Honeywell R7120D, R7120D1002, R7120D2000, R7120D3007 Installation Instructions Manual
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R7120D
WARNING
Burner Control Modules
INSTALLATION INSTRUCTIONS
APPLICATION
The R7120D is a microprocessor-based functional plug in
replacement for the Fireye D and E Series system utilizing the
existing wiring subbase. The R7120D is an integrated control
for automatically fired gas, oil, or combination fuel on/off or
modulating single burner applications. The R7120D system
consists of a relay module, amplifier, and purge card. Options
include keyboard display module (KDM), Data ControlBus™
Module, ModBus™ Module, remote display mounting. See the
Honeywell Programmer Control Cross Reference (form
number 70-8313 available on the web site
www.customer.honeywell.com) for correct parts and feature
selection options.
Functions provided by the R7120D include automatic burner
sequencing, flame supervision, system status indication,
system or self-diagnostics and troubleshooting.
R7120D models available:
R7120D1002 for Fireye D10 or E1XX
R7120D2000 for Fireye D20 or E2XX
R7120D3007 for Fireye D30 or E3XX
SPECIFICATIONS
Electrical Ratings (See Table 2):
Voltage and Frequency:
120 Vac (+10/-15%), 50/60 Hz (± 10%).
Power Dissipation: 10W maximum.
Maximum Total Connected Load: 2000 VA.
Fusing Total Connected Load: 15A Fast Blow, type SC or
equivalent.
Environmental Ratings:
Ambient Temperature:
Operating: -40°F to 140°F (-40°C to +60°C).
Storage: -40°F to 150°F (-40°C to +66°C).
Humidity: 85% relative humidity continuous, noncondensing.
Vibration: 0.5G environment.
Approvals:
cULus component listed: File No. MP268, Guide No.
MCCZ.
Federal Communications Commission: Part 15, Class B,
Emissions.
Required Components for operation (order separately):
Choice is based on configuration of the Fireye Control being
replaced:
Purge Timer
Flame Amplifier
Flame Detector
Contents
Application ........................................................................ 1
Specifications ................................................................... 1
Installation ........................................................................ 1
General Instructions ......................................................... 2
Safety Shutdown .............................................................. 10
Operation .......................................................................... 10
Settings and Adjustments ................................................. 12
System Checkout ............................................................. 13
Optional Components:
S7800A1001 Keyboard Display Module
S7810M1003 Modbus Module
S7820A1007 Cover for Remote Reset
INSTALLATION
Fire or Explosion Hazard.
Can cause severe injury, death or property
damage.
Follow applicable safety requirements when installing
a control on a burner to prevent death or severe injury.
66-1196EF-01
R7120D BURNER CONTROL MODULES
WARNING
WARNING
CAUTION
WARNING
TERMINAL SCREW
M32654
Electrical Shock Hazard.
Can cause serious injury, death or equipment
damage.
Disconnect power supply before beginning installation.
More than one disconnect may be required.
When Installing this Product…
1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous condition.
2. Installer must be a trained, experienced, flame safe-
guard service technician.
3. After installation is complete, perform the System
Checkout provided in these instructions.
IMPORTANT
1. Two flame detectors can be connected in parallel
with the exception of Flame Detectors C7915,
C7927,C7961 and C7952.
2. This equipment generates, uses and can radiate
radio frequency energy and, if not installed and used
in accordance with the instructions, can cause
interference with radio communications. It has been
tested and found to comply with the limits for a Class
B computing device of Part 15 of FCC rules.
3. This digital apparatus does not exceed the Class B
limits for radio noise for digital apparatus set out in
the Radio Interference Regulations of the Canadian
Department of Communications.
GENERAL INSTRUCTIONS
Fire or Explosion Hazard.
Can cause severe injury, death or property
damage.
Close all manual fuel shutoff valve(s) before starting
the replacement of these controls.
Electrical Shock Hazard.
