Honeywell RM7800L1087 Installation Instructions Manual

RM7800L1087; RM7840G1022,L1075;
EC7840L1014 Relay Modules
with Valve Proving

INSTALLATION INSTRUCTIONS

APPLICATION

The Honeywell RM7800L/40L and EC7840L Relay Modules
are microprocessor-based integrated burner controls for
automatically fired gas, oil, or combination fuel single burner
applications. The RM7800L/40L and EC7840L Relay Modules
are used for UL/CSA Modulating and FM/IRI Modulating
burner applications. The
consists of a Relay Module. Keyboard Display Modules
(standard with RM7800), Dust Cover (standard with RM7840/
EC7840L), Subbase, Amplifier, and Purge Card. Options
include Personal Computer Interface, DATA CONTROLBUS
MODULE™, Remote Display Mounting, First-Out Expanded
Annunciator and Combustion System Manager™ Software.

Functions provided by the RM7800L/40L, EC7840L include
automatic burner sequencing, flame supervision, system
status indication, system or self-diagnostics and
troubleshooting.

RM7800L1087/RM7840G1022,L1075; EC7840L1014 offer
the Valve Proving test feature.

Using the S7800A1142 Keyboard Display (standard on
RM7800L1087) the following features can be set up:

• Post Purge time—Up to 66 minutes—Device shipped
with 15 seconds Post purge.

• Valve Proving features including:

— VPS test time
— When (Never, Before, After, Split or Both)

See S7800A1142 Instructions (65-0288) for its features.
Series 5 can be programmed for Modbus communication.

At commissioning time, the Valve Proving System may be
scheduled to occur at one of five different times:

• Never—Device default as received—Valve proving
does not occur.

• Before—Valve proving before run concurrent with Pre-Purge.

• After—Valve proving occurs after the Run state, before
the device goes to Standby (Concurrent with Post­Purge, if selected.)

• 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.

RM7800L/40L, EC7840L

system

The following assumptions apply when using the RM7840G,L,
RM7800L, EC7840L:

MV1

VP

SW.

INLET

1

CAUTION: VALVE ENERGIZING TIMING IS BASED ON HONEYWELL VALVE

1

OPENING TIMES OF 13 SECONDS MAXIMUM.

MV1—Wired to terminal 9. It is located in the most upstream
position of the main gas valve train.

VPS—Valve Proving Switch: Setpoint at 1/2 of Main Valve
inlet pressure.

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

The PII—Pre-Ignition Interlock (or Proof of Closure Switch) for
terminal 20 can be installed on MV1, MV2, or as a series
connection through both valves.

Appendix B lists many wiring options for single and dual fuel
along with the Valve Proving options.

− 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).

Fig. 1. The valve proving system.

MV2

OUTLET

M24161

SPECIFICATIONS

Electrical Ratings, see Table 3:

Voltage and Frequency:

RM78xx—120 Vac (+10/-15%), 50 or 60 Hz (±10%).

EC78xx—220–240 Vac (+10/-15%), 50 or 60 Hz (±10%).
Power Dissipation: RM7800/RM7840/EC7840L: 10W
maximum in the Run mode.

66-1162-2

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING

Maximum Total Connected Load: 2000 VA.

Fusing: 15A maximum, Type SC or equivalent Fast Blow.

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: RM7800L/40G,L:

Underwriters Laboratories Inc. Listed: File No. MP268,

Guide No. MCCZ.
Canadian Standards Association Certified: LR9S329-3.
Factory Mutual Approved: Report No. J.I.1V9A0.AF.
IRI Acceptable.
Federal Communications Commission, Part 15,

Class B—Emissions.

Approvals: EC7840L:

Factory Mutual Approved: Report No. J.I.1V9A0.AF.
IRI Acceptable.
Federal Communications Commission, Part 15,

Class B—Emissions.

