RM7890A1056

RM7890A1056, RM7890B1048
7800 SERIES Relay Modules

INSTALLATION INSTRUCTIONS
APPLICATION The following assumptions apply when using the

RM7890A1056 or RM7890B1048 Valve Proving testing:
The Honeywell RM7890A1056 and RM7890B1048 Relay

Modules are microprocessor based integrated burner controls MV1 MV2
for automatically fired, gas only (if Valve Proving feature is
going to be used), single burner on/off applications. The
RM7890A1056 and RM7890B1048 System consists of a relay VP
SW.
module, subbase, and amplifier. Options include keyboard
display module (KDM) and remote display mounting.
INLET OUTLET
Functions the RM7890 provides include automatic on/off

burner sequencing, flame supervision, system status
indication, system or self-diagnostics and troubleshooting. 1
RM7890A1056 and RM7890B1046 Relay Modules offer the 1 CAUTION: VALVE ENERGIZING TIMING IS BASED ON VALVE OPENING
following additional features: TIMES OF 13 SECONDS MAXIMUM.
− FOR VALVES WITH TIMINGS GREATER THAN 13
SECONDS - A BYPASS SOLENOID (RATED AS A SAFETY
• Preignition Interlock Input SHUTOFF VALVE) VALVE (1/4”, 120 VAC) IS REQUIRED TO
• Selectable Intermittent/Interrupted Pilot Function (full pilot OBTAIN THE PROPER TEST PRESSURES.
− THE BYPASS VALVE WILL BE WIRED IN PARALLEL TO THE
flame and main flame establishing periods apply if VALVE IT IS BYPASSING (TERMINAL 9 FOR MV1 OR
interrupted pilot feature selected). TERMINAL 17 FOR MV2). M22660B
• Run/Test Switch for interrupted pilot setup.
• Blinkum fault annunciation on safety shutdown (power LED Fig. 1. Valve Proving System—simplified diagram.
blinks a fault code.
• Built-in features set up only using the S7800A1142 display. MV1—Wired to terminal 9. It is located at the most upstream
• Valve Proving System. position of the main gas valve train.
The Valve Proving System feature provides a systematic way
of testing the valve seat integrity to assure the valves are VPS—Valve Proving Switch (Rated 1/2 of main valve inlet
indeed in the closed state when the system is in Standby. pressure.
At commissioning time, the Valve Proving System may be MV2—Wired to terminal 17. It is the main valve located
scheduled to occur at one of five different times: closest to the burner.
1. Never—Device default as received; valve proving does The Proof of Closure Switch (or PII—Preignition Interlock) for
not occur. terminal 20 can be installed on MV1, MV2, or both valves.
2. Before—Valve proving after standby and safe start
check, prior to ignition trials.
3. After—Valve proving occurs after the Run state before
the device goes to Standby. WARNING
4. Both—Valve proving occurs at both times Before and Explosion Hazard.
After noted above. Can cause severe injury, death or property
5. Split—The downstream (high pressure) seat test is per- damage.
formed at the Before time and the upstream (low pres- Be sure to select adequate testing times when the
sure) seat test is performed during the After time. Valve Proving feature is enabled. A shorter time can
result in inadequate leak testing of the valves.
SIL3
Capable 66-1150-02
RM7890A1056, RM7890B1048 7800 SERIES RELAY MODULES
This document provides installation and static checkout

instructions. Other applicable publications are: WARNING
65-0084: Q7800A,B 22-Terminal Wiring Subbase Product Electrical Shock Hazard.
Data. Can cause personal injury, death or equipment
65-0288: S7800A1142 Keyboard Display Module Product damage.
Data. Disconnect the power supply before beginning
65-0091: S7810A Data ControlBus Module™ Product Data. installation.
65-0095: S7820 Remote Reset Module Product Data.
65-0097: 221729C Dust Cover Installation Instructions.
65-0109: R7824, R7847, R7848, R7849, R7851, R7861, When Installing this Product...
R7886 Flame Amplifiers for the 7800 SERIES Product Data. 1. Read these instructions carefully. Failure to follow them
65-0131: 221818A,C Extension Cable Assembly Product could damage the product or cause a hazardous
Data. condition.
65-0229: 7800 SERIES Relay Modules Checkout and 2. Check the ratings given in the instructions and marked
Troubleshooting. on the product to make sure the product is suitable for
65-0249 S7810M ModBus Module. the application.
3. Installer must be a trained, experienced, flame
safeguard service technician.
SPECIFICATIONS 4. After installation is complete, check out the product
operation as provided in these instructions.
Electrical Ratings (See Table 3): IMPORTANT
Voltage and Frequency: 1. Wiring connections for the relay modules are unique;
RM7890: 120 Vac (+10/-15%), 50/60 Hz (±10%). refer to Fig. 2 or the appropriate Specifications for
Power Dissipation: 10W maximum. individual subbase wiring.
Maximum Total Connected Load: 2000 VA. 2. Wiring must comply with all applicable codes,
Fusing Total Connected Load: 15A maximum, type SC or ordinances and regulations.
equivalent, fast blow. 3. Wiring must comply with NEC Class 1 (Line Voltage)
wiring.
Environmental Ratings: 4. Loads connected to the RM7890 must not exceed
Ambient Temperature: those listed on the RM7890 label or the
Operating: -40°F to +140°F (-40°C to +60°C). Specifications; see Tables 3, 4, and 5.
Storage: -40°F to +150°F (-40°C to +66°C). 5. Limits and interlocks must be rated to simultaneously
Humidity: 85% relative humidity continuous, noncondensing. carry and break current to the ignition transformer,
Vibration: 0.5G environment. pilot valve, and main fuel valve(s).
6. All external timers must be listed or component-
SIL 3 Capable: recognized by authorities who have proper
SIL 3 Capable in a properly designed Safety Instrumented jurisdiction.
System. See form number 65-0312 for Certificate Agree- 7. For on-off gas-fired systems, some authorities who
ment. have jurisdiction prohibit the wiring of any limit or
operating contacts in series between the flame
Approvals: safeguard control and the main fuel valve(s).
RM7890A,B: 8. Two flame detectors can be connected in parallel
Underwriters Laboratories Inc. Listed: File No. MP268, with the exception of Infrared Flame Detectors
Guide No. MCCZ. (C7915) and solid state models C7927, C7952, and
Canadian Standards Association Certified: LR95329-3. C7961.
Factory Mutual Approved: Report No. J.I.1V9A0.AF. 9. This equipment generates, uses and can radiate
Swiss Re (formerly Industrial Risk Insurers) : Acceptable. radio frequency energy and, if not installed and used
Federal Communications Commission: Part 15, Class B, in accordance with the instructions, can cause
Emissions. interference with radio communications. It has been
tested and found to comply with the limits for a Class
B computing device of Part 15 of FCC rules which
INSTALLATION are designed to provide reasonable protection
against such interference when operated in a
commercial environment. Operation of this
WARNING equipment in a residential area can cause

interference, in which case, the users, at their own
Fire or Explosion Hazard. expense, may be required to take whatever
Can cause property damage, serious injury, or measures are required to correct this interference.
death. 10.This digital apparatus does not exceed the Class B
To prevent possible hazardous burner operation, verify limits for radio noise for digital apparatus set out in
safety requirements each time a control is installed on the Radio Interference Regulations of the Canadian
a burner. Department of Communications.
66-1150—02 2
Location 3. Disconnect the power supply from the main disconnect

before beginning installation to prevent electrical shock
and equipment damage. More than one disconnect can
Humidity be required.
Install the relay module where the relative humidity never 4. All wiring must comply with all applicable electrical
reaches the saturation point. The relay module is designed to codes, ordinances and regulations. Wiring, where
operate in a maximum 85% relative humidity continuous, required, must comply with NEC, Class 1 (Line Voltage)
noncondensing, moisture environment. Condensing moisture wiring.
can cause a safety shutdown. 5. Use recommended wire routing of leadwires:
a. Do not run high voltage ignition transformer wires in
the same conduit with the flame detector, Data
Vibration ControlBus Module™, or Remote Reset Module
Do not install the relay module where it can be subjected to wiring.
vibration in excess of 0.5G continuous maximum vibration. b. Do not route flame detector, Data ControlBus
Module™, or Remote Reset Module leadwires in
Weather conduit with line voltage circuits.
The relay module is not designed to be weather tight. When c. Enclose flame detector leadwires without armor
installed outdoors, protect the relay module in an approved cable in metal cable or conduit.
weather-tight enclosure. d. Follow directions in flame detector, Data ControlBus
Module™, or Remote Reset Module Instructions.
6. For KDM: Because the KDM is powered from a low
Mounting Wiring Subbase voltage, energy limited source, it can be mounted
See Fig. 2 for the internal block diagram of RM7890 Relay outside of a control panel if it is protected from
Module. mechanical damage.
1. Mount the subbase in any position except horizontally NOTE: Use 13 Vdc power supply any time more than two
with the bifurcated contacts pointing down. The KDM or Data ControlBus Modules™ are used or are
standard vertical position is recommended. Any other placed more than 100 feet (31 meters) from the relay
position decreases the maximum ambient temperature module.
rating. 7. Maximum wire lengths:
2. Select a location on a wall, burner or electrical panel. a. RM7890 leadwires: The maximum leadwire length
The Q7800 can be mounted directly in the control is 300 feet (91 meters) to terminal inputs (Control,
cabinet. Be sure to allow adequate clearance for Running/Lockout Interlock/Preignition Interlock).
servicing, installation, access or removal of the b. Flame Detector leadwires: The maximum flame
RM7890, expanded annunciator, KDM, flame amplifier, sensor leadwire length is limited by the flame signal
flame amplifier signal voltage probes, run/test switch, strength.
electrical signal voltage probes and electrical field c. Remote Reset leadwires: The maximum length of
connections. wire is 1000 feet (305 meters) to a Remote Reset
3. For surface mounting, use the back of the subbase as a pushbutton.
template to mark the four screw locations. Drill the pilot d. Data ControlBus Module™: The maximum Data
holes. ControlBus Module™ cable length depends on the
4. Securely mount the subbase using four no. 6 screws number of system modules connected, the noise
(not provided). conditions and the cable used. The maximum length
of all Data ControlBus Module™ interconnecting
Wiring 8.
wire is 4000 feet (1219 meters).
For recommended wire size and type, see Table 1.
9. The KDM, Data ControlBus Module™ (for remote
mounting) must be wired in a daisy chain configuration,
WARNING 1(a)-1(a), 2(b)-2(b), 3(c)-3(c). The order of
Electrical Shock Hazard. interconnection of all the devices listed above is not
Can cause personal injury or equipment damage. important. Be aware that modules on the closest and
Disconnect the power supply before beginning farthest end of the daisy chain configuration string may
installation. require a 120 ohm (1/4 watt minimum) resistor
termination across terminals 1 and 2 of the electrical
1. For proper subbase wiring and sequence chart, refer to connectors for connections over 100 feet (31 meters).
Fig. 3. 10. For recommended grounding practices, see Table 2.
2. For proper remote wiring of the KDM, refer to the 11. Be sure loads do not exceed the terminal ratings. Refer
Specifications for the KDM (65-0288), Data ControlBus to the label on the RM7890 or to the terminal ratings in
Module™ (65-0091) or Extension Cable Assembly (65- Table 3.
0131).
3 66-1150—02
Table 1. Recommended Wire Sizes and Part Numbers.

