Honeywell 2RM7800L1087 Service manual

INSTALLATION INSTRUCTIONS
66-1162-2
RM7800L1087; RM7840G1022,L1075;
EC7840L1014 Relay Modules
with Valve Proving
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
RM7800L/40L, EC7840L system
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 Post-
Purge, 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.
The following assumptions apply when using the RM7840G,L,
RM7800L, EC7840L:
Fig. 1. The valve proving system.
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.
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.
MV1 MV2
VP
SW.
M24161
OUTLET
INLET
1 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).
1

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 2
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:
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.
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

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
366-1162—2
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
RM7800L/40L,
EC7840L
, Expanded Annunciator, Keyboard Display
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.
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 (Con-
trol, Pre-Ignition Interlock, Running/Lockout Inter-
lock, 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 fre-
quency tolerance must match those of the
RM7800L/40L, EC7840L. A separate power supply cir-
cuit 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.

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 4
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.
TTW60C, THW75C, THHN90C.
Keyboard Display Module (KDM) 22 AWG two-wire twisted pair with ground,
or five wire.
Belden 8723 shielded cable or
equivalent.
Data ControlBus Module™ 22 AWG two-wire twisted pair with ground,
or five wire.
Belden 8723 shielded cable or
equivalent.
Remote Reset Module 22 AWG two-wire twisted pair, insulated for
low voltage.
—
Communications Interface ControlBus™
Module
22 AWG two-wire twisted pair with ground. Belden 8723 shielded cable or
equivalent.
13 Vdc full-wave rectified transformer
power input.
18 AWG wire insulated for voltages and
temperatures for given application.
TTW60C, THW75C, THHN90C.
FLAME
DETECTOR
PLUG IN FLAME
AMPLIFIER
HIGH FIRE
SWITCH
PILOT
VALVE
MAIN
VALVE 1
LIMITS CONTROLLER
DEMAND
DEMAND (VALVE
PROVING)
L1 (HOT) L2
PRE-IGNITION INTERLOCK
1K
5K 2K
LOW FIRE
SWITCH
6
20
17
4
7
4K
3K
6K
7K
2K
8
9
18
19
F
G
22
BLOWER
5
ALARM
INTERNAL
ELECTRONICS
3
L2
IGNITION
10
DETECTOR
SHUTTER
21
HIGH FIRE
15 SECOND INTERRUPTED OR MV2 IF VALVE PROVING DEMAND (T17) USED.
COMMON
MODULATE
LOW FIRE
12
13
15
14
INTERNAL RELAY OPTO FEEDBACK
FIELD WIRING
INTERNAL WIRING
M24162
VALVE PROVING SWITCH
AIR FLOW
SWITCH
16
1
1
RM7800L/RM7840L 120 VAC 50/60 HZ
EC7840L 220-240 VAC 50/60 HZ
2
2

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
566-1162—2
Table 2. Recommended Grounding Practices.
Table 3. Terminal Ratings.
aThe relay module must have an earth ground providing a connection between the subbase and the control panel or the
equipment. The earth ground wire must be capable of conducting the current to blow the 15A fuse (or breaker) in event of an
internal short circuit. The relay module requires a low impedance ground connection to the equipment frame, which, in turn,
requires a low impedance connection to earth ground.
b2000 VA maximum connected load to relay module assembly.
cSee Tables 4 and 5.
d220/240 Vac to 120 Vac, 10 VA (minimum) stepdown transformer (not provided) must be used to drive the shutter.
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
ControlBus™ Module).
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.
Terminal No. Description
Ratings
120 Vac 220/230/240 Vac
GFlame Sensor Grounda——
Earth G Earth Ground — —
L2(N) Line Voltage Common — —
3 Alarm 1A pilot duty
120 Vac (+10%/-15%),
50 or 60 Hz (±10%)
220-240 Vac (+10%/-15%),
50 or 60 Hz (±10%)
4Line Voltage Supply (L1)b
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 c4A at PF = 0.5, 20A Inrush
9 Main Fuel Valve c4A at PF = 0.5, 20A Inrush
10 Ignition c2A at PF = 0.2
F(11) Flame Sensor 60 to 220 Vac,
current limited
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
or MV2
c4A at PF = 0.5, 20A Inrush
22 Shutter 0.5A d

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 6
Table 4. Combinations for Terminals 8, 9, 10 and 21.
Table 5. Explanation of Each Combination.
aPilot Duty refers to solenoid-type valves.
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.
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
AB CD F
4.5A ignition. 50 VA Pilot Dutyaplus
4.5A ignition.
180 VA ignition plus
motor valve with:
660 VA inrush, 360 VA
open, 260 VA hold.
2A Pilot Duty.a64 VA Pilot Dutyaplus
motor valves with:
3850 VA inrush, 700 VA
open, 250 VA hold.

