Honeywell The-Honeywell RM7840 is a microprocessor bated integrated ‘burner control for automatically “fired gas, oil, or combination fuel single burner ap- plications. The RM7840 consists of a Relay Module. Subbase, Amplifier and Purge Card are required to complete the system. Options include Keyboard Dis- play Module, Personal Computer Interface, DATA CONTROLBUS MODULE™, Remote Display Mounting, First-Out Expanded Annunciator and COMBUSTION SYSTEM MANAGER™ software. The RM7840 is programmed to provide a level of safety, functional capability and features beyond the capacity of conventional controls. Functions provided by the RM7840 include auto- matic burner sequencing, flame supervision, system status indication, system or self-diagnosties and troubleshooting, 5, 7800 SERIES RM7840E,G,L,M Relay Module MSafety features: . —lnerlock check. 1 “closed loop logie txt =:Dynamic AMPLI-CHECK™, [Dynamie.inpui check. “Dynamic sefety.relay tes. “Dynamic self-check logic. =-Enpanded safe-start check, High Fre Purge Switch test. “internal harcwate status monitoring ~ Low Fire Start Switch test. % Temper resistant timing and logic. Access for external electrical voltage checks. ‘Application flexibility. Communication interfece capability Depedate,lngierm operation provide by micteom- pater technology Mi Firstout annuncietion and system diagnostics are pro- vided by an optional 2row by 20column Vacuum Fluor tay (VED) located on, the Keyboard Display ‘Module (optional). WW First-out expanded annumciation with 26 Light Emitting Diodes (LEDs) for limits and interlocks (optional) Five LEDs for sequence information. Five funciion Run/Test Switch, Inwerchangeable plug-in flame amplifiers. Local or remote annunciation of RM7840 operation and fault information. Nonvolatile memory RM7R40 retains history files and sequencing stetus after oss of power. Reméfe reset (optional) Report‘generalion (optional). Buinér controller data (optional): 4:Expanded annuticiator stats, —Flame signal strength, “Mata satos = Loskout/alarm status. querce status ; Sequence time. » Total cycles of operation. i —Total hours of operation. —Fault history, providing for the six most recent’ faults: + Cycles of operation at she time of the fault. + Expanded anmunciator data at the time ofthe fault + Fault message and code. + Hours of operation atthe time of the fault. + Sequence statas atthe ime of the fault.) =! + Sequence time at the time of the fault. , .° iagnostic infomation: e Device type. Flame amplifier type. ‘Flame failure tesponse time, et Manufacturing cose. On/OEF suits ofall digital inputs and oupats, Selected prepurge time. Software revision and version of RM7840 and ‘optional Keyboard Display Module. + Status of configuration jumpers. + Status of Run/fest Switch, Specifications: ‘Ordering Laformation... Principle Technical Féatures Safety: Provisions Installation UNM ACA S.H.+ Rev. 9-92 + ©Honeywell Inc. 1992 + Form Number 65-0087-—2 AAU .+ Specifications ELECTRICAL RATINGS (See Table 1 ‘Maximum Total Connected Load: 2000 VA. ‘ltageand Frequency: 120 Vac +10/-15%),500r60 Hz Fasing: Total Connected Load: 20A maximumn, type FRN Gf 10%).? ‘or equivalent. mun, ‘TABLE 1—TERMINAL RATINGS. , Description Ratings Flame Sensor Ground! Earth Ground" Line Voltage Common Alacm 120 Vac, 1A pilot duty 55 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50 or 60 Hz (4/- 10%). ‘Burner Motor 120 Vac, 9.8 AFL, 58.8 ALR Cinrush). Burner Controller and Limits 120 Vac, 1 mA. _ Lockout/Running Interlock 120 Vac, 9A. Pilot Valve/lgnition 120 Vac, 4.5A Ignition and SOVA pilot duty.? ‘Main Fuel Valve 120 Vac, 2A pilot dnty.* Ignition 120 Vac, 4.5 Ignition? _ Flame Sensor 60 to 220 Vac, current limited. Firing Rate High Fire 120 Vac, 75 VA pilot duty. Fang Rate Counnon 120 Vac, 15 VA pilot duty. 14 Firing Rate Low T____ | 120 Vae, 75'VA pilot daty. 15. Firing Rate’ Modulate “5 120 Vac, 75 VA pilot duty. 16, Unued 17 Unused side oc 18 | Low Fire Switch Input ‘| “120 Vac, 1 mA. = 19, High Fire Switch Input 120 Vac, 1 mA. 20, ai Preignition Interlock Input 120 Vac, | mA. a Interrupted/Intermittent Pilot Valve): First Stage Oil Valve. 120 Vac, 2A pilot duty. 2, Shute FTT'120 Va0, 0.5. T7ng KM7840 must have an earth ground providing a connection between the subbase and ine conuel panel or Wie equipmeat, The catih ground wire must be capable of conducting the curreat to blow the 20A fuse (or breaker) in eveat of an intemal short circuit ‘Thé RM7840 needs alow impedance ground connection tothe equipment frame which, in urn, needs alow impedance connection to éarth ground, For 4 ground path to be low impedance at RE frequencies, the connection must be made with minimum length corgctors that have maximum surface areas. Wide straps or brackels raher than leadwites are preferred. Be careftl to ensire that incchanically tightened joins along the ground path, such as pipe or condait threads or surfaces bald together with fsteners, are fiee of noncondvetive coatings and are protected against mating surface corrosion. 22900 VA maximum connected Joad to RM7840 Assembly. 30 + 3can algo be 120 Vac, 1A pilot duty. sr ne *Cai also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold. Operating frequency chosen by RM7840'selection. Mi," -E2oy eam LANBsGO): cH a NCS BS uid, rferstheRADELINE® Cala forcomglete oni ‘Wha purchasing replacement and rode se. I yqa have ational questions, need fuher infor }y_ Your leeal Home and Building Conot les Oc (eh 2. Home and Buildsg Control Customer Satisietion®y Honeywel lac, 1889 Douglas Unive nont 1 Minneapolis, Minaesoa 55422-4386 (612) 9511000 4x Canada-~Hoveyvrell LinitedHoneywel Limito! 140 Blctmare ‘Mlprincpal ies of te wold, Manyactring ins Kingdom, US.A ratesRM7840E,G,L.M SPECIFICATIONS ENVIRONMENTAL RATINGS: ‘WEIGHT: RM7840 with Dust Cover: 1 pound 13 ounces, ‘Ambient Temperature: unpacked. Operating: -40° F to 140°F. Storage: 40° F to 150° F. | cu, a eIMPORTANT: Flame Deiection System available for use Humidity: 85% RH continuous, noncondensing. with RM7840. To select your Plug-in Flame Signal Vibration: 0.5G environment, Amplifier and matching Flame Deiector, se Table 2. DIMENSIONS: Refer io Figs. 1 and 2. ‘TABLE 2—FLAME DETECTION SYSTEMS (Figs. 3,4, 5) jignal Amplifiers ‘Applicable Flame Detectors Flame Failure Salt. Response Type Color | Checking _| Model__| Time Fuel__| Twe Models Reciification | Green | No RIS47A | Bor3sec | Gas | Reotifying | C7004, FlameRod | C7007, Holders" C7011 CompleteAssemblies: ©7008, C7009, Q179. No RIBATA | Bor3see | Ol Rectifying | C7003, C7010, Photocell _| C1013, C7014" No RIBIA | 330¢ Gas, oil, | Utraviolet | CTO12A,C* coal" | urplePecpe)| Dynami | RIB47B™ | Bor3sce | Gas | Rectifying | C7004, C7007, AMPLI- FiameRod | C701L CHEE Holdecs® Compieto Aaaomblieo: C7008, C7009, Q179. Dynamic | R1B47B° | Sor 3seo | Oil Rectifying | €7003, C7010, AMPLI- Photoeelt — | €7013, C7014 |_CHECK™ _ Dynamic | R7847B* | 3 sec Gas, oil, | Ultraviolet | C7012A.C* AMPLI- coal "| Purple CHECK™ _ Peeper) Dynamic | R7847C? | 3.sec Gas,oil, | Ultraviolet | C7012. ~ sett: coal "| Purple Cheek Peeper) Tafiared Red | No RIBABA [| Ssee Gas, oil, | Infrared C7015. _ 7 coal "| (Lead Sulfide) Dynamic | RIB4HR™ | 3sec Gas,oil | Infrared CIOS. ANPLI- coal | (Lead Sulfide) | CHECK™ Ultavielar | Purple | No RIRAVA_| Bordsec | Gas,oil | Ulaviole — | C7027, C7035, (Minigeeper) | C7044." ‘Dynamic | R7840B° | Bor3sec | Gas,oil | Ultrviotet ‘C7027, C7035, ‘AMPLI- (Minipeeper) | C7044." |__| cuecx™ {Blue | Dynamic [R7B86A" | 3sec Gas, oil, | Usaviole | C7076. Self- coal | (Adjustable Check Sensiivity) The C7012A.C, C7027, C7035 and C7044 flame detectors should be used only on bumers that cycle on-off at Ieast once every twenty-four hours. Appliances with burers that remain on for twenty-lour hours continuously or longer should use the C7012E F Flame Detector with the R7847C Amplifier or the C7076A Flame Detector with the R7886A Amplifier as he altreviolet flame detection sysicin *Circuitry tess all electronic components in the flame detection system (amplifier and detector) 12 times a minute during bumer operation and shuts dawn the burner if the detection system fails, *Cisuuitn, tests the flome signal amplifier atleast 12 times a minute during bumer operation and shuts down the burner if the amplifier fails. Order flame rod separately; see holder Instructions. "Use only Honeywell Photocell, part no. 38316. 3 65-0872‘SPECIFICATION SEQUENCE ‘TIMING FOR NORMAL OPERATION ‘ Post Fring) Enerey | Anproval Fame dtatishing Petod | | Purge | Interoek | Rate | Saving | Code evieg_| tntate[stnauy| purge [ior —]—Hain—|un | int | Cire Peepurge | Dade RM78408 | 10 sec. . | dorlOsec. | 10or 15 see. * | 15sec. |Preignition,) 4-wire Yes PM/IRE Tock, | modulating Moding High and - . Low BEGG] ae | | = [tertOme [10 somar [| ace [Pcie No | ULESA Intent tame, Mossi Lowa | S wairaact | me | * | [taides fiOw idee | * | Se |Peigntion| No | FWRI Toston, Modulating Rare] xe | + [autowe | aowca [> | owe [Peignson| 20ie | No | ULESA Jntermivent Running, | isoltated On-Off Lowe |On-01-0n | coat | © STANDBY and RUN can bea infinite period +8 DURGE will bodetcmined by which ST7OOA purge card ie elstd "The MFEP will be determined by which terminal used, configuration jumper selected or jumper wire added, see Figs. 7, 8, 9 10, and 21. APPROVAL BODIES: ‘Underwriters Laboratories Inc, listed, File No. MP258, Guide No. MCCZ. Canadian Standards Association certified, LR9S329:3, Factory Mutual approved: Report No. JILWYAUAR, TRT acceptable, Federal Communications Commission: Part 15, Class B—Emissions, MOUNTING: Q7800A for pane! mourt or Q7800B for wall oF burner mou. REQUIRED COMPONENTS: Plug-in Flame Signal Amplifier, sec Table 2. Plugrin Purge Timor Cards: selectable ST7800A: two seconds (0:30 ininutes. Q7800A or Q780B ACCESSORIES: Optional: ‘ControlBus 5-Wire Electrical Connector—part no. 203541. COMBUSTION SYSTEM MANAGER™—partno, ZM7850A 1001 Communication Interface Base Unit—part no. Q7T00A1014. ‘Communication Interface ControlBus Module—part no, QS7800A 1001, DATA CONTROLBUS MODULE™—pat wu. S7B10A1009. Dust Cover—part no, 2217294, Expanded Annaneiator—par no. $7830A 1005. Flame Simulators: ‘part no.203659 UV Flame Simulator pari no. 123514A Rectification Simulator. Keyboard Display Module—part no, $7800A 1001 Remote Display Mounting Bracket—partno, 203755. Remote Display Power Supply—part no. 203963A Plagein Remote Reset Module—part no. $7820A1007. re 1 Sixty-inch Cable Assembly—part no, 221818. ‘Tester—part no, A7800A 1002. jee ; ind Q7B00A Subbase, in Inches [millimeters]. Fig. 1—4tounting dimensions of FIM7840 Relay Module a =o eS Honeywell [eumenconino.] ait s B we BA ‘avi 5 = ci as ora To B p Onl = 7 Bp iS a ao I sien. | shina AN ranoveomvron tenwnas est Accsi ‘ RM7840E.G,LM SPECIFICATIONS Fig. 2~Mounting dimensions of RM7640 Relay Module and Q7800B Subbase, in inches [millimeters]. 9 £ Tne Honeywell eunnen control 5 5 8 . p " ‘ 5) Ci a 8 Fy |A HA |-—_ — sran $e, ———_| ‘A\ rewove oer Fon resauerest 00ess ves Fig. 3—Rectification detectors. BUR. (@178C ONLY) CERAMC Fete Len ‘ak-s4npTOR rarer vasenpa stra cseiead |.) — cro14a seer 5 65-0872‘BV7B40E,5,LM ‘SPECIFICATIONS Fig, 4—Uitraviolet detectors. |< +109 +} jeroornaonere, -] | oaupum [2 BEN enc a Choe. | | eae ? és —te— 1 fae A ay - t i rt ib 1 aR ay, As go 28 5 "Hl Lope ITH 1/2054 NPSM t os [09 METE course || restr”! eal, Axwoos snare wnistroorrasueren icsownes, | 1] A\ onaronorencrtsaoe kas 11 059. TERIAL THREADS ‘A woos. avagasie wi pu comsecron ava wes TERNAL, "READS WETEAB Gr CLAP Pe COMNECTOR. Tae | A\ on areRvc coskons AS 4 68-F NTERNNL HEADS, oy Fh]. s mooes avateaie wm 7907 eS NETER ERIS an a C7035 foor}.sa mereR) teowncea , tM crema Fig. 5 infrared detector. 2100S I. fae: 2MErER] FleN@Le CoNOUT jsustnec wit uGNerING LensRM7840E,G,LN PRINCIPAL TECHNICAL FEATURE! Principal Technical Features ‘The RM7840 provides all customary flame safeguard functions while supplying significant advancements in the areas of safety, ann jon and system diagnostics, SAFETY SHUTDOWN (LOCKOUT) OCCURS IF: 1. INITIATE Period a, Purge card is not insialled or removed, . Paige card is bad. ©. Configuration jumpers have been changed (alter 200 hours). 4. AC line power errors occurred, see Operation. . Four minute INITIATE period has been exceeded. 2, STANDBY Period a, Flame signal is present after 40 seconds. b, Preignition Interlock is open an accumulative time of 30 seconds «. Interlockcheck feature isenabledand the Interlock Swing (including aisflow switch) is closed for 120 seconds with controller closed. 4, Ignition/pilot valve/intermittent pilot valve termi- nal ic energized . Main valve terminal is energized. Internal system fault occurred. Purge card is not installed or removes, , Purge card is bad. 3. PREPURGE Pesiod a, Preignition Interlock opens anytime during PREPURGE period (RM7840E.L). b. Flame signal is detected after first ten seconds during PREPURGE (RM7840EL). . High Fire Switch fails toclose within Jour minutes and fifteen seconds after the firing rate motor is commanded to drive to the high fire position atthe start of PREPURGE (RM7840EL). . Low Fire Switch fails to close within four minutes and fifteen seconds afier the firing rate motor is commanded to drive to the low fire position atthe end of PREPURGE. ¢. Running Interlock doesrotclose within 30seconds (RM7#40G,M). £, Lockout Interlock does notclose within 10seccnds (RM7S40E,L). g. Lockout Interlock opens during PREPURGE (RM7840EL), h. Ignition/pilot valvefinterniteent pilot valve termi- nal is energized, 4’ Main valve terminal is energized. Jj Internal system fault occurred. . Purge card is removed. 1. Purge card is bad. PILOT FLAME ESTABLISHING Periol (PFEP) a. Low Fire Switch opens. ’b. Lockout Interlock opens (RM7840E,L). ¢. Ignition‘pitot valvesintermittent pilot valve termi- nal is not energized 4. Early spark termination terminal is energized after five seconds, ¢. No flame is present at end of PFEP. £. Main valve terminal is energized (RM7800G,M).. ¢g. Internal system fanlt occurred. h, Purge card is removed, i: Purge card is bad. ". MAIN FLAME ESTABLISHING Period (MFEP) a, Low Fire Switch opens. ’b, Lockout Interlock opens (RM7840E,L). ¢. Tgnition/pilor valve/intermitent pilot valve termi- nal is not energized. 4. Main valve terminal is not energized. ©. No flame is present at end of MFEP. f. Internal system fault occurred. Purge cart is removed. hh. Purge card is bad. RUN Period a. No flame is present. . Lockout Interlock opens (RM7840E,L). - ¢, Interrupted pilot valve terminal is energized (RM78406.M). 4. Main valve terminal is not energized. ¢. Internal system fault occurred. f. Purge card is removed. & Purge cardis bad, . POSTPURGE Period a. Preignition Interlock does not close in five seconds and opens after five second time period. b, Ignition/pilot valve/intermittent pilot valve termi- nal is energized. : . Main valve terminal is energized. 4. Internal system fault occurred. e, Purge cari is removed. £. Purge cardis bed. 65-0872RIM7840E:G:C,M SAFETY PROVISIONS = properly; ie., the m: * Safety Provisions INTERNAL HARDWARE STATUS MONITORING ‘The RM7840 checks the purge card for correct parity to prevent purge timing shifts and circuitry failures. 