RM7840L1075

RM7800L1087, RM7840G1022, RM7840L1075, EC7840L1014
RM7800L2087, RM7840G2022, RM7840GL2075, EC7840L2014

Relay Modules with Valve Proving
INSTALLATION INSTRUCTIONS
APPLICATION • Both—Valve proving occurs at both times Before and

After, noted above.
The Honeywell RM7800L/40G,L and EC7840L Relay • Split—The main valve 2 (MV2) (high pressure) seat
Modules are microprocessor-based integrated burner test is performed at the Before time and the main
controls for automatically fired gas, oil, or combination fuel valve 1 (MV1) (low pressure) seat test is performed
single burner applications. The RM7800L/40G,L and during the After time.
EC7840L Relay Modules are used for UL/CSA Modulating The following assumptions apply when using the
and FM/IRI Modulating burner applications. The RM7840G,L, RM7800L, EC7840L:
RM7800L/40G,L, EC7840L system consists of a Relay
Module. Keyboard Display Modules (standard with MV1 MV2
RM7800), Dust Cover (standard with RM7840/EC7840L),
Subbase, Amplifier, and Purge Card. Options include DATA
CONTROLBUS MODULE™, Remote Display Mounting, VP
First-Out Expanded Annunciator and Modbus™ SW.
communications capable.
INLET OUTLET
Functions provided by the RM7800L/40G,L, EC7840L
include automatic burner sequencing, flame supervision,
system status indication, system or self-diagnostics and
troubleshooting. 1
1 CAUTION: VALVE ENERGIZING TIMING IS BASED ON HONEYWELL VALVE

Using the S7800A2142 Keyboard Display (standard on OPENING TIMES OF 13 SECONDS MAXIMUM.
RM7800L2087) the following features can be set up: − FOR VALVES WITH TIMINGS GREATER THAN 13
SECONDS OR THOSE THAT DO NOT OPEN THE ACTIVE
VALVE WITHIN THE ENERGIZED TIME, A BYPASS SSOV
• Post Purge time—Up to 60 minutes—Device shipped RATED SOLENOID VALVE (1/4”, 120 VAC) IS REQUIRED TO
with 15 seconds Post purge. OBTAIN THE PROPER TEST PRESSURES.
− THE BYPASS VALVE WILL BE WIRED IN PARALLEL TO THE
• Valve Proving features including: VALVE IT IS BYPASSING (TERMINAL 9 FOR MV1 OR
— VPS test time TERMINAL 21 FOR MV2).
M24161A
— When (Never, Before, After, Split or Both)
• See S7800A1142 Instructions (65-0288), also see Fig. 1. The valve proving system.
S7800A2142 Instructions. Series 5 can be MV1—Wired to terminal 9. It is located in the most
programmed for Modbus communication. upstream position of the main gas valve train.
At commissioning time, the Valve Proving System may be
scheduled to occur at one of five different times: VPS—Valve Proving Switch: Setpoint at 1/2 of Main Valve
inlet pressure.
• Never—Device default as received—Valve proving
does not occur. MV2—Wired to terminal 21. It is the main valve located
closest to the burner.
• Before—Valve proving before run concurrent with Pre-
Purge. The PII—Pre-Ignition Interlock (or Proof of Closure Switch)
• After—Valve proving occurs after the Run state, for terminal 20 can be installed on MV1, MV2, or as a
before the device goes to Standby (Concurrent with series connection through both valves.
Post-Purge, if selected.)
Appendix B lists many wiring options for single and dual
fuel along with the Valve Proving options.
SIL3
Capable 32-00142-01
RELAY MODULES WITH VALVE PROVING
SPECIFICATIONS This document provides installation and static checkout

instructions. Other applicable publications are:
Electrical Ratings, see Table 3: Publication
Voltage and Frequency: No. Product
RM78xx—120 Vac (+10/-15%), 50 or 60 Hz (±10%).
EC78xx—220–240 Vac (+10/-15%), 50 or 60 Hz 65-0084 Q7800A,B 22-Terminal Wiring Subbase
(±10%). Product Data
Power Dissipation: RM7800/RM7840/EC7840L: 10W 65-0288 S7800A1142 Keyboard Display Module
maximum in the Run mode. Product Data
65-0091 S7810A Data ControlBus™ Module
Maximum Total Connected Load: 2000 VA.
Product Data
Fusing: 15A maximum, Type SC or equivalent Fast Blow. 65-0095 S7820 Remote Reset Module Product
Data
Environmental Ratings:
65-0097 221729C Dust Cover Installation
Ambient Temperature:
Instructions
Operating: -40°F to +140°F (-40°C to +60°C).
Storage: -40°F to +150°F (-40°C to +66°C). 65-0101 S7830 Expanded Annunciator Product
Humidity: 85% relative humidity continuous, noncon- Data
densing. 65-0109 R7824, R7847, R7848, R7849, R7851,
Vibration: 0.5G environment. R7852, R7861, R7886 Flame Amplifiers
for the 7800 SERIES Product Data
SIL 3 Capable:
RM7800/RM7840E, G, L, M are SIL 3 Capable in a prop- 65-0131 221818A Extension Cable Assembly
erly designed Safety Instrumented system. See Product Data
http://www.exida.com/SAEL/Honeywell_7800 for 65-0229 7800 SERIES Relay Modules Checkout
Certificate Agreement. and Troubleshooting Product Data
65-0249 S7810M ModBus Module
Approvals: RM7800L/40G,L:
Underwriters Laboratories Inc. Listed: File No. MP268,
Guide No. MCCZ. INSTALLATION
Factory Mutual Approved: Report No. 1V9A0.AF.
Swiss Re (formerly IRI): Acceptable. When Installing this Product...
Federal Communications Commission, Part 15, Class B—
Emissions. 1. Read these instructions carefully. Failure to follow
them could damage the product or cause a
Approvals: EC7840L: hazardous condition.
Factory Mutual Approved: Report No. is still not known. 2. Check the ratings given in the instructions and
Swiss Re (formerly IRI): Acceptable. marked on the product to make sure the product is
Federal Communications Commission, Part 15, Class B— suitable for the application.
Emissions. 3. Installer must be a trained, experienced, flame
safeguard service technician.
4. After installation is complete, check out the product
operation as provided in these instructions.
WARNING
Fire or Explosion Hazard.
Can cause property damage, severe injury,
or death.
To prevent possible hazardous burner operation,
verify safety requirements each time a control is
installed on a burner.
WARNING
Electrical Shock Hazard.
Can cause serious injury or death.
Disconnect the power supply before beginning
installation. More than one power supply
disconnect may be required.
32-00142—01 2
IMPORTANT Mounting Wiring Subbase

1. Wiring connections for the relay modules are
unique; therefore, refer to Figs. 3, 4, 6, 7, or 1. Mount the subbase in any position except horizontally
Appendix B for proper subbase wiring. with the bifurcated contacts pointing down. The
2. Wiring must comply with all applicable codes, standard vertical position is recommended. Any other
ordinances and regulations. position decreases the maximum ambient
3. Wiring must comply with NEC Class 1 (Line Volt- temperature rating.
age) wiring. 2. Select a location on a wall, burner or electrical panel.
4. Loads connected to the RM7800L/40G,L, EC7840L The Q7800 can be mounted directly in the control
must not exceed those listed on the cabinet. Be sure to allow adequate clearance for
RM7800L/40G,L, EC7840L label or the Specifica- servicing, installation, access or removal of the
tions, see Table 3. RM7800L/40G,L, EC7840L, Expanded Annunciator,
5. Limits and interlocks must be rated to simultane- Keyboard Display Module, flame amplifier, flame
ously carry and break current to the ignition trans- amplifier signal voltage probes, Run/Test Switch,
former, pilot valve, and main fuel valve(s). electrical signal voltage probes and electrical field
6. All external timers must be listed or component connections.
recognized by authorities who have jurisdiction for 3. For surface mounting, use the back of the subbase
the specific purpose for which they are used. as a template to mark the four screw locations. Drill
7. For on-off gas-fired systems, some authorities the pilot holes.
who have jurisdiction prohibit the wiring of any 4. Securely mount the subbase using four no. 6 screws.
limit or operating contacts in series between the
flame safeguard control and the main fuel valve(s). Wiring Subbase
8. Two Flame Detectors can be connected in parallel
with the exception of Infrared Flame Detectors NOTE: There are now two different subbase models that
(C7015, C7915), Ultraviolet (C7927, C7961), or Visi- can be purchased. It is important to note which
ble (C7962). subbase is compatible with the relay module
9. This equipment generates, uses and can radiate when purchasing repair or replacement parts.
radio frequency energy and, if not installed and
used in accordance with the instructions, may Series 1000 Subbase
cause interference to radio communications. It
has been tested and found to comply with the All relay product codes that start with a 1 (example:
limits for a RM7840G1014/U) needs to be used with existing
Class B computing device of Part 15 of FCC rules subbase Q7800A1005/U.
which are designed to provide reasonable
protection against such interference when Series 2000 Subbase
operated in a commercial environment. Operation All relay product codes that start with a 2 (example:
of this equipment in a residential area may cause RM7840G2014/U) needs to be used with subbase
interference; in which case, the users at their own Q7800A2005/U.
expense may be required to take whatever
measures are required to correct this interference.
10.This digital apparatus does not exceed the Class B
Subbase Compatibility
limits for radio noise for digital apparatus set out Any relay module in the updated 1000 series will be fully
in the Radio Interference Regulations of the Cana- backward compatible with any legacy subbase
dian Department of Communications. (Q7800A1005/U) installed in the field as well as all newly
purchased updated 1000 and 2000 series relay modules.
Location Any relay module in the new 2000 series will only be able
to be installed on subbase Q7800A2005/U, and will not
Humidity be backward compatible with any Q7800A1005/U legacy
subbases already installed in the field.
Install the relay module where the relative humidity never
reaches the saturation point. The relay module is designed IMPORTANT
to operate in a maximum 85 percent relative humidity Make sure to check the relay model number and
continuous, noncondensing, moisture environment. check the subbase compatibly prior to ordering or
Condensing moisture may cause a safety shutdown. attempting a new installation or field upgrade.
Vibration
Do not install the relay module where it could be subjected WARNING
to vibration in excess of 0.5G continuous maximum Electrical Shock Hazard.
vibration. Can cause serious injury, death or equipment
damage.
Disconnect the power supply before beginning
Weather installation to prevent electrical shock, equipment
The relay module is not designed to be weather tight. and control damage. More than one power supply
When installed outdoors, protect the relay module using disconnect may be required.
an approved weather-tight enclosure.
3 32-00142—01
1. For proper subbase wiring, refer to Figs. 3, 4, 6, 7, or c. Enclose flame detector leadwires without armor
Appendix B. cable in metal cable or conduit.
2. For proper remote wiring of the Keyboard Display d. Follow directions in flame detector, Data Control-
Module, through a 203541 5-wire Connector, refer bus Module™, or Remote Reset Module Instruc-
to the Specifications for the Keyboard Display tions.
Module 8. Keyboard Display Module (KDM): Because the KDM
(65-0288), Data ControlBus Module™ (65-0091) or is powered from a low voltage, energy limited source,
Extension Cable Assembly (65-0131). it can be mounted outside of a control panel if it is
3. Disconnect the power supply from the main discon- protected from mechanical damage.
nect before beginning installation to prevent electri-
cal shock and equipment damage. More than one NOTE: A 13 Vdc power supply must be used any time
disconnect may be required. more than one Keyboard Display Module is used.
4. All wiring must comply with all applicable electrical
codes, ordinances and regulations. Wiring, where 9. Maximum wire lengths follow:
required, must comply with NEC, Class 1 (Line Volt- a. RM7800L/40G,L, EC7840L leadwires—The maxi-
age) wiring. mum length of leadwire is 300 feet to terminal
5. Recommended wire size and type: see Table 1. inputs (Control, Pre-Ignition Interlock, Run-
6. Recommended grounding practices: see Table 2. ning/Lockout Interlock, High Fire Switch and Low
Fire Switch).
b. Flame Detector leadwires—The maximum flame
sensor leadwire length is limited by the flame
WARNING signal strength.
Keyboard Display Module and/or Data c. Remote Reset leadwires—The maximum length
Controlbus Module is powered from internally of wire is 1000 feet to a Remote Reset pushbut-
fused low voltage source and shares the voltage ton.
supply with Relay Module. The fuse is non- d. Data Controlbus Module™—The maximum Data
replaceable. Excessive current draw or short at Controlbus Module™ cable length depends on
display connection may cause fuse to blow out the number of system modules connected, the
resulting in dead, unpowered system. noise conditions and the cable used. The maxi-
mum length of all Data Controlbus Module™
interconnecting wire is 1000 feet.
The Keyboard Display Module, Data ControlBus Module™ 10. Make sure loads do not exceed the terminal ratings.
(for remote mounting or communications), through a Refer to the label on the
203541 5-wire Connector must be wired in a daisy chain RM7800/RM7840/EC7840L or to the ratings in
configuration, (1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). The order of Tables 3, 4 and 5.
interconnection of all the devices listed above is not
important. Be aware that modules on the closest and
farthest end of the daisy chain configuration string
Final Wiring Check
require a 120 ohm (1/4 watt minimum) resistor 1. Check the power supply circuit. The voltage and fre-
termination across terminals 1 and 2 of the electrical quency tolerance must match those of the
connectors, for connections over 100 feet. RM7800L/40G,L, EC7840L. A separate power sup-
ply circuit may be required for the
7. Recommended wire routing of leadwires: RM7800/RM7840/EC7840L. Add the required dis-
a. Do not run high voltage ignition transformer connect means and overload protection.
wires in the same conduit with the flame 2. Check all wiring circuits and complete the Static
detector, Data Controlbus Module™, or Remote Checkout, see Table 9, before installing the
Reset Module wiring. RM7800L/40G,L, EC7840L on the subbase.
b. Do not route flame detector, Data Controlbus 3. Install all electrical connectors.
Module™, or Remote Reset Module leadwires in 4. Restore power to the panel.
conduit with line voltage circuits.
32-00142—01 4
120 Vac 50/60 Hz
L1 (HOT) L2
INTERNAL
4 L2
ELECTRONICS
ALARM
3
3K
BLOWER
5
6K
DEMAND
LOW FIRE
LIMITS CONTROLLER 18
SWITCH
6
17 HIGH FIRE
DEMAND (VALVE 19
SWITCH
AIR FLOW PROVING)
SWITCH PILOT
7 8 VALVE
VALVE PROVING SWITCH 1K 4K
MAIN
16 9
VALVE 1
2K
20 10 IGNITION
5K 2K
PRE-IGNITION INTERLOCK
21 1
7K
FLAME F PLUG IN FLAME