Can cause serious injury, death or equipment
damage.
Disconnect power supply before beginning installation.
More than one disconnect may be required.
1. Disconnect the power supply from the main disconnect
before beginning installation to prevent electrical shock
and equipment damage. More than one disconnect can
be required.
2. Loosen the mounting screw to remove the Fireye Con-
trol from the wiring base.
3. Check all wiring at the subbase for correct connections,
tight terminal screws, correct wire, and proper wiring
techniques. Replace all damaged or incorrectly sized
wires.
4. Replace faulty controllers, limits, interlocks, actuators,
valves, transformers, motors and other devices, as
required. Do not bypass limits and interlocks.
5. Be sure loads do not exceed the terminal ratings. Refer
to the label on the R7120D.
6. See Table 1 for recommended grounding practices. The
R7120D is a microprocessor based control and proper
grounding is important for safe, reliable operation.
Installing Honeywell Flame Detectors
1. Fireye Infrared and Ultraviolet flame detectors SHOULD
NOT be used with the R7120D.
2. See the Honeywell instruction sheets for proper installa-
tion of the flame detector. NOTE: the wire for the Honeywell F terminal is connected to the Fireye Subbase
terminal S1. The G terminal wire is connected to the Fireye S2 terminal.
3. Applications that require shutter type flame detectors:
Connect one of the shutter leadwires to the terminal
screw found on the back of the R7120D. See Fig. 1.
Use extreme care while testing the system. Line voltage is
present on most terminal connections when power is on.
Ensure proper selection of configuration jumpers before
starting the burner operation.
66-1196EF—01 2
Electrical Hazard.
Can cause equipment damage or failure.
Do not perform a dielectric test with the relay module
installed. Internal surge protectors can break down,
allowing relay module to fail the dielectric test and
destroy the internal lightning and high current
protection.
Fig. 1. R7120D terminal screw.
R7120D BURNER CONTROL MODULES
WARNING
Replacing Fireye D10 or E1XX devices with R7120D
1. Locate the wire that is located on the D terminal that
goes to the High Fire (or Purge Rate) Switch.
2. Remove that wire and connect it to the M terminal.
Installing the R7120D Relay Module
1. Make sure no subbase wiring is projecting beyond the
terminal blocks. Route wiring against the back of the
subbase so it does not interfere with engagement of the
subbase terminals into the controller base.
2. Check the electrical tabs on the back of the chassis. If
they are bent out of position, reposition them with your
fingers so that they are in line.
3. Position the R7120 control into the mounting tabs of the
existing wiring base, and pivot the control into place. If a
shutter wire was installed for the Honeywell flame
detector, make sure the wire is not being pinched.
Refer to Fig. 8 for mounting information.
Table 1. Recommended Grounding Practices.
Ground Type Recommended Practice
Earth ground (subbase and relay
module).
Signal ground (Keyboard Display
Module, Data ControlBus™ Module,
Modbus Module.
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. Use wide straps or brackets to provide minimum length, maximum surface area
ground conductors. If a leadwire is required, use 14 AWG copper wire.
3. Make sure that mechanically tightened joints along the ground path are free of
nonconductive coatings and protected against corrosion on mating surfaces.
Use the shield of the signal wire to ground the device to the signal ground terminal 3(c) of
each device. Connect the shield at both ends of the daisy chain to earth ground.
4. Gently press the control onto the subbase to engage the
terminal blades and secure with the one captivated
mounting screw at the center top of the R7120D control
housing.
5. Tighten the mounting screws enough to seat the R7120
to the wiring base but DO NOT OVERTIGHTEN.
6. If installed in an electrical panel, be sure there is ade-
quate clearance behind the closed door of the panel so
there is no interference with the R7120.
Mounting Other System Components
Refer to Fig. 9 for exploded view of installation, or the
applicable specification sheet for mounting other system
components.
Fire or Explosion Hazard.
