66-2062—01 - 7800 series burner management and … - 7800 series burner management and fuel air...

INSTALLATION INSTRUCTIONS

66-2062-01

YP7899A1002 - 7800 SERIES Burner Management and Fuel Air Ratio Control Panel - Single Fuel

APPLICATIONThe 7800 SERIES Burner Management and Fuel Air Ratio Control Panel is a packaged, pre-wired panel that includes the RM7800L1087 burner control, the R7999A ControLinks fuel air ratio control and a Modbus® interface. The included S7999D color touchscreen interface allows commissioning of the ControLinks system as well as monitoring and control of it and the RM7800 control, all with user-friendly menus. On board switches, buttons and alarm lights are included for customer convenience. The ML7999A2001 universal direct coupled actuators are purchased separately as well as the burner control purge card, amplifier and flame detector.

This document provides installation instructions and operation information. Other applicable publications are:

— 65-0238, R7999 ControLinks Controller— 65-0240, Q7999A ControLinks Universal Wiring Sub-

base— 65-0288, S7800A1142 Keyboard Display Module 7800

SERIES

— 65-0239, ML7999A Universal Parallel-Positioning Actuator

— 65-0321, S7999D1048 System Display— 66-1152, RM7800L1087 Relay Module with Valve

Proving— 65-0029, 7800 Series Relay Module Checkout and

Test— 65-0084, Q7800A 7800 SERIES 22-Terminals Univer-

sal Wiring Subbase— 66-2034, R78xx Amplifiers for 7800 SERIES and

R7140 Relay Modules— 65-0089, ST7800A,C 7800 SERIES Plug-In Purge

Timer— 65-0249, S7810M Modbus Module— 60-2026, C7027, C7035, C7044, C7927 Minipeeper

UV Flame Detector— 65-0267, C7961 Dynamic Self-checking Solid State

UV Flame Detector— 60-0292, C7915 Infrared Flame Detector— 65-0277, C7962 Visible Light Flame Detector— 60-2024, C7007, C7008, C7009 Flame Rod Detector— 95-8269, C7076 Adjustable Sensitivity UV Flame

Detector— 60-2398, C7012 Ultraviolet Flame Detectors

FEATURES— Pre-wired and ready to install— Includes the RM7800L1087 burner control with wir-

ing subbase, S7810M modbus module, R7999 fuel air ratio control with wiring subbase and S7999D touchscreen display

— Commission, monitor and control ControLinks through the touchscreen interface

— Fuel selector switch— Burner on/off selector switch— Alarm lights— Reset buttons— Unit shutdown / Emergency stop button— Auto/manual switch— Manual operation potentiometer— S7999D touchscreen display is modbus ready— VPS (Valve Proving System) capability via flame

safeguard control

YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL

66-2062—01 2

SPECIFICATIONSElectrical Ratings120 Vac, 50/60 Hz, 10 AmpsFor individual ratings, see component literature for details.

Environmental RatingsEnclosure: NEMA 12.For individual ratings, see component literature for details.

HumidityInstall the panel where the relative humidity never reaches the

saturation point. The relay module inside the panel is designed to operate in a maximum 85 percent relative humidity continuous, non-condensing, moisture environ-ment.

VibrationDo not install the panel where it could be subjected to vibra-

tion in excess of 0.5G continuous maximum vibration.

GeneralOverall panel size: 30in. high x 24 in. wide x 8 in. deep

(excluding door and door mounted components)Panel weight: approx. 91 poundsMounting holes are 0.44 in. typical diameter, 18 in. on center.

ApprovalsComponents are individually approved by the nationally recognized agencies. Please see component literature for details. The panel has UL 508A approval. Panel is assembled and wired to the UL Standards.

INSTALLATIONWhen Installing This Product…

1. Read these instructions and the appropriate product lit-erature carefully. Failure to follow them could damage the product or cause a hazardous condition.