22 DETECTOR
DETECTOR AMPLIFIER SHUTTER
G
HIGH FIRE
12
8K1
COMMON
13
8K2 MODULATE
INTERNAL RELAY OPTO FEEDBACK
15
FIELD WIRING 9K1
9K2
INTERNAL WIRING LOW FIRE
14
1 15 SECOND INTERRUPTED OR MV2 IF VALVE PROVING DEMAND (T17) USED.
Fig. 2. Internal block diagram of the RM7800L/40L, EC7840L (See Figs. 3, 4, 6 or 7 for individual detailed wiring
instructions).
Table 1. Recommended Wire Sizes and Part Numbers.

Application Recommended Wire Size Recommended Part Number(s)
Line voltage terminals 14, 16 or 18 AWG copper conductor, 600 THW75C, THHN90C.
volt insulation, moisture-resistant wire.
Keyboard Display Module (KDM) 22 AWG two-wire twisted pair with Belden 8723 shielded cable or
ground, or five wire. equivalent.
Data ControlBus Module™ 22 AWG two-wire twisted pair with Belden 8723 shielded cable or
ground, 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 THW75C, THHN90C.
power input. temperatures for given application.
5 32-00142—01
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 must be used, 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 (KDM, Data Use the shield of the signal wire to ground the device to the signal ground
ControlBus Module™ terminals [3(c)] of each device. Connect the shield at both ends of the chain to
earth ground.
Table 3. Terminal Ratings.

Ratings
Terminal
No. Description 120 Vac 220/230/240 Vac
G Flame Sensor Ground a — —
Earth G Earth Ground — —
L2(N) Line Voltage Common — —
3 Alarm 1A pilot duty 220-240 Vac (+10%/-
120 Vac (+10%/-15%), 15%), 50 or 60 Hz (±10%)
4 Line Voltage Supply (L1)b 50 or 60 Hz (±10%)
5 Burner Motor 9.8 AFL, 58.8 ALR (inrush) 4A at PF = 0.5, 20A Inrush
6 Burner Controller and Limits Demand (NOT Valve 1 mA 1 mA
Proving)
7 Lockout/Running Interlock 8A run, 43A inrush 8A run, 43A inrush —
8 Pilot Valve/Ignition c 4A at PF = 0.5, 20A Inrush
9 Main Fuel Valve c 4A at PF = 0.5, 20A Inrush
10 Ignition c 2A at PF = 0.2
F(11) Flame Sensor 60 to 220 Vac, 60 to 220 Vac,
current limited current limited
12 Firing Rate High Fire 75 VA pilot duty 0.5A at PF = 0.5
13 Firing Rate Common 75 VA pilot duty 0.5A at PF = 0.5
14 Firing Rate Low Fire 75 VA pilot duty 0.5A at PF = 0.5
15 Firing Rate Modulate 75 VA pilot duty 0.5A at PF = 0.5
16 Valve Proving Switch 1 mA 1 mA
17 Demand — Valve Proving 1 mA 1 mA
18 Low Fire Switch Input 1 mA 1 mA
19 High Fire Switch Input (7800/40L only) 1 mA 1 mA
20 Pre-Ignition Interlock Input 1 mA 1 mA
21 Interrupted/Intermittent Pilot Valve/First Stage Oil Valve c 4A at PF = 0.5, 20A Inrush
or MV2
22 Shutter 0.5A d
a The relay module 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 fuse (or breaker) in event
of an internal short circuit. The relay module requires a low impedance ground connection to the equipment frame,
which, in turn, requires a low impedance connection to earth ground.
b 2000 VA maximum connected load to relay module assembly.
c See Tables 4 and 5.
d 220/240 Vac to 120 Vac, 10 VA (minimum) stepdown transformer (not provided) must be used to drive the shutter.
32-00142—01 6
Table 4. Combinations for Terminals 8, 9, 10 and 21.

Pilot Fuel 8 Main 9 Ignition 10 Valve 21
C F No Load No Load
B F No Load No Load
No Load F No Load B
F F A No Load
No Load F A F
D F A No Load
No Load D A D
D D A No Load
No Load D A D
Table 5. Explanation of Each Combination.

A B C D F
4.5A ignition. 50 VA Pilot Duty a plus 180 VA ignition plus 2A Pilot Duty.a 64 VA Pilot Dutya plus
4.5A ignition. motor valve with: motor valves with:
660 VA inrush, 360 VA 3850 VA inrush, 700 VA
open, 260 VA hold. open, 250 VA hold.
a Pilot Duty refers to solenoid-type valves.
Mounting RM7800L/40G,L, NOTE: 1xxx series is compatible with any subbase. 2xxx
series requires the 2xxx subbase.
EC7840L
3. Make sure no subbase wiring is projecting beyond
Relay Module (Fig. 9) the terminal blocks. Tuck in wiring against the back
1. Mount the RM7800L/40G,L, EC7840L vertically on of the subbase so it does not interfere with the
the Q7800 Subbase, or mount horizontally with the knifeblade terminals or bifurcated contacts.
knifeblade terminals pointing downward. When
IMPORTANT
mounted on the Q7800A, the RM7800L/40G,L,
The RM7800L/40G,L, EC7840L must be installed
EC7840L must be in an electrical enclosure.
with a plug-in motion rather than a hinge action.
2. When mounting in an electrical enclosure, provide
adequate clearance for servicing, installation and 4. Mount the RM7800L/40G,L, EC7840L by aligning
removal of the RM7800L/40G,L, EC7840L, the four L-shaped corner guides and knifeblade ter-
Keyboard Display Module, flame amplifier, flame minals with the bifurcated contacts on the wiring
amplifier signal voltage probes, electrical signal subbase and securely tighten the two screws without
voltage probes, and electrical connections. deforming the plastic.
a. Allow an additional two inches below the
RM7800L/40G,L, EC7840L for the flame ampli-
fier mounting.
b. Allow an optional three-inch minimum to both
sides of the RM7800L/40G,L, EC7840L for elec-
trical signal voltage probes.
7 32-00142—01
SERIES 90
FIRING RATE SERIES 90
Q7800 MOTOR CONTROLLER
HIGH FIRE
G 12 B B
FOR DIRECT SPARK IGNITION (OIL
OR GAS)
COMMON
L2 13 R R
IGNITION
10 TRANSFORMER
LINE VOLTAGE LOW FIRE
3 14 W W
ALARM
8 L2
MODULATE
4 (L1) 15
9 2ND STAGE
FUEL VALVE
BURNER MOTOR (OPTIONAL)
(BLOWER) 5 16
BURNER 6 17
CONTROLLER/LIMITS
2
LOCKOUT INTERLOCKS LOW FIRE

(INC. AIR FLOW SWITCH) 7 18
START SWITCH
1 120V, 50/60 Hz (EC7840L 220-240 VAC) POWER SUPPLY.
10 SEC. INTERRUPTED 8 HIGH FIRE PROVIDE DISCONNECT MEANS AND OVERLOAD
PILOT/IGNITION 19
PURGE SWITCH PROTECTION AS REQUIRED.
2 DO NOT WIRE TO ANY UNUSED TERMINALS.