Application Recommended Wire Size Recommended Part Numbers
Line voltage terminals 14, 16, or 18 AWG copper conductor, 600 TTW60C, THW75C, THHN90C.
volt insulation wire.
Keyboard Display Module 22 AWG two-wire twisted pair with ground, Belden 8723 shielded cable or
or five-wire. equivalent.
Data ControlBus Module™ 22 AWG two-wire twisted pair with ground, Belden 8723 shielded cable or
or five-wire. equivalent.
Remote Reset Module 22 AWG two-wire twisted pair, insulated for —
low voltage.
13 Vdc full-wave rectified transformer 18 AWG wire insulated for voltages and TTW60C, THW75C, THHN90C.
power input. temperatures for given application.
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.
2. Use wide straps or brackets to provide minimum length, maximum surface area
ground conductors. If a leadwire is required, use 14 AWG copper wire.
3. Make sure that mechanically tightened joints along the ground path are free of
nonconductive coatings and protected against corrosion on mating surfaces.
Signal ground (Keyboard Display Use the shield of the signal wire to ground the device to the signal ground terminals—
Module, Data ControlBus Module™. 3(c)—of each device. Connect the shield at both ends of the daisy chain to earth
ground.
Table 3. Terminal Ratings.

Terminal Number Description Ratings (RM7890A,B)
G Flame Sensor Ground —
Earth G Earth Grounda —
L2(N) Line Voltage Common —
3 Line Voltage Supply (L1) 120 Vac (+10%/-15%), 50 or 60 Hz (±10%).b
4 Alarm 120 Vac, 1A pilot duty.
5 Unused —
6 Burner Controller and Limits 120 Vac, 1 mA.
7 Jumper 120 Vac, 8A run, 43A inrush.
8 Pilot Valve/Ignition. 120 Vac.c
9 Main Fuel Valve 1. 120 Vac.c
10 Ignition 120 Vac, 4.5A ignition.c
F(11) Flame Sensor 60 to 220 Vac, current limited.
12 to 15 Unused. —
16 Valve Proving Switch 120V, 1 mA.
17 MV2 (for Valve Proving) 120 Vac.c
18 Unused —
19 Unused —
20 Preignition Interlock 120V, 1 mA
21 Unused —
22 Shutter 120 Vac, 0.5A (RM7890B).
66-1150—02 4
a
The RM7890 must have an earth ground providing a connection between the subbase and the control panel or the equipment.
The earth ground wire must be capable of conducting the current to blow the 15A, type SC, fast blow, fuse (or breaker) in
event of an internal short circuit. The RM7890 needs a low impedance ground connection to the equipment frame which, in
turn, needs a low impedance connection to earth ground. For a ground path to be low impedance at RF frequencies, the
connection must be made with minimum length conductors having maximum surface areas. Wide straps or brackets rather
than leadwires are preferred. Be careful to verify that mechanically tightened joints along the ground path, such as pipe or
conduit threads or surfaces held together with fasteners, are free of nonconductive coatings and are protected against mating
surface corrosion.
b
2000 VA maximum connected load to the RM7890 Assembly.
c
See Tables 4 and 5 for device load combinations.
Table 4. Combinations for Terminals 8, 9,17 and 10.

Pilot Fuel 8 Main 9 (MV1) Main 17 (MV2) Ignition 10
C F F No Load
B F F No Load
F F F A
F No Load No Load A
D F F A
D D D A
D No Load No Load A
Table 5. Composition of Each Combination.
A B C D F
4.5A ignition 50 VA Pilot Duty 180 VA ignition plus motor 2A Pilot Duty. 65 VA Pilot Duty plus motor
plus 4.5A ignition. valves with: 660 VA inrush, valves with: 3850 VA inrush,
360 VA open, 250 VA hold. 700 VA Open, 250 VA hold.
Final Wiring Check

1. Check the power supply circuit. The voltage and WARNING
frequency tolerance must match those of the Explosion Hazard.
RM7890. A separate power supply circuit can be Can cause serious injury, death or equipment
required for the RM7890. Add the required disconnect damage.
means and overload protection. 1. Close all manual fuel shutoff valve(s) before starting
2. Check all wiring circuits and complete the Static these tests.
Checkout in Table 7 before installing the RM7890 on the 2. Use extreme care while testing the system. Line
subbase. voltage is present on most terminal connections
3. Install the relay module. when power is on.
4. Restore the panel power. 3. Open the master switch before installing or
removing a jumper on the subbase.
4. Before continuing to the next test, be sure to
STATIC CHECKOUT remove test jumper(s) used in the previous test.
5. Replace all limits and interlocks that are not
operating properly. Do not bypass limits and
After checking all wiring, perform this checkout before interlocks.
installing the RM7890 on the subbase. These tests verify the
Q7800 Wiring Subbase is wired correctly, and the external
controllers, limits, interlocks, actuators, valves, transformers,
motors and other devices are operating properly. CAUTION
Equipment Damage Hazard.
Can cause equipment damage or equipment
failure.
Do not perform a dielectric test with the RM7890
installed. Internal surge protectors break down and
conduct a current, causing the RM7890 to fail the
dielectric test or possibly destroy the internal lightning
and high current protection.
5 66-1150—02
Equipment Recommended 7. Check all wiring for proper connections, tight terminal
screws, and appropriate wire and wiring techniques.
1. Voltmeter (1M ohm/volt minimum sensitivity) set on the 8. Replace all damaged or incorrectly sized wires.
0 to 300 Vac scale. 9. Replace faulty controllers, limits, interlocks, actuators,
2. Two jumper wires, No. 14 wire, insulated, 12 in. valves, transformers, motors and other devices, as
(304.8 mm) long with insulated alligator clips at both required.
ends. An ammeter can replace the jumper so the load 10. Make sure normal operation is obtained for each
ratings of the ignition transformer or valves (terminals 8, required test before continuing the checkout.
9, 10, or 17) can be compared to their respective rat- 11. After completing each test, be sure to remove the test
ings. jumper(s).
General Instructions
1. Perform all applicable tests listed in the Static Checkout, WARNING
Table 6, in the order listed. Explosion Hazard.
2. Make sure all manual fuel shutoff valves are closed. Can cause serious injury or death.
3. For each test, open the master switch and install the Be sure all manual fuel shutoff valves are closed.
jumper wires between the subbase wiring terminals
listed in the Test Jumpers column. IMPORTANT
4. Close the master switch before observing the operation. Low fuel pressure limits, if used, could be open.
5. Read the voltage between the subbase wiring terminals Bypass them with jumpers for the remaining static
listed in the Voltmeter column. tests (if required).
6. If there is no voltage or the operation is abnormal, check
the circuits and external devices as described in the last
column.
Table 6. Static Checkout.

