Install Instructions

ManualsBrandsHoneywell ManualsHeating SuppliesOn-Off Primary Control w/ VPS

INSTALLATION INSTRUCTIONS

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66-1161-04

SIL

Capable

RM7898A

7800 SERIES Valve Proving Primary

Relay Modules

APPLICATION

The RM7898 is a microprocessor-based integrated burner

control for automatically fired gas, oil or combination fuel single

burner applications. The RM7898 system consist of a relay

module, subbase, amplifier, and purge card. Options include

Keyboard Display Module (KDM), Personal Computer Interface,

Data ControlBus™ Module, remote display mounting, Expanded

Annunciator and Combustion System Manager® Software.

Functions provided by the RM7898 include automatic burner

sequencing, flame supervision, system status indication,

system or self-diagnostics and troubleshooting.

The RM7898 provides unique functions to a standard primary

control.

As received, the RM7898 offers the following features:

• Interrupted pilot with 10 second pilot flame establishing period.

• Main valve operation with 10 second MFEP.

• Pre-Ignition Interlock (POC) input.

• Shutter-driven output when appropriate amplifier is

selected (R7861A, R7886A, R7851C).

• Blinking Fault Code Power LED on safety shutdown.

RM7898A1018 offers early spark shutoff when flame is sensed.

Available features when appropriate terminals are energized:

• Intermittent pilot T8 (Terminal 19).

• Direct spark feature for Valve Proving System (VPS)

(Terminal 18).

• Valve Proving System function (Terminal 17).

• See “Appendix b - ignition options” on page 23 for

examples of 24 single or dual fuel system combinations

with or without using the Valve Proving feature.

Programmable features using the S7800A1142 Keyboard

Display Module (KDM) (not included):

• Postpurge time—(up to 60 minutes).

• Valve Prove System features, including:

— VPS test time

— When in burner sequence to conduct VPS time

(Never, Before, After, Both or Split):

NOTE: The S7800A1142 Series 5 or higher can be programmed

for ModBus Communication. (See 65-0288 Spec Sheet.)

At commissioning time, the Valve Proving System may be

scheduled to occur at one of five different times:

1. Never—Device default as received; valve proving does

not occur. (Demand wired to Terminal 6.)

2. Before—Valve proving after standby and safe start

check, prior to ignition trials, concurrent with Pre-Purge.

3. After—Valve proving occurs after the Run state before

the device goes to Standby, concurrent with postpurge.

4. Both—Valve proving occurs at both times Before and

After noted above.

Split—The Main Valve 2 (MV2) (high pressure) seat test is

performed at the Before time and the Main Valve 1 (MV1)

(low pressure) seat test is performed during the After time.

To perform Valve Proving, it must be commissioned and

Demand Input (Terminal 17) must be used.

The following assumptions apply when using the RM7898

Valve Proving testing.

Fig. 1. Valve Proving System—simplified diagram.

MV1—Wired to terminal 9. It is located at the most upstream

position of the main gas valve train.

VPS—Valve Proving Switch (Rated 1/2 of main valve inlet pressure).

MV2—Wired to terminal 21. It is the main valve located

closest to the burner.

The Pre-Ignition Interlock switch or Proof of Closure for

Terminal 20 can be installed on MV1, MV2, or as a series

connection through both valves.

MV1

MV2

SW.

M24161

OUTLET

INLET

CAUTION: VALVE ENERGIZING TIMING IS BASED ON HONEYWELL VALVE

OPENING TIMES OF 13 SECONDS MAXIMUM.

− FOR VALVES WITH TIMINGS GREATER THAN 13

SECONDS OR THOSE THAT DO NOT OPEN THE ACTIVE

VALVE WITHIN THE ENERGIZED TIME, A BYPASS

SOLENOID VALVE (1/4”, 120 VAC) IS REQUIRED TO

OBTAIN THE PROPER TEST PRESSURES.

− THE BYPASS VALVE WILL BE WIRED IN PARALLEL TO THE

VALVE IT IS BYPASSING (TERMINAL 9 FOR MV1 OR

TERMINAL 21 FOR MV2).