MAIN FUEL VALVE(S) 9 20 PREIGNITION
INTERLOCK
3 SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
5 SECOND IGNITION FOR CORRECT WIRING.
(EARLY SPARK 10 21
15 SEC.
TERMINATION) INTERRUPTED
PILOT VALVE
F 22
FLAME DETECTOR
L1
(HOT)
3 1
L2
MASTER
SWITCH M27706
RM7800/RM7840L/EC7840L
INITIATE PREPURGE PREPURGE PFEP
(INITIAL HOLD HOLD 10 SEC.
POWERUP 00 DRIVE TO 00 TIMED 00 DRIVE TO 00(4 SEC. IF 10 20 25 00 15
ONLY) STANDBY HIGH FIRE PREPURGE LOW FIRE JR1 CLIPPED MFEP RUN POSTPURGE STANDBY
POWER POWER POWER POWER POWER POWER POWER POWER POWER POWER
LED PILOT PILOT PILOT PILOT PILOT
DISPLAY
FLAME FLAME FLAME FLAME FLAME
MAIN MAIN MAIN MAIN MAIN
ALARM ALARM ALARM ALARM ALARM
BURNER BURNER/BLOWER MOTOR 5
10 IGN. 5 SEC.
10 SEC. IGN./PILOT 8
15 SEC. PILOT 21
MAIN VALVE 9
OPERATING
LIMITS AND BURNER CONTROLLER CLOSED L1 TO 6
CONTROLS
AND
INTERLOCKS INTERLOCK. CHECK LOCKOUT INTERLOCKS CLOSED 6 TO 7 IC
PREIGNITION INTERLOCK CLOSED 4 TO 20 PII
5 TO 19 HIGH FIRE SW. LOW FIRE SW. 5 TO 18
FLAME
SAFE START CHECK FLAME PROVING SSC
SIGNAL
SWITCHING 13 TO 15
13 TO 12 13 TO 14 13 TO 14
FIRING
RATE MOTOR ACTION
MOTOR
Fig. 3. Typical wiring subbase and sequence for RM7800L/40L, EC7840L without enabled Valve Proving.
32-00142—01 8
SERIES 90
HIGH FIRE
G 12 B B
OR GAS)
COMMON
L2 13 R R
IGNITION
10 TRANSFORMER
LOW FIRE
LINE VOLTAGE 3 14 W W
ALARM 9 MAIN VALVE 1
L2
MODULATE
4 (L1) 15
21 MAIN VALVE 2
BURNER MOTOR VALVE PROVING

(BLOWER) 5 16 SWITCH
LIMITS
6 17
BURNER CONTROL
2
LOCKOUT INTERLOCKS LOW FIRE
START SWITCH
1 120V, 50/60 Hz (EC7840L 220-240 VAC) POWER SUPPLY.
10 SEC. INTERRUPTED 8 HIGH FIRE PROVIDE DISCONNECT MEANS AND OVERLOAD
PILOT/IGNITION 19
PURGE SWITCH PROTECTION AS REQUIRED.

MAIN FUEL VALVE 1 9 20 PREIGNITION
INTERLOCK 3 SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
5 SECOND IGNITION
(EARLY SPARK 10 21 MV2 VALVE
4 JR2 INTACT ON RM7800L/40L/EC7840L FOR DSI
TERMINATION)
FUNCTION.
F 22
FLAME DETECTOR
L1
(HOT)
3 1
L2
MASTER
SWITCH M27708
RM7800/RM7840L/EC7840L
INITIATE PREPURGE PREPURGE PFEP
(INITIAL HOLD HOLD 10 SEC.
POWERUP 00 DRIVE TO 00 TIMED 00 DRIVE TO 00(4 SEC. IF 10 20 25 00 15
ONLY) STANDBY HIGH FIRE PREPURGE LOW FIRE JR1 CLIPPED MFEP RUN POSTPURGE STANDBY
POWER POWER POWER POWER POWER POWER POWER POWER POWER POWER
DISPLAY
10 IGN. 5 SEC.
10 SEC. IGN./PILOT 8 2
MV2 21 1
MAIN VALVE 9
OPERATING
CONTROLS
AND
INTERLOCKS INTERLOCK. CHECK LOCKOUT INTERLOCKS CLOSED 7 IC
5 TO 19 HIGH FIRE SW. LOW FIRE SW. 5 TO 18
FLAME
SAFE START CHECK FLAME PROVING SSC
SIGNAL
SWITCHING 13 TO 15
13 TO 12 13 TO 14 13 TO 14
FIRING
RATE MOTOR ACTION
MOTOR
1 MV2 IS MAIN VALVE CLOSEST TO THE BURNER.
2 JR2 REMOVED FOR PILOT SEQUENCE. M27709
Fig. 4. Wiring subbase and sequence for RM7800L/40L, EC7840L with Valve Proving feature enabled.
9 32-00142—01
BEFORE
HF T19 FINISH
CLOSED 5 3
PURGE
4 SEC. 3 SEC. TEST TIME 4 SEC. 3 SEC. TEST TIME IGNITION TRIALS
CONTROLLER L1-17
AIRFLOW 17-7
MV2 (21)
MV1 (9)
VPS (16) 1 VPS (16) 2
PII (20) PII (20) PII (20)
POST FINISH POST
AFTER PURGE 4
PURGE
RUN 4 SEC. 3 SEC. TEST TIME 4 SEC. 3 SEC. TEST TIME STANDBY
CONTROLLER L1-17
L1-7
MV2 (21) MV1 (9)
VPS (16) 1 VPS (16) 2
PII (20) PII (20)
HF T19 FINISH POST
CLOSED POST PURGE PURGE
SPLIT 3 4
4 SEC. 3 SEC. TEST TIME BURNER RUN TIME 4 SEC. 3 SEC. TEST TIME STANDBY
CONTROLLER L1-17
LOCKOUT INTERLOCKS L1-7
MV1 (9) MV2 (21)
VPS (16) 2 VPS (16) 1
PII (20) PII (20)
1 LOCKOUT IF ON, MV1 LEAKING (LOW PRESSURE TEST). 3 TEST IS RUN CONCURRENT WITH PRE PURGE TIME.
2 LOCKOUT IF OFF, MV2 LEAKING (HIGH PRESSURE TEST). 4 TEST IS RUN CONCURRENT WITH POSTPURGE, IF POSTPURGE TIME IS ENABLED.
5 RM7800/40L/EC7840L ONLY. M24094A
Fig. 5. RM7800L/40G,L and EC7840L Relay Module operation, Valve Proving test options.
32-00142—01 10
SERIES 90
HIGH FIRE
G 12 B B
COMMON
L2 13 R R
LOW FIRE
120V ALARM 3 14 W W
MODULATE
4 (L1) 15
BURNER MOTOR FOR DIRECT SPARK IGNITION

5 16 3 (OIL OR GAS)
(BLOWER)
IGNITION
10 TRANSFORMER
BURNER 6 17
CONTROLLER/LIMITS
4
1ST STAGE
21 FUEL VALVE L2
RUNNING INTERLOCKS LOW FIRE
START SWITCH
9 2ND STAGE
FUEL VALVE
10 SEC. INTERRUPTED 8 2 (OPTIONAL)
PILOT/IGNITION 19
JUMPER WIRE FOR 30s MFEP
MAIN FUEL VALVE(S) 9 20 PREIGNITION

INTERLOCK
1 120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT
5 SECOND IGNITION MEANS AND OVERLOAD PROTECTION AS REQUIRED.
(EARLY SPARK 10 21 15 OR 30 SEC.
TERMINATION) INTERRUPTED/
INTERMITTENT 2 ADD JUMPER FOR 30 SECOND MAIN FLAME
PILOT VALVE ESTABLISHING PERIOD (MFEP).
F 22
FLAME DETECTOR 3 DO NOT WIRE TO ANY UNUSED TERMINALS.
L1
4 (HOT) 4 SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
L2 FOR CORRECT WIRING.
MASTER M12260C
SWITCH 1
RM7840G
INITIATE PREPURGE PFEP
(INITIAL HOLD 10 SEC.
POWERUP 00 TIMED 00 DRIVE TO 00(4 SEC. IF 10 20 25 00 15
ONLY) STANDBY PREPURGE LOW FIRE JR1 CLIPPED MFEP RUN POSTPURGE STANDBY
POWER POWER POWER POWER POWER POWER POWER POWER POWER
DISPLAY
10 IGN. 5 SEC.
10 SEC. IGN./PILOT 8
1 21
MAIN VALVE 9
OPERATING LIMITS AND BURNER CONTROLLER CLOSED L1 TO 6

CONTROLS
AND
INTERLOCKS INTERLOCK. CHECK RUNNING INTERLOCKS CLOSED 6 TO 7 IC
LOW FIRE SW. 5 TO 18
FLAME FLAME PROVING

SAFE START CHECK SSC
SIGNAL
RM7840G SWITCHING 13 TO 15
13 TO 12 13 TO 14 13 TO 14
FIRING
RATE MOTOR ACTION
MOTOR
M24169B
1 15/30 SEC. INTERRUPTED/INTERMITTENT PILOT VALVE
Fig. 6. Typical wiring subbase and sequence for RM7840G without Valve Proving enabled.
11 32-00142—01
SERIES 90
HIGH FIRE
G 12 B B
OR GAS)
COMMON
L2 13 R R
IGNITION
10 TRANSFORMER
LOW FIRE
120V ALARM 3 14 W W
L2
9 MV1
MODULATE
4 (L1) 15
21 MV2
BURNER MOTOR VALVE PROVING 4
(BLOWER) 5 16 SWITCH 2
RECYCLE LIMITS
6 17
BURNER CONTROLLER
3
RUNNING INTERLOCKS 7 18 LOW FIRE

(INC. AIR FLOW SWITCH) START SWITCH
1 120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT
10 SEC. INTERRUPTED 8 MEANS AND OVERLOAD PROTECTION AS REQUIRED.
PILOT/IGNITION 19

MAIN FUEL VALVE 1 9 20 PREIGNITION 3
INTERLOCK SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
5 SECOND IGNITION 4
(EARLY SPARK 10 21 MAIN JR3 INTACT FOR DSI FUNCTION.
TERMINATION) VALVE 2
F 22
FLAME DETECTOR
L1
(HOT)
3 1
L2
MASTER M24095
SWITCH
RM7840G
INITIATE PREPURGE PFEP
(INITIAL HOLD 10 SEC.
POWERUP 00 TIMED 00 DRIVE TO 00(4 SEC. IF 10 20 25 00 15
ONLY) STANDBY PREPURGE LOW FIRE JR1 CLIPPED MFEP RUN POSTPURGE STANDBY
POWER POWER POWER POWER POWER POWER POWER POWER POWER
DISPLAY
10 IGN. 5 SEC.
10 SEC. IGN./PILOT 8 1
MAIN VALVE 2 21 2
MAIN VALVE 1 9
OPERATING
CONTROLS
AND
INTERLOCKS INTERLOCK. CHECK RUNNING INTERLOCKS CLOSED 7 IC
LOW FIRE SW. 5 TO 18
FLAME FLAME PROVING

SAFE START CHECK SSC
SIGNAL
RM7840G SWITCHING 13 TO 15
13 TO 12 13 TO 14 13 TO 14
FIRING
RATE MOTOR ACTION
MOTOR
M24096B
1 JR3 REMOVED FOR PILOT SEQUENCE 2 MV2 IS MAIN VALVE CLOSEST TO THE BURNER
Fig. 7. Typical wiring subbase and sequence for RM7840G with Valve Proving enabled.
32-00142—01 12
WIRING
SUBBASE
RUN/TEST DIN RAIL MOUNT BASE:

SWITCH SHOWN Q7800XX
RELAY
MODULE
CONFIGURATION
JUMPERS
PURGE
TIMER
BASE SECURITY PIN
RESET
BUTTON
CAPTIVE
MOUNTING
SCREW
BURNER CONTRO
L
SCROLL
MODE
- SAVE -
2-LINE VFD
KEYBOARD
DISPLAY
MODULE FLAME
(STANDARD ON AMPLIFIER
RM7800E,G,L,M)
4-LINE LCD
KEYBOARD DISPLAY MODULE
(SOLD AS AN OPTIONAL
ACCESSORY, SEE PG. 21)
Fig. 8. RM7800L/40L, EC7840L Relay Module exploded view.
VALVE PROVING SYSTEM Before—Valve Proving occurs concurrently with Pre-