This document provides installation and static checkout
instructions. Other applicable publications are:

Publication

No. Product

63-2278 Q7700 Network Interface Unit Product Data
65-0084 Q7800A,B 22-Terminal Wiring Subbase

Product Data

65-0288 S7800A1142 Keyboard Display Module

Product Data

65-0091 S7810A Data ControlBus™ Module Product

Data
65-0095 S7820 Remote Reset Module Product Data
65-0097 221729C Dust Cover Installation

Instructions
65-0101 S7830 Expanded Annunciator Product Data
65-0102 ZM7850A Combustion System Manager™

Operating Instructions
65-0109 R7824, R7847, R7848, R7849, R7851,

R7861, R7886 Flame Amplifiers for the

7800 SERIES Product Data
65-0131 221818A Extension Cable Assembly

Product Data
65-0229 7800 SERIES Relay Modules Checkout and

Troubleshooting Product Data
65-0092 QS7800A ControlBus™ Module, Standard
65-0227 QS7800B ControlBus™ Module, Multidrop
65-0249 S7810M ModBus Module

INSTALLATION

When Installing this Product...

1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous
condition.

2. Check the ratings given in the instructions and marked
on the product to make sure the product is suitable for
the application.

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.

IMPORTANT

1. Wiring connections for the relay modules are unique;

therefore, refer to Figs. 3, 4, 6, 7, or Appendix B 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 RM7800L/40L, EC7840L must

not exceed those listed on the RM7800L/40L,
EC7840L label or the Specifications, see Table 3.

5. Limits and interlocks must be rated to simultaneously

carry and break current to the ignition transformer,
pilot valve, and main fuel valve(s).

6. All external timers must be listed or component

recognized by authorities who have jurisdiction for
the specific purpose for which they are used.

7. For on-off gas-fired systems, some authorities who

have jurisdiction prohibit the wiring of any limit or
operating contacts in series between the flame
safeguard control and the main fuel valve(s).

8. Two Flame Detectors can be connected in parallel with

the exception of Infrared Flame Detectors (C7015,
C7915), Ultraviolet (C7927, C7961), or Visible
(C7962).

9. This equipment generates, uses and can radiate

radio frequency energy and, if not installed and used
in accordance with the instructions, may cause
interference to radio communications. It has been
tested and found to comply with the limits for a
Class B computing device of Part 15 of FCC rules
which are designed to provide reasonable protection
against such interference when operated in a
commercial environment. Operation of this
equipment in a residential area may cause
interference; in which case, the users at their own
expense may be required to take whatever
measures are required to correct this interference.

10.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.

66-1162—2 2

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING

Location

Humidity

Install the relay module where the relative humidity never
reaches the saturation point. The relay module is designed to
operate in a maximum 85 percent relative humidity
continuous, noncondensing, moisture environment.
Condensing moisture may cause a safety shutdown.

Vibration

Do not install the relay module where it could be subjected to
vibration in excess of 0.5G continuous maximum vibration.

Weather

The relay module is not designed to be weather tight.
When installed outdoors, protect the relay module using an
approved weather-tight enclosure.

Mounting Wiring Subbase

1.

Mount the subbase in any position except horizontally
with the bifurcated contacts pointing down. The standard
vertical position is recommended. Any other position
decreases the maximum ambient temperature rating.

2.

Select a location on a wall, burner or electrical panel. The
Q7800 can be mounted directly in the control cabinet. Be
sure to allow adequate clearance for servicing,
installation, access or removal of the
EC7840L
Module, flame amplifier, flame amplifier signal voltage
probes, Run/Test Switch, electrical signal voltage probes
and electrical field connections.

3. For surface mounting, use the back of the subbase as a
template to mark the four screw locations. Drill the pilot
holes.

4. Securely mount the subbase using four no. 6 screws.

, Expanded Annunciator, Keyboard Display

RM7800L/40L,

Wiring Subbase

WARNING

Electrical Shock Hazard.
Can cause serious injury, death or equipment
damage.

Disconnect the power supply before beginning
installation to prevent electrical shock, equipment
and control damage. More than one power supply
disconnect may be required.

1. For proper subbase wiring, refer to Figs. 3, 4, 6, 7, or
Appendix B.

2. For proper remote wiring of the Keyboard Display
Module, through a 203541 5-wire Connector, refer to
the Specifications for the Keyboard Display Module
(65-0288), Network Interface Unit (63-2278), Data
ControlBus Module™ (65-0091) or Extension Cable
Assembly (65-0131).