Summary of content (28 pages)

PAGE 1
RM7898A 7800 SERIES Valve Proving Primary Relay Modules INSTALLATION INSTRUCTIONS APPLICATION The RM7898 is a microprocessor-based integrated burner control for automatically fired gas, oil or combination fuel single burner applications. The RM7898 system consist of a relay module, subbase, amplifier, and purge card. Options include Keyboard Display Module (KDM), Personal Computer Interface, Data ControlBus™ Module, remote display mounting, Expanded Annunciator and Combustion System Manager® Software.
PAGE 2
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES WARNING Explosion Hazard Can cause severe injury, death or property damage. Be sure to select adequate testing times when the Valve Proving feature is enabled. A shorter time can result in inadequate leak testing of the valves. Storage: -40°F to 150°F (-40°C to +66°C). Humidity: 85% relative humidity continuous, noncondensing. Vibration: 0.5G environment. SIL 3 Capable: SIL 3 Capable in a properly designed Safety Instrumented System.
PAGE 3
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES IMPORTANT 1. Wiring connections for the relay modules are unique; refer to Figs. 4 and 5 or the appropriate Specifications for proper subbase wiring. 2. Wiring must comply with all applicable codes, ordinances and regulations. 3. Wiring must comply with NEC Class 1 (Line Voltage) wiring. 4. Loads connected to the RM7898 must not exceed those listed on the RM7898 label or the Specifications; see Table 3. 5.
PAGE 4
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES L2 L1 INTERNAL ELECTRONICS 5 LIMITS CONTROLLER DEMAND AIRFLOW SWITCH 6 L2 3 ALARM 4 BLOWER 8 PILOT VALVE 9 MAIN VALVE 1 10 IGNITION 21 MAIN VALVE 2 22 DETECTOR SHUTTER 3K DEMAND OR 6K 17 VALVE PROVING SWITCH 7 1 1K 4K 16 2K PILOT SELECT 19 5K DSI SELECT FOR VP MODE 18 PREIGNITION INTERLOCK 2K 7K FLAME DETECTOR 20 F G PLUG IN FLAME AMPLIFIER INTERNAL RELAY OPTO FEEDBACK FIELD WIRING INTERNAL WIRING 1 ALTERNATE CONN
PAGE 5
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES BEFORE 3 CONTROLLER 4 SEC. 3 SEC. TEST TIME 3 SEC. 4 SEC. PURGE TEST TIME L1-17 L17-7 MV2 (21) MV1 (9) VPS (16) VPS (16) 1 PII (20) 2 PII (20) PII (20) AFTER CONTROLLER RUN 4 SEC. 3 SEC. 3 SEC. 4 SEC. TEST TIME STANDBY TEST TIME L1-17 L1-7 MV2 (21) MV1 (9) VPS (16) VPS (16) 1 2 PII (20) PII (20) SPLIT CONTROLLER STANDBY 4 SEC. 3 SEC. PURGE BURNER RUN TIME TEST TIME 4 SEC. 3 SEC.
PAGE 6
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Q7800 SUBBASE 2 G 12 L2 13 LINE VOLTAGE ALARM 3 14 BURNER MOTOR (BLOWER) 4 15 5 16 BURNER CONTROL 6 17 AIRFLOW INTERLOCK 7 18 INTERRUPTED PILOT/ IGNITION 6 8 19 MAIN FUEL VALVE #1 9 20 7 10 21 FLAME DETECTOR 11 22 LIMITS IGNITION 1 L1 3 6 PRE-IGNITION INTERLOCK (POC) L1 L2 MASTER SWITCH INITIATE (INITIAL POWERUP ONLY) POWER LED DISPLAY BURNER 00 STANDBY POWER PFEP PFEP 10SEC. SEC. 5 10 (4 SEC.
PAGE 7
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Q7800 SUBBASE 2 G 12 L2 13 LINE VOLTAGE ALARM 3 14 BURNER MOTOR (BLOWER) 4 15 5 (L1) 16 VALVE PROVING SWITCH 6 17 BURNER CONTROL AIRFLOW INTERLOCKS 7 18 8 INTERMITTENT/ INTERRUPTED PILOT/ 6 IGNITION 8 19 6 MAIN FUEL VALVE 1 9 20 PREIGNITION INTERLOCK (POC) 10 21 MAIN FUEL VALVE #2 11 22 IGNITION 7 FLAME DETECTOR 4 LIMITS 9 L1 (HOT) INITIATE (INITIAL POWERUP ONLY) POWER LED DISPLAY 00 TIMED PFEP 10 SEC.
PAGE 8
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Fig. 5. Wiring subbase and sequence chart for RM7898 operating Valve Proving. Table 2. Recommended Grounding Practices. Ground Type Earth ground (subbase and relay module). Recommended Practice 1. Use to provide a connection between the subbase and the control panel of the equipment. Earth ground must be capable of conducting enough current to blow the 15A, type SC, fast blow fuse (or breaker) in the event of an internal short circuit. 2.
PAGE 9
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 4. Combinations for Terminals 8, 9, 10 and 21. Combination Number Pilot Fuel 8 Main 9 Ignition 10 Main Valve 2 (21) 1 C F No Load C 2 B F No Load B 3 F F A F 4 F F A F 5 F F A F 6 D F A D 7 D D A D 8 D D A D 9 D No Load A D Table 5. Composition of each Combination. Ba A 4.5A ignition a 50 VA Pilot Duty a plus 4.5A ignition.