Can cause severe injury, death or property
damage.
Follow applicable safety requirements when installing
a control on a burner to prevent death or severe injury.
3 66-1196EF—01
R7120D BURNER CONTROL MODULES
L1
RUN/TEST
SWITCH
RESET
PUSHBUTTON
STATUS LEDs
LIMITS CONTROLLER
2
6K1
3K1
KEYBOARD
DDL
DDL
COMMUNICATIONS
DISPLAY MODULE
RS485
1
2
CONFIGURATION
JUMPERS
SAFETY RELAY
CIRCUIT
R1
PII
13
LOW FIRE SWITCH
D
PURGE INTERLOCK
SWITCH
8
REMOTE
3
RESET
L1
(HOT) L2
1
MICROCOMPUTER
2K
3K
RUNNING/
LOCKOUT
INTERLOCK
9K2
4K
5K
6K
7K
8K
9K
1K
HIGH FIRE
COMMON
MODULATE
9K1
LOW FIRE
RELAY
DRIVE
CIRCUIT
3
8K1
8K2
120 Vac,
50/60 Hz
POWER SUPPLY
P
PLUG-IN PURGE
TIMER CARD
FLAME SIGNAL
1K1
X
10
11
12
TEST
4K1
7K1
2K2
TEST
JACK
F
PLUG-IN
FLAME
AMPLIFIER
RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS
CONTROL
POWER
INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLT INPUTS
FIELD WIRING
INTERNAL WIRING
G
17
R1
5
6
7
M
A
PILOT
PILOT/V2
MAIN VALVE
BLOWER
ALARM
L2
1
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
R7120D2000 DOES NOT HAVE A PURGE INTERLOCK
2
Fig. 2. Internal block diagram of the R7120D1002 and D2000.
66-1196EF—01 4
M32636
R7120D BURNER CONTROL MODULES
LED
DISPLAY
BURNER
OPERATING
CONTROLS
AND
INTERLOCKS
FLAME
SIGNAL
FIRING
RATE
MOTOR
INITIATE
(INITIAL
POWERUP
ONLY)
POWER
STANDBY
POWER
SAFE START CHECK
PREPURGE
HOLD
00
DRIVE TO
HIGH FIRE
POWER
PII CLOSED
M
SWITCHING
R7120D1002, D2000
PREPURGE
00 00 10 25 00 15 20
TIMED
PREPURGE
POWER
PILOT
FLAME
MAIN
LIMITS AND BURNER CONTROLLER CLOSED
LOCKOUT INTERLOCKS CLOSED
HIGH FIRE SW.
8TO
10
TO
MOTOR ACTION
HOLD
DRIVE TO
LOW FIRE
POWER
PILOT
FLAME
MAIN
BURNER/BLOWER MOTOR
13
1
2
X
TO
00
3
PFEP
10 SEC.
(4 SEC. IF
JR1
CLIPPED
POWER
PILOT
FLAME
MAIN
10 SEC. IGN./PILOT
15 SEC. PILOT 6
LOW FIRE SW.
M D
10 12
MFEP
RUN
POWER
PILOT
FLAME
MAIN
ALARM ALARM ALARM ALARM
MAIN VALVE
3TO
TO
FLAME PROVING
TO
POWER
PILOT
FLAME
ALARM
M
5
3
TO
13
L1
P
10 11
MAIN
TO
POSTPURGE
7
1
1
POWER
TO
10 12
STANDBY
POWER
SSC
1
PII MEANS PRE-IGNITION INTERLOCK.
R7120D1002 ONLY
2
FOR R7120D2000
3
- CLIP JR2 FOR INTERRUPTED PILOT WITH 15 SECONDS MFEP
- CLIP JR2 AND ADD JUMPER BETWEEN TERMINAL 8 AND M FOR INTERRUPTED PILOT WITH 30 SECOND MFEP
Fig. 3. Operating sequence for R7120D1002.