Purge.
The Valve Proving System feature provides a systematic After—Valve Proving occurs after the Run state before
way of testing the valve seat integrity to assure the valves the internal Safety Relay dropout state and concurrent
are in the closed state whenever the sequence of with Post Purge (if configured).
operation requires them to be closed. It is designed to
detect a leak greater than 0.1% of the burner input Both—Valve proving occurs at both times Before and
capacity. For example, a 10 million Btu/hr natural gas- After noted above.
fueled burner would have a fuel input capacity of
approximately 1,000 ft3/hr. A leak rate greater than 0.1% Split—The downstream seat (high pressure) test is per-
of 1,000 ft3/hr or 1 ft3/hr in either valve will be detected formed at the Before time and the upstream seat (low
with the Valve Proving System. Smaller leaks will not be pressure) test is performed during the After time.
detected.
At commissioning time, the Valve Proving System may be The Valve Proving items programmed are:
scheduled to occur at one of five different times: Never, 1. Specify when to perform Valve Proving. Demand
Before, After, Both, and Split. input to terminal 17 actually enables the function of
Never—Device default as received: in this case Valve Valve Proving.
Proving does not occur. 2. Specify the time duration of the test (calculated from
Appendix A).
13 32-00142—01
Typical Valve Proving System D. MV1 is commanded to be open while MV2 remains
closed, to pressurize the space. After 4 seconds, MV1 is
Function commanded closed again.
Valve proving consists of monitoring the pressure in the
E. This is followed by a three second delay, during
space between two shutoff valves, MV1 (upstream) and
which the valve proving pressure switch (VPS) is
MV2 (downstream). The valve proving function, identified
ignored.
by letters A through F, operates as follows:
The tolerance on all valve proving timing values is ±10%. F. Thereafter, the VPS is monitored for the duration of
the valve proving test time and, if it turns off, then a
The following are steps performed during valve proving lockout occurs. (Because the gas pressure has
tests. This section is for background information and does decreased due to a leaky downstream valve.) (High
not define the exact behavioral requirements. pressure test.)
A. MV2 is commanded to be open while MV1 remains Pressure Switches for Valve Proving
closed; to depressurize the space. After 4 seconds, MV2
is commanded closed again. System
The Valve Proving System requires a pressure switch to be
B. This is followed by a three second delay during which installed to monitor the pressure in the internal space
the valve proving pressure switch (VPS) is ignored. between the two shutoff valves. Recommended pressure
switches are the following Honeywell non-manual reset
C. Thereafter, the VPS is monitored for the duration of models:
the valve proving test time and, if it turns on, then a
lockout occurs. (Because the gas pressure has
increased due to a leaky upstream valve.) (Low pressure
test.)
Table 6. Honeywell Pressure Switch Selection for Valve Proving System.

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 Adjustment
the upstream valve; for example, 5.0 psi (140 in. wc). 1. Refer to the instructions for the C6097A Pressure
2. Divide the inlet pressure by two (2.5 psi [70 in. wc], Switch, form number 65-0237.
for example). 2. Install the C6097A Pressure Switch according to the
3. From column 2 in Table 6 find the operating range instructions.
upper limit that is closest to but greater than the 3. Adjust the setpoint to 50% of the maximum operat-
inlet pressure divided by two. In the example given, ing inlet pressure for the upstream valve.
the possible selections from column 1 are the 4. Complete the operation and checkout procedures in
C6097A1129 and C6097A1137 with an operating the instructions.
range upper limit of 7 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 mini- Setup (Programming) of Valve
mum, so the next higher range must be selected.)
4. From column 6, select the preferred mounting type,
Proving Function
1/4 in. NPT or Flange. For example, if a flange mount Prior to setup of the Valve Proving Function, follow the
is required, the pressure switch choice from column procedures in the appendix to complete the worksheet
1 would be the C6097A1137. and obtain the Valve Proving Test Time.
An S7800A1142 or S7800A2142 Keyboard Display
Module (KDM) is required for this setup.
32-00142—01 14
System operation requires the Valve Proving function

setup and demand input must be connected to terminal
17.
SETUP: ValveProve SU
NOTE: The S7800A1142 and/or S7800A2142 Keyboard ± VP When: BEFORE
Display is NOT supplied on RM7840G,L or
EC7840L device. BACK
Edit: - + ENTER
When the RM7800L/40G,L, EC7840L is installed and
powered, “STANDBY” will be shown on the first line of the M22664B
display.
Fig. 12. SETUP: Valve Prove screen.
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.
STANDBY NOTE: Use Never (as shipped) on initial startup so gas line
Setup purging and System Checkout can be performed.
Then come back to set final operation
BACK
configuration. Be sure to conduct final VPS System
Edit:
checkout when Setup is complete.
- + ENTER
M22662B
Fig. 9. STANDBY/Setup screen.

2. Enter the Setup submenu by pressing the far right key on =Save changes
the display. Note that the second line now reads “BC Pass- =Restart
word”.
BACK
Edit: - + ENTER
STANDBY SU M22665B
± BC Password: 00 Fig. 13. Save Changes screen.

9. Use the down arrow to save changes. After pressing
BACK the down arrow, “Getting Data” is displayed.
Edit: - + ENTER
M22663B
Fig. 10. Password screen. SETUP: ValveProve SU

3. Use the +/- buttons to enter the first number—7. ±VP Time: 00:00
4. Use the far right key to shift over one space.
5. Use the +/- buttons to enter the second number—8. BACK
6. Press Enter (left/right arrow simultaneously). Edit: - + ENTER
M22666B
Fig. 14. Valve Prove time screen.

=Select
=Restart This screen sets up how long the RM7800L/40G,L,
EC7840L will conduct the Valve Proving Test for a given
time. VP TIme: 00:00 is shown.
BACK
Edit: - + ENTER 10. Enter the appropriate Valve Proving test time from
the worksheet in the appendix.
M22764B
Use the (+) button to increase time and the (-) button to
Fig. 11. Select/Restart screen.
decrease. Time changes:
7. To get to the next screen, press the down arrow. “Get- a. 0 to 60 seconds in 1-second intervals.
ting Data” will be displayed, then the following b. 60 to 600 seconds in 10-second intervals.
screen. c. 10 to 60 minutes in 1-minute intervals.
Press ENTER when correct time is displayed.
15 32-00142—01
=Save changes =Save changes

=Restart =Restart
BACK BACK
Edit: - + ENTER Edit: - + ENTER
M22665B M22665B
Fig. 15. Save Changes screen. Fig. 18. Save Changes screen.
15. Use the down arrow to save changes. “Getting Data”

is displayed momentarily.
=Select The following steps are to confirm your selections.
=Restart
BACK
Edit: - + ENTER CONFIRM:ValvProve SC
±VP When: BEFORE ?
M22764B
Fig. 16. Select/Restart screen. BACK

Edit: - + ENTER
11. Press down arrow to select.
12. “Getting Data” will be momentarily displayed, fol- M22670B
lowed by the screen shown in Fig. 12.
Fig. 19. Confirmation Acknowledgement screen. (The
Valve Proving Test location is shown.)
Changing the Installed Postpurge
16. Press ENTER.
SETUP:Postpurge SU
±PostTime: 00:30 =Confirm correct
=Incorrect
BACK
Edit: - + ENTER BACK
Edit: - + ENTER
M22668
M22671B
Fig. 17. Setting Postpurge time.
This screen allows for setting up the Postpurge for the Fig. 20. Confirmation Correct screen.
RM7800L/40G,L, EC7840L. This will be the time that the 17. Use the down arrow to confirm correct.
Combustion Fan (terminal 5) will remain energized after
the demand ends. NOTE: Using the up arrow during this step will take you
back to the beginning of the setup routine.
NOTE: The device comes standard with 15-second Post-
purge. “Getting Data” will be displayed.
13. Use the +/- buttons to adjust the postpurge time.
Time changes:
0 to 60 seconds in 1-second intervals. CONFIRM: ValveProve SC

VP Time: 00:30 ?
60 to 600 seconds in 10-second intervals.
10 to 60 minutes in 1-minute intervals. BACK

Edit: - + ENTER
14. Press Enter (Left/Right arrow keys simultaneously)

when the correct postpurge time is displayed. M22672A
Fig. 21. Confirm screen.
32-00142—01 16
18. Press Enter. 23. Press and hold the relay module RESET button for
five seconds to program the Valve Proving setup into
the relay module.
The Release Reset screen will appear on the KDM.
=Confirm correct
=Incorrect
BACK
Edit: - + ENTER
SETUP DONE:
... release Reset
M22671B
Fig. 22. Confirm Correct screen. BACK

Edit: - + ENTER
19. Use the down arrow to confirm correct.
M22765B
“Getting Data” will be displayed.
The following steps are used to confirm your selection. Fig. 26. Release Reset screen.
Once the system is in operation, the settings of the Valve

Proving and Postpurge can be viewed in Diagnostics,
using your S7800 Keyboard Display Module (KDM).
CONFIRM: Postpurge SC
±PostTime: 00:30 ? Future changes to the Valve Proving and Postpurge
features are still possible. With the relay module in
standby, scroll to the Setup line and enter the password to
BACK change the settings.
Edit: - + ENTER
M22674A
SAFETY SHUTDOWN
Fig. 23. Confirm Postpurge time.
20. Press Enter. Safety Shutdown (Lockout) occurs