Test If Operation is Abnormal, Check the Items
No. Test Jumpers Voltmeter Normal Operation Listed Below
1 — 4-L2 Line Voltage. 1. Master switch.
2. Power connected to the master switch.
3. Overload protection (fuse, circuit breaker,
etc.) has not opened the power line.
2 — 6-L2 Line Voltage. 1. Limits.
2. Burner control.
3 — 20-L2 Line Voltage Preignition Interlock.
4 4-10 — Ignition spark (if ignition 1. Watch for spark or listen for buzz.
transformer is connected to a. Ignition electrodes are clean
terminal 10). b. Ignition transformer is okay.
5 4-8 — 1. Ignition spark (if ignition 1. Watch for spark or listen for buzz:
transformer is connected to a. Ignition electrodes are clean.
terminal 8). b. Ignition transformer is okay.
2. Automatic pilot valve opens (if
2. Listen for click or feel head of valve for
connected to terminal 8). activation:
a. Actuator, if used.
NOTE: Refer to wiring diagram of b. Pilot valve.
system being tested.
6 3-4 — Alarm (if used) turns on. 1. Alarm.
66-1150—02 6
Table 6. Static Checkout. (Continued)

Test If Operation is Abnormal, Check the Items
No. Test Jumpers Voltmeter Normal Operation Listed Below
7 4-9 — Automatic fuel valve(s) opens. If Same as test number 4. If using direct spark
using direct spark ignition, check ignition, check the first stage fuel valve(s) instead
the first stage fuel valve(s) instead of the pilot valve.
of the pilot valve.
7a — 16-L2 Line Voltage Conduct after test 7. Valve Proving Switch should
close to pressure trapped between Valves 1 and
2.
7b 4-17 — Automatic Fuel Valve 2 opens.
FINAL
CAUTION
Equipment Damage Hazard.
Can cause serious equipment damage.
After completing these tests, open the master switch, remove all test jumpers from the subbase terminals, and
remove any bypass jumpers from the low fuel pressure limits to prevent equipment damage.
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
PRE-IGNITION 1 NUMBERS IN CIRCLES ARE RELAY MODULE

INTERLOCK TERMINAL NUMBERS.
20 PROVIDE DISCONNECT MEANS AND

2 OVERLOAD PROTECTION AS REQUIRED;
120 VAC, 50/60 HZ POWER SUPPLY.
TERMINAL 7 MUST BE POWERED. IF VALVE
3 PROVING OPTION IS “NEVER” OR “BEFORE”,
A JUMPER MAY BE INSTALLED BETWEEN
SUBBASE TERMINALS 6 AND 7 .
M23030A
Fig. 2. Internal block diagram of the RM7890.
7 66-1150—02
Mounting RM7890 Relay Module IMPORTANT

Install the RM7890 with a plug-in motion rather than
1. Mount the RM7890 vertically on the Q7800 Subbase, or a hinge action.
mount horizontally with the knife blade terminals
pointing down. When mounted on the Q7800A, the 4. Mount the RM7890 by aligning the four L-shaped corner
RM7890 must be in an electrical enclosure. guides and knife blade terminals with the bifurcated
2. When mounting in an electrical enclosure, provide contacts on the wiring subbase and securely tightening
adequate clearance for servicing, installation and the two screws without deforming the plastic.
removal of the RM7890, KDM, flame amplifier, flame
amplifier signal voltage probes, electrical signal voltage
probes, and electrical connections. Mounting Other System Components
a. Allow an additional two inches (51 mm) below the
RM7890 for flame amplifier mounting. (Fig. 4)
b. Allow an optional three-inch (76 mm) minimum to Refer to the applicable specifications for mounting other
both sides of the RM7890 for electrical signal system components.
voltage probes.
3. Make sure no subbase wiring is projecting beyond the
terminal blocks. Tuck in wiring against the back of the
subbase so it does not interfere with the knife blade
terminals or bifurcated contacts.
66-1150—02 8
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
MAIN FUEL PRE-IGNITION

9 20 INTERLOCK
VALVE 1
IGNITION 10 21
4
FLAME DETECTOR F 5 22
00 00 4/10 20
SAFE- PFEP
LED 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
Fig. 3. Wiring subbase and operating sequence chart for RM7890.
5. Mount the RM7890 by aligning the four L-shaped corner

guides and knife blade terminals with the bifurcated
Mounting Other System Components
contacts on the wiring subbase and securely tightening (Fig. 4)
the two screws without deforming the plastic. Refer to the applicable specifications for mounting other
system components.
9 66-1150—02
WIRING
SUBBASE
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
M11588A
Fig. 4. RM7890 Relay Module exploded view.
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 way Both—Valve proving occurs at both times Before and After
of testing the valve seat integrity to assure the valves are in noted above.
the closed state whenever the sequence of operation required
them to be closed. It is designed to detect a leak greater than Split—The downstream (high pressure) seat test is
0.1% of the burner input capacity. For example, a 10 million performed at the Before time and the upstream (low
Btu/hr natural gas fueled burner would have a fuel capacity of pressure) seat test is performed during the After time.
approximately 1000 ft3/hr. A leak rate greater than 0.1% of
1000 ft3/hr or 1 ft3/hr in either valve will be detected with the The Valve Proving items programmed:
Valve Proving System. Smaller leaks will not be detected.
1. Enable Valve proving and when to perform it.
At commissioning time, the Valve Proving System may be 2. Define the time duration of the test is calculated using
scheduled to occur at one of five different times: Never, Appendix A.
Before, After, Both, and Split.
Never—Device Fault as received: in this case Valve Valve Proving Function
Proving does not occur. Valve proving consists of monitoring the pressure in the space
between two shutoff valves, MV1 (upstream) and MV2
Before—Valve Proving occurs after Standby and Safe (downstream). The valve proving function, identified by letters
Start Check, but before Run. A through G, operates as follows:
The tolerance on all valve proving timing values is ±10%.
66-1150—02 10
The following are steps performed during valve proving tests. E. MV1 is commanded to be open, while MV2 remains
This section is for background information and does not define closed, to pressurize the space. After four seconds, MV1 is
the exact behavioral requirements. commanded closed again.
A. The RM7890 must have an input on terminal 7 (to power F. This is followed by a three second delay, during which
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 occurs.
B. MV2 is commanded to be open while MV1 remains (Because the gas pressure has decreased due to a leaky
closed; to depressurize the space. After four seconds, MV2 downstream valve [high pressure test].)
is commanded closed again.
C. This is followed by a three second delay during which Pressure Switches for Valve Proving
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 the installed to monitor the pressure in the internal space between
valve proving test time and, if it turns on, a lockout occurs. the two shutoff valves. Recommended pressure switches are
(Because the gas pressure has increased due to a leaky the following Honeywell non-manual reset models:
upstream valve [low pressure test].)
Table 7. Honeywell Pressure Switch Selection for Valve Proving System.

1 2 3 4 5 6
Maximum Maximum
Operating Differential Continuous Rated Switch Action at
Model Number Pressure Range (Additive) Pressure (psi) Setpoint Mounting Type
C6097A1004 0.4 to 5 in. wc 0.24 in. wc 2.9 Breaks N.O. to C 1/4 in. NPT
C6097A1053 3 to 21 in. wc 0.48 in. wc 5.0 connection on
pressure fall.
C6097A1061 Flange
C6097A1079 12 to 60 in. wc 2.4 in. wc 1/4 in. NPT
C6097A1087 Flange
C6097A1129 1.5 to 7 psi 0.3 psi 9.3 1/4 in. NPT
C6097A1137 Flange
C6097A1210 0.4 to 4 in. wc 0.24 in. wc 2.9
Pressure Switch Selection Pressure Switch Installation and

1. Determine the maximum operating inlet pressure for the Adjustment
upstream valve; for example, 5.0 psi (140 in. wc). 1. Refer to the instructions for theC6097A Pressure
2. Divide the inlet pressure by two (2.5 psi [70 in. wc], for Switch, form number 65-0237.
example). 2. Install the C6097A Pressure Switch according to the
3. From column 2 in Table 7 find the operating range upper instructions.
limit that is closest to but greater than the inlet pressure 3. Adjust the setpoint to 50% of the maximum operating
divided by two. In the example given, the possible inlet pressure for the upstream valve.
selections from column 1 are the C6097A1129 and 4. Complete the operation and checkout procedures in the
C6097A1137 with an operating range upper limit of 7 instructions.
psi. (The C6097A1079 and C6097A1087 with an upper
limit of 60 in. wc are close, but 60 in. wc is less than the
70 in. wc minimum, so the next higher range must be Setup of Valve Proving Function
selected.) Prior to setup of the Valve Proving Function, follow the
4. From column 6, select the preferred mounting type, 1/4 procedures in the appendix to complete the worksheet and
in. NPT or Flange. For example, if a flange mount is obtain the Valve Proving Test Time.
required, the pressure switch choice from column 1
would be the C6097A1137. An S7800A1142 Keyboard Display Module (KDM) is required
for this setup and the RM7890 must have the Valve Proving
function.
When the RM7890 is installed and powered, “STANDBY” will

be shown on the first line of the display.
11 66-1150—02
1. Scroll down until the “Setup” is displayed in the second NOTE: This screen sets up when to do the Valve Proving
line. (Setup is only available when the control is in Test.
Standby or Lockout state.)
8. Use the up/down arrows to select from Never, Before,
After, Both, or Split, then press ENTER.
NOTE: Use Never on initial startup so gas line purging and

STANDBY System Checkout can be performed. Then come
Setup back to set final operation configuration. Be sure to
conduct final checkout of VPS System when this
BACK setup is complete.
Edit: - + ENTER
M22662B
Fig. 5. STANDBY/Setup screen. =Save changes

=Restart
2. Enter the Setup submenu by pressing the far right key
on the display. Note that the second line now reads “BC BACK
Password”. Edit: - + ENTER
M22665B
STANDBY SU Fig. 9. Save Changes screen.

