YP7899A1002 - 7800 SERIES Burner Management and Fuel Air Ratio Control Panel - Single Fuel INSTALLATION INSTRUCTIONS — — — — — — — — — — — — — — — APPLICATION The 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 Subbase — 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 Universal 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 wiring 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 66-2062-01 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL SPECIFICATIONS WARNING Fire 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. Electrical Ratings 120 Vac, 50/60 Hz, 10 Amps For individual ratings, see component literature for details. Environmental Ratings Enclosure: NEMA 12. For individual ratings, see component literature for details. WIRING Humidity Install 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 environment. WARNING Electrical 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. Vibration Do not install the panel where it could be subjected to vibration in excess of 0.5G continuous maximum vibration. Ground Connection Earth 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. General Overall panel size: 30in. high x 24 in. wide x 8 in. deep (excluding door and door mounted components) Panel weight: approx. 91 pounds Mounting holes are 0.44 in. typical diameter, 18 in. on center. Approvals Components 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. Electrical Connections 1. 2. INSTALLATION 3. When Installing This Product… 1. Read these instructions and the appropriate product literature 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 service technician. 5. Disconnect the power supply before beginning installation 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, ordinances and regulations. 7. After installation is complete, check out product operation as provided in the appropriate product installation instructions. 66-2062—01 4. Refer to the appropriate product data sheet for details. Wire size and length will vary, depending on the component. Refer to the component literature for specific wire lengths, sizes and type recommendations. Wire according to specifications, following all local ordinances and requirements. Field knockouts are required for the wiring. When drilling holes, take care to protect the electronics from metal pieces and debris. IMPORTANT Run line voltage and low voltage wiring in separate conduit to avoid signal interference. Carefully check field wiring and terminal designations in this document and the associated wiring diagram. They are different from those of the individual components. Panel Inspection After 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. 2 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL Final Wiring Check and Static Checkout CAUTION Test each limit and interlock to ensure system operates correctly as defined in the 7800 Series "Checkout and Test" document (Form #65-0229). All wiring shall be in accordance with the National Electric Codes (NEC) and local electrical codes. 1. 2. 3. 4. Check the power supply circuit. The voltage and frequency must match the specification listed. Check wiring terminations and routing to ensure proper connections. Follow any system checkout recommendations for individual components as found in the component literature. Restore power to the panel. WARNING Explosion 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 voltage is present on most terminal connections when power is on. 3. Replace all limits and interlocks that are not operating properly. Do not bypass limit and interlocks. 3 66-2062—01 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL TROUBLESHOOTING System Diagnostics RM7800L control also have LED fault blink codes. Refer to the appropriate product instruction sheet for further troubleshooting information and diagnostic codes. The 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 Field Wiring Table 1. Field Wiring and Terminal Designation.1 To Connecting Device Terminal # Description 120Vac Power Supply, 10A Max. Provide disconnect means and overload protection as required. 