if any of the following occur during
the indicated period:
=Confirm correct 1. Anytime:
=Incorrect a. Purge card is not installed or removed.
b. Purge card is bad.
BACK c. Configuration jumpers are changed (after 200
Edit: - + ENTER hours of operation).
d. Internal system fault.
M22671B e. Demand present at terminals 6 and 17 at the
same time.
Fig. 24. Confirm correct/incorrect screen. f. Failure of the Valve Proving test.
g. Demand at terminal 17 and device at default
21. Press Enter.
“Never.”
22. Press the down arrow to confirm the correct post-
2. INITIATE Period:
purge time. “Getting Data” will be displayed until the
a. AC line power errors occurred, see Operation
screen in Fig. 20 appears.
section.
b. Four minute INITIATE period has been exceeded.
3. STANDBY Period:
a. Flame signal is present after 240 seconds.
b. Pre-Ignition Interlock is open an accumulative
SETUP DONE: Press time
of 30 seconds.
Reset for 5 sec . . .
c. Interlock check feature is enabled (L only with
JR3 clipped) and the Interlock String (including
BACK airflow switch) is closed for 120 seconds with
Edit: - + ENTER controller closed.
d. Ignition/pilot valve/intermittent pilot valve ter-
M22676B
minal is energized.
e. Main valve terminal(s) energized.
Fig. 25. Setup Done screen. f. Internal system fault occurred.
17 32-00142—01
4. PREPURGE Period:
a. Pre-Ignition Interlock opens anytime during
OPERATION
PREPURGE period (except during VP test). (L
model only)
b. Flame signal is detected after first ten seconds
Sequence of Operation
during PREPURGE (RM7800L/40L, EC7840L). The RM7800L/40G,L, EC7840L has the following
c. High Fire Switch fails to close within four min- operating sequences, see Fig. 4, 5, 7, and 8. The
utes and fifteen seconds after the firing rate RM7800L/40L, EC7840L LED provide positive visual
motor is commanded to drive to the high fire indication of the program sequence: POWER, PILOT,
position at the start of PREPURGE FLAME, MAIN and ALARM.
(RM7800L/40L, EC7840L).
d. Low Fire Switch fails to close within four minutes Initiate
and fifteen seconds after the firing rate motor is
The RM7800L/40G,L, EC7840L enters the INITIATE
commanded to drive to the low fire position at
sequence when the Relay Module is powered. The
the end of PREPURGE.
RM7800L/40G,L, EC7840L can also enter the INITIATE
e. Running Interlock does not close within 30 sec-
sequence if the Relay Module verifies voltage fluctuations
onds (RM7840G).
of +10/-15 percent or frequency fluctuations of +/-10
f. Lockout Interlock does not close within 10 sec-
percent during any part of the operating sequence. The
onds (RM7800L/40L, EC7840L).
INITIATE sequence lasts for ten seconds unless the
g. Lockout Interlock opens during PREPURGE
voltage or frequency tolerances are not met. When the
(RM7800L/40L, EC7840L).
tolerances are not met, a hold condition is initiated and
h. Ignition/pilot valve/intermittent pilot valve ter-
displayed for at least five seconds. When the tolerances
minal is energized.
are met, the INITIATE sequence restarts. If the condition is
i. Main valve terminal is energized (except during
not corrected and the hold condition exists for four
Valve Proving testing).
minutes, the RM7800L/40G,L, EC7840L locks out.
j. Internal system fault occurred.
Causes for hold conditions in the INITIATE sequence:
5. PILOT FLAME ESTABLISHING Period (PFEP):
a. Low Fire Switch opens. a. AC line dropout is detected.
b. Lockout Interlock opens (RM7800L/40L, b. AC line noise prevents a sufficient reading of the
EC7840L). line voltage inputs.
c. Ignition/pilot valve/intermittent pilot valve ter- c. Low line voltage brownouts occur.
minal is not energized. The INITIATE sequence also delays the burner motor
d. Early spark termination terminal is energized starter from being energized and de-energized from an
after five seconds. intermittent AC line input or control input.
e. No flame is present at the end of PFEP.
f. Main valve terminal is energized (RM7840G).
6. MAIN FLAME ESTABLISHING Period (MFEP):
Standby
a. Low Fire Switch opens. The RM7800L/40G,L, EC7840L is ready to start an
b. Lockout Interlock opens (RM7800L/40L, operating sequence when the operating control
EC7840L). determines a call for heat is present. (Terminal 6, or
c. Ignition/pilot valve/intermittent pilot valve ter- Terminal 17 if Valve Proving is required.) The burner
minal is not energized. switch, limits, operating control and all microcomputer
d. Main valve terminal is not energized. monitored circuits must be in the correct state for the
e. No flame is present at the end of MFEP. RM7800L/40G,L, EC7840L to continue into the
7. RUN Period: PREPURGE sequence.
a. No flame is present.
b. Lockout Interlock opens (RM7800L/40L, Prepurge
EC7840L).
The ST7800 purge timers provide 15 Pre-Purge timings
c. Interrupted pilot valve terminal is energized.
selectable from 2 seconds to 30 minutes:
d. Main valve terminal is not energized.
8. POSTPURGE Period: a. The operating control (terminal 6, or terminal 17
a. Pre-Ignition Interlock does not close in five sec- for valve proving), Running Interlocks, Pre-Igni-
onds OR opens after five-seconds during POST- tion Interlocks, Burner Switch, Run/Test Switch,
PURGE period (except during VP testing). Lockout Interlocks and all microcomputer moni-
b. Ignition/pilot valve/intermittent pilot valve ter- tored circuits must be in the correct operating
minal is energized. state.
c. Main valve terminal is energized (except during b. The blower motor output, terminal 5, is powered
VP testing). to start the PREPURGE sequence. The firing rate
motor is driven to the high fire position
(RM7800L/40L, EC7840L). The PREPURGE
timing does not begin until the Lockout Interlock
String and High Fire Switch are both closed.
32-00142—01 18
c. If Before, Split or Both Valve Proving tests are c. Terminal 21 action:

selected (and demand input T17 is used), the (1) RM7800/40L, EC7840L - turned off15-sec-
RM7800L/40G,L, EC7840L will sequence the onds after Terminal 9 is energized.
main valves to conduct the VP tests concurrently (2) The RM7840G:
with Pre-Purge (beginning at 10 seconds into the (a) Not turned off, (intermittent pilot).
purge time). (b)Turns off 15-seconds after Terminal 9 is
d. The Pre-Ignition Interlock input must remain energized (if configuration jumper 2
closed throughout PREPURGE (except during VP removed).
testing); otherwise, control returns to the (c)Turns off 30-seconds after Terminal 9 is
STANDBY state and holds (30 seconds) for the energized (if configuration jumper 2
RM7840G or safety shutdown occurs for the removed and terminal 5 is jumpered to ter-
RM7800L/40L, EC7840L. minal 19).
e. The Lockout Interlock or Running Interlock d. The RM78XX releases to modulation (RUN) 15-
inputs (interlock circuit including Airflow Switch) seconds (30 seconds for RM7840G with terminal
must close by ten seconds after demand; 5 to 19 jumpered) after terminal 9 is energized if
otherwise, a recycle to the beginning of flame is present.
PREPURGE for the RM7840G will happen or a
safety shutdown for the RM7800L/40L, Valve Proving Ignition Trials (demand on
EC7840L occurs.
f. When PREPURGE timing is complete, the firing terminal 17) -Pilot Lighted System (Not
rate motor drives to the low fire position, VP DSI). (Configuration jumper 2 on
RM7800L/40G,L, EC7840L. RM7800L/40L, EC7840L or Jumper 3 on
g. When the firing rate motor reaches low fire posi-
tion, the Low Fire Switch, terminal 18, input must RM7840G MUST be removed).
be energized before entering the Ignition Trial 1. Pilot Flame Establishing Period (PFEP):
state. a. With the firing rate motor at the low fire position
(Low Fire Start Switch-terminal 18 enabled):
Ignition Trials—Pilot Lighted System (Non b. Terminals 8, 10, are energized.
VP Operation System) (demand into NOTE: Low Fire Start Switch-terminal 18 enabled
terminal 6) must remain closed until the
1. Pilot Flame Establishing Period (PFEP): RM7800L/40G, L, EC7840L releases to
a. With the firing rate motor at the low fire position modulation - or a safety shutdown will
(Low Fire Start Switch-terminal 18 enabled): occur.
b. Terminals 8, 10 and 21, are energized.
The Pre-Ignition Interlock input is ignored
NOTE: Low Fire Start Switch-terminal 18 enabled throughout the Ignition Trial state.
must remain closed until the
RM7800L/40G,L, EC7840L releases to c. After five seconds, the ignition, terminal 10, is
modulation - or a safety shutdown will de-energized for early spark termination.
occur. d. Flame must be proven by the end of the ten-sec-
ond PFEP (four-seconds if JR1 is clipped). If
The Pre-Ignition Interlock input is ignored flame is not proven by the end of the PFEP, a
throughout the Ignition Trial state. safety shutdown occurs.
2. Main Flame Establishing Period (MFEP):
c. After five seconds, the ignition, terminal 10, is a. Terminal 9 and 21 are energized when the pres-
de-energized for early spark termination. ence of flame is verified at the end of a 10- sec-
d. Flame must be proven by the end of the ten-second Pilot Flame Establishing Period (PFEP) (four
ond PFEP (four-seconds if JR1 is clipped). If seconds if JR1 is clipped).
flame is not proven by the end of the PFEP, a b. Terminal 8 is turned off 10 seconds after Termi-
safety shutdown occurs. nal 9 and 21 are energized.
2. Main Flame Establishing Period (MFEP): c. The RM7800L/40G, L, EC7840L releases to
a. Terminal 9 is energized when the presence of modulation (RUN) 15-seconds terminal 9 and 21
flame is verified at the end of a 10-second Pilot are energized if flame is present.
Flame Establishing Period (PFEP).
b. Terminal 8 is turned off 10 seconds after Termi-
nal 9 is energized.
19 32-00142—01
Ignition Trials—Valve Proving with DSI Postpurge

System The RM7800L/40G,L, EC7840L provides a programmable
1. Demand connected to Terminal 17: (default is 15 seconds) POSTPURGE following the
— JR2 Intact on RM7800L/40L, EC7840L completion of the RUN period. The blower motor output is
— JR3 Intact on RM7840G powered to drive all products of combustion and any
a. Ignition, Main Valve 1 and Main Valve 2, Termi- unburned fuel from the combustion chamber. It also
nals 10, 9, and 21 turn on together. supplies combustion air to burn fuel being purged from
b. Flame must be proven at the end of the 4 second the fuel line downstream of the fuel shutoff valve.
Main Flame Establishing Time. 1. The main fuel valve and intermittent pilot valve,
c. Ignition, Terminal 10 is turned off. System now in Terminals 9 and 21, are de-energized and the firing
Run. rate motor is commanded to the low fire position to
d. If Flame is not proven, safety lockout occurs. begin the POSTPURGE period.
2. The Pre-Ignition Interlock closes within the first five
Run seconds after the demand opens.
1. A ten-second stabilization period occurs at the 3. If Valve Proving option—After, Split or Both have
beginning of the RUN period. been selected, then the Valve Proving test will be
2. The firing rate motor releases to modulation. conducted concurrent with Postpurge. If Postpurge
3. The RM7800L/40G,L, EC7840L is now in RUN and timing remains after the Valve Proving test is com-
remains in RUN until the controller input, terminal 6, pleted, the Postpurge timing will complete before
opens (terminal 17, on VP applications), indicating the RM7800/40G,L, EC7840L go into standby.
that the demand is satisfied or a limit opened.
Table 7. Sequence Timing for Normal Operation.