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
766-1162—2
Fig. 3. Typical wiring subbase and sequence for RM7800L/40L, EC7840L without enabled Valve Proving.
M23158
G
L2
3
4
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
LOCKOUT INTERLOCKS
(INC. AIR FLOW SWITCH)
MASTER
SWITCH
LOW FIRE
START SWITCH
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
MAIN FUEL VALVE(S)
BURNER
CONTROLLER/LIMITS
BURNER MOTOR
(BLOWER)
HIGH FIRE
COMMON
LOW FIRE
MODULATE
120V ALARM
10 SEC. INTERRUPTED
PILOT/IGNITION
PREIGNITION
INTERLOCK
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
FLAME DETECTOR
120V, 50/60 Hz (EC7840L 220-240 VAC) POWER SUPPLY.
PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
DO NOT WIRE TO ANY UNUSED TERMINALS.
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
FOR DIRECT SPARK IGNITION (OIL
OR GAS)
IGNITION
TRANSFORMER
2ND STAGE
FUEL VALVE
(OPTIONAL)
R
W
B
R
W
B
L1
(HOT)
L2 1
8
9
10
L2
Q7800
15 SEC.
INTERRUPTED
PILOT VALVE
2
1
3
3
HIGH FIRE
PURGE SWITCH
2
RM7800/RM7840L/EC7840L
POWER
00
OPERATING
CONTROLS
A
ND
INTERLOCKS
BURNER
FLAME
SIGNAL
FIRING
RATE
MOTOR
INITIATE
(INITIAL
POWERUP
ONLY)
POWER
STANDBY
POWER
PREPURGE
HOLD
DRIVE TO
HIGH FIRE
PREPURGE
HOLD
DRIVE TO
LOW FIRE
POWER
PILOT
FLAME
MAIN
POWER
PFEP
10 SEC.
(4 SEC. IF
JR1
CLIPPED
PILOT
FLAME
MAIN
POWER
MFEP
PILOT
FLAME
MAIN
RUN
POWER
POSTPURGE
POWER
STANDBY
00 00 10 25 00 1520
SWITCHING
MOTOR ACTION
BURNER/BLOWER MOTOR
IGN.
15 SEC. PILOT
LIMITS AND BURNER CONTROLLER CLOSED
LOCKOUT INTERLOCKS CLOSED
PREIGNITION INTERLOCK CLOSED
LOW FIRE SW.
SAFE START CHECK FLAME PROVING
10 SEC. IGN./PILOT 8
10
5
5 SEC.
21
6
TO
7TO
20TO
518
TO
13 15
TO
13 12
TO
M24091
INTERLOCK. CHECK
HIGH FIRE SW. 19TO
13 14
TO 13 14
TO
5
4
6
L1
MAIN VALVE 9
NOTE: SEE APPENDIX FOR APPLICATION OPTIONS.
TIMED
PREPURGE
POWER
FLAME
MAIN
PILOT
ALARM
POWER
FLAME
MAIN
PILOT
ALARMALARMALARMALARM
00
IC
PII
SSC
LED
DISPLAY

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 8
Fig. 4. Wiring subbase and sequence for RM7800L/40L, EC7840L with Valve Proving feature enabled.
M24092
G
L2
3
4
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
17
18
19
20
21
22
12
LOCKOUT INTERLOCKS
(INC. AIR FLOW SWITCH)
MASTER
SWITCH
LOW FIRE
START SWITCH
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
MAIN FUEL VALVE 1
BURNER MOTOR
(BLOWER)
HIGH FIRE
COMMON
LOW FIRE
MODULATE
120V ALARM
10 SEC. INTERRUPTED
PILOT/IGNITION
PREIGNITION
INTERLOCK
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
FLAME DETECTOR
120V, 50/60 Hz (EC7840L 220-240 VAC) POWER SUPPLY.
PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
DO NOT WIRE TO ANY UNUSED TERMINALS.
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
JR2 INTACT ON RM7800L/40L FOR DSI FUNCTION.
FOR DIRECT SPARK IGNITION (OIL
OR GAS)
IGNITION
TRANSFORMER
MAIN VALVE 2
BURNER CONTROL
R
W
B
R
W
B
L1
(HOT)
L2 1
9
21
10
L2
Q7800
MV2 VALVE
MAIN VALVE 1
2
1
3
4
3
HIGH FIRE
PURGE SWITCH
2
VALVE PROVING
SWITCH
LIMITS
BURNER
CONTROLLER
RM7800/RM7840L/EC7840L
POWER
00
OPERATING
CONTROLS
A
ND
INTERLOCKS
BURNER
FLAME
SIGNAL
FIRING
RATE
MOTOR
INITIATE
(INITIAL
POWERUP
ONLY)
POWER
STANDBY
POWER
PREPURGE
HOLD
DRIVE TO
HIGH FIRE
PREPURGE
HOLD
DRIVE TO
LOW FIRE
POWER
PILOT
FLAME
MAIN
POWER
PFEP
10 SEC.
(4 SEC. IF
JR1
CLIPPED
PILOT
FLAME
MAIN
POWER
MFEP
PILOT
FLAME
MAIN
RUN
POWER
POSTPURGE
POWER
STANDBY
00 00 10 25 00 1520
SWITCHING
MOTOR ACTION
BURNER/BLOWER MOTOR
IGN.
LIMITS AND BURNER CONTROLLER CLOSED
LOCKOUT INTERLOCKS CLOSED
PREIGNITION INTERLOCK CLOSED
LOW FIRE SW.
SAFE START CHECK FLAME PROVING
10 SEC. IGN./PILOT 8
10
5
5 SEC.
6
TO
7
20TO
518
TO
13 15
TO
13 12
TO
M24093
INTERLOCK. CHECK
HIGH FIRE SW. 19TO
13 14
TO 13 14
TO
5
4
L1
MAIN VALVE 9
MV2 IS MAIN VALVE CLOSEST TO THE BURNER. JR2 REMOVED FOR PILOT SEQUENCE.
1
TIMED
PREPURGE
POWER
FLAME
MAIN
PILOT
ALARM
POWER
FLAME
MAIN
PILOT
ALARMALARMALARMALARM
00
IC
SSC
LED
DISPLAY
PII
MV2 21 1
2
2