3. Disconnect the power supply from the main disconnect
before beginning installation to prevent electrical shock
and equipment damage. More than one disconnect may
be required.

4. All wiring must comply with all applicable electrical
codes, ordinances and regulations. Wiring, where
required, must comply with NEC, Class 1 (Line Voltage)
wiring.

5. Recommended wire size and type: see Table 1.

6. Recommended grounding practices: see Table 2.

The Keyboard Display Module, Data ControlBus Module™
(for remote mounting or communications), through a 203541
5-wire Connector, or Communication Interface ControlBus
Module must be wired in a daisy chain configuration,
(1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). The order of 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 require a 120 ohm (1/4 watt minimum)
resistor termination across terminals 1 and 2 of the electrical
connectors, for connections over 100 feet.

7. Recommended wire routing of leadwires:
a. Do not run high voltage ignition transformer wires in

the same conduit with the flame detector, Data
Controlbus Module™, or Remote Reset Module
wiring.

b. Do not route flame detector, Data Controlbus

Module™, or Remote Reset Module leadwires in
conduit with line voltage circuits.

c. Enclose flame detector leadwires without armor

cable in metal cable or conduit.

d. Follow directions in flame detector, Data Controlbus

Module™, or Remote Reset Module Instructions.

8. Keyboard Display Module (KDM): Because the KDM is
powered from a low voltage, energy limited source, it
can be mounted outside of a control panel if it is
protected from mechanical damage.

NOTE: A 13 Vdc power supply must be used any time more

than one Keyboard Display Module is used.

9. Maximum wire lengths follow:
a. RM7800L/40L, EC7840L leadwires—The maximum

length of leadwire is 300 feet to terminal inputs (Con­trol, Pre-Ignition Interlock, Running/Lockout Inter­lock, High Fire Switch and Low Fire Switch).

b. Flame Detector leadwires—The maximum flame

sensor leadwire length is limited by the flame signal
strength.

c. Remote Reset leadwires—The maximum length of

wire is 1000 feet to a Remote Reset pushbutton.

d. Data Controlbus Module™—The maximum Data

Controlbus Module™ cable length depends on the
number of system modules connected, the noise
conditions and the cable used. The maximum length
of all Data Controlbus Module™ interconnecting
wire is 1000 feet.

10. Make sure loads do not exceed the terminal ratings.
Refer to the label on the RM7800/RM7840/EC7840L or
to the ratings in Tables 3, 4 and 5.

Final Wiring Check

1. Check the power supply circuit. The voltage and fre­quency tolerance must match those of the
RM7800L/40L, EC7840L. A separate power supply cir­cuit may be required for the RM7800/RM7840/
EC7840L. Add the required disconnect means and
overload protection.

2. Check all wiring circuits and complete the Static
Checkout, see Table 9, before installing the
RM7800L/40L, EC7840L on the subbase.

3. Install all electrical connectors.

4. Restore power to the panel.

3 66-1162—2

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING

2

L1 (HOT) L2

DEMAND

6

17

16

20

F

G

INTERNAL
ELECTRONICS

DEMAND (VALVE
PROVING)

7

1K

PLUG IN FLAME
AMPLIFIER

3K

6K

4K

2K

2K

5K

7K

HIGH FIRE

COMMON

MODULATE

LOW FIRE

L2

3

5

LOW FIRE

SWITCH

HIGH FIRE

SWITCH

8

9

10

21

22

12

13

15

14

ALARM

BLOWER

18

19

PILOT
VALV E

MAIN
VALV E 1

IGNITION

1

DETECTOR
SHUTTER

M24162

4

LIMITS

VALVE PROVING SWITCH

PRE-IGNITION INTERLOCK

FLAME
DETECTOR

1

2

CONTROLLER

AIR FLOW
SWITCH

INTERNAL RELAY OPTO FEEDBACK
FIELD WIRING
INTERNAL WIRING

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

RM7800L/RM7840L 120 VAC 50/60 HZ
EC7840L 220-240 VAC 50/60 HZ

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

volt insulation, moisture-resistant wire.