M32637
5 66-1196EF—01
R7120D BURNER CONTROL MODULES
FLAME
DETECTOR
(UV)
LOCKOUT
ALARM
2
PURGE INTERLOCK
D10/EP100 OR D20/EP200
TYPICAL WIRING
S2
S1
A
2
8
X
P
D
M
1
LOW FIRE START
INTERLOCK
RUNNING
INTERLOCK
BURNER/
BLOWER
MOTOR
MAIN FUEL
VALVE(S)
PILOT
VALVE(S)
IGNITION
TRANSFORMER
11 12 10 X
1
AUTO
LO COM HI
B
R
W
W R B
1
USED ONLY ON D10 OR EP100 SERIES PROGRAMMERS.
LOCATE THE PURGE INTERLOCK WIRE CONNECTION ON TERMINAL D, REMOVE AND CONNECT TO TERMINAL M.
2
R120D2000, JUMPER WIRE ADDED BETWEEN 8 AND M PROVIDES 30 MFEP ON TERMINAL 6, IF JR2 IS REMOVED.
3
7
6
5
13
12
1
FLAME MONITOR
TERMINALS
135 OHM
FIRING RATE
MOTOR
135 OHM
CONTROLLER
3
3
L2/N
L1/L
11
1
10
1
1
11 12 10
AUTO
LO
COM
VALVE
PROOF OF
CLOSURE
X
HI
F
4-20mA
CONTROLLER
BURNER
SWITCH
FLAME MONITOR
TERMINALS
4-20 mA
MOTOR
MASTER
SWITCH
LIMIT
OPERATING
SWITCHES
L2
L1
M32638
Fig. 4. Internal block diagram of the R7120D3007 with pre-ignition interlocks.
66-1196EF—01 6
R7120D BURNER CONTROL MODULES
INTERNAL
ELECTRONICS
M32639
CONFIGURATION
JUMPERS
PURGE
TIMER
FLAME
AMPLIFIER
ALARM
BLOWER
INTERMITTENT
PILOT
1R1
3K1
6K1
A
M
6
MAIN VALVE
7
LF
D
F
G
17
L1
L1
L2
L2
15 SECOND
INTERMITTENT
PILOT VALVE
5
4K1
7K1
2K2
1K1
P
AIRFLOW
3
13
LIMITS
CONTROLLER
1R1
X
10
PRE-
IGNITION
11
8K2
9K1
12
9K2
LED
DISPLAY
BURNER
OPERATING
CONTROLS
AND
INTERLOCKS
FLAME
SIGNAL
DAMPER
MOTOR
Fig. 5. Internal block diagram of R7120D3007.
INITIATE
(INITIAL
POWERUP
ONLY)
POWER
1
STANDBY
PII MEANS PRE-IGNITION INTERLOCK.
00 00 10 25 00 15 20
TIMED
PREPURGE
POWER
LIMITS AND BURNER CONTROLLER CLOSED
SAFE START CHECK FLAME PROVING
R7120D SWITCHING
10 11
MOTOR ACTION
Fig. 6. Operating sequence for R7120D3007.
R7120D 3007
PREPURGE
HOLD
DRIVE TO
LOW FIRE
POWER
PILOT
FLAME
MAIN
BURNER/BLOWER MOTOR
PII CLOSED
TO
POWER
PILOT
FLAME
MAIN
RUNNING INTERLOCKS CLOSED
PFEP
10 SEC.
00
(4 SEC. IF
JR1
10 SEC. IGN./PILOT
INTERMITTENT PILOT VALVE
1
LOW FIRE SW.