1: also analyzes the integrity of the configuration jumpers and internal hardwaro. The POWER LED will blink every four seconds, signifying an intemal hardware check. CLOSED LOOPLOGIC TEST ‘The test verifies the integrity ofall safety critical loads, terminals 8, 9, 10 and 21. If the loads are not energized valve terminal is powered during PREPURGE, the RM7840 will lockout on safety shutdown. ‘The RM7840 must react 19 input changes but avoid the ‘occurrence of nuisance shuidown events, Signal condition ing is applied to line voltage inputs to verify proper opera tion in the presence of normal electrical line noise such as transient high voltage spikes or short periods of tine drop out. Signal conditioning is tolerant of synchronous noise ine noise events that occur at the same time during each line eycle). DYNAMIC AMPLI-CHECK™ Dynamic AMPLI-CHECK™ circuitry tests the flame signal amplifier during burner operation and shuts down the RM7#40 if the flame amplifier fails. DYNAMIC FLAME AMPLIFIER AND SHUTTER CHECK Self-checking circuitry tests all electronic components in the flame deection system and amplifier 10 to 12 times per minute and shuts down the RM7840 if the detection system fails. DYNAMIC INPUT CHECK ‘All system input circuits are examined o verify the M7840 is capable of recognizing the truc status of external controls, limits and interlocks. If any input fails this test, a safety shuudown occurs and the fault is znnunciated. DYNAMIC SAFETY RELAY TEST Checks the ability of the dynamic safety relay contacts lo open and close. Verifies thatthe safety critical loads, ermi- nals §,9, 10 and 21, can be de-energized, as required, by tre Dynamic Self-Check logic. DYNAMIC SELF-CHECK SAFETY CIRCUIT The microcomputer tests iiself and related hardware while at the same time the safety relay system tests the microcomputer operation. Ifa microcomputer orsaety relay failure occursand doesnotellow properexecutionof the self- check routine, safety shutdown will occur and all safely ritical loads Will be de-energized. EXPANDED SAFE-START CHECK “The conventional sufe-aart check, which proventsbumer star-up if Mame is indicated at star-up, is expanded to include a flame signal check during STANDBY a preigni- + tion interlock check, an inveslock check, and a safety critical Toad check. HIGH FIRE PURGE AND LOW FIRE START SWITCH TESTS High Fire Purge Switch Test (RM7840E,L) examines the urge Position Interlock S witch atthe moment the firing rate ‘motoris commanded tothe high fie position, [the switch is bypassed, welded or otherwise closed prematurely, the sys- tem will automatically add 30 seconds 10 allow additional dive time for the firing rate motor to reach or near the open * position before starting the purge timing; otherwise, purge timing starts when the High Fire Switch isclosed, This switch will also cause hold (four minutes, fifteen seconds) condi tion when the switch is open before purge of opens during purge. Tho RM7840E.L will lockout and annunciate aa alarm ifthe switch failsto close within the botd time period. Low Fire Start Switch Test examines the Low Fire Start Switch at the moment PREPURGE is completed. If the ‘witch is bypassed, welded or otherwise prematurely closed, fe system will aulomatically add 30 seconds to allow the firingrate motor additional time to reach or near the low fire sat position before ignition trials; oherwise, ignition tals, start ater he Low Fire Switch closes. The test also is used 10 prove that the firing rate motor is at low fire position throughout the ignition trial period This switch also will causea hold (four minutes, fifteen seconds) condition if the switch opens after purging is complete, The RM7840 wil lockout ard annunziatc an alarm ifthe switch fails to close within the hold tie period. MANDATORY PURGE Iflockout occurs after the initiation of ignition trials (or ‘al any-time during a sequence when the fuel valves may ‘have been energized),a mandatory POSTPURGE period is imposed. {ORF CYCLE (STANDBY OR PREPURGE) FLAME, IGNAL CHECK ‘The flame detection subsystem (flame detector and amplifier) is monitored during STANDBY. If a flame ‘simulating condition or an actual flame exists, a system hold occurs and start-up is prevented. I the flame signal ‘exists at any time after the first 40 seconds of STANDBY, a safety shuidown will occur and be annunciated. shutter-check amplifier and self-checking detector are energized for the first 40 seconds during STANDBY and the last wo seconds before exiting STANDBY. Ifaflame exists, a safety shutdown occurs. An AMPLI-CHECK™ Amplifier is energized continually through STANDBY ‘and PREPURGE to detect any possibility of a runaway detector or a flame. If either situation happens, a safety shutdown occurs. A standard amplifier is energized con- finually through STANDIRY and PREPHIRGE. If cithor situation happens, a safety shutdown cours. fgitne- PREIGNITION OUTPUT CIRCUIT CHECK ‘At the end of PREPURGE, the Dynamic Safety Relay operation is checked. Also, all safety critical loads terminals 8,9, 10 and 21, are checked to verify the terminals are not powered, Ifthe Dynamic Safety Relay operationis faulty, or if any of the safety cuitical loads are powered, safety shut- down occurs and is annunciated, : TAMPER RESISTANT TIMING AND LOGIC i Safety and logic mings are inaccessible and cannot be , altered or defeated. ® VERIFIED SPARK TERMINATION ‘The ignition terminal is monitored to verify early spark teriination (fiveseconds ignition and pilotand five seconds pilot only). FIRST-OUT ANNUNCIATION AND SELF-DIAGNOSTICS Sequence Status Lights (LEDs) provide positive visual indication of the program sequence: POWER, PILOT, BLAME, MAIN and ALARM. The green POWER LED ' blinks every four seconds, signifying that the RM7840 {Optionalimut-furctionKeyboard Display Module shows “elapsedtimeduring PREPURGE, PILOT IGN, MAIN IGN, "aid POSTPURGE, Ae an additional roubleshiating af, i provides Sequence tining, diagnostic information, historical / antorrilioh and expanded annunciaot information when ‘Safely’ shutdowa or Hold or noimal operation occurs, ‘shutdowii' or identifies the cause. Of a failure to start or “) continue theburner control sequence withanEnglishtextand, || mumbered code via the optional Keyboard Display Module. Temonitors all field input circuits, including the lame signal ‘amplifier and firing rate position switches. The system distinguishes 118 modes of failure and detects and annanci- ates diffcul-to-find intermittent failures. Self Diagnosticsadds to the First-out Annunciation by allowing the RM7840 to distinguish between field (exter nal device) and intemal (system elated) problems. Faults associated within the flame detection subsystem, RM7840, or Plug-in Purge Card, are igolated and reported by the optional Keyboard Display Module, see the 7800 SE- RIES System Annunciation Disgnostics and Trouble- shooting, form 65-0118. a 8 BS: £33 5 2 =e INTERLOCK REQUIREMENTS ‘The following interlock inputsare provided: Low Pire Interlock (RM7840 ALL) ‘This interlock verifies the firing rate motoris in the low fire position before and during ignition trials. High Fire Interlock (RM7840E,L) ‘This imerlock verifies the firing rate motor isin the high firepositionbeforeand duringPREPURGE, Ifthe HighFire Switch is jumpered on the RM7840B, the Energy Saving Function will not be performed. , RM7640E, ! “SAFETY PROVISION Running Intérlock (RM7840G,M) This interidck (LK) inpot signifies a Running Interlock, If-a-RunningInterlock is open at the beginning of PREPURGE, a'30 seoond hold condition is initiated. 1°30 secends elapse and the Running Interlock stillhasnot closed, a lockoit will occur. Affer entering PREPURGE, if the Running Trtérlack opens during the first en seconds, the purge timer willbe eset This providesacontinuousPURGE, to ov6ui withoiiirteimuption before the Pilot Flame Estab- lishing Period..1f the Running Interlock opens after ten seconds into PREPURGE, it will eeycle beck to the begin- ning of PREPURGE. [fit opens anytime during the Ignition it will proceed to POSTPURGE. ‘A typical Rumning Interlock string contains an Airflow Switch (sce Fig. 9 and 11). The Interlock Check is a site configurable option (see ‘Table 6). If this featnre is enabled, theRM7840 willlockoutafter 120 seconds whenevercontrol 6 is energized, and the Running Interlock string (including Airflow Switch) is closed daring STANDBY. ‘Lockout Interlock (RM7840E,L) ‘This intedock (ILK) input signifies a Lockout Interlock, If the Lockout Interlock is open for more than ten seconds into PREPURGE, the RM7800E Lwilllockout. After enter- ing PREPURGE, if the Lockout Interlock opens during the fies: en secmds, the purge timer will be reset. Tas provides a continuous PURGE to occur without interruption before the Pilot Flame Establishing Period. Ifa Lockout Interlock ‘opens anytime after ten seconds into PURGE, during the Ignition Trials or Run, it causes a lockout. A typical Lockout Interlock string contains an Airflow ‘Switch (see Figs, 8 and 10). The Intetlock Check is a site ‘configurable option (see Table 6). I tis feature is enabled, the RM7840willlockout after 120 seconds whenevercontrol terminal 6 is energized, and the Lockout Interlock string ((ncluding Airflow Switch) is closed daring STANDBY. NOTE: For the RM7840E, the ten second time frame docs not begin until the blower motor is recognized. Preignition Interlock (RM7840 ALL) ‘The Preignition Interlock inputis typicelly connected to aproof-of-closure switch for afuel valve(s), The Preignition Interlock must be energized throughout PREPURGE. If the reignition Interiock opens during STANDBY, it causes a, hold (30 seconds). The RM7840 will lockout ifthe interlock does not close within 30 seconds during STANDBY. If the reignition Interock opens daring PREPURGE, it will re- cycle to: STANDBY (RM7840G.M) or will lockout (RM7840E_L). Ifthe Preignition Interlock is open after five seconds intoPOSTPURGE, thc RM7640 will lockout. The PreignitionInterlockis ignored during the ignition tials state and during RUN. 65-0872M7840E,GiL.M ISTALLATION /)\ WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SERVERE INJURY, OR DEATH To prevent possible hazardous burner operation, verification of safety requirements must be per- formed each time a contol is installed on a ee 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 theratings givenin the instructionsandmaiked ‘on the product to make sure the product is suitable for your application. 3. Installer must be a trained, experienced, Mame safe- guard service technician. 4, Alicr installation is complete, check out the product ‘operation as provided in these insructions. Fig. 8—intemal block diagram of M7840 (see Figs. 7, 8, 9 of 10 for detailed wiring instructions), STATI Le ot Mie, on ue Fc} RENDORRD, ih Sersionns | 9"-E cowoy G . K npcnes rem ens om woouate + AROUNEVOKTINRUS 8Binwmcrnons costae NS BRU 2S PAOWOE DISCONNECT MEANS AND OVERLOAD PROTECTION ASREQURED. 10JN CAUTION | Disconnect the power supply before beginning installation to prevent electrical shock, equip- ‘mentand control damage. More than one power supply disconnect may beinvelved. 2. Wiring connections for theRM7840 are nique; therefore, refer toFigs.6, 7,8,90r 1Oor he cor- rect Specifications for proper subbase wiring. 3. Wiring must comply with all applicable codes, ordinances and regulations, 4, Wiring, whererequired, must comply withNEC, Class 1 (Line Voltage) wiring, 5, Loads connected to the RM7840 must not ex- ceed those fisted on the RM7840 label or the Specifications, see Table 1, 6. Limits and interlocks must be rated to carry and brea current simultaneously to the ‘ignition transformer, pilot valve, and main fuel valve(s). 7, Allextemal timers must be listed or component. recognized by authorities who have jurisdiction forthe specific purpose for which they are used, IMPORTANT: 1. For on-off gas-fired svstems. some authorities who have jurisdiction prohibit the wiring of any limit or operaing contacts in series between. the flame safe- guard controland ihe main fuel valve(s). 2. Two detectors can be connected in parallel with the excepion of Infrared detectors (C7015A). 4. This equipment generates, uses and can radiate radio ‘frequency energy and, if rot installed and used in ‘accordance with the insiruetions, may cause iterfer- ence to radio communications. It has been tested and foundio comply with helimisforaClassB computing device of Part 15 of FCC rules, which are designed 10 provide reasonable protection against such interjer- ‘ence when operated in a commercial environment. Operationof this equipmentin aresidential area may cause interference, in which case, the users at thelr ‘awn expense may be required to take whatever mea- sures are required to correct this interference. INSTALLATION WIRING 4, This digital apparatus does not exceed the Class B limits for radio noise of digital apparatus set ow inthe Radio Interference Regulations of the Canadian De- partment of Communications. HUMIDITY Install the RM7840 where the relative humidity never reaches the saturation point. The RM7840 is designed to ‘operate ina maximum 85% RE continuous, noncondensing, ‘moisture environment. Condensing moisture may cause @ safety shutdown, VIBRATION ‘Do not install the RM7840 where it could be subjectedto vibration in excess of 0.5G continuous maximum vibration. WEATHER ‘The RM7840 is not designed to be weather tight. If installed outdoors, the RM7840 must be protected by an approved weather-tight enclosure. MOUNTING WIRING SUBBASE ‘NOTE: For installation dimensions, see Figs. 1 or 2 1, Mount the subbase in any position except horizontally with the bifurcated contacts pointing down. The standard vertical position is recommended. Any other position de- ‘creases the maximum ambien! temperature rating, 2, Select a location on a wall, bumer or electrical panel. The Q7800 can be mounted directly in the control cabinet, Be sure to allow adequate clesrance for servicing, installation, access and removal of the RM7840, Dust Cover, flame amplifier, flame amplifier signal voltage probes, Run/Test Switch, electrical signal voltage probes and electrical field connections. 3. For surface mounting, usc the back of the subbase as a template to mark the four screw locations. Drill the pilot holes. 4, Securely mount the subbase using foar no. 6 screws. Wiring. 1. a. For proper subbase wiring, refer to Figs 7, 8,9, oF 10. b. Focproperremote wiring of the Keyboard Display Module, refer o ue Specifications for the Key- board Display Module (65-0090), Communica- tion Interface Base Unit(63-2278), DATA CON- ‘TROLS MODULE™ (65.0091) or Extension Cable Assembly (65-0731), 2. Disconnect the power supply from the main discon- cet before boginning installation 10 prevent electrical shock and equipment damage. More than one disconnect nl may be involved. 3, Allwiringmust comply with ll appropriate electrical codes, ordinances and regulations. Wiring, where required, ‘must comply with NEC, Class 1 (Line Voliage) wiring. 4, Recommended wire size and type: a, Allline voltage terminals useno. 14, 16, 018 cop- perconductor (ITW0C or THW 75CorTHHNGC) 600 volt insulation wire. For high temperature Insallations, use wire selected for a vemperaure rating shove the maximum operating temperature, Allleadwires stould be moisture resistant." 