Flame Establishing Period Post-
Purge Firing Rate Approval
Device Initiate Standby Purge Pilot Maina, c Run Timingd Interlock Circuits Circuit Code Bodies
RM7840G 10 sec. * ** 4 or 10 sec. 10, 15 sec. or * 15 sec. Pre-Ignition, Running, 4-wire UL/CSA
intermittentb Low Fire modulating Modulating
RM7800L/R 10 or 15 sec.b Pre-Ignition, Lockout, FM/IRI
M7840L/ High and Low Fire Modulating
EC7840L
* STANDBY and RUN can be an infinite time period.
**PURGE determined by which ST7800A purge card is selected.
a The MFEP is determined by which terminal is used, configuration jumper selected or jumper wire added.
See Fig. 2, 3, 4, 6, and 7.
b If DSI is Enabled on a VP application (JR2 intact on RM7800L/40L, EC7840L or JR3 intact on RM7800/40G) then Igni-
tion (terminal 10) and MV1 (terminal 9), and MV2 (terminal 21) are energized together. After 4 seconds terminal 10 shuts
off, and system goes to Run.
c If DSI is disabled on a VP application then MFEP is 10 seconds.
d Default is 15 seconds. Can be programmed as long as 66 minutes.
32-00142—01 20
Keyboard Display Module Options actions. The scroll bar adjusts to give a relative position of
the current view with respect to all lines that the page can
display.
Vacuum Fluorescent Display (VFD)
The Keyboard Display Module (see Fig. 5) is provided with When a line has a right arrow symbol positioned on the
the RM7800 Relay Module (but is not required for right hand side it indicates that this line can navigate to
operation) and is an option for the RM7840 Relay Module. another page, “Next page”, related to the subject of the line
The first line of the Vacuum Fluorescent Display (VFD) when that line has input focus. A “Right arrow” or “OK”
provides: button can be pressed when the focus is on this line to
navigate to the next page.
• Current status of the burner sequence (STANDBY,
PURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE). Run/Test Switch
• Timing information (PURGE, PILOT IGN, MAIN IGN and
POSTPURGE) in minutes and seconds.
• Hold information (PURGE HOLD: T19).
• Lockout information (Lockout, Fault Code, Message WARNING
Explosion Hazard.
and Sequence).
Can cause serious injury or death.
The extreme right side of the first line is either blank or
Do not use the Run/Test switch during the Pilot
shows a small arrow pointing to the second line followed
Flame Establishing Period for the RM7800L/40G,
by a
EC7840L when using Direct Spark Function,
two-letter code (DI-Diagnostic Information, Hn-Fault
because it turns on the main gas valve, causing an
History Information, and EA-Expanded Annunciator).
accumulation of fuel in the burner.
When the arrow and two-letter code are displayed, it
indicates the second line is showing a selectable message The Run/Test Switch is located on the top side of the
submenu. The second line displays selectable or RM7800L/40G,L, EC7840L, see Fig. 29. The Run/Test
preemptive messages. Switch allows the burner sequence to be altered as
follows:
A selectable message supplies information for flame
strength, system status indication, system or self- 1. In Pre-Purge Drive To High Fire Position
diagnostics and troubleshooting. (RM7800L/40L, EC7840L), the Run/Test Switch,
when placed in the TEST position, holds in PRE-
A preemptive message has parentheses around the PURGE with the firing rate motor in the High Fire
message and supplies a detailed message to support the position.
sequence status information. A preemptive message can 2. In the measured PREPURGE sequence, the
also be a lockout message. A preemptive message Run/Test Switch, when placed in the TEST position,
replaces a selectable message to support the sequence causes the PREPURGE timing to stop. The firing rate
status information. It also replaces a selectable message motor is in the High Fire (RM7800L/40L, EC7840L)
after 60 seconds if it or a lockout message is available. position (Run/Test Switch is ignored while the Valve
Proving test is being conducted by the
4-Line LCD Display RM7800L/40L, EC7840L).
The 4-line LCD Keyboard Display Module (See Fig. 5) 3. In Pre-Purge Drive to Low Fire position, the Run/Test
S7800A2142/U is available as an option for the RM7800 Switch, when placed in the TEST position, holds the
and RM7840 Relay Modules. This display must be burner sequence in PREPURGE with the firing rate
purchased separately. This display offers more lines of text motor in the Low Fire position.
displaying the full trouble-shooting guide. (It is important 4. In PFEP, the Run/Test Switch, when placed in the
to note that this display's lower end temperature rating is TEST position, stops the timer during the first eight
0 °F). seconds when a ten second PFEP is selected or
during the first three seconds when a four second
The first line of the Home and Lockout pages on the LCD PFEP is selected, allowing pilot-turn-down test and
display use a larger font size than all other pages so that other burner adjustments to be made. This activates
information on them can be more easily viewed from a fifteen second flameout timer that permits pilot
distances farther away from the display module (refer to flame adjustment without nuisance safety
document number 32-00110 for full details on operation). shutdowns. The Run/Test Switch is ignored during
PFEP for the RM7800L/40G,L, EC7840L if
Up to 4 lines of text are displayed at a time on the page. Terminals 8 and 9 or 9 and 21 are jumpered.
When the page has more than 4 lines of text to display a 5. During Run, the Run/Test Switch, when placed in the
scroll bar is present on the right-hand side of the page to TEST position, drives the firing rate motor to the Low
indicate this situation. The “Up arrow” and “Down arrow” Fire position.
buttons are used to scroll up and down the lines of the
page. Each line is highlighted with a white background to NOTE: When RM7800L/40G,L, EC7840L is switched to
indicate that it currently has input focus for any button the Test mode, it stops and holds at the next
Run/Test Switch point in the operating sequence.
Make sure that the Run/Test Switch is in the RUN
position before leaving the installation.
21 32-00142—01
SETTINGS AND ADJUSTMENTS

Selectable Site-Configurable Jumpers
The RM7800L/40G,L, EC7840L has three site-configurable jumper options, see Fig. 29 and Table 8. If necessary, clip the
site-configurable jumpers with side cutters and remove the resistors from the Relay Module.
SELECTABLE CONFIGURATION JUMPERS
RUN/TEST SWITCH
NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.

M12301
Fig. 27. Selectable site-configurable jumpers.
Table 8. Site Configurable Jumper Options.

Jumper RM7800L/40L,
Number Description Intact Clipped EC7840L Type
JR1 Pilot Flame Establishing Period c 10 seconds 4 seconds G, L
JR2 DSI with Valve Proving c Enabled Disabled L
JR2 Pilot Valvea/Main Flame Intermittent Interrupted Gb
Establishing Period (MFEP)
JR3 Start-Up Interlock Check Disabled Enabled L
JR3 DSI with Valve Proving c Enabled Disabled G
a Pilot Valve /First Stage Oil Valve Terminal 21 cannot be used in this arrangement if Valve Proving feature is selected.
b A 30-second MFEP can be accomplished by adding a jumper wire between terminals 19 and 5, ignored if VP is active.
c DSI Enabled allows for Valve Proving test to be performed, then during PFEP both terminals 9 and 21 energize to light
the Main Flame—note PFEP will not occur and the MFEP will automatically be 4 seconds regardless.
32-00142—01 22
STATIC CHECKOUT 3. Ammeter can be used to verify valve loads con-

nected to the wiring subbase.
After checking all wiring, perform this checkout before
installing the RM7800L/40G,L, EC7840L on the subbase. General Instructions
These tests verify the Q7800 Wiring Subbase is wired
1. Perform all applicable tests listed in Static Checkout,
correctly, and the external controllers, limits, interlocks,
Table 8, in the order listed.
actuators, valves, transformers, motors and other devices
2. Make sure all manual fuel shutoff valve(s) are
are operating properly.
closed.
3. Perform only those tests designated for the specific
RM7800L/40G,L, EC7840L model being tested.
WARNING 4. Raise the setpoint of the operating controller to sim-
Explosion and Electrical Shock Hazard. ulate a call for heat.
Can cause serious injury, death or equipment 5. For each test, open the master switch and install the
damage. jumper wire(s) between the subbase wiring termi-
1. Close all manual fuel shutoff valve(s) before nals listed in the Test Jumpers column.
starting these tests. 6. Close the master switch before observing operation.
2. Use extreme care while testing the system. Line 7. Read the voltage between the subbase wiring termi-
voltage is present on most terminal connections nals listed in the Voltmeter column.
when power is on. 8. If there is no voltage or the operation is abnormal,
3. Open the master switch before installing or check the circuits and external devices as described
removing a jumper on the subbase. in the last column.
4. Before continuing to the next test, be sure to 9. Check all wiring for correct connections, tight termi-
remove test jumper(s) used in the previous test. nal screws, correct wire, and proper wiring tech-
5. Replace all limits and interlocks that are not niques. Replace all damaged or incorrectly sized
operating properly. Do not bypass limits and wires.
interlocks. 10. Replace faulty controllers, limits, interlocks, actua-
tors, valves, transformers, motors and other devices
as required.
CAUTION
Equipment Damage Hazard.
11. Make sure normal operation is obtained for each
required test before continuing the checkout.
Improper testing can damage equipment. 12. After completing each test, be sure to remove the
Internal surge protectors can break down and test jumper(s).
conduct a current, causing the RM7800L/40G,L,
EC7840L to fail the dielectric test or possibly
destroy the internal lightning and high current
protection. Do not perform a dielectric test with the
WARNING
Explosion Hazard.
RM7800L/40G,L, EC7840L installed. Can cause serious injury or death.
Make sure all manual fuel shutoff valves are closed
Equipment Recommended before performing static checkout.
1. Voltmeter (1M ohm/volt minimum sensitivity) set on

the 0-300 Vac scale.
2. Two jumper wires; no. 14 wire, insulated, 12 inches
(304.8 mm) long with insulated alligator clips at
both ends.
Table 9. Static Checkout.

RM7800/RM
Test 7840/EC784 Test If Operation is Abnormal,
No. 0 Models Jumpers Voltmeter Normal Operation Check the Items Listed Below
1 All None 4-L2 Line voltage at Terminal 4. 1. Master Switch.
2. Power connected to the Master
Switch.
3. Overload protection (fuse, circuit
breaker, etc.) has not opened the
power line.
2 All 6-L2 Line voltage at Terminal 6. 1. Limits.
17-L2 For VP applications. (Terminal 2. Burner Controller.
17)
3 All 16-L2 Line voltage at 16 Valve Proving switch.
4 All 20-L2 Line voltage at Terminal 20. 1. Pre-Ignition interlocks.
23 32-00142—01
Table 9. Static Checkout. (Continued)

RM7800/RM
Test 7840/EC784 Test If Operation is Abnormal,
No. 0 Models Jumpers Voltmeter Normal Operation Check the Items Listed Below
5 All 4-5 7-L2 1. Burner motor (fan or blower) 1. Burner motor circuit.
starts. a. Manual switch of burner motor.
2. Line voltage at Terminal 7 b. Burner motor power supply,
within 10 seconds. overload protection, and starter.
c. Burner motor.
2. Running or Lockout Interlocks
(including Airflow Switch).
6 All 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.
7 All 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 b. Pilot valve.
of system being tested.
8 All 4-21 * — Same as test no. 6 for Same as test no. 6. If using direct spark
connections to Terminal 8. If ignition, check the first stage fuel
using direct spark ignition, check valve(s) instead of the pilot valve.
the first stage fuel valve(s)
instead of the pilot valve or MV2
for VP tests.
9 All 4-9 * — Automatic main fuel valve(s) 1. Listen for and observe operation of
open. the main fuel valve(s) and actuator(s).
If using direct spark ignition on a 2. Valve(s) and actuator(s).
model with intermittent pilot on
Terminal 21, check the optional
second stage fuel valve, if used.
10 All 4-3 — Alarm (if used) turns on. 1. Alarm.
11 All 4-5 18-L2 Firing rate motor drives open; 1. Low Fire Start Switch.
and zero volts at Terminal 18 after 2. Firing rate motor and transformer.
12-13 motor starts driving open.
12 All 4-5 18-L2 Firing rate motor drives closed; 1. Low Fire Start Switch.
and line voltage at Terminal 18 after 2. Firing rate motor and transformer.
14-13 motor is in Low Fire position.
13 RM7800L; 4-5 19-L2 Firing rate motor drives open; 1. High Fire Purge Switch.
RM7840L; and line voltage at Terminal 19 after 2. Firing rate motor and transformer.
EC7840L 12-13 motor is in High Fire position.
14 RM7800L; 4-5 19-L2 Firing rate motor drives closed; 1. Low Fire Start Switch.
RM7840L; and zero volts at Terminal 19 after 2. Firing rate motor and transformer.
EC7840L 14-13 motor starts driving closed.
15 All 15-13 — 1. Raise setpoint of Series 90 1. Series 90 Controller.
controller—firing rate motor 2. Firing rate motor and transformer.
should drive toward open.
2. Lower setpoint of Series 90
controller—firing rate motor
should drive toward closed.
Final All
CAUTION
Equipment Damage Hazard.
Improper wiring can damage equipment.
On completing these tests, open the master switch and remove all test jumpers from the
subbase terminal. Also remove bypass jumpers from the low fuel pressure limits (if used) to
prevent equipment damage.
* An ammeter can be used to verify the proper connected loads.
32-00142—01 24
TROUBLESHOOTING portion of the fault code (two slow blinks is 2). Three fast
blinks followed by two slow blinks would be fault code 32.
(See Table 10 for Blink Fault Code list.)
Troubleshooting can be accomplished by using the S7800
Keyboard Display Module (KDM) or a blinking POWER The LED code repeats as long as the fault exists. To clear
LED. the fault, press the RESET button.
The POWER LED provides fault identification when the Use Table 10 to identify fault code numbers, possible
relay module locks out on an alarm. Fault identification is system failure and recommended troubleshooting
a series of fast and slow blinking LED lights. The fast procedures.
blinks identify the tens portion of the fault code (three fast
blinks is 30), while the slow blinks identify the units
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
Code 1-2 Excessive noise or meet specifications.
*AC Quality device running on 4. Check the backup power supply, as appropriate.
Problem* slow, 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
*Unexpected flame is expected errors.
Flame Signal* during STANDBY or 2. Make sure that the flame amplifier and flame detector are compatible.
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 detec-
tor.
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 chamber. Inspect the connections to the fuel pressure switches. Make
Establishing Period or sure they are functioning properly.
during RUN. 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 instal-
lation instructions.
7. Replace the flame amplifier and/or the flame detector, if necessary.
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.
tor.
25 32-00142—01
Table 10. Blinking Fault Codes and Recommended Troubleshooting. (Continued)