7 66-1196EF—01
CLIPPED
POWER
PILOT
FLAME
MAIN
3
10 12
TO
13TO
MFEP
POWER
PILOT
FLAME
MAIN
ALARM ALARM ALARM ALARM
5
MAIN VALVE
L1
3
TO
M
TO
D
RUN
POWER
PILOT
FLAME
MAIN
ALARM
M
6
13
PTO
10 11
TO
POSTPURGE
7
POWER
10 12
TO
STANDBY
POWER
SSC
M32640
R7120D BURNER CONTROL MODULES
L1
L2
S2
S1
A
8
7
6
5
13
12
X
P
D
M
3
L2/N
L1/L
11
10
FLAME
DETECTOR
(UV)
BURNER/
BLOWER
MOTOR
VALVE
PROOF OF
CLOSURE
LIMIT
OPERATING
SWITCHES
BURNER
SWITCH
RUNNING
INTERLOCK
LOW FIRE START
INTERLOCK
MASTER
SWITCH
LOCKOUT
ALARM
MAIN FUEL
VALVE(S)
INTERMITTENT
PILOT
VALVE(S)
INTERUPTED
PILOT
VALVE(S)
M32641
Fig. 7. Wiring hookup diagram for R7120D3007.
BURNER CONTROL
5
(127)
POWER
PILOT
FLAME
MAIN
ALARM
RESET
2
5-51/64 (147)
Fig. 8. Mounting dimensions of R7120D2000, R7120D1002, R7120D3007 Burner Control Module in in. (mm).
Terminal Typical Load Maximum Rating at 120 Vac, 60 Hz
5 or 6 Ignition
7 Main Fuel Valve(s) (solenoid/
66-1196EF—01 8
Transformer/Pilot
Valve/First Stage Fuel Valve
motorized/diaphragm) and
Vent Valve, if required
4.5A ignition and 50 VA pilot duty, or
2.5A ignition and 75 VA pilot duty.
250 VA pilot duty or 65 VA pilot duty in parallel with motorized valve(s) using a total of
1150 VA locked rotor (inrush), 460 VA to open, and 250 VA to hold or motorized valve(s)
using a total of 1500 VA locked rotor (inrush), 600 VA to open, and 250 VA to hold.
(51)
Table 2. Terminal Ratings.
5 (127)
5-45/64 (145)
7
(178)
M32698
R7120D BURNER CONTROL MODULES
WIRING
SUBBASE
BURNER CONTROL
RELAY
MODULE
ADAPTER
PLATE
KEYBOARD
DISPLAY
MODULE
(OPTIONAL)
RESET
POWER
PILOT
FLAME
MAIN
ALARM
FLAME
AMPLIFIER
M32642
PURGE
TIMER
RESET
BUTTON
CONFIGURATION
JUMPERS
RUN/TEST
SWITCH
SEQUENCE
STATUS
LED PANEL
Table 3. Sequence Timing for Normal Operation.
Flame
Device Initiate Standby Purge
R7120D
10 sec. * ** 4 or 10
2000
Establishing
Period
10, 15
sec.
sec.a or
Post
Purge
Run
Timing Interlock Circuits
* 15 sec. Pre-Ignition,
Running, Low Fire
Firing
Rate
Circuit
4-wire
modulating
Energy
Approval
Saving
Pre-Purge
BodiesPilot Main
No UL/CSA
Modulating
intermittent.
R7120D
1002
10 or 15
sec
Pre-Ignition,
Lockout High and
FM/IRI
Modulating
Low Fire
R7120D
3007
10 sec. or
intermittent
Pre-Ignition,
Running, isolated
Low Fire.
2-wire
isolated
On-Off-On
UL/CSA
On-Off.
contacts
a
15 second MFEP with JR2 clipped, and 30 seconds with JR2 clipped and jumper from terminal M to terminal 8.
* STANDBY and RUN can be an infinite time period.
** PURGE will be determined by which ST7800A purge card is selected; 15 timings are available from 2 seconds to 30 minutes.
Code
Fig. 9. R7120D Relay Module, exploded view.