± BC Password: 00
9. Use the down arrow to save changes. After pressing the
BACK
down arrow, “Getting Data” is displayed.
Edit: - + ENTER
M22663B
SETUP: ValveProve SU
Fig. 6. Password screen. ±VP Time: 00:00
3. Use the up/down arrows to enter the first number—7. BACK

4. Use the far right key to shift over one space.
Edit: - + ENTER
5. Use the up/down arrows to enter the second number 8.
6. Press ENTER (left/right arrow simultaneously). M22666B
Fig. 10. Valve Prove time screen.
=Select This screen sets up how long the RM7890 will conduct the
=Restart Valve Proving Test for a given time. VP Time: 00:30 is shown.
10. Enter the appropriate Valve Proving test time from the
BACK
worksheet in the appendix.
Edit: - + ENTER
Use the up arrow to increase time. Time increases:
M22764B
a. 0 to 60 seconds in 1-second intervals.
b. 60 to 600 seconds in 10-second intervals.
Fig. 7. Select/Restart screen. c. 10 to 60 minutes in 1-minute intervals.
7. To get to the next screen, press down arrow. “Getting NOTE: The minimum default test time is 10 seconds.
Data” will be displayed, then the following screen.
Press ENTER when correct time is displayed.
SETUP: ValveProve SU
± VP When: BEFORE
=Save changes
=Restart
BACK
Edit: - + ENTER
BACK
M22664B
Edit: - + ENTER
Fig. 8. SETUP: Valve Prove screen. M22665B
Fig. 11. Save Changes screen.
66-1150—02 12
11. Use the down arrow to save changes. After pressing the 15. Press ENTER.
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. 15. Confirm Correct screen.
BACK
Edit: - + ENTER 16. Use the down arrow to confirm correct.
“Getting Data” will be displayed.
M22670B
Fig. 12. Confirmation Acknowledgement screen.
13. Press ENTER. The Valve Proving test location is SETUP DONE: Press
shown. Reset for 5 sec . . .
BACK
Edit: - + ENTER
=Confirm correct
=Incorrect M22676B
BACK Fig. 16. Setup Done screen.

Edit: - + ENTER
17. Go to the relay module and press and hold the RESET
M22671B button for five seconds to program the Valve Proving
setup into the relay module.
Fig. 13. Confirmation Correct screen. The Release Reset screen will appear on the KDM.
14. Use the down arrow to confirm correct.
NOTE: Using the up arrow during the confirmation will take

you back to the beginning of the setup routine. SETUP DONE:
... release Reset
“Getting Data” will be displayed, followed by the Selected
Value Proving time.
BACK
Edit: - + ENTER
M22765B
CONFIRM: ValveProve SC
Fig. 17. Release Reset screen.
±VP Time: 00:30 ?
Changing the Valve Proving features is still possible. With the
BACK relay module in Start Switch, scroll to the Setup line and enter
Edit: - + ENTER the password to change the settings.
M22672B Once the system is in operation, the settings of the Valve
Proving can be viewed un Diagnostics, using your S7800
Fig. 14. Confirm screen. Keyboard Display Module (KDM).
13 66-1150—02
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)
1 LOCKOUT IF ON, M1 LEAKING (LOW PRESSURE TEST).
2 LOCKOUT IF OFF, MV2 LEAKING (HIGH PRESSURE TEST).

M22669E
Fig. 18. RM7890 Sequence for Valve Proving System.
PRINCIPAL TECHNICAL a. Ignition/pilot valve terminal is not energized.

b. Internal system fault occurred.
FEATURES c. Main valve terminal (1 or 2) is energized.
d. No flame present at end of PFEP.
5. RUN PERIOD
The RM7890 provides all customary flame safeguard a. Ignition terminal is energized.
functions as well as significant advancements in safety, b. Internal system fault occurred.
annunciation, and system diagnostics. c. Main valve terminal (1 or 2) is not energized.
d. No flame present and configuration jumper is
Safety Shutdown (Lockout) Occurs selected for lockout.
e. Pilot valve terminal is not energized (Intermittent
if: Operation).
1. INITIATE PERIOD f. Pilot Valve terminal is energized (Interrupted
a. AC line power errors occurred, see Operation. Operation selected).
b. Configuration jumpers have been changed (after
200 hours).
c. Four minute INITIATE period has been exceeded. OPERATION
2. STANDBY PERIOD
a. Flame signal is present after 240 seconds.
b. Ignition/pilot valve terminal is energized. Sequence of Operation
c. Internal system fault occurred. The RM7890 has the operating sequences listed below; see
d. Main valve terminal (1 or 2) is energized. Fig. 2. The RM7890 LED provide positive visual indication of
e. Three second Flame Failure Response Time the program sequence: POWER, PILOT, FLAME, MAIN and
(FFRT) Amplifier is installed and configuration ALARM.
jumper is selected for relight (see Table 3).
f. Pre-Ignition Interlock opens after 30 seconds.
3. SAFE START CHECK Initiate
a. Ignition/pilot valve terminal is energized. The RM7890 enters the INITIATE sequence when the relay
b. Internal system fault occurred. module is powered. The RM7890 can also enter the INITIATE
c. Main valve terminal (1 or 2) is energized. sequence if the relay module verifies voltage fluctuations of
d. Pre-Ignition Interlock opens. +10/-15% or frequency fluctuations of ±10% during any part of
4. PILOT FLAME ESTABLISHING PERIOD (PFEP) the operating sequence. The INITIATE sequence lasts for ten
seconds unless the voltage or frequency tolerances are not
66-1150—02 14
met. When the tolerances are not met, a hold condition is

initiated and is displayed on the optional KDM for at least five
SETTINGS AND ADJUSTMENTS
seconds. When the tolerances are met, the INITIATE
sequence restarts. If the condition is not corrected and the
hold condition exists for four minutes, the RM7890 locks out.
Selectable Site-Configurable
Causes for hold conditions in the INITIATE sequence: Jumpers
a. AC line dropout detection. The RM7890 has two site-configurable jumper options, see
b. AC line noise that can prevent a sufficient reading of Fig. 4 and Table 7. If necessary, clip the site-configurable
the line voltage inputs. jumpers with side cutters and remove the resistors from the
c. Brownouts caused by a low line voltage. relay module.
NOTE: If a 3.0 second flame failure response amplifier is SERVICE NOTE

installed and configuration jumper JR2 is intact, the Clipping and removing a site-configurable jumper enhances
RM7890 locks out. JR2 must be clipped. the level of safety. If using three-second amplifier,
site-configurable jumper JR2 must be clipped and removed. If
not removed, an F46 Lockout occurs.
Standby
The RM7890 is ready to start an operating sequence when
the operating control input (terminal 6) recognizes a call for
heat. The burner switch, limits, operating limit control and all
microcomputer monitored circuits must be in the correct state
SELECTABLE CONFIGURATION JUMPERS
for the RM7890 to continue into the Safe Start Check. The
RM7890 must also have an input on terminal 7.
Normal Start-Up Safe Start Check

The RM7890 verifies that a flame or flame simulating
condition does not exist and proceeds into the Ignition Trial. If
a flame or flame simulating condition is present, the
RM7890 remains in the STANDBY period.
Valve Proving occurs here if Before, Both, or Split sequence is

selected.
Ignition Trials
a. Pilot Flame Establishing Period (PFEP):
(1) The pilot valve and ignition transformer,
terminals 8 and 10, are energized. The RM7890
M22777A
has an intermittent pilot valve, terminal 8.
(Interrupted if JR3 is removed).
(2) Flame must be proven by the end of the four- or Fig. 19. Selectable site-configurable jumpers.
ten-second PFEP or a safety shutdown occurs.
(3) Once flame is proven: Table 8. Site-Configurable Jumper Options.
(a)Intermittent—the ignition, terminal 10, is Jumper
de-energized and the main valves, terminal 9 Number Description Intact Clippedb
and 17, are energized.
(b)Interrupted—at the end of the timed PFEP, JR1 Pilot Flame 10 seconds 4 seconds
terminal 10 is de-energized and the main Establishing Period
Valve 1 (terminal 9) and main valve 2 (terminal (PFEP)
17) are energized. After a 10-second Main JR2 Flame Failure Action Relighta Lockout
Flame Establishing time, the Pilot Valve
(terminal 8) is de-energized. JR3 Pilot Valve (T8) Intermittent Interrupted
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 demand JR2 is not clipped and removed.
is satisfied or a limit has opened. bClipping and removing a site-configurable jumper after 200
hours of operation results in a hard lockout, code 110.
The Pre-Ignition Interlock must close five seconds after
terminal 6 opens. (It is ignored during Valve-On time in the
Valve Proving Sequence if After, Split, or Both option is
chosen for Valve Proving tests.) Pre-Ignition Interlock input is SYSTEM CHECKOUT
required five seconds after the valve output is de-energized.
IMPORTANT
Perform Static Checkout Procedures before starting
these procedures.
15 66-1150—02
3. Limit trial for pilot to ten seconds. Limit the attempt to

WARNING light main burner to two seconds after fuel reaches the
burner nozzle. Do not exceed manufacturer nominal
Explosion Hazard. lightoff time.
Can cause severe injury, death or property
damage. IMPORTANT
1. Do not allow fuel to accumulate in the combustion 1. If the system fails to perform properly, note the fault
chamber for longer than a few seconds without code, fault message, equipment status, and
igniting to prevent danger of forming an explosive sequence time on the display. Then refer to the
mixture. Troubleshooting section.
2. Close manual fuel shutoff valve(s) if flame is not 2. Repeat all required Checkout tests after all
burning at the end of the specified time. 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 sensitivity)
1. Use extreme care when testing system. Line voltage with:
is present on most terminal connections when a. 0-300 Vac capability.
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.
1. Make sure all manual fuel shutoff valve(s) are closed
Checkout Summary
before starting initial lightoff check and Pilot Turndown Table 8 provides an overview of checkout steps performed for
tests. each applicable system.
2. Do not put the system into service until you have
See the Installation instructions for location of component
satisfactorily completed all applicable tests in this
parts and/or Q7800 specifications for terminal locations.
section and any others recommended by the original
equipment manufacturer.
Table 9. Checkout Steps and Applicable 7800 Series Systems.