1 L1 Panel Power 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 2 10 Blower Motor Combustion blower motor line voltage output from burner control 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 14 4 Main Valve(s) Main fuel valve(s) connection to burner control output 7,8 DR1 Air Actuator DR1 command input 7,8 203 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 210 S Fuel 1 Actuator potentiometer S output 2117,8 CCW Fuel 1 Actuator potentiometer CCW output 6 18-2 202 7,8 66-2062—01 4 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL Table 1. Field Wiring and Terminal Designation.1 (Continued) To Connecting Device Terminal # Description GND7,8 Ground Fuel 1 Actuator ground 2147,8 DR1 FGR/4th Channel Actuator DR1 command input 7,8 DR2 FGR/4th Channel Actuator DR2 command input 7,8 216 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 215 222 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 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 responsibility 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 ignition cable from other wires to avoid interference. Ignition cable to the spark electrode must be run in separate conduit (if applicable). 6If VPS (Valve Proving System) usage is required with the RM7800 burner control, contact factory for advice regarding wiring. 7 Low voltage wire to the firing rate actuators must be run in separate conduit. Line voltage wiring to actuators provided by customer. 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 Modbusenabled 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. 5 66-2062—01 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL Fig. 1. 24 (610) 30 (762) NOTES: 1. THE CIRCUIT PROTECTION INCORPORATED INTO THIS CONTROL PANEL IS DESIGNED TO SERVE AS SUPPLEMENTAL PROTECTION ONLY. IT IS THE RESPONSIBILITY 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. INDICATES TERMINALS AND WIRING IN MAXON CONTROL PANEL. (MAIN TERMINAL BLOCK). 2. JUMPER ALL UNUSED LIMITS AND INTERLOCKS. INDICATES COMPONENT TERMINALS INDICATES EXTERNAL WIRING INDICATES TERMINALS IN MAXON VALVES 3. THE USE OF A HIGH TEMPERATURE LIMIT IS STRONGLY RECOMMENDED ON ALL APPLICATIONS. THIS DEVICE IS TO BE SUPPLIED BY THE CUSTOMER, IN THE FIELD. IF AFTER CAREFUL REVIEW OF YOUR APPLICATION (BY QUALIFIED PERSONNEL) IT IS DETERMINED THIS DEVICE IS NOT REQUIRED, THEN IT MAY BE OMITTED. WIRE CODE FUNCTION 220VAC (HOT) 220 VAC (NEUTRAL) 120 VAC (HOT) 120 VAC (NEUTRAL) EXTERNAL POWER SOURCE DRY CONTACTS VDC 24 VAC 4-20mA SIGNAL TYPE J THERMOCOUPLE TYPE K THERMOCOUPLE FSG RESETS/DISPLAY/CONTROL BUS GROUND 4. FIELD WIRING SHOWN FOR BLOCK AND BLEED VALVE ARRANGEMENT. 5. FIELD WIRE TO THE DETECTOR SHOULD BE #14 AWG. TYPE TW 600V INSULATED WIRE OR EQUAL. WIRE MUST NOT BE IN THE SAME CONDUIT WITH POWER WIRING. 6. IGNITION CABLE TO THE SPARK ELECTRODE MUST BE RUN IN SEPARATE CONDUIT. (IF APPLICABLE) 7. WIRE TO THE FIRING RATE ACTUATOR MUST BE RUN IN SEPARATE CONDUIT. 8. INSTALLATION, OPERATION AND MAINTENANCE SHALL CONFORM WITH NATIONAL FIRE PROTECTION ASSOCIATION STANDARDS, NATIONAL AND LOCAL CODES, AND AUTHORITIES HAVING JURISDICTION. COLOR AWG 16 (MTW) BLACK 16 (MTW) WHITE 16 (MTW) RED 16 (MTW) WHITE 16 (MTW) YELLOW 16 (MTW) YELLOW 16 (MTW) BLUE 16 (MTW) BROWN 16 (MTW) BLUE 20 (POLYVINYL) WHITE/RED 20 (POLYVINYL) YELLOW/RED 22 (AWG) TWISTED PAIR BELDON 14 (MTW) GREEN M34546 66-2062—01 6 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL Fig. 2 - Part 1. 120/1/60 L1 L2 USE 16 AWG MTW WIRE 1 100 2 FU101 10A 101 3 EMERGENCY STOP PB101 1 NOTE 1 4 2 102 NOTE 3 NOTE 2 27 103 COMBUSTION AIR PRESSURE 27 PS103 27 from 210 LOW GAS PRESSURE PS103A 5 FIELD DEVICE HIGH GAS PRESSURE PS103B 6 FIELD DEVICE 7 FIELD DEVICE CUSTOMER INTERLOCKS FIELD DEVICE 8 2 HIGH TEMP LIMIT HTL 9 FIELD DEVICE 104 LT105 9 105 2 W 106 INTERLOCKS PROVEN HONEYWELL RM7800L-1087 FSG107 9 107 7 L2 27 108 6 5 BRN CTRL LIMITS 12 VALVE PROVING SWITCH HIGH FIRE 17 110 14 DEMAND VALVE PROVING 4 111 LOW FIRE 13 15 COMMON 229 4 113 3 4 200 L1 LINE VOLTAGE SUPPLY MODULATE SHUTTER FLAME SENSOR FLAME SENSOR GROUND CLR . from 228 228 FLAME 225 SAFEGUARD from 229 RESET PB113 from 228 201 RED . BLK . 