2. Refer to the installation manuals and wiring diagrams provided with this panel for the embedded products.

3. Check the ratings given in the instructions and on the product to make sure that the product is suitable for your application.

4. Installer must be a trained, experienced combustion ser-vice technician.

5. Disconnect the power supply before beginning installa-tion to prevent electrical shock and equipment damage. More than one disconnect may be involved.

6. All wiring must comply with the National Electric Code (NEC) and any applicable local electrical codes, ordi-nances and regulations.

7. After installation is complete, check out product opera-tion as provided in the appropriate product installation instructions.

WARNINGFire or Explosion Hazard. Can cause severe injury, death or property damage.To prevent possible hazardous burner operation, verify safety requirements each time a controller is installed on a burner.

WIRING

WARNINGElectrical Shock Hazard. Can cause serious injury, death or equipment damage.Disconnect the power supply before beginning wiring to prevent electrical shock, equipment and control damage. More than one disconnect may be involved.

Ground ConnectionEarth ground is required for proper operation of the panel and components. The earth ground must be capable of conducting enough current to blow the fuse or breaker in the event of an internal short. Ensure the panel is bonded to a substantial earth ground. Make sure that mechanically tightened joints along the ground path are free of nonconductive coatings and protected against corrosion on mating surfaces.

Electrical Connections1. Refer to the appropriate product data sheet for details.2. Wire size and length will vary, depending on the compo-

nent. Refer to the component literature for specific wire lengths, sizes and type recommendations.

3. Wire according to specifications, following all local ordi-nances and requirements.

4. Field knockouts are required for the wiring. When drill-ing holes, take care to protect the electronics from metal pieces and debris.

IMPORTANTRun line voltage and low voltage wiring in separate conduit to avoid signal interference.

Carefully check field wiring and terminal designa-tions in this document and the associated wiring dia-gram. They are different from those of the individual components.

Panel InspectionAfter mounting and wiring, but before powering the panel, inspect all internal panel wire connections. Each panel is fully tested at the factory, however, wires may loosen during transit. Verify that all internal wire connections are secure from the Q7999 and Q7800 subbases to the components mounted on the door and the S7999D touchscreen interface.


3 66-2062—01

Final Wiring Check and Static CheckoutAll wiring shall be in accordance with the National Electric Codes (NEC) and local electrical codes.

1. Check the power supply circuit. The voltage and fre-quency must match the specification listed.

2. Check wiring terminations and routing to ensure proper connections.

3. Follow any system checkout recommendations for indi-vidual components as found in the component literature.

4. Restore power to the panel.

CAUTIONTest each limit and interlock to ensure system operates correctly as defined in the 7800 Series "Checkout and Test" document (Form #65-0229).

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

1. Close all manual fuel shutoff valves before starting these tests.

2. Use extreme care while testing the system. Line volt-age is present on most terminal connections when power is on.

3. Replace all limits and interlocks that are not operat-ing properly. Do not bypass limit and interlocks.


66-2062—01 4

TROUBLESHOOTING

System DiagnosticsThe S7999D touchscreen interface indicates the current fault and keeps a fault history log. The R7999 ControLinks control, the ML7999A Universal Parallel-Positioning Actuator and the

RM7800L control also have LED fault blink codes. Refer to the appropriate product instruction sheet for further troubleshooting information and diagnostic codes.

Field Wiring

Table 1. Field Wiring and Terminal Designation.1

Terminal #To Connecting

Device Description

12 L1 Panel Power 120Vac Power Supply, 10A Max. Provide disconnect means and overload protection as required.

2 L2 Panel Neutral

GND Panel Ground

4 L1 L1 customer convenience wire point - provided for 4 actuators - 120Vac, 50/60Hz

2 L2 L2 customer convenience wire point - provided for 4 actuators

GND Panel Ground GND customer convenience wire point - provided for 4 actuators

27-53 Airflow Switch Combustion airflow (pressure) switch

5-63 LP Switch Fuel low pressure/temperature switch

6-73 HP Switch Fuel high pressure/temperature switch

7-83 Interlocks Fuel customer interlocks and limits, including LWCO, high-limit, etc.