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
966-1162—2
Fig. 5. RM7800L/40G,L and EC7840L Relay Module operation, Valve Proving test options.
M24
09
4A
1
SPLIT
3 SEC. TEST TIME 3 SEC. STANDBY
TEST TIME
L1-17
L1-7
MV1 (9) MV2 (21)
VPS (16) VPS (16)
PII (20) PII (20)
2 1
BURNER RUN TIME
LOCKOUT IF ON, MV1 LEAKING (LOW PRESSURE TEST).
LOCKOUT IF OFF, MV2 LEAKING (HIGH PRESSURE TEST).
2
4 SEC. 4 SEC.
3 4
CONTROLLER
LOCKOUT INTERLOCKS
TEST IS RUN CONCURRENT WITH PRE PURGE TIME.
TEST IS RUN CONCURRENT WITH POSTPURGE, IF POSTPURGE TIME IS ENABLED.
RM7800/40L/EC7840L ONLY.
3
4
BEF
O
RE
3 SEC. TEST TIME 3 SEC. IGNITION TRIALS
L1-17
17-7
MV2 (21)
MV1 (9)
VPS (16) VPS (16)
PII (20) PII (20)
AFTER
3 SEC. TEST TIME 3 SEC. STANDBY
RUN TEST TIME
TEST TIME
L1-17
L1-7
MV2 (21) MV1 (9)
VPS (16) VPS (16)
PII (20) PII (20)
1 2
1 2
CONTROLLER
4 SEC.
4 SEC.
4 SEC.
4 SEC.
PII (20)
4
HF T19
CLOSED 3
FINISH
PURGE
AIRFLOW
POST
PURGE FINISH POST
PURGE
CONTROLLER
POST PURGE
FINISH POST
PURGE
HF T19
CLOSED
5
5

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 10
Fig. 6. Typical wiring subbase and sequence for RM7840G without Valve Proving enabled.
M12260C
G
L2
3
4
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
RUNNING INTERLOCKS
(INC. AIR FLOW SWITCH)
MASTER
SWITCH
LOW FIRE
START SWITCH
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
MAIN FUEL VALVE(S)
BURNER
CONTROLLER/LIMITS
BURNER MOTOR
(BLOWER)
HIGH FIRE
COMMON
LOW FIRE
MODULATE
120V ALARM
10 SEC. INTERRUPTED
PILOT/IGNITION
PREIGNITION
INTERLOCK
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
FLAME DETECTOR
120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT
MEANS AND OVERLOAD PROTECTION AS REQUIRED.
ADD JUMPER FOR 30 SECOND MAIN FLAME
ESTABLISHING PERIOD (MFEP).
DO NOT WIRE TO ANY UNUSED TERMINALS.
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
FOR DIRECT SPARK IGNITION
(OIL OR GAS)
IGNITION
TRANSFORMER
2ND STAGE
FUEL VALVE
(OPTIONAL)
R
W
B
R
W
B
L1
(HOT)
L2
1
21
9
10
1ST STAGE
FUEL VALVE L2
Q7800
3
15 OR 30 SEC.
INTERRUPTED/
INTERMITTENT
PILOT VALVE
2
2
1
3
4
4
4
JUMPER WIRE FOR 30s MFEP
RM7840G
POWER
OPERATING
CONTROLS
AND
INTERLOCKS
BURNER
FLAME
SIGNAL
FIRING
RATE
MOTOR
INITIATE
(INITIAL
POWERUP
ONLY)
POWER
STANDBY
PREPURGE
HOLD
DRIVE TO
LOW FIRE
POWER
PILOT
FLAME
MAIN
POWER
PFEP
10 SEC.
(4 SEC. IF
JR1
CLIPPED
PILOT
FLAME
MAIN
POWER
MFEP
PILOT
FLAME
MAIN
RUN
POWER
POSTPURGE
POWER
STANDBY
00 00 10 25 00 1520
MOTOR ACTION
BURNER/BLOWER MOTOR
IGN.
15/30 SEC. INTERRUPTED/INTERMITTENT PILOT VALVE
LIMITS AND BURNER CONTROLLER CLOSED
RUNNING INTERLOCKS CLOSED
PREIGNITION INTERLOCK CLOSED
LOW FIRE SW.
SAFE START CHECK FLAME PROVING
10 SEC. IGN./PILOT 8
10
5
5 SEC.
21
6
TO
7TO
20TO
518
TO
13 15
TO
13 12
TO
M24169B
INTERLOCK. CHECK
13 14
TO 13 14
TO
4
6
L1
MAIN VALVE 9
TIMED
PREPURGE
POWER
FLAME
MAIN
PILOT
ALARM
POWER
FLAME
MAIN
PILOT
ALARM
1
ALARMALARMALARM
00
IC
PII
SSC
LED
DISPLAY
RM7840G SWITCHING
1

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
11 66-1162—2
Fig. 7. Typical wiring subbase and sequence for RM7840G with Valve Proving enabled.
M24095
G
L2
3
4
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
RUNNING INTERLOCKS
(INC. AIR FLOW SWITCH)
MASTER
SWITCH
LOW FIRE
START SWITCH
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
MAIN FUEL VALVE 1
BURNER MOTOR
(BLOWER)
HIGH FIRE
COMMON
LOW FIRE
MODULATE
120V ALARM
10 SEC. INTERRUPTED
PILOT/IGNITION
PREIGNITION
INTERLOCK
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
FLAME DETECTOR
120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT
MEANS AND OVERLOAD PROTECTION AS REQUIRED.
DO NOT WIRE TO ANY UNUSED TERMINALS.
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
JR3 INTACT FOR DSI FUNCTION.
FOR DIRECT SPARK IGNITION (OIL
OR GAS)
IGNITION
TRANSFORMER
MV1
R
W
B
R
W
B
L1
(HOT)
L2 1
9
10
L2
Q7800
MAIN
VALVE 2
MV2
21
1
2
3
4
4
3
3
VALVE PROVING
SWITCH 2
RECYCLE LIMITS
BURNER CONTROLLER
RM7840G
POWER
OPERATING
CONTROLS
AND
INTERLOCKS
BURNER
FLAME
SIGNAL
FIRING
RATE
MOTOR
INITIATE
(INITIAL
POWERUP
ONLY)
POWER
STANDBY
PREPURGE
HOLD
DRIVE TO
LOW FIRE
POWER
PILOT
FLAME
MAIN
POWER
PFEP
10 SEC.
(4 SEC. IF
JR1
CLIPPED
PILOT
FLAME
MAIN
POWER
MFEP
PILOT
FLAME
MAIN
RUN
POWER
POSTPURGE
POWER
STANDBY
00 00 10 25 00 1520
MOTOR ACTION
BURNER/BLOWER MOTOR
IGN.
LIMITS AND BURNER CONTROLLER CLOSED
RUNNING INTERLOCKS CLOSED
PREIGNITION INTERLOCK CLOSED
LOW FIRE SW.
SAFE START CHECK FLAME PROVING
10 SEC. IGN./PILOT 8
10
5
5 SEC.
21
17
TO
7
20TO
518
TO
13 15
TO
13 12
TO
M24096B
INTERLOCK. CHECK
13 14
TO 13 14
TO
4
L1
MAIN VALVE 1 9
TIMED
PREPURGE
POWER
FLAME
MAIN
PILOT
ALARM
POWER
FLAME
MAIN
PILOT
ALARMALARMALARMALARM
00
IC
PII
SSC
LED
DISPLAY
RM7840G SWITCHING
MAIN VALVE 2
1
1 2
2
JR3 REMOVED FOR PILOT SEQUENCE MV2 IS MAIN VALVE CLOSEST TO THE BURNER