PAGE 10
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 6. Static Checkout. Test Relay Module Test Number Model Jumpers Voltmeter Normal Operation If Operation is Abnormal, Check Items Listed Below 1 All None 5-L2 Line voltage at terminal 5. 1. Master switch. 2. Power connected to master switch. 3. Overload protection (fuse, circuit breaker, etc.) has not opened power line. 2 All None 6-L2 or 17-L2 Line voltage at terminal 6 or 17. For Valve Proving. 1. Limits. 2. Burner controller.
PAGE 11
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Typical Valve Proving System Function c. Thereafter, the VPS is monitored for the duration of 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) d. MV1 is commanded to be open while MV2 remains closed, to pressurize the space. After 4 seconds, MV1 is commanded closed again. e.
PAGE 12
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Setup of Valve Proving and Post Purge Functions SETUP: ValveProve ± VP When: BEFORE Prior to setup of the Valve Proving and Post Purge functions, follow the procedures in the appendix to complete the worksheet and obtain the Valve Proving Test Time. BACK An S7800A1142 Keyboard Display Module (KDM) is required for this setup and the RM7898 must have the Valve Proving function. Edit: Scroll down until the “Setup” is displayed in the second line.
PAGE 13
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Press ENTER when correct time is displayed. =Save changes =Restart =Save changes =Restart BACK Edit: - ENTER + BACK Edit: - M22665B ENTER + Fig. 15. Save Changes screen. M22665B 15. Use the down arrow to save changes. “Getting Data” is displayed momentarily. The following steps are to confirm your selections. Fig. 12. Save Changes screen.
PAGE 14
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES 23. =Confirm correct =Incorrect Press and hold the relay module’s RESET button for five seconds to program the Valve Proving setup into the relay module. The Release Reset screen will appear on the KDM. BACK Edit: - ENTER + SETUP DONE: ... release Reset M22671B Fig. 19. Confirm Correct screen. BACK Edit: 19. Use the down arrow to confirm correct. “Getting Data” will be displayed.
PAGE 15
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES PRINCIPAL TECHNICAL FEATURES 6. The RM7898 provides all customary flame safeguard functions as well as significant advancements in safety, annunciation, and system diagnostics. Safety Shutdown (Lockout) Occurs if: 1. 2. 3. 4. 5. INITIATE PERIOD a. Purge card is not installed or removed. b. Purge card is bad. c. Configuration jumpers have been changed (after 200 hours)—Fault Code 110. d. AC line power errors occurred.
PAGE 16
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Pre-Purge RM7898A1018 will shut off the ignition when flame is sensed, but the establishing period continues. (3) If flame is not proven by the end of this main flame establishing period, safety shutdown occurs. (4) The Pre-Ignition Interlock is ignored throughout the trial for ignition period.
PAGE 17
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES WIRING SUBBASE RUN/TEST SWITCH HONEYWELL RELAY MODULE CONFIGURATION JUMPERS PURGE TIMER SEQUENCE STATUS LED PANEL POWER RESET BUTTON PILOT FLAME MAIN ALARM OPTIONAL KEYBOARD DISPLAY MODULE (STANDARD ON RM7800G,L) CAPTIVE MOUNTING SCREW RESET BURNER CONTRO L SCROLL FLAME AMPLIFIER MODE - SAVE - M23166 Fig. 24. Sequence Status LEDs.
PAGE 18
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 8. Site-configurable jumper options. Jumper Number SELECTABLE CONFIGURATION JUMPERS RUN/TEST SWITCH (EC7895C; RM7895C,D; RM7896C,D) JR1 Description Pilot Flame Establishing Period (PFEP) Intact Clipped 10 4 seconds seconds JR2 Flame Fail Recycle Lockout JR3 Interlock Recycle Lockout TROUBLESHOOTING The POWER LED provides fault identification when the Relay Module locks out on an alarm.
PAGE 19
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 9. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code Code 2-3 *Flame Signal Overrange* System Failure Flame signal value is too high to be valid. Code 3-1 Running or Lockout *Running/ Interlock fault during Interlock Switch Pre-Purge. Problem* Code 3-2 *Running/ Interlock On During Standby* Lockout Interlock powered at improper point in sequence or On in Standby. Recommended Troubleshooting 1.