8-93 High Limit High limit device

10 Blower Motor Combustion blower motor line voltage output from burner control

144 Shutter Drive Shutter drive output connection from burner control

164 F Flame detector F lead connection from burner control

GND4 Panel Ground Flame detector G lead connection from burner control

25-28 Burner Control On/off burner operating control

XF-25 Ignition Spark ignition transformer

4-193 POC Switch 1 Main fuel valve 1 proof of closure switch (pre-ignition interlock switch)

19-203 POC Switch 2 Main fuel valve 2 proof of closure switch (pre-ignition interlock switch)

17-2 Pilot Vavle(s) Pilot fuel valve(s) connection to burner control output - 10 second interrupted pilot

18-26 Main Valve(s) Main fuel valve(s) connection to burner control output

2027,8 DR1 Air Actuator DR1 command input

2037,8 DR2 Air Actuator DR2 command input

2047,8 CW Air Actuator potentiometer CW output

2057,8 S Air Actuator potentiometer S output

2067,8 CCW Air Actuator potentiometer CCW output

GND7,8 Ground Air Actuator ground

2077,8 DR1 Fuel 1 Actuator DR1 command input

2087,8 DR2 Fuel 1 Actuator DR2 command input

2097,8 CW Fuel 1 Actuator potentiometer CW output

2107,8 S Fuel 1 Actuator potentiometer S output

2117,8 CCW Fuel 1 Actuator potentiometer CCW output


5 66-2062—01

1Carefully check field wiring and terminal designations in this document and the associated wiring diagram. They are different from those of the individual components.

2The circuit protection incorporated into this control panel is designed to serve as supplemental protection only. It is the responsi-bility of the end user to provide appropriate protection on the service to this control panel. Refer to the National Electric Code and UL standard 1077 for more information on this subject.

3Jumper all unused limits and interlocks.4Refer to the appropriate flame detector product sheet for wiring size and length information. Run flame detector F and G leads in

their own conduit, independent of other power carrying leadwires. Flame detector power and shutter wires (if applicable) must be run in their own conduit as well, avoiding other electrical noise carrying wiring. The scanner wires should remain separated a minimum of 2 inches from other line voltage wires in the control panel to the flame safeguard device.

5Refer to the appropriate ignition transformer product sheet for wiring size and length information. Separate the high voltage igni-tion cable from other wires to avoid interference. Ignition cable to the spark electrode must be run in separate conduit (if applica-ble).

6If VPS (Valve Proving System) usage is required with the RM7800 burner control, contact factory for advice regarding wiring.7Low voltage wire to the firing rate actuators must be run in separate conduit. Line voltage wiring to actuators provided by cus-

tomer. Run line voltage wires in separate conduit. Refer to the ML7999A product sheet for details.8Connect the shield ground of the ML7999A actuator(s) to the earth ground strip provided in the Q7999 universal subbase, on the

low voltage side. Connect the shield at the controller end only. Refer to the ML7999A product sheet for details.9COM 2 on the S7999D is wired to the S7810M Modbus module on the RM7800L burner control. Customer may wire Modbus-

enabled UDC2500/3200/3500 controls in a daisy-chain fashion to the customer terminals provided for display on the S7999D. Refer to the S7999D and UDC control product manuals for further information on wiring and S7999D display set-up.

10Installation, operation and maintenance shall conform with National Fire Protection Association standards, national and local codes and authorities having jurisdiction.

11For detailed device wiring information, refer to the RM7800, Q7999, R7999, Q7999A, ML7999A and S7999D1048 product sheets.

12Spare/unused terminals are provided for customer field use.