Keyboard Display Module (KDM) 22 AWG two-wire twisted pair with ground,

or five wire.

Data ControlBus Module™ 22 AWG two-wire twisted pair with ground,

or five wire.

Remote Reset Module 22 AWG two-wire twisted pair, insulated for

low voltage.

Communications Interface ControlBus™

22 AWG two-wire twisted pair with ground. Belden 8723 shielded cable or

Module

13 Vdc full-wave rectified transformer
power input.

66-1162—2 4

18 AWG wire insulated for voltages and
temperatures for given application.

TTW60C, THW75C, THHN90C.

Belden 8723 shielded cable or
equivalent.

Belden 8723 shielded cable or
equivalent.

—

equivalent.

TTW60C, THW75C, THHN90C.

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING

Table 2. Recommended Grounding Practices.

Ground Type Recommended Practice

Earth ground (subbase and relay
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 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 ControlBus
Module™, Communications Interface

Use the shield of the signal wire to ground the device to the signal ground terminals
[3(c)] of each device. Connect the shield at both ends of the chain to earth ground.

ControlBus™ Module).

Table 3. Terminal Ratings.

Ratings

Terminal No. Description

G

Flame Sensor Ground

a

120 Vac 220/230/240 Vac

——

Earth G Earth Ground — —

L2(N) Line Voltage Common — —

3 Alarm 1A pilot duty

4

Line Voltage Supply (L1)

b

120 Vac (+10%/-15%),
50 or 60 Hz (±10%)

220-240 Vac (+10%/-15%),
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 Proving) 1 mA 1 mA

7 Lockout/Running Interlock 8A run, 43A inrush 8A run, 43A inrush —

8 Pilot Valve/Ignition

9 Main Fuel Valve

10 Ignition

F(11) Flame Sensor 60 to 220 Vac,

current limited

c

c

c

4A at PF = 0.5, 20A Inrush

4A at PF = 0.5, 20A Inrush

2A at PF = 0.2

60 to 220 Vac,
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

a

The relay module must have an earth ground providing a connection between the subbase and the control panel or the

d

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.

5 66-1162—2

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING

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

Combination No. Pilot Fuel 8 Main 9 Ignition 10 Valve 21

1 C F No Load No Load

2 B F No Load No Load

3 No Load F No Load B

4 F F A No Load

5 No Load F A F

6 D F A No Load

7 No Load D A D

8 D D A No Load

9 No Load D A D

Table 5. Explanation of Each Combination.

AB CD F

4.5A ignition.

50 VA Pilot Duty

4.5A ignition.

a

Pilot Duty refers to solenoid-type valves.

a

plus

180 VA ignition plus
motor valve with:
660 VA inrush, 360 VA
open, 260 VA hold.

2A Pilot Duty.

a

64 VA Pilot Dutya plus
motor valves with:
3850 VA inrush, 700 VA
open, 250 VA hold.

Mounting RM7800L/40L, EC7840L Relay Module (Fig. 9)

1. Mount the RM7800L/40L, EC7840L vertically on the
Q7800 Subbase, or mount horizontally with the
knifeblade terminals pointing downward. When
mounted on the Q7800A, the RM7800L/40L, EC7840L
must be in an electrical enclosure.

2. When mounting in an electrical enclosure, provide
adequate clearance for servicing, installation and
removal of the RM7800L/40L, EC7840L, Keyboard
Display Module, flame amplifier, flame amplifier signal
voltage probes, electrical signal voltage probes, and
electrical connections.

a. Allow an additional two inches below the

RM7800L/40L, EC7840L for the flame amplifier
mounting.

b. Allow an optional three-inch minimum to both sides

of the RM7800L/40L, EC7840L for electrical signal
voltage probes.

3. Make sure no subbase wiring is projecting beyond the
terminal blocks. Tuck in wiring against the back of the
subbase so it does not interfere with the knifeblade
terminals or bifurcated contacts.