65-08727840E,G,.LM ‘ING % Recommended grounding practices a. Use theearth ground to provide a connection be- tween the subbase and the contol panel or the equipment, The earth ground wire mustbe capable of conducting the current to blow the 20A fuse (or breaker) in event of an internal short circuit. ‘The RM7840 needs alow impedance ground con- nection to the equipment frame which, in tum, needs a low impedance conection ioearth ground. For a ground path to be low impedence at RF frcquencies, the connection must be made. with minimum length conductors that have a maximum surface area. Wide straps or brackets are preferred rather than Teadwires. Be careful to ensure that mechanically tighicned join'salong the ground path, such as pipe or conduit tareads or surfaces held togeiher with fasteners, are free of nonconductive coatings and are protected against mating surface corrosion, Each RM7840 has an earth ground terminal that ‘mus: be grounded to the metal control panel with wireas shortas practical, Each ground wire must be capable ofcarrying a faultcurrentequalio therating Of the protective fuse (20A). A number 14 copper conductor is adequate but wide straps or brackets are preferred rather than leadwires. 6. Recommended wire routing: a. Flame detector leadwires: Fig. 7—Wiring RM7B40E. cones Fore sencs.e0 a (Lowery ee C reer eR mccain FLOW sre) Lane vet breanation ren.necrevne are] Ree sap Saree) Fuawe Derecror on 1 1 | [evecrn, oreaen, OF lei cal 1 1 L on on [SSEAEEFOR owe | Yom [ero Ucravouer| TT Tt Ct. — Te bee LM pu 1 TonunroTesancionTon oe enars) Ata, 2 He POWER SUPPLY, PROVIDE OISCONNEST MEANS AO OVERLOAD PROTECTION AS AEQUIRED, ‘Avoonor wie ro my unuseo TERMINALS, 123RM7840E,G, WIRIN 1, Do not mn high voltage ignition transformer b. For flame detector eadwires, the maximum flame wires in the same conduit with the flame detec- sensorleadwire length is limited by the flame signal tion wiring. strength. 2. Do not route scanner wires in conduit with line 8. Make sure loads do not excecd the terminal ratings. voltage circuits. Refer to the label on the RM7840 or to the ‘ratings in 3, Bnolose scanner wires without armor cablein Specifications, see Table 1. metal cable or cond 4 9, Check the power supply circuit. The voltage and 4, Follow directions given in theflame detector frequency tolerance must match those ofthe RM7840, A. Instructions. separate power supply cireuit may berequired forthe RM7840. 7. Maximum wire lengtl ‘Add the required disconnect means and overload protection. a, For RM7840, the maximum length of leadwire is 10. Check all wiring circuits and complete Static Check- 300 feet to terminal inputs (Control, Preignition cut, see Table 4, before installing the M7840 on the Interlock, RunninglLockout Interlock, High Fire subase. ‘Switch and Low Fire Switch). LL, Install all electrical connectors. 12, Restore power to the pane! Fig. 8—Wiring RM7840G. : 1 Flmerare sens: Siege senso fons SSNRSen woenaeetion 5B) Tolle 1 fad COMMON 1 ty it peom—_—_$_-lo @/=4o}4® , ' 5 1 Duy @pev= \ 1 1 | EI A_@ a 1 ' [conroucntnrs 5 @ : 1 1 | _ RRR TO OP kai Beet |} Eae J 1¢ a || Rae > @L Te . | es © aa | ee He ¢ ewer] | le @t ete. I RATT : u 1 — tn ‘ reeassese” | ++ aA 1 abled At [sae ! of [i ‘ | are FRET Joey | RRC TENT woe FEaremme [se | ES ey = =” «dS O} Rained 1 (yeson RAS Eh evo] et ©; ERS au ere TTT te (orion) As tv eas Home SvBPLY. PROVIDE CISCOIMECTNEANS AND OVERLOAD PROTECTION AS PEUIAED ‘Asoc rue etasunarenCo wren {Boone we ro any vos TERNS _ 3 65-0087M7B40E,G'i,M RING. “Fig. 9—Wwiring RM7B40L, sence eo FIANG ARTE SERIES 90 7200 Maron CONTROL: igs Fie poocceseccoe conan TeaT ALAR MODULATE BUMMER HOTOR| fouowery eovrnowenuirs TocKouT NTERLOGS eves AR-LOW SWE) eae, wreRRUPTED] PLoTigniTON. aan FUEL] WANES) Tower: Sra ScTOH eau Sameer 11 | WHITE, 1) ik RE ae tbo ee yy 4 bee ee lA {Av taov cove rome ae, Prowec OS NECT EMS iN CERLOAD PROTECTION AS ECURED 2\2O NOT WIRE TO ANY UNUSED TERMINALS, i susoan 1“RM7&408 Gl WIRING * ASSEME Fig, 10—Wiring RM7840M. 1 i : 1 [iaav ALAR | % | th i meee I foower oe Q ! eR @ Ik I = a & is np 4 i ferme tow aurTon ean sare 1 | fosecwrereurren) - oe | Leet: Il Freecom ayron RreRoTTENT JH I NATION peer ! atl I ‘ ro Foe} tion My oh iz 1 oF I on t en | woe [oar pane, [aves F lane OerecToR 4 U ‘oR ! ; [esnow | Sroeh8 feanouer 5 UELIANE icerionat) AS env. co mePowen PPL. mOUE OBLEANEET MEANG 1D CNERLOND PROTECTION AS RECUIRED Acyuzano capes voron on.ow Af SATs UseD, JUMPERTENA, 1 TOTERMA. 8, #0 CONOT AX sono one 70 ANY USED TERMINALS, ae Assembly MOUNTING RM7840 2, Select the location inthe electrical enclosure. Be sure vo allow adequate clearance for servicing, installation and ‘NOTE: For installation dimensions, see Figs. 1 or 2. removal of the RM7840, Dust Cover ,flameampilifier, flame amplifier signal voltage probes, elecvical signal voltage RELAY MODULE MOUNTING probes and electrical connections. 4. Mount the RM7340 vertically, soe Figs. 11 or 12, or a, Allowan additional two inches below the RM7840 mount horizontally with the knife blade terminals pointing for the fame amplifier mounting. downward. When mounted.on the Q780UA, the RO17354U bi. Allow an optional thrce-inch minimum wbolh sides rmustbe in an clectrical enclosure, of the RM7840 for electrical signal voltage-probes. 15 65-0872RM7840E,6,L,M ASSEMBLY a, 3. Make sure no subbase wiring is projecting beyond the 3. Make sure the ST7800selectedhas the desired timing. minal blocks. Tuck wiring i against the back of the subbase soitdoes not interfere with the knife blade terminals 4, insert dhe Purge Card into the opening of the M7840 compartment, see Fig. 13. or bifurcated contacts, 3.x. 5, Reinstall the Dust Cover, Keyboard Display Module, aDATA CONTROLBUS MODULE™ or Extonsion Cable IMPORTANT: The 7840 must be installed witha plug-in “Assembly ontothe RM7840and restore powerto the device. motion rather than a hinge action ‘A4)1.6..Run the bummer system through atleast one complete _c2.gjele 0 verify the sysiem is operating as desired. 4, Mount the RM7340 by aligning the four L shaped fL. } ‘comer guides and knife blade terminals with the bifurcated IOUNTING DUST COVE! contacts on thewiring subbaseand tightening the wo screws ., uh {Align thetwointeslockingearsof the Dust Coverwith securely without deforming the plastic. | gt the two mating slots on the RM7840, see Fig. 14, “cay 2. Insert the two interlocking cars into the two mating ‘Slotsand, with ahingeaciion, pusiion the uppercornersof the Fig. 11—Electtical panel installation. Dust Cover to secure it 0 the RM7840. 073, Be sure the Dust Cover is firmly in place. INSTALLING $1780) PURGE CARD 1, Remove the Dust Cover, Keyboard Display Module, DATA CONTROLBUS MODULE™ or Extension Cable Assembly. 2, Remove the cusrent T7800 from the RM7840 by pulling upward on the plastic suppost coverINSTALLING PLUG-IN FLAME SIGNAL AMPLIFIER Disconnect the power supply before beginning instal- on to prevent electical shock and equipment darnaye, More than one disconnect may be involved. 2. Align the amplifier cixcuit board edge connector with 45—Flamo signal amplifier mounting, RM7840€,G,L,M ASSEMBLY the Keyedlreceptacte on the RM7849, Verily the amplifier rmameplate faces-away from the Relay Module, see Fig. 15. 3sPush-in the amplifier until the circuit board is fully inserted into the receptacle and then push the amplifier toward the RM7840 relaining clasp. 4, Vaiify the aiiplifier is firmly in place. 5. Perform all required checkout tests. INSTALLING FLAME DETECTOR NOTE: Table? lists the flame detection sysiems available for, use, with the, RM7840. Make sure the correct Gomnbinalidn'S!Aniplifier and flame detector(s) suse. Propttilld deidoidriniatlationis the basis ofa safe and reliable latte Safeguird installation. Refer othe Instructions packed Wil the flarnie,detector and the equipment manufac- nurerinistfncHins, See Fi Kein fine gral lea ihe: flling delécior'td the wiring subbase, Capacitance in- creadés With IR&dwire' length, reducing the signal strength. ‘The maximum permissible leadwire length depends on the ype of fame detector, leadwire and conduit. ‘The ultimate limiting factor in the flame detector leadwire is the flame signal, see Table 6 Fig. 16—Flame FE IG-Flome——reanro crs Cama ULTRAVIOLET (C7027I07025/C7048) ‘C7O7GA,D ULTRAVIOLET DETECTOR eure AL | SOLID STATE SELF-CHECKING ULTRAVIOLET (C7012E,F) HOSOOaLE] . ‘SOLID STATE ULTRAVIOLET (C7012A,0) FLAME ROD a ‘A, eureoeresron.eno ang co.0h cue, ules MT BECOMECTED TS NE ER 5 PHOTOCELL Foe tee re sana THE UY SENSING TUBE ISPOLARTY SENSITIVE, REVERGING THE LEADS EVEN A\ rumseoerecronusans ane co.on cone, NONENTABILY, Get BAWAGE OR DESTROY Ee 1 LEAD WS BECONNECTED TO THE FTEAIMRA. AKO THE YELLOM waeusng HB [6 POLAAIY SENGITNE. REVERSING THELEAOS EVEN (65-0872M7B40E,G,L,M PERATION Operation Sequence of Operation “The RM7840 has the following operating sequences, see Figs. 17, 18 , 19 and 20. INITIATE ‘The RM78040 eaters the INITIATE sequence when the Relay Module is powered. ‘The RM7840.can also enter the INITIATE sequence if the Relay Module verifies volage fluctuations of +10/-15 %or frequency flucuations of +/-10% during any part of the operating sequence. The INITIATE ‘sequence lass for ten secondsunless the voltageor frequency tolerancesare not met, When the tolerancesare not met, aa hold condition will be initiated. for atleast five seconds. ‘When the tolerances are met, the INITIATE. sequence will reslart. Ifthe condition is not comected and hold condition cexists for four minutes, the RM7840 will lockout. Causes for hold conditionsin the INITIATE sequence: a. AC line dropout is detected. . AC fine frequency ercor caused by using a 60 Az device on a 50 Hz line, or vice versa. ©. AC Hine noise that can prevent 2 sufficient reading of the line voltage inputs. 4G. Brownouls caused by tow line volage. ‘The INITIATE sequence also delays the burner motor starter from being energized and de-energized from an* intermittent AC line inpat or control input. STANDBY ‘The RM78A0 is ready to start an operating sequence ‘when the operating control input determines 2 call for heat is present. The burner switch, limits, opecating limit con- trol and all microcomputer monitored circuits must be in the correct stale for the RM7840 to continue into the PREPURGE sequeace, ‘NORMAL START-UP PREPURGE ‘The RM7840 provides a selectable PREPURGE timing, from two seconds to 30 minutes with power applied and the M7840 operating control indicating a call for heat. a. Running Interlocks, Preignition Interlocks, Burner Switch, Run/Test Switch, Lockout Interlocks and all microcomputer monitored circuits must be in the correct operating state \. The blower motor ouput, terminal 5, is powered to start the PREPURGE sequence, except for the RMT8A0E. The firing rate motor is driven to the high fire position. The PREPURGE timing for the RMT840E,L does not begin until the Lockout Inter: Jock string and High Fire Switch are both closed. The blower motoroutput for the RM7840E isnotenergized until the High Fire Switch is closed. c. The Preignition Interlock input must remain closed throughcut PREPURGE; otherwise, the conuol re- tnene to the STANDRY state and holds (30 seconds) for the RM7840G,M or safety shutdown for the RM78408 [occurs ry ‘4: The Lockout Interlock or Running Taterlock inputs (nterlockcircuitincluding Airflow Switch) mustclose by ten seconds or within specified purge card timing "into PREPURGE; otherwise, 2hold or recycle back to the beginning of PREPURGE for the RM7&40G.M will happen ora salety shutdown for the RM78405,L, ¢. Afler the firing rae motor reaches the PREPURGE, rate position and PREPURGE tiningis completed, the firing rate motor will drive to the low fire position, RMRBA0E,GL. f. When the firing rate motor reaches low fire position, the Low Fire Switch, terminal 18, input must be enorgized before entering the Ignition Trial state IGNITION TRIALS a, Pilot lame Establishing Petiod (PFEPY: 1. With the firing rate motor in the low fire position: a. The pilot valve and ignition transformer, ter- minals 8, 10 and 21, are energized. The RM7840M has an intermittent pilot valve, ter- ‘minal 21. The RM7840G hasan interrupted or intermittent plo! valve. terminal 21. depending ‘on the selection of configuration jumper JR2 “The RM7840E,Lhasa fifteen sccond interrupted pilot valve, terminal 21. All the RMI7840s have a ten second interrupted pilot valvejignition, terminal 8. ». During the PFEP, the Low Fite Switch must re- mainclosed. fitopens,asafety shuidown occurs. c. The Preignition Interlock input is ignored throughout the Ignition ‘Trial state. 2, Flame must be proven by the end of te four or ten second PFEP to allow the sequence to continue. If » flame is not proven by the end of PFEP, a safety shutdown occurs, 3. With flame proven, the ignition, terminal 10, is de- energized for early spark termination. 'b. Main Flame Establishing Period (MFEP): i 1. The RM7840E,L has a ten second or fifteen second MFEP. After the Ignition Trials, and with the presence offlame, the main fuel valve, terminal 9, is powered. If a flameout occurs, the RM7840 will lockout within 8 oc 3 seconds, depending on the Flame Failure Response Time (FFRT) of the amplifier. 2, Tho RM7840G has a ten second or fifteen second or thirty second MFEP. After the Ignition Trials, and with the presence of flame, the main fuel valve, terminal 9, is powered. If 2 flameout occurs, the RM7&0 will lockout within .8 or 3 seconds, de- + pending on the FFRT of the amplifier, 3. The RM7S40M has a ten second MFEP. After the Ignition Trials, and with the presence of flame, the + tai fuel valve, eantinal 9,is powered, Tea flame ‘outoccurs, the RM7840 will lockout within .8 0r3 “seconds, depending on the FFRT of the amplifier,: RIM7840E,G,LIN OPERATION RUN ‘motor outputis powered todriveall combustion productsand 1. Aten second stabilization period occars at the begin- any unburned fuel from the combustion chamber. It also ning of the RUN period. supplies combustion air to burn fuel being purged from the 3, The firing rate motor releases to modulation _fuel line downstream of the fuel shutoff valve. (RM78/08,6,L). 1. The main fuel valve and intermittent pilot valve, 3. The RM7840 is now in RUN and will remain in RUN ‘until the coniroller input, terminal 6, opens, indicating that the demand is satisfied oc a limit has opened. POSTPURGE, ‘The RM7840 provides a fifteen second POSTPURGE, following the completion of the RUN period. The blower terminals 9 and 21, are de-energized and the fring rate motor is commanded to the low fire position to begin the POSTPURGE period. 2, ‘The Preignition Interlock clases within the fist five seconds of POS TPURGE. 