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 12
Fig. 8. RM7800L/40L, EC7840L Relay Module exploded view.
VALVE PROVING SYSTEM
The Valve Proving System feature provides a systematic way
of testing the valve seat integrity to assure the valves are in
the closed state whenever the sequence of operation requires
them to be closed. It is designed to detect a leak greater than
0.1% of the burner input capacity. For example, a 10 million
Btu/hr natural gas-fueled burner would have a fuel input
capacity of approximately 1,000 ft3/hr. A leak rate greater than
0.1% of 1,000 ft3/hr or 1 ft3/hr in either valve will be detected
with the Valve Proving System. Smaller leaks will not be
detected.
At commissioning time, the Valve Proving System may be
scheduled to occur at one of five different times: Never,
Before, After, Both, and Split.
Never—Device default as received: in this case Valve
Proving does not occur.
Before—Valve Proving occurs concurrently with Pre-
Purge.
After—Valve Proving occurs after the Run state before the
internal Safety Relay dropout state and concurrent with
Post Purge (if configured).
Both—Valve proving occurs at both times Before and After
noted above.
Split—The downstream seat (high pressure) test is per-
formed at the Before time and the upstream seat (low
pressure) test is performed during the After time.
The Valve Proving items programmed are:
1. Specify when to perform Valve Proving. Demand input
to terminal 17 actually enables the function of Valve
Proving.
2. Specify the time duration of the test (calculated from
Appendix A).
HONEYWELL
POWER
PILOT
FLAME
MAIN
ALARM
RESET
KEYBOARD
DISPLAY
MODULE
(STANDARD ON
RM7800E,G,L,M)
PURGE
TIMER
WIRING
SUBBASE
CAPTIVE
MOUNTING
SCREW
RUN/TEST
SWITCH
CONFIGURATION
JUMPERS
RELAY
MODULE
SEQUENCE
STATUS
LED PANEL
RESET
BUTTON
FLAME
AMPLIFIER
SCROLL MODE
-SAVE-
BURNERCONTROL
M16353

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
13 66-1162—2
Typical Valve Proving System Function
Valve proving consists of monitoring the pressure in the space
between two shutoff valves, MV1 (upstream) and MV2
(downstream). The valve proving function, identified by letters
A through F, operates as follows:
The tolerance on all valve proving timing values is ±10%.
The following are steps performed during valve proving tests.
This section is for background information and does not define
the exact behavioral requirements.
A. MV2 is commanded to be open while MV1 remains
closed; to depressurize the space. After 4 seconds, MV2 is
commanded closed again.
B. This is followed by a three second delay during which
the valve proving pressure switch (VPS) is ignored.
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. This is followed by a three second delay, during which
the valve proving pressure switch (VPS) is ignored.
F. Thereafter, the VPS is monitored for the duration of the
valve proving test time and, if it turns off, then a lockout
occurs. (Because the gas pressure has decreased due to a
leaky downstream valve.) (High pressure test.)
Pressure Switches for Valve Proving System
The Valve Proving System requires a pressure switch to be
installed to monitor the pressure in the internal space between
the two shutoff valves. Recommended pressure switches are
the following Honeywell non-manual reset models:
Table 6. Honeywell Pressure Switch Selection for Valve Proving System.
Pressure Switch Selection
1. Determine the maximum operating inlet pressure for the
upstream valve; for example, 5.0 psi (140 in. wc).
2. Divide the inlet pressure by two (2.5 psi [70 in. wc], for
example).
3. From column 2 in Table 6 find the operating range upper
limit that is closest to but greater than the inlet pressure
divided by two. In the example given, the possible
selections from column 1 are the C6097A1129 and
C6097A1137 with an operating range upper limit of 7
psi. (The C6097A1079 and C6097A1087 with an upper
limit of 60 in. wc are close, but 60 in. wc is less than the
70 in. wc minimum, so the next higher range must be
selected.)
4. From column 6, select the preferred mounting type, 1/4
in. NPT or Flange. For example, if a flange mount is
required, the pressure switch choice from column 1
would be the C6097A1137.
Pressure Switch Installation and Adjustment
1. Refer to the instructions for the C6097A Pressure
Switch, form number 65-0237.
2. Install the C6097A Pressure Switch according to the
instructions.
3. Adjust the setpoint to 50% of the maximum operating
inlet pressure for the upstream valve.
4. Complete the operation and checkout procedures in the
instructions.
Setup (Programming) of Valve Proving
Function
Prior to setup of the Valve Proving Function, follow the
procedures in the appendix to complete the worksheet and
obtain the Valve Proving Test Time.
An S7800A1142 Keyboard Display Module (KDM) is required
for this setup.
System operation requires the Valve Proving function setup
and demand input must be connected to terminal 17.
NOTE: The S7800A1142 Keyboard Display is NOT supplied
on RM7840G,L device.
When the RM7800L/40L, EC7840L,G is installed and
powered, “STANDBY” will be shown on the first line of the
display.
123456
Model Number
Operating
Pressure Range
Maximum
Differential
(Additive)
Maximum
Continuous Rated
Pressure (psi)
Switch Action at
Setpoint Mounting Type
C6097A1004 0.4 to 5 in. wc 0.24 in. wc 2.9 Breaks N.O. to C
connection on
pressure fall.
1/4 in. NPT
C6097A1053 3 to 21 in. wc 0.48 in. wc 5.0
C6097A1061 Flange
C6097A1079 12 to 60 in. wc 2.4 in. wc 1/4 in. NPT
C6097A1087 Flange
C6097A1129 1.5 to 7 psi 0.3 psi 9.3 1/4 in. NPT
C6097A1137 Flange
C6097A1210 0.4 to 4 in. wc 0.24 in. wc 2.9