IMPORTANT

The RM7800L/40L, EC7840L must be installed with
a plug-in motion rather than a hinge action.

4. Mount the RM7800L/40L, EC7840L by aligning the four
L-shaped corner guides and knifeblade terminals with
the bifurcated contacts on the wiring subbase and
securely tighten the two screws without deforming the
plastic.

66-1162—2 6

120V ALARM

A

BURNER MOTOR
(BLOWER)

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING

SERIES 90

L2

G

3

4

5

Q7800

(L1)

12

13

14

15

16

HIGH FIRE

COMMON

LOW FIRE

MODULATE

FIRING RATE
MOTOR

B

R

W

SERIES 90
CONTROLLER

B

R

W

FOR DIRECT SPARK IGNITION (OIL
OR GAS)

IGNITION

10

TRANSFORMER

8

2ND STAGE

9

FUEL VALVE
(OPTIONAL)

L2

BURNER
CONTROLLER/LIMITS

LOCKOUT INTERLOCKS
(INC. AIR FLOW SWITCH)

10 SEC. INTERRUPTED
PILOT/IGNITION

MAIN FUEL VALVE(S)

5 SECOND IGNITION
(EARLY SPARK
TERMINATION)

FLAME DETECTOR

3

10

17

6

7

8

9

F

18

19

20

21

22

2

LOW FIRE
START SWITCH

HIGH FIRE
PURGE SWITCH

PREIGNITION
INTERLOCK

15 SEC.
INTERRUPTED
PILOT VALVE

MASTER
SWITCH

L1
(HOT)

L2

1

120V, 50/60 Hz (EC7840L 220-240 VAC) POWER SUPPLY.
PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.

2

DO NOT WIRE TO ANY UNUSED TERMINALS.

3

SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.

1

M23158

RM7800/RM7840L/EC7840L

INITIATE
(INITIAL
POWERUP
ONLY)

POWER

LED
DISPLAY

BURNER

OPERATING
CONTROLS

ND

INTERLOCKS

FLAME
SIGNAL

FIRING
RATE
MOTOR

INTERLOCK. CHECK

STANDBY

POWER

PREIGNITION INTERLOCK CLOSED

PREPURGE
HOLD

00

DRIVE TO
HIGH FIRE

SAFE START CHECK

SWITCHING

00 00 10 25 00 1520

POWER

LIMITS AND BURNER CONTROLLER CLOSED

19TO

5

TIMED
PREPURGE

POWER

PILOT

FLAME

MAIN

LOCKOUT INTERLOCKS CLOSED

HIGH FIRE SW.

13 12

MOTOR ACTION

PREPURGE
HOLD
DRIVE TO
LOW FIRE

POWER

PILOT

FLAME

MAIN

BURNER/BLOWER MOTOR

10

20TO

4

TO

PFEP
10 SEC.

00

(4 SEC. IF
JR1

CLIPPED

POWER

PILOT

FLAME

MAIN

IGN.

5 SEC.

10 SEC. IGN./PILOT

15 SEC. PILOT

LOW FIRE SW.

MFEP

POWER

PILOT

FLAME

MAIN

ALARMALARMALARMALARM

8

21

MAIN VALVE

TO

L1

6

18

5

TO

FLAME PROVING

13 14

TO

RUN

POWER

PILOT

FLAME

MAIN

ALARM

5

6

7TO

13 15

TO

POSTPURGE

9

POWER

TO

13 14

STANDBY

POWER

IC

PII

SSC

NOTE: SEE APPENDIX FOR APPLICATION OPTIONS.

M24091

Fig. 3. Typical wiring subbase and sequence for RM7800L/40L, EC7840L without enabled Valve Proving.