Infrared Flame Ultraviolet Flame
Checkout Step Piloted Systems Detectors Flame Rod Systems Detectors
Preliminary Inspection X X X X
Flame Signal X X X X
Measurement
Initial Lightoff Check for X
Proved Pilot
PIlot Turndown Test X
Ignition Interference X
Test
Hot Refractory X
Saturation Test
Hot Refractory Hold-in X X X X
Test
Ignition Spark Pickup X
Response to Other X
Ultraviolet Sources
Flame Signal with Hot X X X X
Combustion Chamber
Safety Shutdown Tests X X X X
Preliminary Inspection 1. Wiring connections are correct and all terminal screws
are tight.
Perform the following inspections to avoid common problems. 2. Flame detector(s) is (are) clean, installed and
Make certain that: positioned properly. Consult the applicable instructions.
3. Combination of amplifier and flame detector(s) is
correctly used. See the amplifier specifications.
66-1150—02 16
4. Burner is completely installed and ready to fire; consult g. After a continuous spark is obtained, open the
equipment manufacturer instructions. master switch and add a jumper on the subbase
5. Fuel lines are purged of air. from terminal L1 power to the pilot terminal 8.
6. Combustion chamber and flues are clear of fuel and fuel Reconnect the leadwire from the pilot valve if it was
vapor. disconnected in step b.
7. Power is connected to the system disconnect switch h. Close the master switch to energize both the ignition
(master switch). transformer and the pilot valve.
8. Lockout is reset (reset button) only if the Relay Module i. If the pilot does not ignite and if the ignition spark is
is powered. still continuous, adjust the pressure regulator until a
9. Run/Test Switch (if present) is in the RUN position. pilot is established.
10. System is in STANDBY condition. STANDBY message j. When the pilot ignites properly and stays ignited,
is displayed in the S7800 Keyboard Display Module. open the master switch and remove the jumper(s)
11. All limits and interlocks are reset. from the terminals of the subbase.
k. Check for adequate bleeding of the fuel line.
l. Reinstall the 7800 SERIES Relay Module on the
Flame Signal Measurement subbase, close the master switch and return to step
See instructions provided with the amplifier. 4.
7. When the pilot ignites, measure the flame signal. If the
pilot flame signal is unsteady or approaching the 1.25
INITIAL LIGHTOFF CHECKS Vdc minimum value, adjust the pilot flame size or
detector sighting to provide a maximum and steady
flame signal.
Proved Pilot Systems 8. Recycle the system to recheck lightoff and pilot flame
signal.
Perform this check on all installations that use a pilot. It should 9. When the MAIN LED turns on, make sure the automatic
immediately follow the preliminary inspection. main fuel valve is open; then smoothly open the manual
Low fuel pressure limits, if used, could be open. If so, bypass main fuel shutoff valve(s) and watch for main burner
them with jumpers during this check. flame ignition. When the main burner flame is
established, go to step 16.
1. Open the master switch. 10. If the main burner flame is not established within five
2. Make sure the manual main fuel shutoff valve(s) is(are) seconds or the normal lightoff time as specified by the
closed. Open the manual pilot shutoff valve. If the pilot equipment manufacturer, close the manual main fuel
takeoff is downstream from the manual main fuel shutoff valve(s).
valve(s), slightly open the main valve to supply pilot gas 11. Recycle the system to recheck the lightoff and pilot
flow. Make sure the main fuel is shut off just upstream flame signal.
from the burner inlet, or disconnect power from the 12. Smoothly open the manual fuel shutoff valve(s) and try
automatic main fuel valve(s). lightoff again. (The first re-attempt may have been
3. Close the master switch and start the system with a call required to purge the lines and bring sufficient fuel to the
for heat by raising the setpoint of the operating burner.)
controller; see the relay module sequence. The 7800 13. If the main burner flame is not established within five
SERIES Relay Module should start the INITIATE seconds or the normal lightoff time specified by the
sequence. equipment manufacturer, close the manual main fuel
4. Let the sequence advance to PILOT IGN (status is shutoff valve(s). Check all burner adjustments.
displayed on the Keyboard Display Module, if used). 14. If the main burner flame is not established after two
PILOT LED turns on, ignition spark should occur and attempts:
the pilot should light. If the pilot ignites, the FLAME LED a. Check for improper pilot flame size.
is energized. Go to step 7. b. Check for excess combustion air at low fire.
5. If the pilot flame is not established in ten seconds (four c. Check for adequate low fire fuel flow.
seconds if configuration jumper JR1 is clipped), safety d. Check for proper gas supply pressure.
shutdown occurs. Let the sequence complete its cycle. e. Check for proper valve operation.
6. Push the reset pushbutton, and let the system recycle f. Check for proper pilot flame positioning.
once. If the pilot still does not ignite, make the following 15. Repeat steps 8 and 9 to establish the main burner
ignition/pilot adjustments: flame; then go to step 16.
a. Open the master switch and remove the 7800 16. With the sequence in RUN, make burner adjustments
SERIES Relay Module from the subbase. for flame stability and Btu input rating.
b. On the subbase, jumper L1 to the ignition terminal; 17. Shut down the system by opening the burner switch or
refer to the appropriate wiring diagram to determine by; lowering the setpoint of the operating controller.
the proper terminal. Disconnect the leadwire to the 18. Restart the system by closing the burner switch and/or
pilot valve if it is connected to the same terminal. raising the setpoint of the operating controller. Observe
c. Close the master switch to energize only the ignition that the pilot is established during PILOT IGN and the
transformer. main burner flame is established during MAIN IGN
d. If the ignition spark is not strong and continuous, within the normal lightoff time.
open the master switch and adjust the ignition 19. Measure the flame signal. Continue to check for the
electrode spark gap setting to the manufacturer proper signal through the RUN period. Check the signal
recommendation. \ at both High and Low Firing Rate positions and while
e. Make sure the ignition electrodes are clean. modulating, if applicable.
f. Close the master switch and observe the spark.
17 66-1150—02
20. Run the burner through another sequence, observing NOTE: If there is no flame for 15 seconds, with the
the flame signal for: RUN/TEST Switch in the TEST position, the relay
a. Pilot flame alone. module locks out.
b. Pilot and main flame together.
c. Main flame alone (unless monitoring an intermittent 8. Repeat step 7 to verify the pilot gas pressure reading at
pilot). Also, observe the time it takes to light the the exact point the FLAME LED goes out.
main flame. Ignition of main flame should be 9. Increase the pilot pressure immediately until the FLAME
smooth. LED comes on, and then turn it down slowly to obtain a
21. Make sure all readings are in the required ranges before pressure reading just above the dropout point or until
proceeding. the flame signal increases to 1.25 Vdc.
22. Return the system to normal operation. 10. Set the Run/Test Switch in the RUN position (if used)
and let the sequence proceed. When the MAIN LED
NOTE: After completing these tests, open the master switch turns on, make sure the automatic main fuel valve(s)
and remove all test jumpers from the subbase opens; then smoothly open the manual main fuel shutoff
terminals, limits/controls or switches. valve(s) (or any other manually-opened safety shutoff
valve(s), if used) and watch for main burner ignition. If
the main burner flame is established, go to step 18.
PILOT TURNDOWN TEST (ALL NOTE: This step requires two people, one to open the
INSTALLATIONS USING A manual valve(s) and one to watch for ignition.
PILOT) 11. If the main burner flame is not established within five
seconds, or within the normal lightoff time specified by
the equipment manufacturer, close the manual main
Perform this test on all installations that use a pilot. The fuel shutoff valve(s) and open the master switch. If the
purpose of this test is to verify that the main burner can be lit lightoff is rough, the pilot flame size is too small.
by the smallest pilot flame that can hold in the flame amplifier 12. Close the master switch to recycle the burner and stop
and energize the FLAME LED. Clean the flame detector(s) to the sequence in the PILOT period by using the Run/Test
make sure that it detects the smallest acceptable pilot flame. Switch.
If using AMPLI-CHECK™ or self-checking amplifier and 1M 13. Increase the pilot flame size by increasing its fuel flow
ohm/volt meter, the flame signal fluctuates every time the until a smooth main flame is accomplished.
amplifier does a self-check or a shutter check. 14. Reposition the flame scanner sight tube or use orifices
until the pilot flame signal voltage is in the range of 1.25
NOTE: Low fuel pressure limits, if used, could be open. If so, to 1.50 Vdc.
bypass them with jumpers during this test. 15. When the main burner lights reliable with the pilot at
turndown, disconnect the manometer (or pressure
1. Open the master switch. gauge) and turn up the pilot gas flow to that
2. Close the manual main fuel shutoff valve(s). recommended by the equipment manufacturer.
3. Connect a manometer (or pressure gauge) to measure 16. If used, remove the bypass jumpers from the subbase
pilot gas pressure during the turndown test. terminals, limits/controls, or switches.
4. Open the manual pilot shutoff valve(s). 17. Run the system through another cycle to check for
5. Close the master switch and start the system with a call normal operation.
for heat. Raise the setpoint of the operating controller. 18. Return the system to normal operation.
The 7800 SERIES sequence should start, and
PREPURGE, if applicable, should begin.
6. After the PILOT LED turns on interrupted pilot
applications, set the Run/Test Switch to the TEST
IGNITION INTERFERENCE TEST
position to stop the sequence. The FLAME LED comes (ALL FLAME RODS)
on when the pilot ignites.
NOTE: If the sequence does not stop, reset the system and Ignition interference can subtract from (decrease) or add to
make sure you set the Run/Test Switch to TEST (increase) the flame signal. If it decreases the flame signal
within the first eight seconds of the PILOT IGN enough, it causes a safety shutdown. If it increases the flame
sequence. signal, it could cause the FLAME LED to come on when the
true flame signal is below the minimum acceptable value.
IMPORTANT Start the burner and measure the flame signal with both
You have 0.8 second or three seconds, depending ignition and pilot (or main burner) on, and then with only the
on the PFEP selected, to position the Run/Test pilot (or main burner) on. Any significant difference (greater
Switch to the TEST position to stop the sequence than 0.5 Vdc) indicates ignition interference.
after the start of the PILOT IGN period.
7. Turn down the pilot pressure very slowly, reading the To Eliminate Ignition Interference
manometer (or pressure gauge) as it drops. Stop 1. Make sure there is enough ground area.
instantly when the FLAME LED goes out. Note the 2. Be sure the ignition electrode and the flame rod are on
pressure. The pilot is at the minimum turndown position. opposite sides of the ground area.
Immediately turn up the pilot pressure until the FLAME 3. Check for correct spacing on the ignition electrode:
LED comes on again or the flame signal increases to
1.25 Vdc.
66-1150—02 18
a. 6000V systems—1/16 to 3/32 in. (1.6 to 2.4 mm). NOTE: Some burners continue to purge oil lines between
b. 10,000V systems—1/8 in. (3.2 mm). the valves and nozzles even though the fuel valves
4. Make sure the leadwires from the flame rod and ignition are closed. Terminating the firing cycle (instead of
electrode are not too close together. opening the master switch) allows purging the
5. Replace any deteriorated leadwires. combustion chamber. This reduces a buildup of fuel
6. If the problem cannot be eliminated, consider changing vapors in the combustion chamber caused by oil line
the system to an ultraviolet flame detection system. purging.
5. If the detector is sensing hot refractory, correct the
HOT REFRACTORY TESTS condition by one or more of the following procedures:
a. Add an orifice plate in front of the cell to restrict the
viewing area of the detector.
b. Resight the detector at a cooler, more distant part of
Hot Refractory Saturation Test (All the combustion chamber. Make sure the detector
Infrared Detectors) properly sights the flame.
Start the burner and monitor the flame signal during the c. Try lengthening the sight pipe or decreasing the
warm-up period. A decrease in signal strength as the pipe size (diameter).
refractory heats up indicates hot refractory saturation. If For details, refer to the detector Instructions and the
saturation is extreme, the flame signal drops below 1.25 Vdc equipment Operating Manual. Continue adjustments until hot
and the system shuts down as though a flame failure refractory hold-in is eliminated.
occurred.
If hot refractory saturation occurs, the condition must be IGNITION SPARK RESPONSE
corrected. Add an orifice plate in front of the cell to restrict the
viewing area, lengthen the sight pipe, or decrease the pipe TEST (ALL ULTRAVIOLET
size (diameter). Continue adjustments until hot refractory
saturation is eliminated. DETECTORS)
Test to make certain that the ignition spark is not actuating the
Hot Refractory Hold-in Test FLAME LED:
(Rectifying Photocell, Infrared 1. Close the pilot and main burner manual fuel shutoff
Detectors, Ultraviolet Detectors) valve(s).
This condition can delay response to flame failure and also 2. Start the burner and use the Run/Test Switch (if
can prevent a system restart if hot refractory is detected. available) to stop the sequence in the PILOT IGN
period. Ignition spark should occur, but the flame signal
Infrared (lead sulfide) detectors can respond to infrared rays should not be more than 0.5 Vdc.
emitted by a hot refractory, even when the refractory has 3. If the flame signal is higher than 0.5 Vdc and the
visibly ceased to glow. Infrared radiation from a hot refractory FLAME LED does come on, consult the equipment
is steady, but radiation from a flame has a flickering operating manual and resight the detector farther out
characteristic. The infrared detection system responds only to from the spark, or away from possible refection. It may
flickering infrared radiation; it can reject a steady signal from be necessary to construct a barrier to block the ignition
hot refractory. The refractory steady signal can be made to spark from the detector view. Continue adjustments until
fluctuate if it is reflected, bent or blocked by smoke or fuel mist the flame signal due to ignition spark is less than 0.5
within the combustion chamber. Be careful when applying an Vdc.
infrared system to verify its response to flame only.
NOTE: The Honeywell Q624A and Q652A,B Solid State
The ultraviolet detector can respond to hot refractory above Spark Generators prevent detection of ignition spark
2300°F (1371°C). when properly applied with C7027, C7035,C7044 or
C7061 Ultraviolet Flame Detectors. The Q624A and
1. Operate the burner until the refractory reaches its Q652B are only for use with gas pilots; the Q652A is
maximum temperature (Infrared Only). If the installation only for oil applications.
has a multi-fuel burner, burn the heavier fuel that is
most likely to reflect, bend or obscure the hot refractory
steady infrared radiation. Response to Other Ultraviolet
2. When the maximum refractory temperature is reached,
close all manual fuel shutoff valves, or open the
Sources
electrical circuits of all automatic fuel valves. Some sources of artificial light (such as incandescent or
3. Visually observe when the burner flame or FLAME LED fluorescent bulbs, mercury sodium vapor lamps and daylight)
goes out. If this takes more than three seconds, the produce small amounts of ultraviolet radiation. Under certain
infrared detector is sensing hot refractory. conditions, an ultraviolet detector responds to these sources
4. Immediately terminate the firing cycle. Lower the as if sensing a flame. To check for proper detector operation,
setpoint to the operating controller, or set the Fuel check the Flame Failure Response Time (FFRT) and conduct
Selector Switch to OFF. Do not open the master switch. Safety Shutdown Tests under all operating conditions.
19 66-1150—02
Flame Signal With Hot Combustion 4. Failure to ignite main (only interrupted pilot application).
a. Open the manual pilot valve(s); leave the main fuel
Chamber (All Installations) manual shutoff valve(s) closed.
1. With all initial start-up tests and burner adjustments b. Depress the RESET button.
completed, operate the burner until the combustion c. Start the system.
chamber is at the maximum expected temperature. d. The pilot should ignite and the flame signal should
2. Observe the equipment manufacturer warm-up be at least 1.25 Vdc but the main burner cannot
instructions. light.
3. Recycle the burner under these hot conditions and e. The flame signal should drop below 1.25 Vdc within
measure the flame signal. Check the pilot alone, the the FFRT of the amplifier and the relay module after
main burner flame alone, and both together (unless the interrupted pilot goes out.
monitoring only the pilot flame when using an f. *Main Flame Ign.* fault is displayed on the
intermittent pilot). Check the signal at both High and Keyboard Display Module. Fault code 19 is
Low Firing Rate positions and while modulating, if displayed to denote the fault.
applicable. g. Safety shutdown occurs.
4. Check the FFRT of the flame amplifier and relay 5. Loss of flame during RUN.
module. a. Open the main fuel manual shutoff valve(s) and
5. Lower the setpoint of the operating controller and open manual pilot shutoff valve(s).
observe the time it takes for the burner flame to go out. b. Depress the RESET button.
This should be within the maximum FFRT. c. Start the system. Start-up should be normal and the
6. If the flame signal is too low or unsteady, check the main burner should light normally.
flame detector temperature. Relocate the detector if the d. After the sequence is in the normal RUN period for
temperature is too high. at least 10 seconds with the main burner firing,
7. If necessary, realign the sighting to obtain the proper close the manual main shutoff valve(s) to extinguish
signal and response time. the main burner flame. (On intermittent pilot
8. If the response time is still too slow, replace the Plug-in applications, also, close the pilot manual shutoff
Flame Signal Amplifier. valve[s].)
9. If the detector is relocated or resighted, or the amplifier e. The flame signal should drop below 1.25 Vdc within
is replaced, repeat all required Checkout tests. the FFRT of the amplifier and the relay module after
the main flame and/or pilot goes out.
f. *Main Flame Fail* fault is displayed on the Keyboard
SAFETY SHUTDOWN TESTS Display Module. Fault code 17 is displayed to
denote the fault.
(ALL INSTALLATIONS) g. Safety shutdown occurs. (RM7890 Relay Modules
will recycle if jumper JR2 is intact, then lock out on
failure to light the pilot.)
Perform these tests at the end of Checkout, after all other 6. Opening a Preignition Interlock after the first five
tests are completed. If used, the external alarm should turn seconds of STANDBY.
on. Press the RESET push button on the relay module to a. Open the main fuel manual shutoff valve(s) and
restart the system. open manual pilot shutoff valve(s).
1. Opening a Preignition Interlock during STANDBY. b. Depress the RESET button.
a. *Preignition ILK* fault is displayed on the Keyboard c. *Preignition ILK* fault is displayed on the Keyboard
Display Module (KDM). Fault code 10 or 33 is Display Module. Fault code 33 is displayed to
displayed to denote the fault. denote the fault.
b. Safety shutdown occurs. d. Safety shutdown occurs.
2. Detection of flame 40 seconds after entry to STANDBY
from RUN, fault code 9. Detection of flame from 10 IMPORTANT
seconds up to 30 seconds into PREPURGE time. 1. If the relay module fails to shut down on any of these
a. Simulate a flame to cause the flame signal voltage tests, take corrective action; refer to Troubleshooting
level to be at least 1.25 Vdc for 40 seconds after and the relay module diagnostic and return to the
entry to STANDBY from RUN. beginning of all Checkout tests.
b. *Flame Detected* fault is displayed on the Keyboard 2. When all Checkout tests are completed, reset all
Display Module. Fault code 9 or 15 or 18 is switches to the original status.
displayed to denote the fault.
c. Safety shutdown occurs.
3. Failure to ignite pilot. TROUBLESHOOTING
a. Close pilot and main fuel manual shutoff valve(s).
b. Cycle burner on. The POWER LED provides fault identification when the Relay
c. Automatic pilot valve(s) should be energized but the Module locks out on an alarm. Fault identification is a series of
pilot cannot ignite. fast- and slow-blinking LED lights. The fast blinks identify the
d. *Pilot Flame Fail* fault is displayed on the Keyboard tens portion of the fault code (three fast blinks is 30), while the
Display Module. Fault code 28 is displayed four or slow blinks identify the units portion of the fault code (two slow
ten seconds, depending on the jumper configuration blinks is 2). Three fast blinks followed by two slow blinks
selection for Pilot Flame Establishing Period (PFEP) would be fault code 32. (See Table 9 for Blinking Fault Code
after the pilot valve(s) is energized to denote the List.)
fault.
e. Safety shutdown occurs.
66-1150—02 20
The LED code repeats as long as the fault exists. To clear the
fault, press the RESET button.
Historical Information Index
The relay module has nonvolatile memory that allows the
The S7800 KDM displays a sequence status message relay module to retain historical information for the six most
indicating: STADBY, PURGE, PILOT IGN, MAIN IGN, RUN recent lockouts. Each of the six lockout files retains the cycle
and POSTPURGE. The selectable messages also provide when the fault occurred, the hour of operation when the fault
visual indication of current status and historical status of the occurred, a fault code, a fault message and burner status
equipment, such as: Flame Signal, Total Cycles, Total Hours, when the fault occurred.
Fault History, Diagnostic Information, and Expanded
Annunciator terminal status (if used). With this information, IMPORTANT
most problems can be diagnosed without extensive trial and Some older relay modules cannot operate without a
error testing. KDM, extension cable assembly with KDM, or a Data
ControlBus™ Module installed.
Diagnostic Information and History Data are available to assist
in troubleshooting the relay module. SERVICE NOTES:
The relay module provides diagnostic information to aid the 1. If the KDM is scrambled, remove and reinstall the KDM,
service mechanic in obtaining information when and reset the 7800 SERIES Relay Module.
troubleshooting the system. Information available in the 2. Reset the 7800 SERIES Relay Module by pressing the
Diagnostic Information includes Device Type, Device Suffix, RESET pushbutton on the 7800 SERIES Relay Module,
Software Revision, Manufacturing Code, Flame Amplifier or by pressing a remote reset pushbutton wired through
Type, Flame Failure Response Time, Selectable Jumper the KDM, Data ControlBus™ Module, or Remote Reset
Configuration Status, Run/Test Switch Status and Terminal Module. A power-up reset causes an electrical reset of
Status. the relay module but does not reset a lockout condition.
3. Use the access slots in the sides of the Q7800A,B
Wiring Subbase to check terminal voltage.
Diagnostic Information Index 4. Maximum ambient temperature of a C7012E,F;Series 1
The relay module monitors input/output terminals and can through 6, is reduced to 125°F because of the duty
display the status of the terminal at the KDM (example: Pilot cycle operation of the relay module.
Valve T8 1). See the applicable relay module installation
instructions for a complete terminal description and number.
The display shows the actual status of the terminal. If voltage
is detected at the terminal, 1 is displayed, but if no voltage is
detected at the terminal, 0 is displayed.
Table 10. Blinking Fault Codes and Recommended Troubleshooting .
Blink Code System Failure Recommended Troubleshooting
Code 1-1 Low AC Line detected. 1. Check the relay module and display module connections.
*Low AC Line 2. Reset and sequence the Relay Module.
Voltage* 3. Check the 7800 power supply and make sure that frequency and voltage meet
Code 1-2 Excessive noise or specifications.
*AC Quality device running on slow, 4. Check the backup power supply, as appropriate.
Problem* fast, or AC line dropout
detected.
Code 2-1 Flame sensed when no 1. Check that flame is not present in the combustion chamber; correct any errors.
*Unexpected flame is expected during 2. Make sure that the flame amplifier and flame detector are compatible.
Flame Signal* STANDBY or PURGE. 3. Check the wiring and correct any errors.
4. Remove the flame amplifier and inspect its connections. Reseat the amplifier.
5. Reset and sequence the relay module.
6. If the code reappears, replace the flame amplifier and/or the flame detector.
7. If the fault persists, replace the relay module.
Code 2-2 No-flame time present 1. Measure the flame signal. If one exists, verify that it meets specifications.
*Flame Signal at the end of the PIlot 2. Make sure that the flame amplifier and flame detector are compatible.
Absent* Flame Establishing 3. Inspect the main fuel valve(s) and valve connection(s).
Period; lost during the 4. Verify that the fuel pressure is sufficient to supply fuel to the combustion
Main Flame Establishing chamber. Inspect the connections to the fuel pressure switches. Make sure
Period or during RUN. they are functioning properly.
5. Inspect the Airflow Switch and make sure that it is functioning properly.
6. Check the flame detector sighting position; reset and recycle. Measure the
flame signal strength. Verify that it meets specifications. If not, refer to the
flame detector and/or flame amplifier checkout procedures in the installation
instructions.
7. Replace the flame amplifier and/or the flame detector, if necessary.
21 66-1150—02
Table 10. Blinking Fault Codes and Recommended Troubleshooting (Continued).