4. Alter the fifteen second POSTPURGE period is com- pleted, che RM7840 reenters STANDBY. Fig. 17—RM7840E,L sequence. RN7840E;L. ‘wen "cave 0 ibweae 2 035 ep. » rosreuner Pree json nsec) AUN sTeNooy @ roves ‘Oruot |ORane O wan 1 asrm [@ Power PONER @ nor ere Quan Eyer @ rower @ ror @ eave @ saw Onaaw @ rower | @ rowen|@ rower OQ puor @ rae ewan Onan (@ Power @ Pur @ rue @ wan oO jooo0 loco Zh RIERRLARERWOTOR o= r Eo) Tar] 5: I FEES GRLPROKEY L a) THAN ALEC OPERATING r TARTS MME COMTRONERDTOSCO _ CDOS) f i Bee ocKs [__NTEROpE CHECK (oxen L TOCKGUT NTERLDOKS CHORD i FRETENITION NTERLOGK CLOSED (ome) I ae [omc Tiga Owe TOWARE Sw rd SIGNAL AFESTARTOHEGK FLAME PROV 3 T AMP@IDE SWITCHING en® ane @ro® ain f reve wotoR 201 Moror Lo Ds FOR THE furasce: THE Hic Fin SWITCH MUST GE WIRED CORRECTLY TO PERFOAM ENERGY SAVING PURGE [OIG a RSG titewe owen woron Goes Hoy StARTONTITHE HGH IRE SHTCH WAS BEEN MADE. wast 19 65-0872srmoey sce [pun _poswunce| erm f@ ronen [9 roves [@ raven] @ ron |@ rowen 460 io f@ riot |@ ruc |O O° uw lo ere fore |O JO 6 eum few fo fo lo aa [Onn lo [6 suman aamenatoe OD [ee = =e feseeUeIONC] ‘ini basen oT TENT TOTAL = Manvae (3) orenaana Tan mo we comTmOUER eeo_C)TOG) as ER] [__ NaanarRBRELOS TOT e pecan TENDERS | TOD LZ [wrnbem, (p70 eae aararaed a = . Taumcos swtronna lar®| Ord ere avo! Fig. 19—RM7@40M sequence. Rwredon ry 0 mc ® “reer 1? wwnare_|sravowy [enennce| _Ainee leaf secl weer (© rowea |@ raven |@ rowen | @ sones [@-20HeR |@ oven Leo lo. lO. iO Ornor f@ruct{"|@ pct aed jo |O ‘Orvaue | @ Fa FLAME lo lo ° Onan JO wane] @ nian oo fo Josarm JO auwn foun oumen Teneo oper TO | =i | TERT PLOTWACIE CD = i Tamave GS oreaaraa Tasha HANETCONTTOUEROGRED (TOC a cecel MERON GeO | | _— MRNNG WTER GORE CLORED” CO) TOC) rasamommrennecaose: (OTE mr __Liowrne sn, [OUD — { [ ORet Sona Gare SRT ESE - FEE oN we rxmsosvarcrne Qn® FRING | Aro nate | ero8 108 ovon ae 20KM Me OPERATION Fig. 20—LED sequence statue display Information. RWEn SEQUENCE: SBM fou: ro RULWTH RAW ese Rave FLAIE peor MAN RTERRUP- (ater: bin vane _ermony fatberen, feRSren) wunae _lanmow icon. TEDPLON EeNTeLon POSTPURSE SAAT fest Bee [ie POuCE] @ ronch]@ rowen |@ rovEn]|@ rowen]@ POvER|@ PovES |@ roven| @ roves ‘@ Powe | @ rowen| S fret [o euer [oruor |Oruor |Orucr |@ mot Jw riot: \Orkory:|@ reer 1 ret Opuot |Ortor Ore lo sue \@ rane |@ name [Orme [@ rane [@ rane |@ riaic:|@ rane [O rane Orme |O rane Sree 1S mam [Onan |Ouan [Onan [Own ]@ van: | nam: [wane 1 van Onan |O wan Owe Lo nurs [O narus [Onan [0 auaru [O aamn |Oatasu |Oant [0 asi 10 nas Ons |@ aann NOTE: SEE TASLE 6 FOR RIRTHER DETALS OF HOLD CONDITIONS. Fig. 21—Relay Module and sequence status sequence, LEDs (Fig. 20). ‘Low Fire position. '4, Ir PFEP, the Run/Test Switch, when placed in the cape ‘TEST position,.will stop the timer daring the fist eight fours seconds when aten second PFEPis selected, or during the first three seconds when a four second PEEP is selected, allows for pilot-tum-down testandother bumer adjustments. ‘This activates a fifteen second flameout timer dhat permits pilot flame adjastment without nuisance safety shutdowns. The Run/Test Switch is ignored daring PFEP for the RMIS40E,L if erminals 8 ard 9 or 9 and 21 are jumpered. 5, DuriagRUN, the Run/TestSwitch, whenplaced inthe ‘TEST positon, drives the finng rate motor die Low Fic position. RM7840, see Fig. 21. The Run/Test Switch allows the baer sequence to be altered as follows: ‘|. In Prepurge Drive To High Fire position, theRun/Test Switen when placed in the TEST position, holds in PREPURGE with the firing rate motor in the High Fire sition, Position. mneasured PREPURGE sequence, theRun/Test SELECTAMLE SITE-CONFIGURABLE JUMPERS Switeh, when placed in the TEST position, causes the eae pe Te stecantgule NPS E “The firing tate motor is in the : 2 PREPURGE timing to stop. The fring rate motor is in the S14 clipped with side cutters andthe resistors removed High Fire position "3. In Prepurge Drive to Low Fire position, the Run/Test from the Relay Module, Switch, when placed in the TEST position, holds the burner AMPLEIER, NOTE: When the RM7840 is switched to the TEST mode, it stops and holds zt the next Run/Test Switch point in the eee, operating sequence. Mate sure’ that the RUN/TEST SWITCH is'in the RUN position before leaving the insiallaion. RUN/TEST SWITCH FUNCTIONS 7 “The RunyTest Switch is located on the top side of the A WARNING NEN ___. Do not use the Run/Test Switch during the Pilot Flame Establishing Period for the RM7840G.M ‘when using direct spark ignition. TABLE 3SITE CONFIGURABLE JUMPER OPTIONS. ‘Jumper Number_| Description Intact Clipped M7840 Type JR1 | Pilot Flame Establishing Period (PEEP) | 10 sec 4 seconds. ALL Pitot Vi 15 oF 30 seconds Imerupted* | RM78406 3R3_| Start-up Inver Enable ALL 1 7 30 second MFEP can be accomplished by adaing juny wire betwoon terinals {and 5 » Pilot ValvelFirst Stage Oil Valve (Valw/Start) Terminal 21. nu 65-0087—2(M7B40E,G,L,M )PERATION « STATIC CHECKOUT ae Fig. 22—Selectable site-configurable jumpers. etectaats conricuramion Juvren’s Hest suc OE" [ara [RM HONEYWELL RELAY MODULE] Pep eT “eeioiwe ery see, | esto. ne ae oer ZS WARNING -,. - A ATTEN “Hegeencarn a SERVICE NOTE: Clipping and removing a site- configurable jumper enhances the level of safely Static Checkout 1, Useextreme care while esting the system. Line voltage is present on most senminal Connections when power ison, . Open the master switch before installing, ce removing a jumperon the subbasc. . Before continuing to the next test, be sure to remove the (est jumper(s) used in the previous teats .. Replace all limits and interlocks not operating properly. Do not bypass limits and intertocks. Close all manual fuet shutoff valve(s) before starting these test, After checking all wiring, perform this checkout before installing the RM7840 on the subbase. These tests verifies that the Q7800 Wiring Suboase is wired correctly, and that the external controllers, mits, interlocks, actuators, valves, transformers, motors and other devices are operating prop- ely. NOTE: Do not perforin a dielectric test with the RM7840 installed, Internal surge protectors will break down and conduct current. This couldcause the RM7840 to fail the ielecuric test or possibly destroy the intemal lightning and high current protection. EQUIPMENT RECOMMENDED 1. Voltmeter (20 kohm/voltminimum sensitivity) seton the 0-300 Vac scale, 2 no. 14 wire, insulated, 12 inches ssulated alligator clips at both ends. 2. Two jumper wir (204.8 mer) Jong, with i GENERAL INSTRUCTIONS 1. Perform all applicable tests lisied in Static Checkout, ‘Table 5, in the order listed. 2. Make swe thar all manual fuel shutoff valve(s) are closed, 3. Perform only these tests designated for the specific RM7EO0 model being teste. ‘4, Raise the set point of the operaling controller to simulate a call for heat "5, Bor each test, open the master switch and install the jumper wize(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 (ermi- ‘als listed in the Voltmeter column, "8, If there is no vollage or the operation is abnormal, ccheckthe circuitsand extemal devices as describedin the las. column. 9, Checkall wiring forcorrectconnections, tightterminal _Serews, correct wite, and proper wiring techniques. Replace * “all'damaged or incorrectly sized wires. 10. Replace faulty contzollers, limits, interlocks, cotwa- tors, valves, wansformers, motors and other devices as ro auired "LL. Obiain normal operation for each required test before * conticuing the checkout. 112. Alter completing each tes, be sure to remove the test Jumpers)__RM7840E,G.L, STATIC CHECKOU ‘TABLE 4 STATIC CHECKOUT. Test | RM7340| Test] Volt. Tr Operation Is Abnormal, No. | Models | Jumpers | meter ‘Normal Operation Check TheItems Listed Below WARNING: ‘Make sure all manual fuel shutoff valves are close * IMPORTANT: Low fuel pressuie limits, Fitsed, could be open. Bypass them with jumpers for the remaining Static Tests iF required), oa? 1 | An | None | 412 | Line votage at terminal 4.”" * 1. Master switch. : |. | 2. Power conmected t the master 1 swith. +5 1-1-5, Overload protection (uses circuit <1 | breaker) has not opened the power line. D | AT | None | @L2 | Line votage terminal. =, | 1. Limis. ; “| 2! Burner contratier. 3_[ al None | 20-12 | Tine voltage at terminal 20. 1, Preignition interlocks. 4 [an | 45 | 72 | 1. Bumermovor (an or blower) | 1. Bumer motor circuit stars ue a, Manual switch of burner motor. 2, Line voltage at terminal 7 within. |b, Burner motor power supply, 1Oseconds : overload protection, and ster c, Bumer motor. 2, Running or Lockout Tuerlocks Gncluding Ailow Switch). 3) AW 410 |) Tanition spark Gif ignition transformer | 1. Watch for spark or Fisten for buzz. iS connected wo terminal 10). aa. Ignition clectrodes are clean . 1. Ignition transformer is okay. 6 | all Ze | — | Ignition spark Grignition T. Watch for spark or listen for buzz. transformer is connected to a. Ignition electrodes are clean terminal 8) b, Ignition transformer is okay. 2, Automaticpilot valve opens(if | 2, Listen for click or feel head of connected (o terminal 8). valve for activation. . NOTE: Referto wiring diagram of | a. Actuator ifused. system being tested. bs Pilot valve. 7} Tan} Sa PY Same as test no, 6for connections | Same astestno, 6, Musing direct wo terminal 8 lrusing direct spark | spark ignition check the first stage ignition, check the fst stage fucl | fuel valve(s) instead of tho pilot valve ‘alve(3) instead ofthe pilot valve. S| TAN} 745) J Automatic main ful valve(S) opens, | 7. Listea for and observe operation using direct spark igulion on a of the main fuel valve(s) and model with irtermitirt pilot on scuuaor(). terminal 21, check the optional 2, Valve(S) and actuator(s). second stage fuel valve, ifased, oan [43 |_| Alain Gifusea) urs on, 7, Alar = is ToT RM7e40 | 45 | 18-12 | Firing rte motor drives open; zero | 1. Low Fire Stat Switch EGL | and tolisat terminal I after motor | 2. Firing rate motor and transformer. models | _ 123 stans driving opes, Ti] M7840 | 45 | WELD | Firing rate motor dives closed: Tine [ 1. Low Fire Stat Switch. EGL | and Yollage at terminal 18 after moor | 2. Fring re motor and transformer. models | 14-13 isin Low Fire position. 12 Trew7aao | £5 | 19-12 | Firing rate motor drives open; line | 1. High Fire Purge Switch. EL | and Nollage at termina 19 ater motor | 2. Firing rae motor and transformer. medels | 12-13 isin High Fire position 2B (continued) 65-0087—2TATIC CHECKOUT « CHECKOUT ‘TABLE 4—STATIC CHECKOUT (Continued) a) Test] RM7840 Volt. If Operation Is Abnors No. | __Madels Meter Normal Oper Check The Items Listed Below WARNING Make sure all manual fuel shuloff valves are closed, 4 13 | RM7840 ] 45 | 19-12 ] Firing rate motor drives closed; zero - | 1. Low Fire Start Switch, EL and yoltsat terminal 19 alter motor 2. Firing rate motor and transformer, models | 14.13 starts driving closed, 14 | RM7840 | 15-13 | — | 1. Raise set pointof series 90 1. Series 90 Controller. EG&L controtler—firing rate motor 2. Firing rate motor and transformer, madels should drive toward open, 2. Lower sel point of series 90 controtler—firing rate motor should drive toward closed. 15 | RM7B40M| 413 | — _| ifdamper motor is used, motor 1, Damper moter. models drives damper open. with Open Damper Contacts 16 | RM7840M| 45 | 18-L2 | damper motor is used, spring retum | 1. Low Fire Stan Switch. models drives motor and damper closed: | 2, Damper moter. with Open line voltage at terminal 18 after Damper motor is in Low Fire position. % * Contacts a7 | RM7B40M| 4-5) 18-12 | If'damper motor is used, motor T, Low Fire Stan Switch, ‘medals | and {drives open; zero.volls at terminal | 2. Damper moter. with | 413 18 alter motor starts diving open, Open : Damper a Contacts i Final All CAUTION (On completing those tests, open the master switch and remove all est jumpers from the sublase terminals. Also remove bypass jumpers from the low fuel pressure limits if used). i Checkout A WARNING . “{J\. CAUTION Dont lfow fuel to accumulate in the combustion {1 1. Ustextreme care while testing the system. Line chamber. Iffuel i allowed to enter the chamber for ‘vollagcis presen.on most terminal connections Jonge then a few seconds without igniting, an swhen power is on explosive mixture could result tis recommended ' 2, Open the master switch before removing oF that you limit he til for pilot to ten seconds, and installing the RM7840. limit the attempt to light the main bumer to-1wo 3, Make sure all manual fuel shutoff valve(s) are seconds from the time the fuel has rezched the closed before starting Une initial lightoff chock ‘burner nozzle. In any case, do not exceed the yun and the Pilot Tumdown tests. nominal lightoff time specified by the equipmen: ,.,, s:jz- 4. Donotputihe system in service until you have manufacturer. Closethemanual fuel shutoff valve(s) satisfactorily completed all applicable tests in if the flame is not baming at the end of the this seotion and any others required by the specified time, equipment manufactorer./\ CAUTION. Ifan RM7840 isreplaced with a lewerfunctioning 7800 SERIES Relay Module, the bumer will not sequence unless wiring changes are made. IMPORTANT: 1. Uf the sysiem fails to perform properly, refer to Troubleshooting section and 7800 SERIES System Annunciation and Troubleshooting, form 65-0118. 2, Repeat ALL required Checlout tests after alladjust- menisare made, ALL tests mustbe satisfied with the Slame detectors) in its FINAL position. EQUIPMENT RECOMMENDED Volt-ohmmeter (20kohny/voltminimur sensitivity with + 0-300 Vac capability + 0-6000 ohm capabiliy. + 0-10 Vée capability, CHECKOUT SUMMARY = Proliminary inapection—all installations. ‘+ Flame signal measuremen'—all installations, + Initiallightoff check for proved pilot—all installations using a pilot. + Initial lightoff check for direct spark ignition of oil— all burners using DSL. + Pilot tumdown test—all installations using a ilo. + Hotrefractory saturation test—all insallalions using Infrared (ead sulfide) Flame Detectors, + Hotrefractory holdin test—~al installations. + Ignition interferencetest—allinstallationsusing flame rods + Ignition spark pickup—all installations using Ultra- violet Flame Detectors. + Response to other ultraviolet sources—all installa- tions using Ultraviolet Flame Detectors. + Flame signal with hot combustion chamber—all in- stallations. + Safety shutdown tests—all installations, ‘See Figs, 1 and? for location of component perts and see Figs. 7, 8, 9, and 10 or Q780X) Specifications for terminal locations, AMT7B40E,C CHECK PRELIMINARY INSPECTION Performhe following inspections to avoid common problems, Make certain that: 1, Wiringconnectionsarecorrestandall terminal screws are tight?" +. 2, Flame ‘détectoris) is clean, installed and positioned properly. Cossilt thé applicable Instructions. 3. Correc:combinationofamplifierand flamedetector(s) is used, See Table 2 in the Specifications. 4, Plag-it amplifier and purge card are securely in place. ‘5. Bumeris completely installed and ready to fire; con- sult equipinent ‘manufacturer instuctions, Fuel lines ere purged of air 6 Combustion chamber and flues arc clear of fuel and fuel vapor. 7. Power is connected to the system disconnect switch, (master switch), 8. Lockout is reset (push in reset button), only if the RM7840is powered, sec Fig. 1 or 2, 9, Run/Test Switch is in RUN position, 10, Systemisiiithe STANDBY condition, POWERLED is energized, 11 All limits and interlocks are reset. FLAME SIGNAL MEASUREMENT (Table5 and Fig.23) Fig. 23—Flame signal measurement. neaarve@ NEAT | L-rosinve (9 Reneatess (e 65.0872RM7840E:G.,LM . CHECKOUT % ‘TABLE 5—FLAME SIGNAL. imum ‘Acceptable Maximum Fame Flame Signal Steady de Expected Detector Amplifier Voltage" de Voltage lame Rod RISATA,B™ 1.25 Ve 5.0 Vde at Keyboard Photocell | CHOWAC Display Module CIO128,F RIBAIC ‘CIOS RISABE OR CHOTA RIBBAB™ 70358 5.0 Vdeata C7044 20 kohm/volt meter CIO76A,D R7886A This minimum or stronger signal should be obtained easily ifthe detector is correctly installed and positioned to properly sense the flame. This volage must be obtained before compicting checkout, > The flame signal amplifier circuitry is tested one-balf second every five seconds during bumer operation and shuts down the bumer if the amplifier fails (all installations). © The flame amplifier is an AMPLI-CHECK™ type. Measure the flame signal atthe appropriate times defined in he following checkouttests, Read the flame signal in volts de atthe flame amplifier test jacks + and {Com). 1, Usea20kohm/voltmeter witha to 10 Véccapability. 2. Sot the 20kohm/volt meter to the 0 10 10 Vde range. 