7 66-1162—2

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING

A

SERIES 90

120V ALARM

BURNER MOTOR
(BLOWER)

LIMITS

BURNER CONTROL

LOCKOUT INTERLOCKS
(INC. AIR FLOW SWITCH)

10 SEC. INTERRUPTED
PILOT/IGNITION

MAIN FUEL VALVE 1

5 SECOND IGNITION
(EARLY SPARK
TERMINATION)

FLAME DETECTOR

3

L2

10

G

3

4

5

6

7

8

9

F

Q7800

(L1)

12

13

14

15

16

17

18

19

20

21

22

HIGH FIRE

COMMON

LOW FIRE

MODULATE

VALVE PROVING
SWITCH

2

LOW FIRE
START SWITCH

HIGH FIRE
PURGE SWITCH

PREIGNITION
INTERLOCK

MV2 VALVE

MASTER
SWITCH

FIRING RATE
MOTOR

B

R

W

SERIES 90
CONTROLLER

L1
(HOT)

L2

B

R

W

1

120V, 50/60 Hz (EC7840L 220-240 VAC) POWER SUPPLY.
PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.

2

DO NOT WIRE TO ANY UNUSED TERMINALS.

3

SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.

4

JR2 INTACT ON RM7800L/40L FOR DSI FUNCTION.

1

FOR DIRECT SPARK IGNITION (OIL
OR GAS)

IGNITION

10

TRANSFORMER

MAIN VALVE 1

9

MAIN VALVE 2

21

17

BURNER
CONTROLLER

L2

M24092

RM7800/RM7840L/EC7840L

INITIATE
(INITIAL
POWERUP
ONLY)

POWER

LED
DISPLAY

BURNER

OPERATING
CONTROLS

ND

INTERLOCKS

FLAME
SIGNAL

FIRING
RATE
MOTOR

INTERLOCK. CHECK

STANDBY

PREIGNITION INTERLOCK CLOSED

PREPURGE
HOLD

00

DRIVE TO
HIGH FIRE

POWER

SAFE START CHECK FLAME PROVING

SWITCHING

00 00 10 25 00 1520

TIMED
PREPURGE

POWER

5

POWER

PILOT

FLAME

MAIN

LIMITS AND BURNER CONTROLLER CLOSED

LOCKOUT INTERLOCKS CLOSED

HIGH FIRE SW.

19TO

13 12

MOTOR ACTION

PREPURGE
HOLD
DRIVE TO
LOW FIRE

BURNER/BLOWER MOTOR

TO

POWER

PILOT

FLAME

MAIN

4

00

10

20TO

PFEP
10 SEC.
(4 SEC. IF
JR1

CLIPPED

POWER

PILOT

FLAME

MAIN

IGN.

5 SEC.

10 SEC. IGN./PILOT

LOW FIRE SW.

5

13 14

MFEP

POWER

PILOT

FLAME

MAIN

ALARMALARMALARMALARM

8

21

MV2

MAIN VALVE

TO

L1

18

TO

TO

RUN

POWER

PILOT

FLAME

MAIN

ALARM

5

2

6

7

13 15

TO

POSTPURGE

1

9

POWER

TO

13 14

STANDBY

POWER

IC

PII

SSC

1

MV2 IS MAIN VALVE CLOSEST TO THE BURNER.

Fig. 4. Wiring subbase and sequence for RM7800L/40L, EC7840L with Valve Proving feature enabled.

66-1162—2 8

JR2 REMOVED FOR PILOT SEQUENCE.

2

M24093

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING

BEFORE

HF T19

5

CLOSED

4 SEC.

CONTROLLER

AIRFLOW

CONTROLLER

CONTROLLER
LOCKOUT INTERLOCKS

LOCKOUT IF ON, MV1 LEAKING (LOW PRESSURE TEST).

1

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

2

L1-17

17-7

PII (20)

AFTER

RUN

L1-17

L1-7

HF T19
CLOSED

SPLIT

L1-17

L1-7

MV2 (21)

POST
PURGE

4 SEC.

MV2 (21)

4 SEC. 4 SEC.

MV1 (9)

3

3 SEC.

3 SEC.

3

3 SEC.

TEST TIME

VPS (16)

PII (20)

4

TEST TIME

VPS (16)

PII (20)

TEST TIME

VPS (16)

PII (20)

FINISH
PURGE

4 SEC.

3 SEC.

MV1 (9)

1

3 SEC.

4 SEC.

MV1 (9)

1

BURNER RUN TIME

2

TEST IS RUN CONCURRENT WITH PRE PURGE TIME.