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.
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.
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 supply-
Interlock Switch Prepurge. ing 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.
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. Correct any errors.
Interlock On point in sequence or On 2. Reset and sequence the relay module.
During in Standby. 3. If the fault persists, measure the voltage between terminal 6 and G (ground),
Standby* then between terminal 7 and G. If there is 120 Vac at terminal 6 when the
controller is off, the controller switch may be bad or is jumpered.
4. If steps 1 through 3 are correct and there is 120 Vac at terminal 7 when the
controller is closed and the fault persists, check for a welded or jumpered
Running Interlock or Airflow Switch. Correct any errors.
5. If steps 1 through 4 are correct and the fault persists, replace the relay module.
Code 3-3 VPS (Valve Proving 1. Check wiring, making sure upstream valve is connected to terminal 9 and
*VPS in Switch) in wrong state downstream valve is connected to terminal 17.
Improper State* during VPS Test. 2. Conduct Valve Seat leakage test using a manometer.
3. Reset and sequence the relay module; if fault repeats, test VPS (connected to
terminal 16) is functioning properly; replace if necessary.
5. If fault persists, replace the relay module.
Code 4-1 No purge card or the 1. Make sure the purge card is seated properly.
*Purge Card purge card timing has 2. Inspect the purge card and the connector on the relay module for any damage
Problem* changed from the or contaminants.
original configuration. 3. Reset and sequence the relay module.
4. If the fault code reappears, replace the purge card.
6. If the fault code persists, replace the relay module.
Code 4-2 Pilot (ignition) valve
*Wiring
Problem/
terminal, main valve,
ignition or Main Valve 2
WARNING
Internal Fault* was on when it should Electrical Shock Hazard; Fire or Explosion Hazard.
be off. Can cause severe injury, death or property damage.
Remove system power and turn off power supply.
1. Remove system power and turn off fuel supply.