9 66-1196EF—01
R7120D BURNER CONTROL MODULES
SAFETY SHUTDOWN
Safety Shutdown (Lockout) occurs if any of the following occur during the indicated period:
1. INITIATE Period:
a. Purge card is not installed or is removed.
b. Purge card is bad.
c. Configuration jumpers are changed (after 200 hours
of operation).
d. AC line power errors occur; see Operation section.
e. Four minute INITIATE period has been exceeded.
2. STANDBY Period:
a. Flame signal is present after 240 seconds.
b. Interlock check feature is enabled and the
Interlock String (including airflow switch) is closed
for 120 seconds with controller closed.
c. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
d. Main valve terminal is energized.
e. Internal system fault occurs.
f. Purge card is not installed or is removed.
g. Purge card is bad.
3. PREPURGE Period:
a. Pre-Ignition Interlock opens anytime during PRE-
PURGE period (R7120D1002).
b. Flame signal is detected after first ten seconds
during PREPURGE (R7120D1002).
c. High Fire Switch fails to close within 4 minutes and
15 seconds after the firing rate motor is commanded
to drive to the high fire position at the start of PRE-
PURGE (R7120D1002).
d. Low Fire Switch fails to close within 4 minutes and
15 seconds after the firing rate motor is commanded
to drive to the low fire position at the end of PRE-
PURGE.
e. Running Interlock does not close within 30 seconds
(R7120D2000, R7120D3007).
f. Lockout Interlock does not close within 10 seconds
(R7120D1002).
g. Lockout Interlock opens during PREPURGE
(R7120D1002).
h. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
i. Main valve terminal is energized.
j. Internal system fault occurs.
k. Purge card is removed.
l. Purge card is bad.
4. PILOT FLAME ESTABLISHING Period (PFEP):
a. Low Fire Switch opens.
b. Lockout Interlock opens (RM7140L).
c. Ignition/pilot valve/intermittent pilot valve terminal is
not energized.
d. Early spark termination terminal is energized after
five seconds.
e. No flame is present at the end of PFEP.
f. Main valve terminal is energized (R7120D2000,
R7120D3007).
g. Internal system fault occurs.
h. Purge card is removed.
i. Purge card is bad.
5. MAIN FLAME ESTABLISHING Period (MFEP):
a. Low Fire Switch Opens.
b. Lockout Interlock opens (R7120D1002).
c. Ignition/pilot valve/intermittent pilot valve terminal is
not energized.
d. Main valve terminal is not energized.
e. No flame is present at the end of MFEP.
f. Internal system fault occurs.
g. Purge card is removed.
h. Purge card is bad.
6. RUN Period:
a. No flame is present.
b. Lockout Interlock opens (R7120D1002).
c. Interrupted pilot valve terminal is energized
(R7120D2000, R7120D3007).
d. Main valve terminal is not energized.
e. Internal system fault occurs.
f. Purge card is removed.
g. Purge card is bad.
7. POSTPURGE Period:
a. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
b. Main valve terminal is energized.
c. Internal system fault occurs.
d. Purge card is removed.
e. Purge card is bad.
OPERATION
Sequence of Operation
The R7120 has the following operating sequences; see Fig. 2
through 6 for internal diagrams, hookup drawings or operating
sequence charts. The R7120 LED provides positive visual
indication of the program sequence: POWER, PILOT, FLAME,
MAIN and ALARM.
Initiate
The R7120 enters the INITIATE sequence when the Relay
Module is powered. The R7120 can also enter the INITIATE
sequence if the Relay Module verifies voltage fluctuations of
+10/-15 percent or frequency fluctuations of ±10 percent
during any part of the operating sequence. The INITIATE
sequence lasts for ten seconds unless the voltage or
frequency tolerances are not met. When the tolerances are
not met, a hold condition is initiated for at least five seconds.
When the tolerances are met, the INITIATE sequence
restarts. If the condition is not corrected and the hold condition
exists for four minutes, the R7120 locks out. Causes for hold
conditions in the INITIATE sequence:
a. AC line dropout is detected.
b. AC line noise prevents a sufficient reading of the
line voltage inputs.
c. Low line voltage brownouts occur.