112 2 10 BURNER MOTOR 16 109 4 2 LINE VOLTAGE COMMON LOCKOUT/ RUNNING INTERLOCKS 11 to 206 12 to 208 13 to 207 22 14 F 16 G GND 3 LT112 BLU WHT NOTE 5 ST112 FIELD DEVICE 115 10 13 XF from 205 LOW FIRE SWITCH INPUT 116 23 117 4 118 MAIN FUEL VALVE SOL127 19 23 from 204 BLOCKING FUEL VALVE SOL130 20 (PROOF OF CLOSURE) (PROOF OF CLOSURE) FIELD DEVICE FIELD DEVICE to 119 18 19 HIGH FIRE SWITCH INPUT 20 PREIGNITION INTERLOCK 8 PILOT VALVE/ IGNITION 9 MAIN FUEL VALVE 17 to 120 FSG ALARM 14 2 NO NC 209 NOTE 6 XF115 24 FSG ALARM X2 SPARK IGNITION TRANSFORMER H1 H2 IGNITION KBD114 24 R CR114 15 15 1 2 3 4 5 6 7 8 HONEYWELL S7810M-1003MODBUS X1 ULTRAVIOLET DETECTOR ALARM 114 15 FIELD DEVICE X1 X2 FIELD DEVICE SPARK PLUG SP115 18 to 124 21 15 SEC INTERR. PILOT VLV, MV2 to 119 2 4 1124734-ECC M34544 7 66-2062—01 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL Fig. 2 - Part 2. 4 2 from 118 17 119 LT119 X1 17 120 17 B PILOT VALVES ENERGIZED X2 FIELD DEVICE SOL120 2 from 115 NOTE 4 121 FIELD DEVICE SOL121 VENT PILOT VALVE MAIN PILOT VALVE FIELD DEVICE SOL122 122 from 118 BLOCKING PILOT VALVE 123 18 124 18 FIELD DEVICE SOL124 from 116 2 GND MAIN FUEL VENT VALVE GND 125 126 18 127 FIELD DEVICE SOL127 2 GND 118 GND NOTE 4 128 MAIN FUEL VALVE 129 18 130 FIELD DEVICE SOL130 2 GND BLOCKING FUEL VALVE 118 GND 131 18 132 LT132 X1 G BURNER ON X2 2 133 134 135 to 200 to 200 4 M34657 66-2062—01 8 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL Fig. 3 - Part 1. 4 CONTROLINKS HONEYWELL R7999A1005 CTRL200 from 135 1 200 4 CONTROL SS201 AUTO MANUAL 4 201 OX 3 21 4 4 5 202 6 203 L1 2 L2 GND AUTO/MAN ALARM FUEL SLCT1 23 204 23 8 to 117 HIGH FIRE PROVEN AIR CW S 24 205 24 9 to 116 11 206 LOW FIRE PROVEN CCW 11 10 DRIVE TO HIGH FIRE 13 11 from 111 21 MODULATE VALVE FUEL 1 CW S 12 208 12 from 110 BURNER SS209 FSG CUSTOMER ALARM ON/OFF OFF ON 4 25 28 CR114 26 OX 209 9 1 3 4 12 DRIVE TO LOW FIRE CCW 13 27 14 to 103 LIMIT/ CTRL IN LIMIT/ CTRL OUT FUEL 2 CW 1 5K OHMS VR213 MANUAL OPERATOR 212 213 214 213 2 3 219 36 220 37 212 38 221 222 215 35 4 .BLK . .CLR . 39 40 REMOTE RESET (RR) MANUAL CNTRL (MNC) 23 24 GRN 204 RED .WHT . .BLK . .BRN . .GRN . CW S TEMP SENS (XmA-) DR2 L2 CW GND 205 S 206 207 L1 CV203 FIELD DEVICE DR1 L1 DR2 L2 CW GND 210 S 211 GND VALVE NOTE 7 209 2 4 from 218 CONTROLINKS CONTROL VALVE CCW 208 4 4 4 2 from 218 GND CONTROLINKS CONTROL VALVE VALVE CCW CV206 NOTE 7 2 27 28 29 31 FG-2 FGR TEMP SENS (XmA+) CCW 32 33 34 .RED . .WHT . .BLK . .BRN . .GRN . 214 FIELD DEVICE 215 216 DR1 L1 DR2 L2 CW GND 217 S 218 GND CNTRL INPUT (CmA+) CCW 4 2 4 from 218 GND CONTROLINKS CONTROL VALVE VALVE CV212 NOTE 7 CNTRL INPUT (CmA-) A RS485 DDL B C BLK 216 22 30 FG-1 RED 3 212 BRN 203 DR1 CONTROLINKS ALARM R 26 CCW CLR CONTROLINKS RESET PB212 BLK FIELD DEVICE LT202 25 F2-1 S 211 WHT 202 GND F2-2 210 19 20 F1-1 F1-2 13 18 RED . GND from 109 207 17 22 22 7 16 A-2 GND 2 15 A-1 FUEL SLCT2 from 135 2 3 217 225 from 229 226 from 228 218 227 from 228 to 203,206,212,219 to 219 2 4 9 M34545 66-2062—01 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL Fig. 3 - Part 2. 4 2 from 218 219 SYSTEM DISPLAY POWER SUPPLY XF220 220 4 4 INPUT 120 VAC (L) 2 2 (N) GND (G) 223 221 FU221 .5A 224 (+) 225 (-) OUTPUT 24VAC 223 222 HMI224 HONEYWELL S7999D1048 +24VAC COM COM2 C COM2 B COM2 A COM1 C COM1 A COM1 B SYSTEM DISPLAY 223 225 .GRN . 229 228 225 .BLK . .WHT . 227 226 226 225 .RED . .BRN . 1 2 3 4 5 6 7 8 224 227 227 228 226 229 225 to 217 to 218 to 218 .BLK . .CLR . .RED . .RED . 225 to 113 .CLR . 2 229 to 112 .BLK . 228 to 112 230 231 232 233 234 235 M34658 66-2062—01 10 from 218 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL Fig 4. 21 (533) 27 (686) M34547 11 66-2062—01 YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL Automation and Control Solutions Honeywell 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