2. Check wiring; correct any errors.
3. inspect Pilot Fuel Valve(s), both places, and connections.
Code 4-3 Flame not sensed, or 1. Check wiring; correct any errors.
*Flame sensed when it should 2. Make sure the flame amplifier and flame detector are compatible.
Amplifier be off. 3. Remove the flame amplifier and inspect the connections. Reseat the amplifier.
Problem* 4. Reset and sequence the relay module.
66-1150—02 22
Table 10. Blinking Fault Codes and Recommended Troubleshooting (Continued).

Code 4-4 The configuration 1. Inspect the jumper connections. Make sure the clipped jumpers were
*Configuration jumpers differ from the completely removed.
Jumper sample taken at startup. 2. Reset and sequence the relay module.
Problem* 3. If the fault persists, replace the relay module.
Code 5-1 Preignition Interlock 1. Check wiring and correct any errors.
*Preignition fault. 2. Check Preignition Interlock switches to assure proper functioning.
Interlock* 3. Check fuel valve operation.
4. Reset and sequence the relay module; monitor the Preignition Interlock status.
Code 5-2 Either High Fire Switch 1. Check wiring and correct any errors.
*High Fire Sw. or Low Fire Switch 2. Reset and sequence the relay module.
or Low Fire failure. 3. Use manual motor potentiometer to drive the motor open and closed. Verify at
Sw.* motor switch that the end switches are operating properly. Use RUN/TEST
switch if manual potentiometer is not available.
Code 5-3 Man-Open Switch, Start 1. Check wiring and correct any errors.
*Man-Open Switch or Control On in 2. Make sure that the Manual Open Valve Switch, Start Switch and Control are
Sw.; Start Sw. the wrong operational operating properly.
or Control On* state. 3. Stat Switch held “On” too long.
5. Reset and sequence the relay module. If the fault persists, replace the relay
module (RM7838A1014; RM7838B1013 or RM7838C1004 only).
Code 6-1 Relay Module self-test 1. Reset and sequence the relay module.
*Internal Faults* failure. 2. If fault reappears, remove power from the device, reapply power, then reset
and sequence the relay module.
Code 6-2 Relay Module Self-Test 1. Reset and sequence the relay module.
*Internal Faults* failure. 2. If fault reappears, remove power from the device, reapply power, then reset
3. If fault does not repeat on the next cycle, check for electrical noise being
copied into the relay module through the external loads or possibly an
electrical grounding issue.
Code 6-3 Fault with special OEM 1. Check wiring and operation of special OEM inputs.
*Device input circuits. 2. Reset and sequence the relay module.
Specific* 3. If fault reappears, remove power from the device, reapply power, then reset
4. If the fault does not repeat on the next cycle, check for electrical noise being
copied into the relay module through the external loads or possibly an
electrical grounding issue.
Code 6-4 Unused at this time. —
*Accessory
Fault*
Code 7-7 Unused at this time. —
*Unused*
23 66-1150—02
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 STANDBY.
WARNING
Explosion Hazard.
The following steps are to determine the test time for the relay Can cause severe injury, death or property
module to verify the valve seats are not leaking at a rate of damage.
greater than/equal to 0.1% of the burner capacity. Be sure to select adequate testing times when the
Valve Proving feature is selected. A shorter time can
The following diagram shows a typical valve train. The legend result in inadequate leak testing of the valves.
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
Fig. 20. Typical valve train layout.
1. Identify items of your system and fill in the “Information” Table 11. Valve Proving Test Time Symbols
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 ft 3 Volume between the two valves to be
IMPORTANT tested.
The tables show information on Honeywell Valves V1 Volume of upstream valve outlet cavity.
only. Contact other valve manufacturers to obtain ft3
data on their specific valves. V2 ft3 Volume of downstream valve inlet cavity.
3. Use appropriate Results column items to fill in the Valve L ft Length of pipe between valves.
Train Volume Formula and the Calculation of Valve D npt Pipe Size—used to define A
Proving Test Time.
A in.2 Pipe Cross Section Area (from Table III)
4. Round up the time to the nearest second.
5. The test time calculated is the time you will enter into Test Seconds Minimum VPS test period.
the VPS Setup. Time
P psi Gas inlet pressure to upstream valve.
Calculation of Valve Train Volume C ft3/hr Burner Capacity.
X = V1 + V2 + (A X L/144)
NOTE: V1 is the outlet cavity of the upstream valve and V2
is the inlet cavity of the downstream valve.
Calculation of Valve Proving Test
Time NOTE: 10 seconds is the minimum test time allowed. If your
calculations are less than 10 seconds, enter 10
Test Time = 187,000 x (P x X)/C seconds.
66-1150—02 24
Example:
We have a 2.5 MBTU burner with 2 psi valve train inlet