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 14
1. Scroll down until the “Setup” is displayed in the second
line. (Setup is only available when the control is in
Standby or Lockout state.)
Fig. 9. STANDBY/Setup screen.
2.
Enter the Setup submenu by pressing the far right key on the
display. Note that the second line now reads “
BC Password ”.
Fig. 10. Password screen.
3. Use the +/- buttons to enter the first number—7.
4. Use the far right key to shift over one space.
5. Use the +/- buttons to enter the second number—8.
6. Press Enter (left/right arrow simultaneously).
Fig. 11. Select/Restart screen.
7. To get to the next screen, press the down arrow. “Get-
ting Data” will be displayed, then the following screen.
Fig. 12. SETUP: Valve Prove screen.
NOTE: This screen sets up when to do the Valve Proving Test.
8. Use the up/down arrows to select from Never, Before,
After, Both, or Split, then press ENTER.
NOTE: Use Never (as shipped) on initial startup so gas line
purging and System Checkout can be performed.
Then come back to set final operation configuration.
Be sure to conduct final VPS System checkout when
Setup is complete.
Fig. 13. Save Changes screen.
9. Use the down arrow to save changes. After pressing the
down arrow, “Getting Data” is displayed.
Fig. 14. Valve Prove time screen.
This screen sets up how long the RM7800L/40L, EC7840L will
conduct the Valve Proving Test for a given time. VP TIme:
00:00 is shown.
10. Enter the appropriate Valve Proving test time from the
worksheet in the appendix.
Use the (+) button to increase time and the (-) button to
decrease. Time changes:
a. 0 to 60 seconds in 1-second intervals.
b. 60 to 600 seconds in 10-second intervals.
c. 10 to 60 minutes in 1-minute intervals.
Press ENTER when correct time is displayed.
Fig. 15. Save Changes screen.
STANDBY
Setup
M22662B
BACK
ENTER
Edit: -+
STANDBY
± BC Password: 00
M22663B
SU
BACK
ENTER
Edit: -+
=Select
=Restart
M22764B
BACK
ENTER
Edit: -+
SETUP: ValveProve
± VP When: BEFORE
M22664B
SU
BACK
ENTER
Edit: -+
=Save changes
=Restart
M22665B
BACK
ENTER
Edit: -+
SETUP: ValveProve
±VP Time: 00:00
M22666B
SU
BACK
ENTER
Edit: -+
=Save changes
=Restart
M22665B
BACK
ENTER
Edit: -+

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
15 66-1162—2
Fig. 16. Select/Restart screen.
11. Press down arrow to select.
12. “Getting Data” will be momentarily displayed, followed
by the screen shown in Fig. 12.
Changing the Installed Postpurge
Fig. 17. Setting Postpurge time.
This screen allows for setting up the Postpurge for the
RM7800L/40G,L, EC7840L. This will be the time that the
Combustion Fan (terminal 5) will remain energized after the
demand ends.
NOTE: The device comes standard with 15-second Post-
purge.
13. Use the +/- buttons to adjust the postpurge time.
Time changes:
0 to 60 seconds in 1-second intervals.
60 to 600 seconds in 10-second intervals.
10 to 60 minutes in 1-minute intervals.
14. Press Enter (Left/Right arrow keys simultaneously)
when the correct postpurge time is displayed.
Fig. 18. Save Changes screen.
15. Use the down arrow to save changes. “Getting Data” is
displayed momentarily.
The following steps are to confirm your selections.
Fig. 19. Confirmation Acknowledgement screen. (The
Valve Proving Test location is shown.)
16. Press ENTER.
Fig. 20. Confirmation Correct screen.
17. Use the down arrow to confirm correct.
NOTE: Using the up arrow during this step will take you back
to the beginning of the setup routine.
“Getting Data” will be displayed.
Fig. 21. Confirm screen.
18. Press Enter.
Fig. 22. Confirm Correct screen.
19. Use the down arrow to confirm correct.
“Getting Data” will be displayed.
The following steps are used to confirm your selection.
=Select
=Restart
M22764B
BACK
ENTER
Edit: -+
M22668
BACK
ENTER
Edit: -+
SETUP:Postpurge
±PostTime: 00:30
SU
=Save changes
=Restart
M22665B
BACK
ENTER
Edit: -+
CONFIRM:ValvProve
±VP When: BEFORE ?
M22670B
SC
BACK
ENTER
Edit: -+
=Confirm correct
=Incorrect
M22671B
BACK
ENTER
Edit: -+
CONFIRM: ValveProve
VP Time: 00:30 ?
M22672A
SC
BACK
ENTER
Edit: -+
=Confirm correct
=Incorrect
M22671B
BACK
ENTER
Edit: -+