The INITIATE sequence also delays the burner motor starter
from being energized and de-energized from an intermittent
AC line input or control input.
Standby
The R7120 is ready to start an operating sequence when the
operating control determines a call for heat is present. The
burner switch, limits, operating control and all microcomputer
monitored circuits must be in the correct state for the R7120 to
continue into the PREPURGE sequence.
66-1196EF—01 10
R7120D BURNER CONTROL MODULES
WARNING
Normal Start-Up Pre-Purge
The R7120 provides a pre-purge timing selectable with the
ST7800 Purge Timer cards, from two seconds to 30 minutes
with power applied and the operating control is indicating a
call for heat:
a. Running Interlocks, Pre-Ignition Interlocks, Burner
Switch, Run/Test Switch, Lockout Interlocks and all
microcomputer monitored circuits must be in the
correct operating state.
b. The blower motor output, terminal M, is powered to
start the PREPURGE sequence. The PREPURGE
timing for the R7120D1002 does not begin until the
High Fire Switch is closed.
NOTE: A jumpered High Fire Switch adds a 30-second hold
before the purge time starts.
c. The Pre-Ignition Interlock input must remain closed
throughout PREPURGE; otherwise, control returns to
the STANDBY state and holds (30 seconds) for the
R7120D2000, R7120D3007 or safety shutdown for the
R7120D1002 occurs.
d. The Lockout Interlock or Running Interlock inputs
(interlock circuit including Airflow Switch) must close
by ten seconds into PREPURGE; otherwise, a
recycle to the beginning of PREPURGE for the
R7120D2000, R7120D3007 will happen or a safety
shutdown for the R7120D1002 occurs.
e. When PREPURGE timing is complete, the firing rate
motor drives to the low fire position.
f. When the firing rate motor reaches low fire position,
the Low Fire Switch, terminal M to D, is energized to
enter the Ignition Trial state.
NOTE: A 30-second hold occurs for a jumpered Low Fire
Switch before the ignition trial period begins.
a. Terminal 7 is energized when the presence of flame is
verified at the end of the Pilot Flame Establishing
Period (PFEP).
b. Terminal 5 is turned off 10 seconds after terminal 7
is energized.
c. Terminal 6 action:
(1) R7120D1002: De-energized 15 seconds after
terminal 7 is energized.
(2) R7120D2000:
(a)Not turned off, or
(b)15 seconds after terminal 7 is energized and
JR2 is clipped, or
(c)30 seconds after terminal 7 is energized and
terminals 8 and M are jumpered and jumper
JR2 is clipped.
(3) R7120D3007: Remain energized as long as call
for heat is present.
Run
1.
Fifteen seconds after the main valve terminal 7 is
energized and flame is maintained, the R7120 goes to
Run.
2.
The firing rate motor releases to modulation
(R7120D1002,2000). Damper motor is energized
(R7120D3007).
3.
The R7120 is now in RUN and remains in RUN until the
controller input, terminal 13 opens, indicating that the
demand is satisfied or a limit opened.
Postpurge
The R7120 provides a 15-second POSTPURGE following the
completion of the RUN period (call for heat ends). The blower
motor output remains powered to drive all products of
combustion and any unburned fuel from the combustion
chamber. It also supplies combustion air to burn fuel being
purged from the fuel line downstream of the fuel shutoff valve.
Ignition Trials
1. Pilot Flame Establishing Period (PFEP):
a. With the firing rate motor at the low fire position:
(1) The pilot valve and ignition transformer,
terminals 5 and 6 are energized.
(a)The R7120D2000 has an interrupted or
intermittent pilot valve, terminal 6, depending
on the selection of configuration jumper 2.
(b) The R7120D1002 has a 15-second inter-
rupted pilot valve, terminal 6.