3

TEST IS RUN CONCURRENT WITH POSTPURGE, IF POSTPURGE TIME IS ENABLED.

4

5

RM7800/40L/EC7840L ONLY.

TEST TIME

VPS (16)

PII (20)

TEST TIME

VPS (16)

PII (20)

POST PURGE

MV2 (21)

4

2

2

3 SEC.

IGNITION TRIALS

FINISH POST
PURGE

TEST TIME

STANDBY

VPS (16)

PII (20)

FINISH POST
PURGE

1

STANDBY

M24094A

Fig. 5. RM7800L/40G,L and EC7840L Relay Module operation, Valve Proving test options.

9 66-1162—2

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING

SERIES 90

G

Q7800

12

HIGH FIRE

FIRING RATE
MOTOR

B

SERIES 90
CONTROLLER

B

120V ALARM

BURNER MOTOR
(BLOWER)

BURNER
CONTROLLER/LIMITS

RUNNING INTERLOCKS
(INC. AIR FLOW SWITCH)

10 SEC. INTERRUPTED
PILOT/IGNITION

MAIN FUEL VALVE(S)

5 SECOND IGNITION
(EARLY SPARK
TERMINATION)

FLAME DETECTOR

4

INITIATE
(INITIAL
POWERUP
ONLY)

POWER

LED
DISPLAY

BURNER

OPERATING
CONTROLS
AND
INTERLOCKS

FLAME
SIGNAL

FIRING
RATE
MOTOR

INTERLOCK. CHECK

COMMON

13

LOW FIRE

14

MODULATE

15

16

17

4

18

19

20

21

22

POWER

PILOT

FLAME

MAIN

LOW FIRE
START SWITCH

JUMPER WIRE FOR 30s MFEP

PREIGNITION
INTERLOCK

15 OR 30 SEC.
INTERRUPTED/
INTERMITTENT
PILOT VALVE

PREPURGE
HOLD
DRIVE TO
LOW FIRE

POWER

PILOT

FLAME

MAIN

STANDBY

POWER

L2

3

4

(L1)

5

6

7

8

9

10

F

00 00 10 25 00 1520

TIMED
PREPURGE

BURNER/BLOWER MOTOR

LIMITS AND BURNER CONTROLLER CLOSED

RUNNING INTERLOCKS CLOSED

PREIGNITION INTERLOCK CLOSED

SAFE START CHECK

RM7840G SWITCHING

13 12

TO

MOTOR ACTION

R

W

MASTER
SWITCH

00

10

10 SEC. IGN./PILOT

LOW FIRE SW.

13 14

2

L1
(HOT)

L2

1

RM7840G

PFEP
10 SEC.
(4 SEC. IF
JR1

CLIPPED

POWER

PILOT

FLAME

MAIN

ALARMALARMALARM

IGN.

5 SEC.

1

20TO

4

TO

R

W

3

1

120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT
MEANS AND OVERLOAD PROTECTION AS REQUIRED.

2

ADD JUMPER FOR 30 SECOND MAIN FLAME
ESTABLISHING PERIOD (MFEP).

3

DO NOT WIRE TO ANY UNUSED TERMINALS.

4

SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.

MFEP

POWER

PILOT

FLAME

MAIN

ALARM

FOR DIRECT SPARK IGNITION
(OIL OR GAS)

IGNITION

10

TRANSFORMER

1ST STAGE

21

FUEL VALVE

2ND STAGE

9

FUEL VALVE
(OPTIONAL)

RUN

POSTPURGE

POWER

POWER

PILOT

FLAME

MAIN

ALARM

STANDBY

POWER

5

8

21

MAIN VALVE

TO

L1

6

9

6

7TO

PII

18

5

TO

FLAME PROVING

13 15

TO

TO

13 14

SSC

L2

M12260C

IC

1

15/30 SEC. INTERRUPTED/INTERMITTENT PILOT VALVE

Fig. 6. Typical wiring subbase and sequence for RM7840G without Valve Proving enabled.

66-1162—2 10

M24169B