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 16
Fig. 23. Confirm Postpurge time.
20. Press Enter.
Fig. 24. Confirm correct/incorrect screen.
21. Press Enter.
22. Press the down arrow to confirm the correct postpurge
time. “Getting Data” will be displayed until the screen in
Fig. 20 appears.
Fig. 25. Setup Done screen.
23. Press and hold the relay module RESET button for five
seconds to program the Valve Proving setup into the
relay module.
The Release Reset screen will appear on the KDM.
Fig. 26. Release Reset screen.
Once the system is in operation, the settings of the Valve
Proving and Postpurge can be viewed in Diagnostics, using
your S7800 Keyboard Display Module (KDM).
Future changes to the Valve Proving and Postpurge features
are still possible. With the relay module in standby, scroll to
the Setup line and enter the password to change the settings.
SAFETY SHUTDOWN
Safety Shutdown (Lockout) occurs if any of
the following occur during the indicated
period:
1. Anytime:
a. Purge card is not installed or removed.
b. Purge card is bad.
c. Configuration jumpers are changed (after 200 hours
of operation).
d. Internal system fault.
e. Demand present at terminals 6 and 17 at the same
time.
f. Failure of the Valve Proving test.
g. Demand at terminal 17 and device at default “Never.”
2. INITIATE Period:
a. AC line power errors occurred, see Operation
section.
b. Four minute INITIATE period has been exceeded.
3. STANDBY Period:
a. Flame signal is present after 240 seconds.
b. Pre-Ignition Interlock is open an accumulative time
of 30 seconds.
c. Interlock check feature is enabled (L only with JR3
clipped) and the Interlock String (including airflow
switch) is closed for 120 seconds with controller
closed.
d. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
e. Main valve terminal(s) energized.
f. Internal system fault occurred.
4. PREPURGE Period:
a. Pre-Ignition Interlock opens anytime during
PREPURGE period (except during VP test).
b. Flame signal is detected after first ten seconds
during PREPURGE (RM7800L/40L, EC7840L).
c. High Fire Switch fails to close within four minutes
and fifteen seconds after the firing rate motor is
commanded to drive to the high fire position at the
start of PREPURGE (RM7800L/40L, EC7840L).
d. Low Fire Switch fails to close within four minutes
and fifteen seconds after the firing rate motor is
commanded to drive to the low fire position at the
end of PREPURGE.
e. Running Interlock does not close within 30 seconds
(RM7840G).
f. Lockout Interlock does not close within 10 seconds
(RM7800L/40L, EC7840L).
g. Lockout Interlock opens during PREPURGE
(RM7800L/40L, EC7840L).
h. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
i. Main valve terminal is energized (except during
Valve Proving testing).
j. Internal system fault occurred.
M22674A
BACK
ENTER
Edit: -+
CONFIRM: Postpurge
±PostTime: 00:30 ?
SC
=Confirm correct
=Incorrect
M22671B
BACK
ENTER
Edit: -+
SETUP DONE: Press
Reset for 5 sec . . .
M22676B
BACK
ENTER
Edit: -+
SETUP DONE:
... release Reset
M22765B
BACK
ENTER
Edit: -+

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
17 66-1162—2
5. PILOT FLAME ESTABLISHING Period (PFEP):
a. Low Fire Switch opens.
b. Lockout Interlock opens (RM7800L/40L, EC7840L).
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 (RM7840G).
6. MAIN FLAME ESTABLISHING Period (MFEP):
a. Low Fire Switch opens.
b. Lockout Interlock opens (RM7800L/40L, EC7840L).
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.
7. RUN Period:
a. No flame is present.
b. Lockout Interlock opens (RM7800L/40L, EC7840L).
c. Interrupted pilot valve terminal is energized.
d. Main valve terminal is not energized.
8. POSTPURGE Period:
a. Pre-Ignition Interlock does not close in five seconds
and opens after five-second time period (except dur-
ing VP testing).
b. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
c. Main valve terminal is energized (except during VP
testing).
OPERATION
Sequence of Operation
The RM7800L/40L, EC7840L has the following operating
sequences, see Fig. 4, 5, 7, and 8. The RM7800L/40L,
EC7840L LED provide positive visual indication of the
program sequence: POWER, PILOT, FLAME, MAIN and
ALARM.
Initiate
The RM7800L/40L, EC7840L enters the INITIATE sequence
when the Relay Module is powered. The RM7800L/40L,
EC7840L 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 and displayed on the VFD 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 RM7800L/40L, EC7840L 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 RM7800L/40L, EC7840L is ready to start an operating
sequence when the operating control determines a call for
heat is present. (Terminal 6, or Terminal 17 if Valve Proving is
required.) The burner switch, limits, operating control and all
microcomputer monitored circuits must be in the correct state
for the RM7800L/40L, EC7840L to continue into the
PREPURGE sequence.
Normal Start-Up Pre-Purge
The ST7800 purge timers provide 15 Pre-Purge timings
selectable from 2 seconds to 30 minutes:
a. The operating control (terminal 6, or terminal 17 for
valve proving), 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 5, is powered to
start the PREPURGE sequence. The firing rate
motor is driven to the high fire position (RM7800L/
40L, EC7840L). The PREPURGE timing does not
begin until the Lockout Interlock String and High Fire
Switch are both closed.
c. If Before, Split or Both Valve Proving tests are
selected (and demand input T17 is used), the
RM7800L/40L, EC7840L will sequence the main
valves to conduct the VP tests concurrently with Pre-
Purge (beginning at 10 seconds into the purge time).
d. The Pre-Ignition Interlock input must remain closed
throughout PREPURGE (except during VP testing);
otherwise, control returns to the STANDBY state
and holds (30 seconds) for the RM7840G or safety
shutdown occurs for the RM7800L/40L, EC7840L.
e. The Lockout Interlock or Running Interlock inputs
(interlock circuit including Airflow Switch) must close
by ten seconds after demand; otherwise, a recycle
to the beginning of PREPURGE for the RM7840G
will happen or a safety shutdown for the RM7800L/
40L, EC7840L occurs.
f. When PREPURGE timing is complete, the firing rate
motor drives to the low fire position, RM7800L/40L,
EC7840L.
g. When the firing rate motor reaches low fire position,
the Low Fire Switch, terminal 18, input must be
energized before entering the Ignition Trial state.
Ignition Trials—Pilot Lighted System (Except VP
System with DSI)
1. Pilot Flame Establishing Period (PFEP):
To get pilot lighted system on VP system, Jumper 2 on
RM7800L/40L, EC7840L or Jumper 3 on RM7840G
must be removed. Default is direct spark ignition.
a. With the firing rate motor at the low fire position:
(1) The pilot valve and ignition transformer,
terminals 8, 10 and 21, are energized. The
RM7840G has an interrupted or intermittent pilot
valve, terminal 21, depending on the selection of
configuration jumper 2. The RM7800L/40L,
EC7840L has a 15-second interrupted pilot
valve, terminal 21. All of the RM7800L/40L,
EC7840Ls have a ten-second interrupted pilot
valve/ignition, terminal 8. If operating as Valve