GND7,8 Ground Fuel 1 Actuator ground

2147,8 DR1 FGR/4th Channel Actuator DR1 command input

2157,8 DR2 FGR/4th Channel Actuator DR2 command input

2167,8 CW FGR/4th Channel Actuator potentiometer CW output

2177,8 S FGR/4th Channel Actuator potentiometer S output

2187,8 CCW FGR/4th Channel Actuator potentiometer CCW output

GND7,8 Ground FGR/4th Channel Actuator ground

220 XmA+ Auxiliary 4-20mA+ input from Stack/Water temperature sensor (used for low fire hold)

212 XmA- Auxiliary 4-20mA- input from Stack/Water temperature sensor (used for low fire hold)

221 CmA+ 4-20mA+ input from Firing Rate control

222 CmA- 4-20mA- input from Firing Rate control

2289 COM 2 A S7999D COM 2 modbus A / Data + terminal

2299 COM 2 B S7999D COM 2 modbus B / Data - terminal

2259 COM 2 GND S7999D COM 2 Modbus C / Ground terminal

Table 1. Field Wiring and Terminal Designation.1 (Continued)

Terminal #To Connecting

Device Description


66-2062—01 6

Fig. 1.

24 (610)

30(762)

INDICATES EXTERNAL WIRING

(MAIN TERMINAL BLOCK).

INDICATES TERMINALS IN MAXON VALVES

INDICATES COMPONENT TERMINALS

INDICATES TERMINALS AND WIRING IN MAXON CONTROL PANEL.

INFORMATION ON THIS SUBJECT.

1. THE CIRCUIT PROTECTION INCORPORATED INTO THIS CONTROL PANEL IS DESIGNEDTO SERVE AS SUPPLEMENTAL PROTECTION ONLY. IT IS THE RESPONSIBILITY OF THEEND USER TO PROVIDE APPROPRIATE PROTECTION ON THE SERVICE TO THIS CONTROLPANEL. REFER TO THE NATIONAL ELECTRIC CODE AND UL STANDARD 1077 FOR MORE

EQUAL. WIRE MUST NOT BE IN THE SAME CONDUIT WITH POWER WIRING.5. FIELD WIRE TO THE DETECTOR SHOULD BE #14 AWG. TYPE TW 600V INSULATED WIRE OR

7. WIRE TO THE FIRING RATE ACTUATOR MUST BE RUN IN SEPARATE CONDUIT.

2. JUMPER ALL UNUSED LIMITS AND INTERLOCKS.

4. FIELD WIRING SHOWN FOR BLOCK AND BLEED VALVE ARRANGEMENT.

6. IGNITION CABLE TO THE SPARK ELECTRODE MUST BE RUN IN SEPARATE CONDUIT.

AUTHORITIES HAVING JURISDICTION.FIRE PROTECTION ASSOCIATION STANDARDS, NATIONAL AND LOCAL CODES, AND

8. INSTALLATION, OPERATION AND MAINTENANCE SHALL CONFORM WITH NATIONAL

(IF APPLICABLE)

NOTES:

3. THE USE OF A HIGH TEMPERATURE LIMIT IS STRONGLY RECOMMENDED ON ALLAPPLICATIONS. THIS DEVICE IS TO BE SUPPLIED BY THE CUSTOMER, IN THE FIELD.IF AFTER CAREFUL REVIEW OF YOUR APPLICATION (BY QUALIFIED PERSONNEL) IT ISDETERMINED THIS DEVICE IS NOT REQUIRED, THEN IT MAY BE OMITTED.

WIRE CODE

120 VAC (NEUTRAL)

TYPE J THERMOCOUPLETYPE K THERMOCOUPLE

VDC

GROUND

220VAC (HOT)220 VAC (NEUTRAL)

120 VAC (HOT)

FUNCTION

16 (MTW)WHITE

20 (POLYVINYL)20 (POLYVINYL)YELLOW/RED

WHITE/RED

GREEN

BLUE

14 (MTW)

16 (MTW)

COLORBLACKWHITE

RED

16 (MTW)16 (MTW)16 (MTW)

AWG

24 VAC BROWN 16 (MTW)

EXTERNAL POWER SOURCE 16 (MTW)YELLOW

4-20mA SIGNAL BLUE 16 (MTW)

DRY CONTACTS 16 (MTW)YELLOW

FSG RESETS/DISPLAY/CONTROL BUS BELDON 22 (AWG) TWISTED PAIR

M34546


7 66-2062—01

Fig. 2 - Part 1.