3, Insert the positive (red) probe into the + jack of the ‘lame amplifier. insert. the negative (black) probe into the - (Com) jack of the flame amplifier (sce Fig. 23) 4, Allow afew seconds for the meter reading o sabilize. 5. Musing AMPLI-CHECK™ or shutter check ampiili- crs, read the average stable voltage, disregarding the peaks caused by the self-checking operation. 6. Thometorreading mustbe as specified in Table 6after all tests are completed and all adjastments made. Asanopiion, the flame signalcan be checked by usingthe optional Keyboard Display Modcle. If the signal is unstable or less than the minimum accepr- able voltage, check the flame detector insallacion andi cuitry, 1. Check the supply voltages at temninals4 (L1} and L2 (N). Make sure the master switch is closed, connections are comect, and the power supply is of the correct voltage, frequency and is sinasoidal. 2. Check the detsctor wiring for defects including: + Incorrect connections. ‘Wrong type of wire. Deleriorated wire. Open circuits. Shon circuits. Leakage paths caused by moisture, soot or accu- mulated dirt, 3. Foraflame rod, make sure: + There is enough ground ares, + The flame rod is properly located in the fame, + ‘The tompemiure at tho flaine rod inaulator ic no seater than S00? F (260° C). 4, For all optical detectors, clean the detector viewing ‘window and inside of the sight pipe as applicable. 5. With tie burner running, check the temperature atthe detector. If it exceeds the detector maximum raled tempera- ture + Adi a heat block to stop conducted heat traveling up the sight pipe. + Add a shield of soreen toreflect radiated heat. + Add cooling (refer to sight pipe ventilation in the detector Instructions). 6. Make sure that the flame adjustment is not too lean. 7. Make sure that the detector is properly sighing the flame, 8, Tfnecessary, resight or reposition the detector. INITIAL LIGHTOFF CHECK FOR PROVED PILOT Perform this check on all installations that use a pilot. It should immediately follow the preliminary inspection. ‘NOTE: Low fuelpressurelimits, fused, could be open. Ifso, bypass them with jumpers during this check. 1, Open the master switch, 2. Makesure thatthe manial main fuel shut off valve(s) is closed. Open the manval pilot shutoff valve. TE he pilot takeoff is downsuream fiom ihe manual main fuel shuvof valve(3), just very slightly open the manual main valve to supply pilotgas low. Make sure the main faelis shutoff just upstream from the burnerinles, or disconnect power fromthe automatic main fuel valve(s). 3, Closethe master switchand startthesystem withacalt {forkcatby raicing thecotpointof the operating contreller, ser Fig. 17,18, 19, 20 or RM7840 Sequence of Operation. Theprogram sequence should stat the ten second INITIATE sequence. ‘4. Let the sequence advance through PREPURGE. Igni tion spark should occur and the pilot should fight. IP the pilot ignites, the FLAME LED will be energized: Proceed 0 step 7. “ 5. If the pilot flame is not established in four o* ten seconds, safety shutdown occurs. Letthe seqiehcecomplete itscycle. Consult heequipment operating manual for further information, 6. Push the reset pushbutton, and let the system recycle ‘orce, Ifthe pil still doesnot ignite, make the following ignition/pilot adjustments: 4. Open the master switch and remove the RM7840 {rom the subbase. b. On the subbase, jumper terminal 4,6 ignition {erminals8, 100r1; refer tothe appropriate wiring diagram to determine the proper terminal, Discon. nec the leadwire tothe pilot valve ifitisccnnected to the same terminal. . ¢. Chose the maser switch to energize only the igni- tion tansformer, 4. Ifthe ignizion spark is not strong and tontinuous, open the maser switch and adjust the ignition electrode spark gap setting to the manifactarer recommendations. ®. Makesure the ignition electrodes are clean, £. Close the master switch and obsorve the spark . After a continuous spark is obtained, open the ‘master switch and add a jumper on the subbase fiom terminal 4 (L1) tothe plo terminal 8 cr 21 Reconnecitheleadwirefrom thepilotvalveifitwas disconnected in step b. +h, Close the master switch to energize both the igni- tion wansformer and the pilot valve. i. the pifot does not ignite and if the ignition spark is still continuous, adjast the pressure regulator inti a pilots established, |i. When the pilot ignites properly and stays ignited, open the master switch and remove the jumpers from terminals4-8,4 -1and4-21 of mesubbase. kc. Check for adequate bleeding of the fuel line. 1, Reinstall the RM7#40 on the subbase and close the 7, When the pilot ignites, measure the flame signal. Ifthe pilot flame signal is unsteady or approaching the 1.25 Vde minimum value, adjust the pilot flame size or detector sight- ing to provide a maximum and steady flame signal. '8. Recycle the system torecheck lightoff and pilot flame signal. ‘9. When the MAIN IGN periodis displayed by the MAIN LED, make sure the automatic main fuel valve is open; then smoothly open the manual main fuel shatoff valve(s) and ‘watch for main burrer flame ignition. When the main bamer fame is established, proceed to step 15. 10, If the main burner flame is not established within five seconds or the normal lightoff time as specified by the ‘equipment manufacturer, close the manval main fuel shutofE valve(s). 7 . BMZBI06 6 CHECKO! 11. Reoyele the system to recheck the lighioff and pilot flame signal, 12, Smocthli/épéo themamsal fuelshutoffvalve(s) andtry lightoff egein, (The firstreatiempt may berequiredto purge the lines and bring sufficient fuel to the bummer.) 13, If themain bumer flame is notistablished within five second or the notinl lightff time specified by the equip- ‘ment ‘manufadtursr, close the manual main fuel shutoff valves(s). Cheek all bumer adjusaments, 14. 1 the main burner flame isnot established after two tempts: °° 4, Check forimproper pilot size, by Check for excess combustion air at low fire. “c, Check for adequate low fire fuel flow. “4. Check for proper gas supply pressure. “ef Check for proper valve operation.” {Check for proper pilot flame positioning. 15." Répeat steps 10 through 14 to establish the main ‘bumer flame'then proceed to step 16. 16, With thesequence in RUN, make bamer adjustments for flame stability and Buu inputrating. 17, Shutdown the system by opening the bumerswitch or by lowering the setpoint ofthe operating controler. Make sure the main flame goes out. There may bea delay duc to gas treppied between the valve(s) and bumer. Make sure all aavtomatic fuel valve(s) close. 18, Restart the system by closing the burner switch and) or raising the setpoint of the operating contraller, Observe thal the pilot is established daring PELOTIGNand the main bumer flame is established during MAIN IGN within the normal lightoff time, 19, Measure the flame signal, Continue to check for the proper signal, see Table 6, through the RUN period. Cneck the signal at bah High and Low Firing Rate positions and while modulating. 20,.Rum the burner through another sequence, cbserving the flame signal for: 2, Pilot flame alone (unless using DSI) ">, Pilot and main flame together. ¢, Main flame alone (unless monitoring an intermit- + tentpiiot). Als observethe imeittakestolight the main flame. Ignition of main flame should be smooth 21; Make sure all readings are in the required ranges before proceeding. ‘22, Return the system (0 normal operation. és NOTE: Afier completing these tests, open the master switch and remove all test jumpers from the subbase terminals, limits/contrals or switches. INITIAL LIGHTOFF CHECK FOR DIRECT SPARK IGNITION ‘This check epplics to gas and oil burners that do not use pilot. Itshould immediately follow the preliminary inspec- tion, Refer to the appropriate sample block diagramn of field ‘witing for tho ignition trancformer and fuel valve(s) hockeup. 65.0872FM7840E,G,L.M" CHECKOUT NOTE: Low fvel pressure linis if used, couldbe open. Iso, ‘bypass them with jumpers during this check. 1. Open the master switch. 2. Comapleie thenonmalready-io fire checkoutof te fuel supply and equipment as recommended by the equipment manufacturer, 3. Closeali manual main fuelshutoff valve(s).Check that the automatic fuel valve(s) are closed. Make sure fuelis not entering the combustion chamber. 4. Close the master switch and startthe system witha call for heat by raising the set point of the operating contolics, see Fig. 17, 18, 19, 20 or RM7£40 Sequence of Operation. ‘Theprogram shouldstarttheten second INITIATE sequence. 5. Letihe sequenceadvance through PREPURGE. lgni- tion spark should occur after PREPURGE period. Listen for the click of the first stage fuel solenoid valve(s). 6. Let the program sequence complete its cycle. 7. Open the manual fuel shutoff valve(s).. 8. Push the reset pushbutton and recycle the program sequence through PREPURGE. 9, Watch for the FLAME LED to heip determine when the first stege burner flame is established. Iitis established, proceed to step 15. 10. Tube fist sue burner lame fs notestablished wishin four seconds, or within the normal lightoff ime specified by the equipment manufacturer, close the manual fuel shutoff valve(6), and open the master switch after POSTPURGE is completed. LL. Check all bumer adjustments, 12. Wait about three minutes. Close the master switch, ‘open the manual fuel shatoff valve(s), and try to lightotf une bummer again, The first alterapt may have been required to ‘urge the linesand bring suificient fuel to the bumer. 13. Ifthe first stage burner flame is not established within four seconds, or within the normal lghtof time specified by the equipment manufacturer, close the manual fuel shutof valve(3) and open the master switch, 14, necessary, repeatsteps 11 through 13 to establish the first stage bumer flame, Then proceed to step 15. 5. When the first stage bumer flame is established, Une sequence will advance toRUN, Makeburner adjustments for flame stability and input rating. Ifa second stage is used, proceed to step 18. 16. Shutdown the systemby opening the bumerswitch or by lowering the set point of the operating controller. Make sure the bumer flame goes out andall automatic fuel valves) clbge. if used, remove the bypass jumpers from the low fuel pressure limit and subbase. 18. If a second stage is used, make sure the automatic second stage fuel vatve(s) has opened, and check the lightoft as follows (otherwise proceed to step 19). a. Open the manual second stage fuel valve(s). b, Restat the system by raising the set point of the operating conwotter. c. When the first stage burner flame is established watch forthe auomatic second stage fuel valve(s) tm open. Observe that the second stage lights olf properly. d, Make bumer adjustments for flame stability and inputratiog. €, Shutdown the system by lowering the set point of the operating controller. Make sure the burner flame goes outandalll antomaticfuelvalve(s)close. £, Proceed to step 19. 19, Restart the system by closing the bumer switch snd/or raising the setpoint of the operating contoller, Observe that the burner flame isestablished duringPILOTIGN, within the ‘normal lightoff time specified by the equipment manufac- ‘wrer. 20, Measure the flame signal. Continue to check for the prope: signal, see Table 6, through the RUN period. Check tte signal atboun high and low firing rate positionsandwhile ‘modulating. Any pulsating or unsteady readings will require further attention. 21. Makesureallreadingsarein therequired ranges before proceeding. NOTE: Upon completing these tests, open the master switch nd remove all test jampers from the subbase terminals, limits/controls or switehes. 22, ‘Retum ihe system 19 normal operation. PILOT TURNDOWN TEST (ALL INSTALLA- TIONS USING A PILOT) Perform this check on all installations that use a pilot, ‘The purpose of this test isto verify that the main burner can be lit by the smallest pilot flame that will hold in the flameamplifier and energize tne FLAME LED, Clean the flame detector(s) to make sure that it will detect the smallest acceptable pifot flame. Tf using AMPLI- CHECK™ or Self-Checking Amplifierand 20 kohm/volt meter, the flame signal will fluctuate every time the amplifier does a self-check or a shutter check. ‘NOTE: Low fuel pressure limits, if used, couldbe open.Ifso, bypass them with jumpers during this test. 1, Open the master switch. 2, Close the manual main fuel shutoff valve(s). 3. Connecta manometer (or pressure gauge) to measure pilot gas pressure daring the turndown test. 4, Open the manual pilot shutoff valve(s) 5. Close the masterswitch and start the system witha call ‘for heat. (aise the set pointof te operating controller) The, rogram sequence shoud stat, and PREPURGE stonld in. “6. When the PILOT IGN bogins, sot the Run/Test Switch to TEST position to stop the sequence. The FLAME LED will come on when the pilot ignites. NOTE: If the sequence does not stop, reset the system ani makesure you settheRun/ Lest Swatchio 1S J witn the firs eight seconds of the PILOT IGN sequence.IMPORTANT: You have eight seconds or three seconds, depending on PFEP selected, o positionthe Runttest Switch inthe TEST position to stop the sequence after the start of the PILOT IGN period. 7. Tum the pilotpressuredown very slowly, reading the manometer (or pressure gauge) as it draps./Stop instantly when te FLAME LED goes out. Note the pressure at the RM7840 flame relay cropout point ‘The pilot is at the :minimom tamdown position. Immediately:tum up the pilot pressure until the FLAME LED comes on-again. NOTE: If there is no flame for fifteen seconds. with the sequence stopped at this point, the RM7840 will lockout. 8, Repeat step 7:0 verify the pilot gas pressure reading at the exact point the FLAME LED light goes out, 9, Increase the pilot pressure Immediately until the FLAME LED comes oa, and then tam-it down slowly to ‘obtain pressure reading justabove the dropourpoint or until the flame signal increases to 1.25 Vde. 10, Setthe Run/Test Switch in the RUN position ard let the sequence proceed, At ten seconds into the Ignition Trial period, make sure theauntomatic main fuel valve(s) opensthen smoothly open the manual main fuel shutoff valve(3) (orany other manually opened safety shutoff valve(s), iF used) and waich for main burner ignition. Ifthe main burner flame is established, proceed to step 18. ‘NOTE: Thissteprequirestwo people one toopen the manual valve(6) and one to watch for ignition, 11. If the main burner flame isnot established within five seconds, or within the normal lightoff time specified by the equipment manufacturer, close the manual main fuel shutofl valve(s)and open the masterswitch. Ifthe lightoff was ough, the pilot flame size is too small. 72. Recycle the bumecand stop the sequence in the PILOT IGN poriod by using the Run/Test Switch. 73. Increase the pilot flame size by increasing itsfuel flow util a smooth main flame 1s accomplished. 4. Reposition the flame scanner sight tbe or use orifices ‘ntilthe pilot flame signal voltageis inthe rangeof 1.25-1.50 Vac. 15. When the main baer lights reliably with the pilot at turndown, disconnect the manometer (or pressure gauge) and turn the pilot gas flow up to that recommended by the equipment manufacturer. 16. IF used, remove the bypass jumpers from the subbass terminals, limits/eontrols or switches, V7, Run the system through another cycle to check for normal operation. 