Code 3-1 Running or Lockout 1. Check wiring; correct any errors.
*Running/ Interlock fault during 2. Inspect the fan; make sure there is no air intake blockage and that it is
Interlock Pre-Purge. supplying air.
Switch 3. Make sure the Lockout Interlock switches are functioning properly and
Problem* the contacts are free from contaminants.
4. Reset and sequence the relay module to Pre-Purge (place the TEST/RUN
Switch in the TEST position, if available). Measure the voltage between
terminal 7 and G (ground); line voltage 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
*Running/ powered at improper properly between terminals 6 and 7. Correct any errors.
Interlock On point in sequence or 2. Reset and sequence the relay module.
During On in Standby. 3. If the fault persists, measure the voltage between terminal 6 and G
Standby* (ground), then between terminal 7 and G. If there is line voltage 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 line voltage 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 during VPS Test. 2. Conduct Valve Seat leakage test using a manometer.
State* 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
Problem* changed from the damage 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
WARNING
Electrical Shock Hazard; Fire or Explosion Hazard.
Internal Fault* 2 was on when it Can cause severe injury, death or property damage.
should be off. 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 on or off. 3. Remove the flame amplifier and inspect the connections. Reseat the
Problem* amplifier.
tor.
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 2. Reset and sequence the relay module.
Problem* startup. 3. If the fault persists, replace the relay module.
32-00142—01 26
Table 10. Blinking Fault Codes and Recommended Troubleshooting. (Continued)

Code 5-1 Pre-Ignition Interlock 1. Check wiring and correct any errors.
*Pre-Ignition fault. 2. Check Pre-Ignition Interlock switches to assure proper functioning.
Interlock* 3. Check fuel valve operation.
4. Reset and sequence the relay module; monitor the Pre-Ignition 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. Ver-
Sw.* ify at 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, 1. Check wiring and correct any errors.
*Man-Open Start Switch or Control 2. Make sure that the Manual Open Valve Switch, Start Switch and Control
Sw.; Start Sw. On in the wrong are operating properly.
or Control On* operational 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, RM7838C1004,
RM7838A2014, RM7838B2013, RM7838C2004 only).
Code 6-1 Relay Module self-test 1. Reset and sequence the relay module.
*Internal failure. 2. If fault reappears, remove power from the device, reapply power, then reset
Faults* and sequence the relay module.
Code 6-2 Relay Module Self-Test 1. Reset and sequence the relay module.
*Internal failure. 2. If fault reappears, remove power from the device, reapply power, then reset
Faults* and sequence the relay module.
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
and sequence the relay module.
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 VPS setup. 1. Make sure Relay Module VP is programmed.
*Accessory 2. T6 and T17 powered at the same time—correct wiring.
Fault* 3. Reset control if fault persists. Replace relay module.
Code 7-7 Unused at this time. —
*Unused*
27 32-00142—01
APPENDIX A
Valve Proving Test
The Valve Proving System feature offers a systematic way of 3. Use appropriate Results column items to fill in the
testing the valve seat integrity to assure the valves are Valve Train Volume Formula and the Calculation of
indeed in the closed position when the system is off-line, in Valve Proving Test Time.
STANDBY. 4. Round up the time to the nearest second.
5. The test time calculated is the time you will enter
into the VPS Setup.
WARNING
Explosion Hazard. Calculation of Valve Train Volume
Can cause severe injury, death or property
damage. X = V1 + V2 + (A X L/144)
Leaking gas valves can result in fire or explosion.
The Valve Proving System is designed to detect Calculation of Valve Proving Test
such leaks. A valve proving test time that is too
short may allow unacceptable leaks to go Time
undetected. Use the procedure in Appendix A to Test Time = 187,000 x (P x X)/C
select sufficient valve test times to detect any
unacceptable leak. Table 11. Valve Proving Test Time Symbols
and Descriptions.
The following steps are to determine the test time for the
relay module to verify the valve seats are not leaking at a Symbol Unit Description
rate of greater than/equal to 0.1% of the burner capacity.
X ft 3 Volume between the two valves to be
Fig. 29 shows a typical valve train. The legend identifies tested.
information that will be used to fill out the worksheet that V1 Volume of upstream valve outlet
ft3
appears at the end of this appendix. cavity.
1. Identify items of your system and fill in the “Informa- V2 ft3 Volume of downstream valve inlet
tion” portion of the worksheet. cavity.
2. Go to the Lookup Tables noted (13, 14 or 15) to get L ft Length of pipe between valves.
the results for your system.
D npt Pipe Size—used to define A
IMPORTANT A Pipe Cross Section Area (from Table
The Tables show information on Honeywell Valves in.2
15)
only. Contact other valve manufacturers to obtain
data on their specific valves. Test Second Minimum VPS test period.
Time s
V1 V2 P psi Gas inlet pressure to upstream valve.
C ft3/hr Burner Capacity.
VP
D SW.
P
NOTE: V1 is the outlet cavity of the upstream valve and
INLET OUTLET V2 is the inlet cavity of the downstream valve.
L
NOTE: 10 seconds is the minimum test time allowed. If
C
X
your calculations are less than 10 seconds, enter
10 seconds.
LEGEND
V1 UPSTREAM VALVE For Example:
V2 DOWNSTREAM VALVE
D PIPE DIAMETER (IN INCHES.) USED TO DETERMINE A;
ARE FOUND IN TABLE III We have a 2.5 MBTU burner with 2 psi valve train inlet
L PIPE LENGTH (IN FEET) pressure. The upstream valve is a proof-of-closure V5044
P VALVE INLET PRESSURE (PSIG) with a solenoid V4295 valve downstream. We have a 2 in.
C BURNER MAX. FIRING (CFH)
X CALCULATED TEST VALVE TRAIN VOLUME M22778
NPT pipe, 1-3/4 ft long, between the valves.
Fig. 28. Typical valve train layout.
32-00142—01 28
Table 12. VPS Worksheet Example.

Item Description Information Lookup Table Results Formula Item
V1 Upstream Valve Volume V5055 12 0.0218 V1
V2 Downstream Valve Volume V4295 13 0.0267 V2
D Pipe Size NPT (in.) 2 in. NPT 14 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 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 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 — —
29 32-00142—01
Table 15. Schedule 40 Pipe Internal Cross-Sectional Area.

Pipe Size NPT (Inches) Cross-Sectional Area (Sq. 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 Volume 12 V1
V2 Downstream Valve Volume 13 V2
D Pipe Size NPT (in.) 14 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.
SAFETY AND SECURITY Modbus & DDL Interface security

Any conducts critical to device functionality (DDL,
Physical device protection Modbus lines etc.) shall be physically protected (installed
outside public access) since they could be damaged or
Device shall be accessible to authorized personnel only – tampered-with by unauthorized people, either
Installation on publicly accessible places is not accidentally or for purpose.
recommended as this could lead to unwanted and
potentially unsafe changes to device (wiring, Modbus RS-485 & DDL protocols do not support security
configuration, etc). features. For DDL interface - only DDL devices shall be
connected to the Burner Controller DDL line.
It is recommended to lock the device in an enclosed
cabinet with access allowed only to approved and trained
personnel. Also, it is strongly advised to keep all the wiring
License agreement
of device physically secure. Copying and reverse engineering is prohibited by the law.
Physical protection of the device is applied via Run/Test
switch label/seal. It is intended to prevent and detect
unauthorized access.
32-00142—01 30
APPENDIX B: RM7800L/40G,L, EC7840L IGNITION OPTIONS

Column 1 lists the ignition option.
Column 2 lists the figure letter that shows the connections for that option. The figure letters refer to the figures on pages
30–32.
Column 3 refers to the fuel changeover switch and how many connections or poles that would be required.
Table 17. RM7800L/40G,L, EC7840L Ignition Options
Ignition Options Figure Letter Fuel Changeover Poles

No Valve Proving
Single Fuel
- MFEP 10s A -
- MFEP 15s B -
- DSI C -
Dual Fuel
MFEP timed for both
- Gas 10s, Oil 10s D 2
- Gas 10s, Oil 15s E 2
- Gas 15s, Oil 10s F 2
- Gas 15s, Oil 15s G 2
- Gas 10s, Oil DSI H 3
- Gas 15s, Oil DSI I 3
- Gas DSI, Oil 10s J 3
- Gas DSI, Oil 15s K 3
- DSI both L 2
Valve Proving on Gas
Single Fuel
- MFEP 10s M -
- MFEP 15s Not Possible
- DSI N -
Dual Fuel
MFEP timed for both
- Gas 10s, Oil 10s O 4
- Gas 10s, Oil 15s P 4
- Gas 15s, Oil 10s Not Possible
- Gas 15s, Oil 15s Not Possible
- Gas 10s, Oil DSI Q 5
- Gas 15s, Oil DSI Not Possible
- Gas DSI, Oil 10s R 4
- Gas DSI, Oil 15s S 4
- DSI Both T 4
Gas Direct Spark Ignition during VPS Selection (powering terminal 17)
automatically chooses 4 second Ignition Trial Period, regardless of configuration
resistor JR1 status
CAUTION! The above options are ONLY suggestions—BE SURE to check local
approval agencies for timings acceptable for your application.
31 32-00142—01
APPENDIX B: 7800 IGNITION OPTIONS

OP. OP.
LIMITS CONTROL
LIMITS CONTROL
L1 T6 T8 L1 T6
PV
T17 T21 GAS IF EA IS USED THEN
INTERLOCKS INTERLOCKS GAS/OIL SWITCHING IS
T9 ALSO NEEDED HERE.
T7
MV
A. NO VP/SINGLE FUEL: L2 T7
M24098A
OP.
OIL
LIMITS CONTROL
INTERLOCKS
L1 T6 T8 T8
PV
T21 T21 PV
T17 1 1
INTERLOCKS
T9
T7 GAS MV
MV
T9
1 RM7840G - CLIP JR2 L2
B. NO VP/SINGLE FUEL M24099A
OIL MV
OP. L2
LIMITS CONTROL 1 RM7840G CLIP JR2
L1 T6 T8
F. NO VP/DUAL FUEL: GAS 10 SECOND MFEP, OIL 15 SECOND MFEP
T21 M24123
T17 1
INTERLOCKS
T9 OP.
T7 LIMITS CONTROL
MV
L2 L1 T6
1 RM7840G - CONNECT DIRECTLY TO TERMINAL 21.
M24120
C. NO VP/SINGLE FUEL: DSI GAS IF EA IS USED THEN
INTERLOCKS GAS/OIL SWITCHING IS
ALSO NEEDED HERE.
OP.
LIMITS CONTROL
L1 T6 T7
IF EA IS USED THEN
GAS
GAS/OIL SWITCHING IS
INTERLOCKS OIL
ALSO NEEDED HERE.
INTERLOCKS
T8
T7 PV
T21
1
OIL INTERLOCKS
GAS MV
T9
T8
PV OIL MV
T21
L2
1 RM7840G CLIP JR2.
GAS MV
T9
G. NO VP/DUAL FUEL: GAS 15 SECOND MFEP, OIL 10 SECOND MFEP
M24124A
OIL MV
L2 OP.
LIMITS CONTROL
D. NO VP/DUAL FUEL: BOTH 10 SECOND MFEP M24121A
L1 T6
OP. GAS IF EA IS USED THEN
LIMITS CONTROL
L1 T6 ALSO NEEDED HERE.
IF EA IS USED THEN
GAS
GAS/OIL SWITCHING IS
INTERLOCKS T7
ALSO NEEDED HERE.
T7 OIL
INTERLOCKS
OIL INTERLOCKS
T8 PV
1
T8 T21
1 PV
T21
GAS MV
T9
GAS MV
T9
OIL MV
OIL MV L2
L2 RM7840G: A SEPARATE POLE NEEDED TO CONNECT OIL MV TO
1
TERMINAL 21.
1 RM7840G CLIP JR2
H. NO VP/DUAL FUEL: GAS 10 SECOND MFEP, OIL DSI
M24122A M24125A
E. NO VP/DUAL FUEL: 15 SECOND MFEP
32-00142—01 32
OP. OP.
LIMITS CONTROL LIMITS CONTROL
L1 T6 L1 T6
GAS IF EA IS USED THEN GAS IF EA IS USED THEN
INTERLOCKS GAS/OIL SWITCHING IS INTERLOCKS GAS/OIL SWITCHING IS
ALSO NEEDED HERE. ALSO NEEDED HERE.
T7 T7
OIL T8
OIL
INTERLOCKS INTERLOCKS
1 T21
T8 PV GAS MV
T9
T21
OIL MV
GAS MV L2
T9
1 RM7840: NO JUMPER - SWITCH FUEL OFF TERMINAL 21.
OIL MV L. NO VP/DUAL FUEL: BOTH DSI M24129A