pressure. The upstream valve is a proof-of-closure V5044 with
a solenoid V4295 valve downstream. We have a 2 in. NPT
pipe, 1-3/4 ft long, between the valves.
Table 12. VPS Worksheet Example.

Item Description Information Lookup Table Results Formula Item
V1 Upstream Valve Volume V5055 13 0.0218 V1
V2 Downstream Valve Volume V4295 14 0.0267 V2
D Pipe Size (in.) 2 in. NPT 15 3.356 A
L Pipe Length (ft) 1.75 ft — 1.75 L
P Valve Inlet Pressure (psig) a 2 — 2 P
C Burner Maximum Firing (cf/hr)b 2.5 mbtu — 2500 C
a
Divide inches w.c. by 27.7 to get psi.
b Divide Btuh by 1000 to get cf/hr for natural gas or by 2550 to get cf/hr for LP gas.
Calculation of Valve Train Volume: Test Time = 187,000 x (P x X ÷ C)
X = V1 + V2 + (A x L ÷ 144) Test Time = 187,000 x (2 x 0.0893 ÷ 2500) = 13.4

seconds.
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 Valve Volumes for Honeywell Valves.

Pipe Size NPT
(inches) V4295 V4297A1013 V4297A1005 V48 V5055 V5097A1004 V5097A1012
3/8 0.0002 — — — — — —
1/2 0.0002 — — — — — —
3/4 0.0008 0.0093 0.0090 0.0010 0.0046 0.0066 —
1 0.0009 0.0093 0.0090 0.0010 0.0046 0.0066 —
1-1/4 0.0045 0.0093 0.0090 0.0035 0.0046 0.0066 —
1-1/2 0.0045 0.0093 — 0.0035 0.0218 0.0066 —
2 0.0089 0.0093 — 0.0048 0.0218 0.0066 0.0285
2-1/2 0.0441 — — 0.0048 0.0227 — 0.0285
3 0.0441 — — 0.0048 0.0227 — 0.0285
4 — — — — 0.0779 — —
Table 14. V2 Downstream Valve Volumes for Honeywell Valves.

Pipe Size NPT
(inches) V4295 V4297A1013 V4297A1005 V48 V5055 V5097A1004 V5097A1012
3/8 0.0011 — — — — — —
1/2 0.0011 — — — — — —
3/4 0.0026 0.0282 0.0232 0.0048 0.0067 0.0093 —
1 0.0036 0.0282 0.0232 0.0048 0.0067 0.0093 —
1-1/4 0.0148 0.0282 0.0232 0.0110 0.0067 0.0093 —
1-1/2 0.0148 0.0282 — 0.0110 0.0238 0.0093 —
2 0.0267 0.0282 — 0.0184 0.0238 0.0093 0.0303
2-1/2 0.0554 — — 0.0184 0.0245 — 0.0303
3 0.0554 — — 0.0184 0.0245 — 0.0303
4 — — — — 0.0801 — —
25 66-1150—02
Table 15. Schedule 40 Pipe Internal Cross-Sectional Area.

Cross-Sectional Area (Sq.
Pipe Size NPT (Inches) In.) “A”
3/8 0.191
1/2 0.304
3/4 0.533
1 0.864
1-1/4 1.498
1-1/2 2.036
2 3.356
2-1/2 4.788
3 7.393
4 12.730
Table 16. VPS Worksheet.

Item Description Information Lookup Table Results Formula Item
V1 Upstream Valve Volumes 13 V1
V2 Downstream Valve Volumes 14 V2
D Pipe Size (in.) 15 A
L Pipe Length (ft) — L
P Valve Inlet Pressure (psig)a — P
C Burner Maximum Firing (cf/hr)b — C
a Divide inches w.c. by 27.7 to get psi.
b Divide Btuh by 1000 to get cf/hr for natural gas or by 2550 to get cf/hr for LP gas.
66-1150—02 26
27 66-1150—02
Automation and Control Solutions

Honeywell International Inc.
1985 Douglas Drive North
Golden Valley, MN 55422
Honeywell Limited-Honeywell Limitée

35 Dynamic Drive
® U.S. Registered Trademark
Toronto, Ontario M1V 4Z9 © 2010 Honeywell International Inc.
66-1150—02 M.S. Rev. 08-10
customer.honeywell.com Printed in U.S.A.

RM7890A1056

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RM7890A1056, RM7890B1048

7800 SERIES Relay Modules

APPLICATION The following assumptions apply when using the

The Honeywell RM7890A1056 and RM7890B1048 Relay

Functions the RM7890 provides include automatic on/off

This document provides installation and static checkout

WARNING equipment in a residential area can cause

Location 3. Disconnect the power supply from the main disconnect

Table 1. Recommended Wire Sizes and Part Numbers.

Table 2. Recommended Grounding Practices.

Table 3. Terminal Ratings.

Table 4. Combinations for Terminals 8, 9,17 and 10.

Table 5. Composition of Each Combination.

Final Wiring Check

Table 6. Static Checkout.

Table 6. Static Checkout. (Continued)

PRE-IGNITION 1 NUMBERS IN CIRCLES ARE RELAY MODULE

20 PROVIDE DISCONNECT MEANS AND

Fig. 2. Internal block diagram of the RM7890.

Mounting RM7890 Relay Module IMPORTANT

MAIN FUEL PRE-IGNITION

Fig. 3. Wiring subbase and operating sequence chart for RM7890.

5. Mount the RM7890 by aligning the four L-shaped corner

Fig. 4. RM7890 Relay Module exploded view.

The tolerance on all valve proving timing values is ±10%.

Table 7. Honeywell Pressure Switch Selection for Valve Proving System.

Pressure Switch Selection Pressure Switch Installation and

When the RM7890 is installed and powered, “STANDBY” will

NOTE: Use Never on initial startup so gas line purging and

Fig. 5. STANDBY/Setup screen. =Save changes

STANDBY SU Fig. 9. Save Changes screen.

3. Use the up/down arrows to enter the first number—7. BACK

Fig. 10. Valve Prove time screen.

Fig. 8. SETUP: Valve Prove screen. M22665B

Fig. 11. Save Changes screen.

Fig. 12. Confirmation Acknowledgement screen.

BACK Fig. 16. Setup Done screen.

14. Use the down arrow to confirm correct.

NOTE: Using the up arrow during the confirmation will take

1 LOCKOUT IF ON, M1 LEAKING (LOW PRESSURE TEST).

2 LOCKOUT IF OFF, MV2 LEAKING (HIGH PRESSURE TEST).

Fig. 18. RM7890 Sequence for Valve Proving System.

PRINCIPAL TECHNICAL a. Ignition/pilot valve terminal is not energized.

met. When the tolerances are not met, a hold condition is

NOTE: If a 3.0 second flame failure response amplifier is SERVICE NOTE

Normal Start-Up Safe Start Check

Valve Proving occurs here if Before, Both, or Split sequence is

3. Limit trial for pilot to ten seconds. Limit the attempt to

WARNING Equipment Recommended

Table 9. Checkout Steps and Applicable 7800 Series Systems.

Table 10. Blinking Fault Codes and Recommended Troubleshooting (Continued).

1. Remove system power and turn off fuel supply.

Table 10. Blinking Fault Codes and Recommended Troubleshooting (Continued).

Fig. 20. Typical valve train layout.

We have a 2.5 MBTU burner with 2 psi valve train inlet

Table 12. VPS Worksheet Example.

Calculation of Valve Train Volume: Test Time = 187,000 x (P x X ÷ C)

X = V1 + V2 + (A x L ÷ 144) Test Time = 187,000 x (2 x 0.0893 ÷ 2500) = 13.4

Table 13. V1 Upstream Valve Volumes for Honeywell Valves.

Table 14. V2 Downstream Valve Volumes for Honeywell Valves.