CUSTOMERINTERLOCKS

FIELD DEVICE

PS103A

LOW GASPRESSURE

FIELD DEVICE

PS103

COMBUSTIONAIR PRESSURE

FIELD DEVICE

PS103B

HIGH GASPRESSURE

FIELD DEVICE

27 5 6 7

FIELD DEVICE

LIMITHIGH TEMP

HTL

FU10110A

PB101

EMERGENCYSTOP

21

43

9

9 2W

LT105

PROVENINTERLOCKS

16

14

GND

CR114

FSGALARM

209

13 14

NONC

15

R

LT112

X1 X2 ALARMFSG

24

23

from 205

24

from 204

23

from 210

27

ULTRAVIOLETDETECTOR

BLU

WHTST112

FIELD DEVICE

20

6

4

12

15

18

19

22

F

G

7 L2

5

8

9

3

10

PREIGNITIONINTERLOCK

BRN CTRLLIMITS

L1LINE VOLTAGE SUPPLY

HIGH FIRE

MODULATE

LOW FIRE SWITCH INPUT

HIGH FIRESWITCH INPUT

FLAMESENSOR

SHUTTER

FLAME SENSORGROUND

LOCKOUT/RUNNING INTERLOCKS

LINE VOLTAGECOMMON

BURNERMOTOR

PILOT VALVE/

IGNITION

MAIN FUELVALVE

ALARM

IGNITION

14

LOW FIRE

13

COMMON

17

DEMAND VALVE PROVING

16

VALVE PROVINGSWITCH

21

15 SEC INTERR.

PILOT VLV, MV2

FSG107RM7800L-1087

HONEYWELL

4 19 20

XF H1 H2TRANSFORMER

SPARK IGNITION

XF115

X2X1FIELD DEVICE

PLUGSPARK

SP115

FIELD DEVICE

2

to 120

17

to 124

18

to 119

4

to 119

2

USE 16 AWG MTW WIRE120/1/60

200

201PB113

FLAMESAFEGUARD

43

RESETfrom 228

225from 229

228from 228

229

SOL127

MAIN FUELVALVE

(PROOF OF CLOSURE)FIELD DEVICE

SOL130

BLOCKING FUELVALVE

(PROOF OF CLOSURE)FIELD DEVICE

to 206

11

to 208

12

to 207

13

CLR

.B

LK.

RE

D.

MODBUS

1 2 3 4 5 6 7 8HONEYWELL

S7810M-1003-

KBD114

1 2

10

8

M34544

NOTE 2

NOTE 6

NOTE 3

NOTE 1

NOTE 5

27

2

15

L1 L2

4

27

9 2 2

15

1124734-ECC

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

4


66-2062—01 8

Fig. 2 - Part 2.

VENT PILOTVALVE

SOL120FIELD DEVICE

MAIN PILOTVALVE

SOL121FIELD DEVICE

BLOCKING PILOTVALVE

SOL122FIELD DEVICE

B

LT119

X1 X2 ENERGIZEDPILOT VALVES

17

17

2

from 115

17

from 1182

to 200

18 2

2

218

18

from 116

18

18G

LT132

X1 X2BURNER ON

MAIN FUELVALVE

SOL127FIELD DEVICE

118

GND

GND

MAIN FUELVENT VALVE

SOL124FIELD DEVICE

GND

GND

BLOCKING FUELVALVE

SOL130FIELD DEVICE

118

GND

GND

M34657

NOTE 4

NOTE 4

2

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

from 1184

to 200

4


9 66-2062—01

Fig. 3 - Part 1.