18, Return the system to normal operation. IGNITION INTERFERENCE TEST (ALL FLAME RODS) ‘Test to make certain that a false signal from a spark ignition oyctom ie not euperimpesed an the Flame signal RM7e40E,G,M ‘CHECKOUT Ignition inteiference can subtract from (decrease) or add {o (increase) the flame signal. It decreases the flame signal enough, it will cause a safety shutdown. If it increases the. flame signal'it could cause the FLAME LED to come on ‘when the true flame signal is below theminimum acceptable vvalug, #2 leur Star‘thé burner and measure the flame signal with both ignition and pitot (ormain bumer)on, and then with only the pilot Cormain burner) on. Any significant difference (greater than .5:Vde) indicates ignition interference. ‘TO ELIMINATE IGNITION INTERFERENCE, 1: Make sure there is enough ground area. 2.:Be sue the ignition electrode and the flame rod are on ‘opposite sides of the ground area, '3. Check for correct spacing on the ignition electrode: a. GQOOV sysiems—1/16 to 3/32 in. (1.6 102.4 mm). b. 10,000V systems-—1/8 in. (3.2mm). 4, Make sure the leadwires from the flame rod and ignition electrode are not too close together. 5, Replace any deteriorated leadwires. 6. IF the problem cannot be eliminated, the sysiem may have to be changed to an ultraviolet flame detection sysiem. HOT REFRACTORY SATURATION TEST (ALL INFRARED DETECTORS) Test to make certain that radiation from hot refractory does not mask the flickering radiation of the flame itself. Stait the bumer and monitor the flame sigmal during the warmup period.A decrease insignal stengthastherefractory heats up indicates hot refraciory saturation. If saturation is extreme, the flame signal will drop below 1.25 Vde and the system will shat down as though a flame failure occurred. Tehot refractory saturation occurs, the condition must be corrected. Add an orficeplatein frontof thecel!torestrictihe ‘viewing area, try to lengthen the sight pipe or decrease the pipe size-(diameter), Continue adjustments until hot refrac- {ory saturation is eliminated. HOT REFRACTORY HOLD-IN TI (RECTIFYING PHOTOCELL OR ALL, INFRARED DETECTORS) ‘Testtomakecertain hotrefractory will rot delay the lame detection system response toa flameout, This condition can delay response to flame failure and also can preventa system restart as long as hot refractory is detected. - ‘To check rectifying photocells for hot refractory hold-in, operate the burner until the refractory reaches its maximam temperature. Then terminate the firing cycte by lowering the ‘set point of the operating controller, or setting the Fuel Selector Switch to OFF. Do not open the master switch. Visually observe when the bamer flame or FLAME LED goes out. If this takes more tian 8 or3 seconds (depending ‘on the FFRT of the amplifier), the photocell is sensing hot relzactory. This conditicn mast be corrected as described in the last paragraph of this test. Infrared (lead sulfide) detectors can respond to infared rayscmittod by a hotrefmactory,even when the refractory has visibly ceased to glow. Infrared radiation from a hot refrac- 65-00872IM7840E,G,LM © CHECKOUT is steady, but radiation from a flame has a flickering / characteristic, The infrazed detection system responds only to flickering infrared radiation; it can reject a steady signal from hotrelractory. Theseftactory steady signal canbe made to fluctuateifitis reflected, bent or blocked by smoke orfuel ‘ist within he combustion chamber. Be carclul when apply- ing an infrared system to verify its response to flame only. "To check infrared (lead sulfide) detectors for hot reirac- tory hold-in, operate the burner until th refractory reaches its ‘maximum temperature, If the installation has a multi-fuel bbumer, bum the heavier fuel that is mos likely t9 reflect, bend o obscure the hot refractory steady infrared radiation. ‘When the maximumrefractory temperature isreached, close allmanual fuel dhutofl valve(s), oropen theclectrical circuits of all automatic fuel valve(3). Visually observe when the bumer flame or FLAME LED goes oul. if this takes more than three seconds, the infrared detector is sensing hot refractory. Immediately terminate the firing cycle, (Lower the set point to the operating contoller, or set the Fuel Selector Switch to OFF.Do not open the master switch.) NOTE: Someburness continue topurge oillinesbetween the valve(s) and nozzle(s) even though the fuel valve() is closed. Terminating the fring cycle (instead of opening the master switch) will allow purging the combustion ‘chamber, This will reduce a bauldup of huel vapors inthe combustion chamber caused by oil Hine purging. Ifthe detectaris sensing hotrefractory, the condition must becorrected. Adan orifice platen frontof thecell iorestrict the viewing area of the detector. If this docs not correct the problem, resight the detectorat a cooler, more distant part of the combustion chamber. While resighting the detector, be aware that it mast also properly sight the flame, Fer an infrared detector, try engtheningihe sight pipeor decreasing the pipe size (diameter). For details, refer to the detector {Instructions and the equipment Operating Manual, Continue adjustments unil hot refractory hold-in is eliminated. ULTRA VIOLET SENSOR, IGNITION SPARK RESPONSE TEST (ALL ULTRAVIOLI DETECTORS) ‘Test to makecertain that he ignition sparkisnotactusting, the FLAME LED: 1. Close the pifot and main bumer manual fuel shutoft valve(s). 2. Startthe burnerand usethe Run/TestSwiich tostopthe sequence in the PILOT IGN period. Igniion spark should ‘oczur, but the flame signal should notbe more than0.5 Vdc 3. If the flame signal is higher than 0.5 Vde and the FLAME LED does come on, corsult the equipment operat- ingmanualand,esightthe detector farther out from thespark, or away from possible reflection, It may be necessary 10 construct @ barrier to block the ignition spark from the dotector view. Continue adjastinents until tie flame signal due to ignition spark is less than 0.5 Vee. 30 NOTE: The Honeywell Q624A Solid State Spark Generator ‘will prevent detection of ignition spack wien properly applied with the C7027, C7035 or C7044 Minipeeper ‘Ultraviolet Flame Detectors. The Q624A is only for use with gas pilots. RESPONSE TO OTHER ULTRAVIOLET SOURCES Some sources of artificial light, such as incandescent or fluorescent bulbs, mercury, sodium vapor lamps and daylight, produce small amounts of ultraviolet radiation, ‘Under certain conditions, an ultraviolet detector will respond to these sources as if itis sensing a flame, To check for proper detector operation, check the FFRT and conduct Safety Shutdown ‘Tests under all operating con- ditions, FLAME SIGNAL WITH HOT COMBUSTION ‘CHAMBER (ALL INSTALLATIONS) ‘Wit all iniial startup tests and bumer adjustments completed, operate the burner until the combustion chamber isatthemaximum expected temperature, Observe the eguip- ‘ment manufacturer warmup instructions, Recycle the bumer ‘under these hot conditions and measure the flame signal ‘Check the pilotalone, the main bummer flame alone, and both together (untess monitoring only the pllor flame when using an intemittent pilot, or only the main burner flame when using DSI). Check the signal at both High and Low Firing. Rate positions and while modulating, if applicable, Check the FFRT of the Flame Amplifier. Lower the set pointot the operating controller and observe the time it takes for the burner flame to go out. This should be within 8 or 3 seconds maximum depending on the amplifier selected. * Ifthe flame signal 1s too low or unsteady, check the flame detector temperature. Relocate the detector if the iempera- lureis too high. Innecessery, realign the sighting 1 obtain the proper signal and response time, If the response time is still too slow, replace the Plug-In Flame Signal Amplifier. IF the detectors relocated orresighted, or the amplifier isreplaced, repeat al required Checkout tests SAFETY SHUTDOWN TESTS (ALL INSTALLATIONS) Perform these tests al the end of Checkout, afterall other testshave teen completed. Ifused, the external alarm should turn on, Pross the RM7840 reset pushbutton to restart dhe system, 1. Opening Preignition Inteslock during STANDBY or PREPURGE period. (Safety shutdown will occur.) 2. Opening, a Lockout Interlock during PREPURGE, PILOT IGN, MAIN IGN or RUN period, (Safety shutdown will occur) 3, Detection offlame40secondsaflerentry toSTANDBY. Detection of flame 10 seconds into Drive to Purge Rate for RMTS40EL or 30 seconds for RM7810GM or during measured PREPURGE time,3M7840E,6,LL.M' TROUBLESHOOTING te Troubleshooting RM7840 SYSTEM DIAGNOSTICS “Troubleshooting of control system equipment failures is made easier with the RM7840self-diagnostics end first-out annunciation. In addition to an isolated spst alarm relay (audible annunciation), the RM7840 provides visual annun- - ciation by displaying the ALARMLED. Self-diagnostics of the RM7840 enable it to detect end annunciate bolh extemal and internal system problems. ‘External faults such as interlock Patwes, fame faifutes end “false flame signals, are annunciated by tie RM7840 lockout, ‘which energizes the ALARM LED, by using the optional ‘Keyboard Display Module or 7800SERIES System Annun- ‘ciation Diagnostics and Troubleshooting, form 65-0118. “The, RM7840 provides diagnostic information w aid the service mechanic to obtain information when toubleshcot- ing the system, see Table 6. "The optional Keyboard Display Module displays se~ ‘quence satusmessages indicating: STANDBY ,PREPURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE. The selectable messages also provide visual indication, current status ard historical status ofthe equipment such as: Flame ‘Signal, Total Cyclee, Total Hours, Fault History, Diagnostic. Information and Expanded Annunciator Terminal Status (if used), With this information, most problems ean be diag- nosed without extensive trial and error testing. Information available in the Diagrostic Information file includes: Device ‘Type, Device Suffix, Software Revision, Manofacturing Code, Flame Amplifier Type, Flame Failure Response Time, Selectable Jumper Configuration Status, Run/Test Switch Status and Terminal Status. Diagnostic Information Index ‘The RM7840 with the optional Keyboard Display Mod- tle can monitor inpoVouput terminals and can display the statusofthe erminal atihe VED (forexample, Pilot Valve TS (ON<),s0¢ $7800 1001 Keyboard Display Module Speci cations. A complete terminal description and number are provided. The display will show the actual status of the terminal. If voltage is detected at the terminal, ON is dis- played; but ifno vollage is detocted at the terminal, OFF is displayed. Historical Information Index ‘The RM7840 has nonvolaiile memory that allows the Relay Module toretainhistarical information for thesix most recent lockouts. Each of the six lockout files etains the cycle ‘whea the fault occurred, the hour of operation when the fall occurred, the Fault message and bumer status when the fault occurred, sce$7800A 1001 Keyboard Display ModuleSpesi- fications. SERVICE NOTE: A Lockout condition or restait of an RM7840 can be accomplished by pressing the reset pushbutton on Une RM7840, or pressing a remove reset yushbution wised through an optional Keyboard Display Module, DATA CONTROLBUS MODULE™, Exten- sion cable Assembly, or Remote Reset Module. A power ‘ip reeed will cansean electrical reset of the RM7840 but will not reset a Lockott condition. SERVICE NOTE: Remove the access slot covers on the. ‘asides of the Q7800A,B to check voltage. /\ CAUTION Sop + Reinstall aceess slot covers on the Q7800A,B sob- ‘ssi base after performing voltage checks. Faseat SERVICE NOTE: Maxinium ambient operating tempera- ‘clue of a C7O12E,F Series 1 through 6 will be reduced to + 125°F because of the duty cycleoperation of theRM7840 ~, Relay Module,RM78402,G,L.M TROUBLESHOOTING ‘TABLE 6 SEQUENCE AND STATUS HOLD MESSAGES, NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type. ——$ Sequence Status " INITIATE ‘The LED indicates the burner status, POWER, whichis a stabilization period for the RM7840 to check for any fluctua- tions in ‘AC line voltage inputs or control input om power up ‘orduring nérmal operation. The timing of the INITIATE eriod is tn seconds before entering STANDBY. If the RM7840 is in an INITIATE HOLD status, the following condiions Gould exist: INITIATE HOLD: (AC Frequency/Noise) ‘The LED indicates the bamer siatus, POWER, and that itis ‘waiting for excess line noise to clear up, The bumer sequence, not advance into STANDBY until the excess line noise, which prevents sufficient reading of the line voltage inputs, ‘ceases ora line frequency error is corrected (perhaps caused. ty using a 60 Fz device on a 50 Hz line, or vice versa). INITIATE HOLD: (AC Line Dropout) ‘The LED indicates the bumer satus, POWER, and that AC line power has‘ momentarily dropped out, The bumer . sequiencé will not advance into STANDBY until the AC line : voliage has stabilized throughout the INITIATE sequence, INITIATE HOLD: (AC requetty),.j,. 0.4. | , The LED indicates the burmer satus, POWER, and that line a uae dee frequency is faster than the expected value, The burner sequience will not advance into STANDBY until the Sine frequency rotama to the propor valve (perhapt caused by - : using a 60 Hz device on a $0 He line). INITIATE HOLD: (Low Line Voltage) ‘The LED indicates the bamer status, POWER, and that low ‘ line voltage has occunred. The burner sequence will not advance into STANDBY until the line voltage is at a sufficient level for proper operating parameters. STANDBY woe "The LED indicates the bumer status, POWER, The burner can be placed in STANDBY by opening the bumer switch or ot if the operating controller indicate its set point has been * satisfied, Ifa demand is present for burner operation, the ‘bummer sequence will not advance from STANDBY to . PURGE until the recycle limits close. Ifthe RM7#40 is ina STANDBY HOLD status, the following conditions could exist: ‘STANDBY HOLD: F/G (Flame Detected) ‘The LEDs indicate the bumer status, POWER and FLAME, and that aflame is detected, A demand is present for bumer operation, The bumer sequence will not advance to PREPURGE because a flame is detected as being present. ‘The sequence will notadvance to PREPURGE until the flame signal clears. Ifthe flame signal does not clear within 40 seconds, the RM7840 will lockout. STANDBY HOLD: 120 (Preignition Interlock) ‘The LED indicates the bumer status, POWER, and that the Preignition Interlock is no: closed. A demand is present for bumer operation, and the burner sequence will not advance to PREPURGE until the Preignition Interlock proves closed. If this time exceeds a 30 second hold, the RM7840 will lockout. ‘STANDBY HOLD: 77 (Lockout Interlock) | The LED indicates the bumer status, POWER, and that the Lockout Interlock is closed. A demand is present for bumer ‘operation, and the bumer sequence will notadvance to PREPURGE until the Lockout Interlock proves opea. If this time exceeds the 120 second hold, the RM17840 will Jockout, (continued) uel atl al eat dea 3B 65-08721M7B40E,G,LM ROUBLESHOOTING ‘TABLE 6—SEQUENCE AND STATUS HOLD MESSAG! (Continued) ‘Sequence ‘STANDBY HOLD: T7 (Running intedock) If the RM7840 is in a PURGE HOLD status, the followi PURGE HOLD: T19 (High Fire Switch) Status “The LED indicates the bamer status, POWER, and that the Running Interlock is closed. If a demand is present for bumer ‘operation, the burner sequence will not advance to PREPURGE until the Running interlock proves open, If tis time exceeds the 120 second hold, the RM7840 will lockout,_ ‘The LED indicates the bumer status, POWER, which is the period of time before Ignition period during which time the blower motor is running. The timing of the PURGE period is selectable ing conditions could exist: ‘The LED indicates the bummer status, POWER, and that the High Fire Switch is not closed. The firing rate motor is driving to its PURGE rate position. If this time exceeds four ‘minutes and filteen seconds, the RM7840 will Jockout. PURGE DELAY: T19 (High Fire Switch Jumpered) ~ PURGE HOLD: TEST (Run/Test Switch) ~ PURGE HOLD: T18 (Low Fire Switch Jumpered) ‘PURGE HOLD: F/G (Fame Detected) PURGE HOLD: T18 (Low Fire Switch) PURGE HOLD: T7 (Ruaning Interlock) “The LED indicates the bnmer status, POWER, and that the High Fire Switch is jumpered. The High Fire Switch is bypassed, welded or otherwise prematurely closed. The system auiomatically adds 30 seconds to allow the firing rate ‘motor additional drive time to reach or near the open damper _position before starting the PURGE sequence, "The LED indicates the burner status, POWER, and that the Run/Test Switch isin tie 1231 positon. 