L2 OP.
1 RM7840G: NOT POSSIBLE. LIMITS CONTROL
I. NO VP/DUAL FUEL: GAS 15 SECOND MFEP, OIL DSI M24126A L1 T6 T8
PV (10SEC)
T17
OP.
LIMITS CONTROL INTERLOCKS T21
L1 T6 T7 MV2
GAS IF EA IS USED THEN IF JR2 IS CLIPPED THEN DSI IS

INTERLOCKS GAS/OIL SWITCHING IS T9
DISABLED AND THE PILOT WILL
ALSO NEEDED HERE. BE USED WHENEVER A VALVE JR2 CLIPPED MV1
PROVING DEMAND IS PRESENT L2
ON T17.
T7
M. VALVE PROVING/GAS ONLY M24130
OIL OP.
INTERLOCKS LIMITS CONTROL
L1 T6 T8
T8 PV
T17
1
INTERLOCKS T21
T21
T7 MV2
GAS MV
T9 WHEN JR2 IS INTACT THEN GAS
T9
DSI IS ENABLED WHENEVER A
JR2 INTACT MV1
VALVE PROVING DEMAND IS
OIL MV PRESENT ON T17. L2
L2 RM7840G IS JR3 INTACT.
1 RM7840G: REQUIRES SEPARATE POLE TO CONNECT GAS MV TO N. VP/GAS ONLY DSI M24131A
TERMINAL 21.
J. NO VP/DUAL FUEL: GAS DSI, OIL 10 SECOND MFEP M24127A OP.
LIMITS CONTROL GAS
T17
OP. L1
LIMITS CONTROL T6
OIL
L1 T6
GAS IF EA IS USED THEN
GAS IF EA IS USED THEN INTERLOCKS GAS/OIL SWITCHING IS
INTERLOCKS GAS/OIL SWITCHING IS ALSO NEEDED HERE.
ALSO NEEDED HERE.
OIL T7
T7 INTERLOCKS
T8
OIL
PV
INTERLOCKS
T21
T8 PV GAS MV2
T21 GAS MV1

T9 1
GAS MV
T9
JR2 CLIPPED
OIL MV
OIL MV L2
1 RM7800/40L/EC7840L: CLIP JR2.
L2
RM7840G: CLIP JR3.
1 RM7840G: NOT POSSIBLE. O. VALVE PROVING/DUAL FUEL: 10 SECOND MFEP BOTH FUELS
K. NO VP/DUAL FUEL: GAS DSI, OIL 15 SECOND MFEP M24132A
M24128A
33 32-00142—01
OP. OP.
LIMITS CONTROL GAS LIMITS CONTROL GAS
T17 T17
L1
L1 T6
T6 OIL
OIL IF EA IS USED THEN
IF EA IS USED THEN GAS GAS/OIL SWITCHING IS
GAS
INTERLOCKS ALSO NEEDED HERE.
ALSO NEEDED HERE.
OIL
T7
INTERLOCKS
OIL T7
INTERLOCKS
THE SOFTWARE DOES
NOT ENERGIZE T8 T8
T8 WHEN GAS IS PV
SELECTED AND T21
PV
JUMPER 2 (JUMPER 3
T21
ON RM7840G) IS INTACT 2
1 GAS MV2
TO INDICATE GAS DSI
FOR A VALVE PROVING
GAS MV2
SYSTEM.
GAS MV1
T9
GAS MV1 JR2 INTACT
T9 OIL MV
L2
JR2 CLIPPED 2 RM7840G: CLIP JR2.

OIL MV
L2 S. VALVE PROVING/DUAL FUEL: GAS DSI, OIL 15 SECOND MFEP. M24135A
1 RM7840G: CLIP JR2 AND JR3.
OP.
P. VALVE PROVING/DUAL FUEL: GAS 10 SECOND MFEP, OIL 15 SECOND MFEP LIMITS CONTROL GAS
T17
M24133B L1
T6
OP. OIL
LIMITS CONTROL GAS IF EA IS USED THEN
T17 GAS GAS/OIL SWITCHING IS
L1 INTERLOCKS ALSO NEEDED HERE.
T6
OIL
OIL
GAS IF EA IS USED THEN T7
THE SOFTWARE DOES INTERLOCKS
ALSO NEEDED HERE. NOT ENERGIZE T8 T8
WHEN GAS IS
SELECTED AND T21
OIL T7 JUMPER 2 (JUMPER 3
INTERLOCKS ON RM7840G) IS INTACT
1 GAS MV2
TO INDICATE GAS DSI
FOR A VALVE PROVING
T8 SYSTEM.
PV GAS MV1
T9
JR2 INTACT
OIL MV
L2
T21
1 RM7840G: CONNECT OIL VALVE DIRECTLY TO TERMINAL 21
1 SIDE OF FUEL SWITCH - DO NOT USE THE JUMPER.
GAS MV2
T. VALVE PROVING/DUAL FUEL: DSI FOR GAS AND OIL M24136A
GAS MV1
T9
RM7840G: CLIP JR2. OIL MV

1 L2
Q. VALVE PROVING/DUAL FUEL: GAS: 10 SECOND MFEP, OIL: DSI
M24163B
OP.
LIMITS CONTROL GAS
T17
L1
T6
OIL
IF EA IS USED THEN
GAS GAS/OIL SWITCHING IS
INTERLOCKS ALSO NEEDED HERE.
OIL
T7
INTERLOCKS
THE SOFTWARE DOES

NOT ENERGIZE T8 T8
WHEN GAS IS PV
SELECTED AND T21
JUMPER 2 (JUMPER 3
ON RM7840G) IS INTACT
TO INDICATE GAS DSI GAS MV2
FOR A VALVE PROVING
SYSTEM.
GAS MV1
T9
JR2 INTACT OIL MV

L2
R. VALVE PROVING: GAS DSI, OIL 10 SECOND MFEP M24134A
32-00142—01 34
35 32-00142—01
For More Information

The Honeywell Thermal Solutions family of products includes
Honeywell Combustion Safety, Eclipse, Exothermics, Hauck,
Kromschröder and Maxon. To learn more about our products,
visit ThermalSolutions.honeywell.com or contact your
Honeywell Sales Engineer.
Honeywell Process Solutions
Honeywell Thermal Solutions (HTS)
1250 West Sam Houston Parkway
® U.S. Registered Trademark
South Houston, TX 77042 © 2017 Honeywell International Inc.
32-00142—01 M.S. 12-17
ThermalSolutions.honeywell Printed in Mexico

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RM7800L1087, RM7840G1022, RM7840L1075, EC7840L1014

RM7800L2087, RM7840G2022, RM7840GL2075, EC7840L2014

APPLICATION • Both—Valve proving occurs at both times Before and

1 CAUTION: VALVE ENERGIZING TIMING IS BASED ON HONEYWELL VALVE

SPECIFICATIONS This document provides installation and static checkout

IMPORTANT Mounting Wiring Subbase

120 Vac 50/60 Hz

FLAME F PLUG IN FLAME

1 15 SECOND INTERRUPTED OR MV2 IF VALVE PROVING DEMAND (T17) USED.

Table 1. Recommended Wire Sizes and Part Numbers.

Table 2. Recommended Grounding Practices.

Table 3. Terminal Ratings.

Table 4. Combinations for Terminals 8, 9, 10 and 21.

Table 5. Explanation of Each Combination.

LOCKOUT INTERLOCKS LOW FIRE

2 DO NOT WIRE TO ANY UNUSED TERMINALS.

BURNER BURNER/BLOWER MOTOR 5

PREIGNITION INTERLOCK CLOSED 4 TO 20 PII

5 TO 19 HIGH FIRE SW. LOW FIRE SW. 5 TO 18

BURNER MOTOR VALVE PROVING

2 DO NOT WIRE TO ANY UNUSED TERMINALS.

BURNER BURNER/BLOWER MOTOR 5

PREIGNITION INTERLOCK CLOSED 4 TO 20 PII

5 TO 19 HIGH FIRE SW. LOW FIRE SW. 5 TO 18

1 MV2 IS MAIN VALVE CLOSEST TO THE BURNER.

2 JR2 REMOVED FOR PILOT SEQUENCE. M27709

5 RM7800/40L/EC7840L ONLY. M24094A

BURNER MOTOR FOR DIRECT SPARK IGNITION

MAIN FUEL VALVE(S) 9 20 PREIGNITION

BURNER BURNER/BLOWER MOTOR 5

OPERATING LIMITS AND BURNER CONTROLLER CLOSED L1 TO 6

PREIGNITION INTERLOCK CLOSED 4 TO 20 PII

LOW FIRE SW. 5 TO 18

FLAME FLAME PROVING

RUNNING INTERLOCKS 7 18 LOW FIRE

2 DO NOT WIRE TO ANY UNUSED TERMINALS.

BURNER BURNER/BLOWER MOTOR 5

PREIGNITION INTERLOCK CLOSED 4 TO 20 PII

LOW FIRE SW. 5 TO 18

FLAME FLAME PROVING

RUN/TEST DIN RAIL MOUNT BASE:

BASE SECURITY PIN

Fig. 8. RM7800L/40L, EC7840L Relay Module exploded view.

VALVE PROVING SYSTEM Before—Valve Proving occurs concurrently with Pre-

Table 6. Honeywell Pressure Switch Selection for Valve Proving System.

Pressure Switch Selection Pressure Switch Installation and

System operation requires the Valve Proving function

Fig. 9. STANDBY/Setup screen.

± BC Password: 00 Fig. 13. Save Changes screen.

Fig. 10. Password screen. SETUP: ValveProve SU

Fig. 14. Valve Prove time screen.

Press ENTER when correct time is displayed.

=Save changes =Save changes

15. Use the down arrow to save changes. “Getting Data”

Fig. 16. Select/Restart screen. BACK

0 to 60 seconds in 1-second intervals. CONFIRM: ValveProve SC

10 to 60 minutes in 1-minute intervals. BACK

14. Press Enter (Left/Right arrow keys simultaneously)

Fig. 21. Confirm screen.

Fig. 22. Confirm Correct screen. BACK