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 18
Proving, Terminal 21 is Main Valve 2 only.
During PFEP, the Low Fire Switch must remain
closed. If it opens, a safety shutdown occurs.
(2) The Pre-Ignition Interlock input is ignored
throughout the Ignition Trial state.
b. Flame must be proven by the end of the ten-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.
c. After five seconds, the ignition, terminal 10, is
de-energized for early spark termination.
2. Main Flame Establishing Period (MFEP):
a. Terminal 9 (and 21 in VP mode) is energized when
the presence of flame is verified at the end of a 10-
second Pilot Flame Establishing Period (PFEP)
(four seconds if JR1 is clipped).
b. Terminal 8 is turned off 10 seconds after Terminal 9
(and Terminal 21) is energized.
c. Terminal 21 action demand on Terminal 6 (without
Valve Proving Function):
(1) RM7800L/40L, EC7840L: De-energized
15 seconds after Terminal 9 is energized.
(2) RM7840G:
(a) Not turned off, Intermittent pilot, or
(b)15 seconds after Terminal 9 is energized and
JR2 is clipped, or
(c)30 seconds after Terminal 9 is energized and
Terminals 5 and 19 are jumpered and jumper
JR2 is clipped.
Ignition Trials—Valve Proving with DSI System
1. Demand connected to Terminal 17:
— JR2 Intact on RM7800L/40L, EC7840L
— JR3 Intact on RM7840G
a. Ignition, Main Valve 1 and Main Valve 2, Terminals
10, 9, and 21 turn on together.
b. Flame must be proven at the end of the 4 second
Main Flame Establishing Time.
c. Ignition, Terminal 10 is turned off. System now in
Run.
d. If Flame is not proven, safety lockout occurs.
Run
1. A ten-second stabilization period occurs at the
beginning of the RUN period.
2. The firing rate motor releases to modulation.
3. The RM7800L/40L, EC7840L is now in RUN and
remains in RUN until the controller input, terminal 6,
opens (terminal 17, on VP applications), indicating that
the demand is satisfied or a limit opened.
Postpurge
The RM7800L/40L, EC7840L provides a programmable
(default is 15 seconds) POSTPURGE following the
completion of the RUN period. The blower motor output is
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.
1. The main fuel valve and intermittent pilot valve,
Terminals 9 and 21, are de-energized and the firing rate
motor is commanded to the low fire position to begin the
POSTPURGE period.
2. The Pre-Ignition Interlock closes within the first five
seconds after the demand opens.
3. If Valve Proving option—After Split or Both have been
selected, then the Valve Proving test will be conducted
concurrent with Postpurge. If Postpurge timing remains
after the Valve Proving test is completed, the Postpurge
timing will complete before the RM7800/40G,L go into
standby.
Table 7. Sequence Timing for Normal Operation.
* STANDBY and RUN can be an infinite time period.
** PURGE determined by which ST7800A purge card is selected.
aThe MFEP is determined by which terminal is used, configuration jumper selected or jumper wire added.
See Fig. 2, 3, 4, 6, and 7.
bIf DSI is Enabled on a VP application (JR2 intact on RM7800L/40L, EC7840L or JR3 intact on RM7800/40G) then Ignition (ter-
minal 10) and MV1(terminal 9), and MV2(terminal 21) are energized together. After 4 seconds terminal 10 shuts off, and sys-
tem goes to Run.
cIf DSI is disabled on a VP application then MFEP is 10 seconds.
dDefault is 15 seconds. Can be programmed as long as 66 minutes.
Device Initiate Standby Purge
Flame Establishing
Period
Run
Post-
Purge
TimingdInterlock Circuits
Firing
Rate
Circuit
Approval
Code
BodiesPilot Maina, c
RM7840G 10 sec. * ** 4 or 10
sec.
10, 15 sec. or
intermittentb
* 15 sec. Pre-Ignition,
Running, Low Fire
4-wire
modulating
UL/CSA
Modulating
RM7800L/
RM7840L/
EC7840L
10 or 15 sec.bPre-Ignition,
Lockout, High and
Low Fire
FM/IRI
Modulating

