.
4. Round up the time to the nearest second. D npt Pipe Size—used to define A
5. The test time calculated is the time you will enter A in.2 Pipe Cross Section Area (from Table III)
into the VPS Setup.
Test Second Minimum VPS test period.
Time s
Calculation of Valve Train Volume P psi Gas inlet pressure to upstream valve.
X = V1 + V2 + (A X L/144) C Burner Capacity.
ft3/hr
Calculation of Valve Proving Test NOTE: V1 is the outlet cavity of the upstream valve and
V2 is the inlet cavity of the downstream valve.
Time
Test Time = 187,000 x (P x X)/C NOTE: 10 seconds is the minimum test time allowed. If
your calculations are less than 10 seconds, enter
10 seconds.
25 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES
32-00205—01 26
RM7890A/B 7800 SERIES RELAY MODULES
27 32-00205—01
RM7890A/B 7800 SERIES RELAY MODULES