PAGE 20
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 9. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code System Failure Recommended Troubleshooting Code 4-4 *Configuration Jumper Problem* The configuration jumpers differ from the sample taken at startup. 1. Inspect the jumper connections. Make sure the clipped jumpers were completely removed. 2. Reset and sequence the Relay Module. 3. If the fault persists, replace the Relay Module.
PAGE 21
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES APPENDIX A: VALVE PROVING TEST The following steps are to determine the test time for the Relay Module to verify the valve seats are not leaking at a rate of greater than/equal to 0.1% of the burner capacity. Fig. 26 shows a typical valve train. The legend identifies information that will be used to fill out the worksheet that appears at the end of this appendix.
PAGE 22
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 11. VPS Worksheet Example. Item Description V1 Upstream Valve Volume Information V5055 Lookup Table 12 Results 0.0218 Formula Item 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 2 — 2 P 2.5 mbtu — 2500 C P Valve Inlet Pressure C Burner Maximum Firing (cf/hr)b (psig)a a Divide inches w.c. by 27.7 to get psi.
PAGE 23
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 14. Schedule 40 Pipe Internal Cross-Sectional Area. Pipe Size NPT (Inches) 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 Item V1 V2 D L P Description Upstream Valve Volume Downstream Valve Volume Pipe Size NPT (in.) Pipe Length (ft) C Burner Maximum Firing (cf/hr)b a b Cross-Sectional Area (Sq. In.) “A” 3/8 Valve Inlet Pressure (psig)a Table 15. VPS Worksheet.
PAGE 24
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES Table 16. Ignition options. (Continued) IGNITION OPTIONS DRAWING I.D. CODE FUEL CHANGEOVER POLES REQUIRED NO VALVE PROVING Direct Spark Ignition Direct Spark Ignition L 2 VALVE PROVING Single Fuel 10 Sec. Interrupted PIlot M -- Intermittent Pilot N -- Direct Spark Ignition O -- Dual Fuel Gas Oil P 2 10 sec. Interrupted Pilot 10 sec. Interrupted Pilot Q 3 10 sec. Interrupted Pilot Direct Spark Ignition R 4 10 sec.
PAGE 25
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES OP. LIMITS CONTROL L1 OP. LIMITS CONTROL T6 T19 (IP SEL.) T6 L1 T19 (IP SEL.) NC GAS INTERLOCKS GAS INTERLOCKS GAS: IP OIL: 10 T7 OIL INTERLOCKS IF EA IS USED THEN GAS/OIL SWITCHING IS ALSO NEEDED HERE. T7 OIL IF EA IS USED THEN INTERLOCKS GAS/OIL SWITCHING IS ALSO NEEDED HERE. T8 PV T21 T8 PV T21 GAS MV T9 GAS MV T9 OIL MV L2 G. DUAL FUEL: GAS INTERMITTENT PILOT, OIL 10 SECOND INTERRUPTED GAS PILOT. OIL MV M23833 L2 D.
PAGE 26
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES OP. LIMITS CONTROL OP. LIMITS CONTROL L1 T6 L1 NC T6 T18 DSIVP SEL. GAS INTERLOCKS 1 T8 T17 T21 T7 T9 INTERLOCKS MV2 T7 MV1 T19 (IP SEL.) IF EA IS USED THEN OIL INTERLOCKS GAS/OIL SWITCHING IS ALSO NEEDED HERE. MGV 1 L2 REQUIRED WIRING IF VALVE PROVING BOTH, SPLIT, OR AFTER IS SELECTED M. VALVE PROVING, GAS: 10 SECOND INTERRUPTED PILOT T8 M23840A PV T9 T19 (IP SEL.) T18 DSIVP SEL. NC OP. LIMITS CONTROL OIL MV L2 J.
PAGE 27
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES OP. LIMITS CONTROL VP GAS OP. LIMITS CONTROL T17 NC 1 GAS INTERLOCKS T8 T6 T19 (IP SEL.) T18 DSI-VP SEL. OIL 1 NC GAS INTERLOCKS T7 OIL IF EA IS USED THEN INTERLOCKS GAS/OIL SWITCHING IS ALSO NEEDED HERE. T8 PV T21 T7 OIL IF EA IS USED THEN INTERLOCKS GAS/OIL SWITCHING IS ALSO NEEDED HERE.
PAGE 28
RM7898A 7800 SERIES VALVE PROVING PRIMARY RELAY MODULES OP. LIMITS CONTROL VP GAS L1 OIL OP. LIMITS CONTROL T17 T6 T19 (IP SEL.) T18 DSI-VP SEL. L1 NC 1 GAS INTERLOCKS GAS T17 L1 T6 OIL L1 1 L1 GAS INTERLOCKS T7 OIL IF EA IS USED THEN INTERLOCKS GAS/OIL SWITCHING IS ALSO NEEDED HERE. T8 T8 OIL MV T21 GAS MV2 GAS MV1 T9 GAS MV1 OIL MV T21 1 IF EA IS USED THEN GAS/OIL SWITCHING IS ALSO NEEDED HERE. PV T8 IS NOT TURNED ON WHEN GAS IS THE SELECTED FUEL IF T18 IS ON.