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
19 66-1162—2
Keyboard Display Module (VFD)
The Keyboard Display Module (see Fig. 9) is provided with the
RM7800 Relay Module (but is not required for operation) and
is an option for the RM7840/EC7840 Relay Module. The first
line of the Vacuum Fluorescent Display (VFD) provides:
• Current status of the burner sequence (STANDBY,
PURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE).
• Timing information (PURGE, PILOT IGN, MAIN IGN and
POSTPURGE) in minutes and seconds.
• Hold information (PURGE HOLD: T19).
• Lockout information (Lockout, Fault Code, Message and
Sequence).
The extreme right side of the first line is either blank or shows
a small arrow pointing to the second line followed by a
two-letter code (DI-Diagnostic Information, Hn-Fault History
Information, SU-Setup, SC-Setup Confirm, and EA-Expanded
Annunciator). When the arrow and two-letter code are
displayed, it indicates the second line is showing a selectable
message submenu. The second line displays selectable or
preemptive messages.
A selectable message is selected by the user to supply
information on flame strength, system status indication,
system or self-diagnostics and troubleshooting.
A preemptive message has parentheses around the message
and supplies a detailed message to support the sequence
status information. A preemptive message can also be a
lockout message. A selectable message is shown for 60
seconds after a user presses any scroll button, even if a
preemptive message (or lockout) is available. If no buttons
have been pressed for 60 seconds, then a preemptive
message will be shown.
The first line has additional details to help describe it;
otherwise the most recent selectable message will appear.
Pressing the third button on the display is a quick way to
return to the latter condition without waiting 60 seconds.
Run/Test Switch
WARNING
Explosion Hazard.
Can cause serious injury or death.
Do not use the Run/Test switch during the Pilot Flame
Establishing Period for the RM7800L/40L,
EC7840LG,M 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
RM7800L/40L, EC7840L, see Fig. 29. The Run/Test Switch
allows the burner sequence to be altered as follows:
1. In Pre-Purge Drive To High Fire Position (RM7800L/
40L, EC7840L), 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 (RM7800L/40L, EC7840L) position (Run/
Test Switch is ignored while the Valve Proving test is
being conducted by the RM7800L/40L, EC7840L).
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 eight seconds
when a ten second PFEP is selected or during the first
three seconds when a four second PFEP is selected,
allowing pilot-turn-down test and other burner
adjustments to be made. This activates a fifteen second
flameout timer that permits pilot flame adjustment
without nuisance safety shutdowns. The Run/Test
Switch is ignored during PFEP for the
RM7800L/40L,
EC7840L
if Terminals 8 and 9 or 9 and 21 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 RM7800L/40L, EC7840L 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 RM7800L/40L, EC7840L has three site-configurable
jumper options, see Fig. 29 and Table 8. If necessary, clip the
site-configurable jumpers with side cutters and remove the
resistors from the Relay Module.
Fig. 27. Selectable site-configurable jumpers.
RUN/TEST SWITCH
NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.
SELECTABLE CONFIGURATION JUMPERS
M12301

RM7800L1087; RM7840G1022,L1075; EC7840L1014 RELAY MODULES WITH VALVE PROVING
66-1162—2 20
Table 8. Site Configurable Jumper Options.
aPilot Valve /First Stage Oil Valve Terminal 21 cannot be used in this arrangement if Valve Proving feature is selected.
bA 30-second MFEP can be accomplished by adding a jumper wire between terminals 19 and 5, ignored if VP is active.
cDSI Enabled allows for Valve Proving test to be performed, then during PFEP both terminals 9 and 21 energize to light the
Main Flame—note PFEP will not occur and the MFEP will automatically be 4 seconds regardless.
STATIC CHECKOUT
After checking all wiring, perform this checkout before
installing the RM7800L/40L, EC7840L on the subbase. These
tests verify the Q7800 Wiring Subbase is wired correctly, and
the external controllers, limits, interlocks, actuators, valves,
transformers, motors and other devices are operating
properly.
WARNING
Explosion and Electrical Shock Hazard.
Can cause serious injury, death or equipment
damage.
1. Close all manual fuel shutoff valve(s) before starting
these tests.
2. Use extreme care while testing the system. Line
voltage is present on most terminal connections
when power is on.
3. Open the master switch before installing or
removing a jumper on the subbase.
4. Before continuing to the next test, be sure to
remove test jumper(s) used in the previous test.
5. Replace all limits and interlocks that are not
operating properly. Do not bypass limits and
interlocks.
CAUTION
Equipment Damage Hazard.
Improper testing can damage equipment.
Internal surge protectors can break down and conduct
a current, causing the RM7800L/40L, EC7840L to fail
the dielectric test or possibly destroy the internal
lightning and high current protection. Do not perform a
dielectric test with the RM7800L/40L, EC7840L
installed.
Equipment Recommended
1. Voltmeter (1M ohm/volt minimum sensitivity) set on the
0-300 Vac scale.
2. Two jumper wires; no. 14 wire, insulated, 12 inches
(304.8 mm) long with insulated alligator clips at both
ends.
3. Ammeter can be used to verify valve loads connected to
the wiring subbase.
General Instructions
1. Perform all applicable tests listed in Static Checkout,
Table 8, in the order listed.
2. Make sure all manual fuel shutoff valve(s) are closed.
3. Perform only those tests designated for the specific
RM7800L/40L, EC7840L model being tested.
4. Raise the setpoint of the operating controller to simulate
a call for heat.
5. For each test, open the master switch and install the
jumper wire(s) between the subbase wiring terminals
listed in the Test Jumpers column.
6. Close the master switch before observing operation.
7. Read the voltage between the subbase wiring terminals
listed in the Voltmeter column.
8. If there is no voltage or the operation is abnormal, check
the circuits and external devices as described in the last
column.
9. Check all wiring for correct connections, tight terminal
screws, correct wire, and proper wiring techniques.
Replace all damaged or incorrectly sized wires.
10. Replace faulty controllers, limits, interlocks, actuators,
valves, transformers, motors and other devices as
required.
11. Make sure normal operation is obtained for each
required test before continuing the checkout.
12. After completing each test, be sure to remove the test
jumper(s).
WARNING
Explosion Hazard.
Can cause serious injury or death.
Make sure all manual fuel shutoff valves are closed
before performing static checkout.
Jumper Number Description Intact Clipped
RM7800L/40L,
EC7840L Type
JR1 Pilot Flame Establishing Period c10 seconds 4 seconds G, L
JR2 DSI with Valve Proving cEnabled Disabled L
JR2 Pilot Valvea/Main Flame Establishing
Period (MFEP)
Intermittent Interrupted Gb
JR3 Start-Up Interlock Check Disabled Enabled L
JR3 DSI with Valve Proving cEnabled Disabled G