1 he Sequence wit rot continue until the Run/Test Switch is placed in the RUN position, ‘The LED indicates the bumer status, POWER, and that the Low Fire Switch is jumpered. The Low Fire Switch is bypassed, welded or otherwise prematurely closed. The system will automatically add 30 seconds to allow the firing rate motor adcitioal drive time to reach or near the closed camper position before starting the ignition sequence, “The LED indicates the burter status, POWER, FLAME, and that a flame is detected. ‘The bumer sequence will not advance through PREPURGE because a flame is detected as being present, The sequence wiil hold waiting for the flame signal to clear. Ifthe time exceeds 30 seconds, the RM7840 vill lockout. _ "The LED indicates the bummer siatus, POWER, and that the Low Fire Switch is not closed. The firing rate motor is Base aN 2a0t pei octal Vennemre / VISTA SUPERIOR ENTRADA DEAGUA RESULADA DEL SSTERAPROVENIENTEDE. AGEDUCTON =e GES PLANTA DE TRATAMIENTO (ps), “TANQUE PARA SOLUCION DE ‘taRURO BE COO —_ VALVULADeBY PES a << ie Gute‘SES BSS a gahbesttteierr: pits .a, Lewatit S 1467 “Lewatit § 1487 is a strongly zcidic, gel-type cation exchange resin cf unform particle size manufactured without the use of solvents, 5 1487 meets the most exacting requirements of the residential and municipal weter troatmont industry. $1467 is specially treated fo eliminate taste, odor, color throw and assures compliance with FDA regulation CFR26 173.28, Lewatit $ 1467 applications: municipal , industrial and domestic softening Physical and chemical properties US Units International Units 2 [lonie form as shipped Ne Nat 4 iMean bead size > 30% mal 08 +005 tml 06 + 008 [Uniformity coefficient Tre OL Tan, it 1 [Shipping weight Ibsif 51.0 ait 820. i Density ail 4.28 Water ratontion Swelga| 42-48 "| ___42-48 [Total capacity, min. tr CaCO, / 436 eal [Volume change Na’ 9H max. %| 8 max. %4 [stability Temperature range "=| __ 14-250 °C] pH range Er ‘Storability of product min yea's| Zz min. years | l temperature range! (104 "| ‘Crevice sole, Te SDD cin ne nonetin a ay evened sare sae Fanaa wn 88 four ‘rcatng '90-68.000 or ¥en0sR2 262 TSO: AGI Seay al Shea wrest aS poses, Hs ecommerce bal ocet of eSB Contact Us: Baker Filtration 4306 West 190th Street Torrance, CA S0504 Phone: 800-310-6569 Fax 310-406-3007 www. bakerfiltration.comjome and Building Control joneywell Inc joneywell Plaza ©. Box 524 finneapolis MN 554080524 5-109 GR. 4.99 Home and Bulg Cnt Howe inte Honey Lint et Yee, Once ana @ eae Zeanoe vwwvachoneywel.comHoneywell APPLICATION These Integrated Gas Valve Train component instalation insiructons are ‘or small valves (3/4 in. to 2 in.) and large valves (2 in, to 3 in.) are identical except where noted, INSTALLATION When Installing this product... 1. Read these Instructions carefully Failure to follow them, ‘could damage the product or cause a hazardous condifon, 2, Check raiings given in these instructions andon the product to make sure the product is suitable for your application. 3, Make sure the inetallor is a trained, experienced service, technician, 4. Use these instuctions io check out product operation after instalation. WARNING Fire or Explosion Hazard. Can cause property damage, serious injury or death. Perfor the safety shutdown test any time work is done on a ges system. Make sure gas is tumed off before starting installation Bolt Torque Specifications “orgue spedfictions forthe two bot sizes are + 3/8 in. 16 bolts: 13 Ib-tt. 2 iB in-t3 bows: 25 bt Valve Assembly Precautions (Fig. 1) 4. Use new, properly reamed, pipe, free from chips. 2. Do not thread pipe too far into pipe adapter. Valve diotorion or malfunction can result from excess pipe in the valve. 3. Do net attach valve actuator untl vaive body installation is complete 4. Make sure O-ring sealing surfaces are clean, 5. Apply moderate amaurt of coos quelity pipe dope, resistant to the action of liquid propane (LP) gas only ‘on the pipe threads. @US, Registered Trademark Copyright © 1200Honeywel Ino. + Al Rights Reserved Integrated Valve Train |S INSTALLATION INSTRUCTIONS - €. Make sure th ge flow sh the drecton of he arow on the gas valve casting. NOTE: Gas flow in the V4297S Normally Open Vent Valve can be in either direction. EXCESS DOPE CAN LOCK -wooiean DECRG a ) i J Loose ‘connect, HPS NORAL Re Save sear Pie REAM PIPE ANOLON oosing on sear) Pee DotPren TOOLaNG, eros YSLYE SEAT A\ use pireoore REssaN To acTON OF Ps Fig. 1. Preparing pipes. Connecting Upstream or Downstream Pipe Adapter to Valve (Fig. 2) 1. Using the groase packet provided (or equivalent, goneral purpose, ithiun grease), grease the O-ring Make sure the grease is applied evenly around the entire Oving. 2. Insort the O-ring into the O-ring groove. 3. Assemble the pipe adapter to the valve using the three bolts, nuts and lock washers as shown in Fig. 2. IO Be-1098INTEGRATED VALVE Tray Fi 2 Connecting the pize adapter to the vaive. Connecting 4297S Normally Open Vent Valve (NOVV) Between Two Vaives (Fig. 3) 1. Using the grease packet Provided (or equivalent, ea BUPOSe,Ithium grease), crest O-ring of 28 fist valvo, Make sure ths grea applied evenly around the entire O-rin, 5 Aitett the Ong Int the Osing groove, 3. Assemble the NOW to the first valvo uainy the three aig, Gul aid iock washers as shear a Fig. 3 4 Using the grease packet Provided (or equivalent, (PORTANT nea PoKer eee wen VAVE lve between 4 ally open vent vat 3. Connecting the aver pound the entre O-ring. 2. Insert the O-ring inio the O-ting groove. & fesombie the NOVY adaptor first valve using the [fee Bolts, nuts and lace washers at ‘Shown in Fig. 4, NOW Adapter to connact the downstream side of {he NOW adaptor with the secant valve, WMPORTANT ¢ Sure tht al bots point out ofthe NOW adapter, se00ng wae Aue Fg 4. Connecting the normally open vent. valve adapter between two valves, Connecting Two Valves in Series (Fig, 5) 1. Using the grease packet provided (or equivalent, thefra PuPeee ltium grease), greass'ine O-ring of {he fst valve. Make sure the grease is applied evenly around the entire Oving 2 Insert the frst O-ring into the O-rng eroove, 3. Using the grease packet provided (orequivalent, general purpose lithium grease), grease the O-ring of ‘he second valve, Nake sure the grease is apptieg tire O-ring. ranly around the entire roove 4 Yar ea Sap sng Site 5. Assemble the frst valve ae * frewbole, nus and lok washers 38 nmIMPORTANT Point the iop two bolts upstream and the third bolt ‘Cownstream when connecting two valves in series. Connecting a C6097 Pressure Switch toa Valve (Fig. 6) 4, Remove the 1/4in. (6 mm) NPT plug from the side Of the valve. +2. Remove the label holding the O-ring in place on the 6097 and make sure the Oving seals in place. 3, Remove the C8097 Cover by rerroving the cover 4 screws. ‘Mount ihe C6097 Pressure Switch on the valve uskig ‘the two screws provided. 5, Replace the C6097 Cover. oy Fig. 5. Connecting two vaives in series. evove rus FERS ney a wet 7, Fig. 6. Connecting C6097 Pressure Switch to Valve. ieting the Assembly (Fig. 7): ; comcomet upsreart and ‘downstream pipes to the valve train 2. Apply a parallel jaw wrench only to the plbe adapter at aeetto the pipe being inserted (Fig. 7). Avirench ‘poled tothe valve body itself, or to the end fertnest Fein ihe pipe being inserted, can distort the casting, Tausing 4 malfunction. Do nct use the valve as 2 lever. 43, Make sure the gas flow in the same direction as the arrow on the valve body. ‘A, Paint the pipe adapters and valve train components with a ich soap and water solution to check for bubbles that indicata a gas leak at the pipe adapter and valve mating surfaces 5, Make sure the power supply is disconnected trom the powored components. Mourt the acurators on the valve bodies ané complete the electrical and linkage Connections by following the instructions packed with the actuators and solensid valves. connect: Waecnrs ew BEI TOPE connect: ‘enctt CORrECTY Sore oENG CORRECT: ene sTaAns VAIMEBODY Fig. 7. Completing the valve train, 66-109Honeywell APPLICATION ‘The V4055 Gas Valve Actuator, in combination with a V5034, \VEB0008, V5055 or V5097 Gas Valve, controls the gas suppl to commercial and industrial burners. | FEATURES \ + The V4055 Actuator, when used with the V5034,— ‘VE5000", V5097 or Y5055 Valve, is rated for final satet} shutoff service. } + The V4055 Actuator can be used with the characterized guide model of the V5055 or V5097 Gas Valve to enhance lightoft smoothness. @US. Registered Trademark Copyright © 2001 Honeywell All Rights Reserved MINIT V4055A,B,D,E On-Off Fluid Power Gas Valve Actuator =) ;PRODUGT DATA + The standard model has an opening time of 26 seconds at 60 Hz or 32 seconds at 50 Hz. A fast-opening model is avallable with timings of 43 seconds at 60Hz or 16 seconds at 50 Hz. + Maximum closing time Is one second, wnich meets code, standard and insurer requirements, + Models available with damper shaft, with or without spring return; shaft extends out both sides and rides, in Teflondike Delrin bushings; used with standard 7816BR Damper Crank arm. + Red OPEN indicator attached to actustor stem shows when valve is even siightly open; yellow SHUT Indicator on valve stem shows only when gas valve Is, fully closed. + Models available with adjustable max flow limit switch. + Ambient temperature rating is -40°F to +150°F (-40°C to 486°C) for 60 Hz models and -10°F to +158°F (-23°C to “470°C) for 50 Hz and 50/60 Hz models. + Valve and actuator combinations can be mounted in any position, with the excoption of the 220 to 240 Vac, ‘50/60 Hz models, which ere mounted vertically. + Models available with factory-installed single pole double throw (spat) field-adjustable Auxiliary Switch. Field-addable Auxiliary Switch kits are also available. ‘Standard enclosure meets NEMA 1 (IP30) requirements; models available with NEMA 4 weatherproof enclosure. + V4055D and high pressure V405SE with Proot-of-Closure Switch and V5055/V5097C or E with valve seal overtravel interlock (double seal) to meet specific code, standard and insurer requirements. 2VE5000 is a European manufactured and approved valve for European use only Contents Application .... Features Specifications ..... ‘Ordering information Installation . Wiring Checkout and Service 60-7308-10V4055A,B.D,E ON-OFF FLUID POWER GAS VALVE ACTUATOR SPECIFICATIONS Models: Table 1. Nominel Opening Time (seconds). ‘V4055A Actuator, with V5055, V5097 or VE5O00 Gas Valves, ail provides on-off control of fuel. With proper adapter (soa Mo ole ake Accessories), itreplaces the V4024 Actuetor on a 5034 [Standard 32 26 Gas Vaive. = \V4055B Actuator is a hgh pressure version of V4055A, restcopeting He: Hs | \V4058D Actuaior is identical to VA0SSA, excapt hae @ Creah SECIS ne Sonce Lead WER VECO EEG: Maximum Closing Time: Ore second whon de-energzed, (double sea) for valve seal overttavel interlock. i . \VA0S5E Actuator is identical to V4055B, except has a ‘aiblent Oneiatieg Tersiseratire Ratha: Prootot Closure Switch. Used with VS0S8E/V5097E Die Made HOFER COC IS SOE (double sea) for valve seal overtravel interlock 50 Ha, BOG Hz Modeler 10°F toe 68°F (29°C 5 470°O). thet : REM S Weeitenproer mociele acs Mounting: V4055 Actuator attaches directly to VS055/V5097 Nominal Opering Time: See Table 1. Valve with two sets of screws postioned 90 degrees apart. Combination is multipoise. NOTE: 220 0 240 Vac, S0/E0 Hz models are vertcal mount only. Pressure Ratings: See Table 2. Table 2. Pressure Ratings of Valve-Actuator Combinations, Retwator > ‘V4055A,D* V4055B E* Ditterentiat™ Gioseor® uimerenuai® | Closeott Valve psi [| mbar_| psi_| bar | pai_| mbar | pal bar_| [VS0SSNVS0O7A,C: 34 I. 5 eas 7 75 [1000 15 7 V5086A,C: 4 In. 3 _—‘(200 15 1 5 340) [15 H i | VE05S/V5097B: 9/4 to S 5 340 15 1 15: 1005 i V0555: din, 3 20018 T 5 Bo [iS Pr VE0SSVECO7D E: 8d, 1-1/4, 1-1221n 5 a0 _—*iS js 5700 [75 5 VE0seVE007D.e:2,2-112,3in (5 ao eS HS [00 [a5 3 * Us V4055D or V4055E (with Proof-cf-Closure Switch) with a V5055/VE097C or VS0S5/V5097E. (with double seal) for valve seal overtravel interlock > Maximum operating proscure differential Maximum closeoff pressure without seat leakage. This is the maximum velve pressure drop allowed while fully closed, and is independent of the valve body rating Electrical Ratings: Soe Tables 3 and 4. ORDERING INFORMATION When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the ‘TRADELINE® Catalog or price sheets for complete ordering number. If you have additional questions, need further information, or would ike to comment on our products or services, please write or phone: 1. Your local Home and Building Control Sales Office (check white pages of your phone cirectory) 2, Home and Building Control Customer Relations Honeywel, 1885 Douglas Drive Noth Minneapolis, Minnesota 55422-4385 (800) 326-5111 1 Canreda—Honey neil Liniteuroney well Liitée, 35 Dynamic Drive, Scarborough, Untano M1V 429. Intemational Seles end Service Offices in all principal cities ofthe world, Manufecturing in Australia, Canada, Fintand, France, Gormany, Japan, Mexice, Netherlands, Spain, Taiwan, United Kingdom, U.S.A. 60-2308—10 2\VA055A,B,D,E ON-OFF FLUID POWER GAS VALVE ACTUATOR Table 3. V4055A,0 Electrical Ratings. ‘Opening (Standard) ‘Opening (Fast) Holding Voltage and Frequency [Inrush| (W) | (A) | VA) | Inrush «wy | (A) | way om) | @ | vA) +100/50-60" a0 Joni f- eeo [rao fico [ios ote [te Troo/s0-60P — —jaao_ [oe [67 wo joor or laa [ota [ia |r20760 jas [800 Joos [esa [ro [ras |reo_ fos low [4 | leoo7s0-60* = [680 jo7o_|158 0 |110 220 ios 00s 16 200/506-8608 480 |os2 [104 i630 (072 [144 [80 [oor 14 22060 je [655 [oss |ia1 [so 760 [oo j176 |90 [o0s |14 | {240/50 [— jis 07a [130 |= 95.0 [1.00 [240 [91 [0.06 [14 (240/60 jze|s10 045 (vi5 [40 [rns loge ieo [92 [0.06 [14 1220-240/50-60" F = — [— |mos ose lise |72 [oor [16 [220-240/60-60! =F E sas [ae 106 [oe [006 [14 60 Hz power supply, » €0 Hz power supply. . © 230 Vac, 50 Hz power supply. 