200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

GND

22

DR1

DR2

CW

S

VALVECONTROL VALVECONTROLINKS

CCW

L1

L2

GND

CV203

FIELD DEVICE

DR1

DR2

CW

S


CCW

L1

L2

GND

CV206

FIELD DEVICE

DR1

DR2

CW

S


CCW

L1

L2

GND

CV212

FIELD DEVICE

SS201CONTROL

AUTO MANUALOX

43

214

to 103

27

to 117

23

to 116

24

from 109

11

from 111

13

from 110

12

SS209BURNER

OFF ONOX43

4 25 CR114

9 1

FSGALARM

222

221

212

220

219

213PB212

CONTROLINKSRESET

43

R

LT202

ALARMCONTROLINKS

4

2

4

2

4

2

GND

GND

GND

2

from 229

225

from 228

226

from 228

227

from 1354

from 1352

to 203,206,212,219

4

to 219

2

from 218

4

from 218

4

from 218

4

BLK. .

CLR. .

RE

D

CLR

BLK

VR213

1

3

5K OHMS

MANUALOPERATOR

2

212

1

16

L1

A-2

15

4AUTO/MAN

5FUEL SLCT1

6FUEL SLCT2

10DRIVE TO

11

12

13

17CW

18S

19CCW

20

21

22

23

24

35

36

37

38

39

40

A-1

7ALARM

8HIGH FIRE

9LOW FIRE

PROVEN

PROVEN

HIGH FIRE

MODULATEVALVE

DRIVE TOLOW FIRE

LIMIT/CTRL IN

AIR

F1-2

CW

S

CCW

F1-1

FUEL 1

REMOTERESET (RR)

MANUAL CNTRL(MNC)

TEMP SENS(XmA+)

TEMP SENS(XmA-)

CNTRL INPUT(CmA+)

CNTRL INPUT(CmA-)

BA CRS485 DDL

2GND

3L2

14LIMIT/CTRL OUT

26F2-2

25

27CW

28S

29CCW

30

31

32

33

34

F2-1

FUEL 2

FG-2

CW

S

CCW

FG-1

FGR

CTRL200R7999A1005HONEYWELL

CONTROLINKS

202

203

204

205

206

207

208

209

210

211

214

215

216

217

218

GND

GND

GND

28ON/OFF

CUSTOMER

RED.

RED

RED. .

WHT

WHT. .

WHT. .

BLK. .

BLK. .

BLK

BRN

BRN. .

BRN. .

GRN

GRN. .

GRN. .

M34545

2

26

4

24

23

22

12

13

11

NOTE 7

NOTE 7

NOTE 7


66-2062—01 10

Fig. 3 - Part 2.

219

220

221

222

223

224

225

226

227

228

229

230

231

232

233

234

235

4 2

GND

FU221.5A

227

226

225

228

229

225

to 218

227

to 218

226

to 217

225

to 112

228to 112

229to 113

225

from 2184

from 2182

BLK

..

WH

T.

.

RE

D.

.

BR

N.

.

GR

N.

.

BLK. .

CLR. .

RED. .

RED. .

CLR. .

BLK. .

1 2 3 4 5 6 7 8

CO

M

+24

VA

C

CO

M1

C

CO

M1

B

CO

M1

A

CO

M2

A

CO

M2

B

CO

M2

C

HONEYWELLS7999D1048

HMI224

SYSTEM DISPLAY

223

INPUT 120 VAC

OUTPUT 24VAC

SYSTEM DISPLAY

XF220

(-)(+)

(G)

(N)(L)

POWER SUPPLY

M34658

2

223 224 225

4 2


11 66-2062—01

Fig 4.

M34547

21 (533)

27(686)


Automation and Control SolutionsHoneywell International Inc.

1985 Douglas Drive North

Golden Valley, MN 55422

customer.honeywell.com

® U.S. Registered Trademark© 2013 Honeywell International Inc.66-2062—01 M.S. 03-13 Printed in United States

66-2062—01 - 7800 series burner management and … - 7800 series burner management and fuel air...

Documents