(c)The R7120D3007 has an intermittent pilot
valve, terminal 6.
NOTE: All of the R7120s have a ten-second interrupted pilot
valve/ignition, terminal 5.
(2) During PFEP, the Low Fire Switch must remain
closed. If it opens, a safety shutdown occurs.
(3) The Pre-Ignition Interlock input is ignored
throughout the Ignition Trial state.
b. Flame must be proven by the end of the 10-second
PFEP (four if JR1 is clipped) to allow the sequence
to continue. If flame is not proven by the end of
PFEP, a safety shutdown occurs.
2. Main Flame Establishing Period (MFEP):
1. The main fuel valve and intermittent pilot valve,
terminals 7 and 6, are de-energized and the firing rate
motor is commanded to the low fire position to begin the
POSTPURGE period.
2. After the 15-second POSTPURGE period is completed,
the blower motor (terminal 8) is de-energized and the
R7120 reenters Standby.
Run/Test Switch
Explosion Hazard.
Can cause serious injury or death.
Do not use the Run/Test switch during the Pilot Flame
Establishing Period for the R7120 when using Direct
Spark Function, because it turns on the main gas
valve, causing an accumulation of fuel in the burner.
The Run/Test Switch is located on the top side of the R7120,
see Fig. 1. The Run/Test Switch allows the burner sequence
to be altered as follows:
11 66-1196EF—01
R7120D BURNER CONTROL MODULES
RUN/TEST SWITCH
NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.
SELECTABLE CONFIGURATION JUMPERS
M12301
1. In Pre-Purge Drive To High Fire Position
(R7120D1002), the Run/Test Switch, when placed in the
TEST position, holds in PREPURGE with the firing rate
motor in the High Fire position.
2. In the measured PREPURGE sequence, the Run/Test
Switch, when placed in the TEST position, causes the
PREPURGE timing to stop. The firing rate motor is in
the High Fire position.
3. In Pre-Purge Drive to Low Fire position, the Run/Test
Switch, when placed in the TEST position, holds the
burner sequence in PREPURGE with the firing rate
motor in the Low Fire position.
4.
In PFEP, the Run/Test Switch, when placed in the TEST
position, stops the timer during the first 8 seconds when a
10-second PFEP is selected or during the first 3 seconds
when a 4-second PFEP is selected, allowing pilot-turndown test and other burner adjustments to be made. This
activates a 15-second flameout timer that permits pilot
flame adjustment without nuisance safety shutdowns. The
Run/Test Switch is ignored during PFEP for the
R7120D1002 if terminals 5 and 7 or 7 and 6 are
jumpered.
5. During Run, the Run/Test Switch, when placed in the
TEST position, drives the firing rate motor to the Low
Fire position.
NOTE: When R7120 is switched to 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.
SETTINGS AND ADJUSTMENTS
Selectable Site-Configurable Jumpers
The R7120 has site-configurable jumper options; see Fig. 10
and Table 4. If necessary, clip the site-configurable jumpers
with side cutters and remove the resistors from the Relay
Module.
Fig. 10. Selectable site-configurable jumpers.
Table 4. Site Configurable Jumper Options.
Jumper Number Description Intact Clipped R7120 Type
JR1 Pilot Flame Establishing
10 seconds 4 seconds All
Period (PFEP)
JR2
a
Pilot Valve
/Main Flame
Establishing Period (MFEP)
10 seconds/
Intermittent
15 or 30 seconds Interrupted
b
R7120D2000 only
JR3 Start-up Interlock Check Disabled Enabled All
a
Pilot Valve/First Stage Oil Valve (Valve/Start) terminal 5.
b
A 30 second MFEP can be accomplished by adding a jumper wire between terminals 8 and M.
SERVICE NOTE: Clipping and removing these site-configurable jumpers enhances the level of safety. Removal after 200 hours
of main valve operation will result in a hard lockout, Code 110.
66-1196EF—01 12
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