4 280 Vac, 80 Hz power supoly. Table 4. V40556,E Electrical Ratings. Voltage and ‘Opening (Standard) ‘Opening (Fast) Holding Frequency Tush] (W) | (A) | (A) inrush] w) | (A) | WA | | A) | AD | [120760 jeu |oes [te | |eo0 joss [ms [es [ore [19 mae TE ose fre fer foe ae \ '220-240/50-60? — — — = = 582 (046 [106 [5.3 {0.06 14 8 290 Vac, 50 Hz power supply. »'230 Vac, 60 Hz power supply. Auxillary Switch and Proof-of-Closure Switch Ratings: Seo Table 5. Table 6, Auailiary Switch and Proot-of-Closure ‘Switch Ratings (1/2 hp [0.37KW)°), NOTE: Damper shaft dives damper rank arm in one direction ony; optional return spring is available on damper shaft to turn damper crank arm in opposita direction. See Table 6. Table 6. Actuator Torque (With and Without Return Spring). Toad [20 240V Full Load 8.88 a9 [Locked Rotor [58.80 (29.48 Maximum total connected power to both Switches (used) Is 1800 VA. Mounting Dimensions: See Fig. tand Table 7. Damper Shaft: Shaft is 9/6 In. (9.5 mm} square, for use with 7616BR Damper Crank Arm (ordered separately) and with or without damper shaft return spring, Naximum Damper Shaft Rotation: 52 angular degrees. Maximum Force: 2-11/16 in, (68.3 mm] radius for 7616BR Damper Crank Arm ordered separately (see Accossorios section), “40 to 20F | 20°F to 150°F (40°C to-7'C) | (7°Cto 466°C) v40g5 Model 1b N ® | N Win reumaprng [5 aaa [10 a5 Without return spring [5 lza2 [20 ‘(09.0 ‘Approvals: Underwriters Laboratories Ino, Listed: File No, MH1639, Guice No. YIOZ Factory Mutual: Approved. International Approval Services (Joint Venture of the ‘American Gas Association [AGA] and the Canadian Gas Association [CGAl): Certified 60 Hz models only. Induotrial lek Insurers: Acceptable, Some V4085 Actuators are epproved as Ciass A valves in accordance with EN101. When used with V5055 Valves: Pin: CE-O063AR1959. When used with VE5000 Series Valves: Pin: CE- ‘0063AP3075. 60-2308—10V40554,0,0,E ON-OFF FLUID POWER GAS VALVE ACTUATOR Accessories: 13539 Short Stem Adapter for mounting actuator on V5034 Valve. 133534A Long Stem Adapter for mounting actuator on V5034 Valve. 133568 Auxiliary Switch Bag Assembly (not for models with maximum flow iimit switch). 183569 Valvo-Closed Indication Switch Bag Assembly (nat for use with V5034 Valve body). Ja— ean ira 7618BR Damper Crank Arm (damper arm and clip). (Q5055A1001 Adapter Assemoly (adapts ITT General V710 Gas Valve to accept Honeywell gas valve actuators, Replaces ITT General AH2 Gas Valve actuators) Available Models: V4055 with NEMA 4 enclosure (weatherproof). rapexourron, ‘ncnconau = ste) oy | ow + A snow tines (102 inn CoEARANCE FOR ACTUATOR REMOVAL, i775 Fig, 1. Approximate mounting dimensions of V4085 Actuators in in. (mm). ‘Table 7. Approximate Mounting Dimensions of V4055 Actuators with VS055 and V5097 Valves. “Bim Dine mC Dino DA tae) Dime Eo vive Sie? in [me mm | | mm | mm [mm] m [nm) m [mm] | mm Sal [4 [aes ro ean fe [re se eae me feo Body fy [ni-178 [283 [70 [aan6 “fae [rie 2s ears [70 eané [oe [ene [et faa] [as _[2-aa_ ro Jeanie rie [fsa 2ea [za |70eare moe [2a [ea 2” [ie [ass 23s [70 ean 46 [1-8 [283 [2am 170 ears [oe (272 [64 [aa ave fare |a [ese pra [faa fee [sam jae _aae forex [v0 lage [2 [irae [aie [sab [oe [eter 5 [a4 se [sae [se ewe fats _|a [102 eeey aaa [iram exe [eas jas [etarslaae jot [eas [ria foe [eae leo [eae for |e [108 ls [trem [ave _(o08 [ao fevartalan joa [ze [itera aie jee jean aa [a __(902 a [iene [a0 oar faa [irae fas free se ® Valve size using accessory pipe adapter iting. 00-2300—10INSTALLATION When Installing This Product... 1. ead these instructions carefully, Failure to follow tham ‘could damage the product or cause a hazardous condition. 2. Check the ratings given in the instructions and on the Product to make sure the product is suitable for your aoplication, 3, Installer must be @ trained, experienced tlame safeguard control technician, 4. Aiter installation is complete, check out product ‘operation as provided in these instructions, A\WARNING Electrical Shock Hazard. Can cause serious injury or deeth. Disconnect power supply before making wiring connections ta prevant electrical shock and equipment damage. IMPORTANT 1. Allwiring must comply with all applicable electrical codes, ordinances, and regulations. All wiring must Be NEU Glass T. 2. Voltage and frequency of the power supply con- nected to this control must agree with those marked on the device. 3. Loads connected to the Auxiliary Switch andior Proot-of- Closure Switch, if used, must not exceed the ratings given in the Specifications section. Install Valve The actuator is mounted directly on the velve bonnet after the valve is installed in the gas supply line. Refer to the insttuctions packed withthe gas valve for installation detals When instaling the gas valve, make sure: 1. Sufficient cearance:is let to instal and service the actuator. 2. Ambient temperatures at the valve location do not exceed actuator ratings. See Specticatione section, 3. Position of the valve permits hookup to the damper if one is controlled Install Accessory Switches (If Needed) An spdt switch can be installed to operate an auxiliary load up to 112 hp (0.37 KW). See Table 5. The ewitch can be adjusted to operate at any point in the valve stroke. A Proot-of-Closure Switch can also be installed with a VS058/ \5097G or E Valve (with double seal) on any V4055 Actuator to provide a vaive seal overtravel intetiock. The spat Proof-of-Closure Switch is installed to make or break a circuit when the valve isin the closed pesition, Tho aniteh ie not adjustable. NOTE: Mark the actuator or valve to indizate any changes mage, ¥V4055A,B,D,E ON-OFF FLUID POWER GAS VALVE ACTUATOR To install the switches: 2 3a. Remove the actuator faceplate (two screws). Removo tho silver-colored barrier to expose the actuator stem. Inzert te Auxiliary Switch in the position indicated In Fig, 2. Fasten with two screws through the actuator base. insert the Proof of-Closure Switch in the positon shown in Fig. 2. The switch mounts against the side of the actuator housing. The mounting holes are spaced to assure mounting the switch in the correct postion, Fasten with two sorews through the actustor base. (The Proof-cf-Closure Switch is not adjustable.) Hfonly ono ewitoh is used, install the narrow barrier included with the switch in the unused space. Mount ihe actuator before making wiring connections and adjustments to the Auxilary Switch, Mount Actuator on Valve 1 Check the final position of the vale body to be sure that the actuator is in the proper posiion when mounted on the valve. This is especially important when the actuator Is used to drive a damper, If two smallor sized valves aro mounted very closely together, as in an Industrial Risk Insurers approved type of valve train, it may be necessaiy ty nivuti thee actuators off center to provide adequate clearance. ase sures 10 Va mhowcanon eure AQUUSTING ‘Simro EACH swWITOH SECURED BY ‘TWO SCxEWS FROM UNDERSIDE OF BASE, IFONLY ONE SWITCH IS USED, INSTALL BARRIER INOPENPOSITION. Fig. 2. V4055 Actuator with cover removed. Slip the bottom collar ofthe actuetor over the valve bonnet assembly. Rotate the actuator to the desired posttion and use a 5/82 in. Allen wrench to securely tighten the two setscrews to 50 to 60 Ib-in (6.7 to 6.8 Nem). Cannect the darnpor linkage, if ueod. Rofor to tho instructions packed with the damper erm. 60-2309—19\V4055A,B,0,E ON-OFF FLUID POWER GAS VALVE ACTUATOR Replace V4034 Actuator on V5034 Valve IMPORTANT When replacing a standard (26 sec.) V4034 Actuator ona V5034 Valve, check the main bumer flame-establishing period (MFEP) of the bumer primary safety control. ithe MFEP is 10 sec. {you must use a fast-opening (13 sec) V4055 ‘Actuator on the older VE0S4 Valve. ‘The intial action of the 4055 Actuator does not immedately open the V5034 Valve because of a difference n stroke length. The pilot may be shut off before the main burrer flame Is established. However, tne fast-ovening V4055 Actuator opens the VE034 Valve quickly enough to establish the ‘main tumer flame within the ten second flame- ‘establishing period. If tis desirable to mainiain the slower opening characteristic of the standard V4034 Actuator, oth the V4034 Actuator and VE0SA Valve should be replaced with a standard V4055 Actuator on @ 5055 Valve. Select the correct adapter, depending on whether the V5034 Valve has a long or short stem (Fig. 3). Fasten the adapter to the V5034 Valve bonnet, and then mount the actvatar on the adapter. Follow the inetiietians for mounting the actuator on the valve. If the V4084 being replacedis equipped with a heater, there is ‘a low limit control connected in series with the V4084 Actuator power supply to prevent actuator operation below 25°F (-4°C). ‘There is also a constant source of line voltage power to the heator and thermostat. SEN 1858a, beara wt Tone sre vse \yse wo, 1s58808 barren wim Hom STEM ves Fig. 3. Use adapters to connect V4055 ‘Actuator with V5034 Valve. 60-2909—10 6 “The V¥4056 Is rated for ambient temperatures down to ~40°F (40°C) for 60 Hz models, or 10°F (-23°C) for 50 Hz and ‘50/60 Hz mocols, and does not require a heater. Remove all the wiring associated with the heater. Disconnect the power supply for the heater et Its source and remove the wires. Sea Fig. 4 ENTER (OVE HEATER oRCUT (COMPLETELY AND. ARIE TERM haus CoNrOL Fig. 4, Remove heater circuits, if installed, ‘when replacing V4034 Actuator. Mount and Adjust 7616BR Damper Crank Arm (If Used) IMPORTANT When a damper crank am is used with a NEMA 4 actuator that iS @xp0Se0 10 ice UF sivet, « suitable shield must be installed to prevent ice or sleet buldup. Follow installation and adjustment directions included with damper crank arn. Maximum pushrod travol is 2-8/16 in. (69 mm] through a siroke of 52 degrees. See Fig. 5. AoraTion neue Save Senet Fig. 5. 7616BR Damper Crank Arm can be attached to ‘actuator shaft to drive a damper when valve is open.40554 .E ON-OFF FLUID POWER GAS VALVE ACTUATOR WIRING AWARNING Electrical Shock Hazard. Gan cause serious injury or death. Disconnect power supply before making wiring ‘connections to prevent electrical shock and equipment damage, Wiring must comply with al applicable oloctical codes, ordinances and regulations. Wiring to the actuator must be NEC Clase 1 Connect the power supply to terminals 1 and 2 on the V4055 terminal strip. Refer to Fig. 6 for Auxiliary Switch connections and Fig. 7 for Max Flow Limit Switeh connections. For typical system hookups, refer to Fig. 8 and to instructions packed with the device used to control the valve. ‘When all wiring connections are complete, replace the actuator faceplate, A\ CAUTION Operation Hazard. Improper wiring oan eause improper and dangerous operation, Label all wires prior to disconnection when servicing valves, Wiring errors can cause improper and dangerous operation, NOTE: Pipe sealant is required on the conduit threads of actuators with NEMA 4 enclosures. Adjust Auxiliary Switch (If Used) The Auxiliary Switch is adjustable throughout the stroke of the actuator. With the switch installed in the actuator, tun the adjusting screw (see Fig. 2) clockwise 77\ to cause the witch to operate earlier in the stroke or counter- clockwise ¥ to cause the switch to operate later in the silroke, PROOF-OF-CLOSURE wren hen SS, Suton A\ power surn.y. paoviee oven.oso provecnon 30 ESCGRNECT MEANS ASREGURED, ‘VALVE 18 SHUT (EENERGIZ=D) ° AX sumonaetieen nese Wo Lexns is OPEN We VALVE IS SHUT (OE ENERGIZED), Fig. 6. External connections to the V4055 Actustor, moses the —a ipsa ee Oho. i ig. 7. Connecting the Max Flow Limit Switch to the actuator. NOTE: The Proof-of-Closure Suitch is not adjustable. Adjust Max Flow Limit Switch (If Used) The Max Flow Limit Switch is adjustable throughout the stroke of the actuator. With the switch installed in the actuator, tum the adjusting screw clockwise “7X to cause the switch to operate eariior in the stroke or counter-clockwise y-\, to cause the switch to operete later in the stroke. 60-2008—10V4055A,B,D,E ON-OFF FLUID POWER GAS VALVE ACTUATOR CHECKOUT AND SERVICE A\ CAUTION Equipment Damage Hazard. Unskilled technicians can cause equipment damage. Only a trained, experienced, flame safeguard technician should check out and service this contol. vss a af ea o Checkout 2 After the installation 's complete, cycle the valve several times with the manual fuel shutoff cock closed before testing the ¢ system in actual operation, Service ‘The actuator is not field repairable except for replacing the Ausiliary Switch, Max Flow Limit Switch or Proof-of-Closure Switch. See Installation section for procedure. Do not disassemble the valve actuator. It the actuator flls to operate properly, replace it AAVIOL LAME SIFEGALRD CONTROLS. InieRAUTe TECTRYING: (exo sabre) Have oerezon sees SERIESe Nore kouanie Sur 90n SA <2 A\ rower supp’. pnovide DISCONNECT MEANS AND OVERLOAD PoOTELTIOW se REQUIRES AX vse alinec crasst wins. SIGHS GLOSED Wo-G WHEN ACTUATOR 8 Fig. 8. Typical application of a V405SD/V5055C/V5097D or V405SE/VS055E/V5097E combination to meet Factory Mutual or Underwriters Laboratories Inc. approved requirements for Proof-of-Closure Switch (valve seal overtravel Interlock). Home and Building Control Tome and Building Control HRS Doles DriveNonh 35 Dynamic Brive Gden Vay, MN 55422 Scarborough, Ontario mivany Wanehs Hong Kong 60-2009—10 GR. Rev.2-01 e Honeywell Asia Pacific Inc, Honeywell E Sun Hang Kai Centre No.3 Hani Road Facer ening at eat 19% Honeywe! Honeywell Latin American 0 Basses 480 Sars Cxport Pachway Belg Suite200, Sunrer FL 23525 nUSA onveojcka ‘wynw-honeywell.com Fosteowar pap terHoneywell C6097A, B _ Pressure Switches APPLICATION ‘The C6097 Pressure Switches are safety devices used in positive-pressure or differenti {gas or air pressure changes. |-pressure systems to sense CP-UM-5109E ‘re ttn: asus No, 2001 ®US. Registered Trademark Copyright © 2001 Honoywol + All Rights Reserved, “ FEATURES + For use with natural gas, liquid propane (LP) gas, oral, iaphragmi-actuated safoty-limit ewltch. + ‘Switch caf be wired to turn on alarm. * €6097A models break control circuit at setpoint on pressure fall. * €6097B models break control circuit at setpoint on pressure rise. + Lockout with manual reset and recycle options. + Lockout models have external manual reset button. + Removable transparent cover protects scaleplate- and.adjusting knob. «Pipe tapings allow selection of positive pressure, differential pressure (air only) or venting connections (NPT mount only). «1/4 in. NPT or flange mount models for direct mounting to Honeywell Integrated Valve Train. * Optional switch position indicator lamp available, * 1IP54 enclosure standard. * Ranges: 0.4 to 5 In. we, 3 to 21 In. we, 12 to 60 in. we or 1.5 to 7 psi. + Surge orifice. Contents Application Features . Speotications Ordering information Instalation Wiring Settings atid Adjustments Operation and Checkout ATAU C5-0287-2.C6097A,B PRESSURE SWITCHES SPECIFICATIONS Models: Dimensions: See Fig. 1 and 2. (C6097A Pressure Switct: Breaks a circult when pressure falls to scale setting, See Table 1. (060978 Pressure Switen: Breaks a circuit when pressure rises to scale setting. See Tatle 1 Table 2 shows switch ratings and Table 8 shows alternate ‘loctrical ratings when used with Honeywell Flame ‘Safeguard Programmers. -+——se1s0 06) [aa ah ‘Minimum Ambient Temperatur -40°F (-40°C). Maximum Amblent Temperature: 140°F (60°C). Connections (Depending on Model): +/4-18 NPT tapping for main or high-pressure connection. 1/8-27 NPT tapping for vent or low-pressure connection (air only. Flange mount for connestion to Honeywell Integrated Valve ‘Train (internal vent only, no external connections). a | Scale Rang 0.4 to 5 in. Wc (0.10 KPe to 1.25 kPa). 8 to 21 in. we (0.75 to 5.23 KPa). 112110 60 in. we (3.0 KPato 15 kPa). 1.8 to 7 psi (10.3 kFa to 48 kPa). e ay frases perenental gis cower Underwriters Laboratories Inc. listed, CONNECTION —-SHNPTWIMIQUSTsEaL EERE ORCHA Canadian Standards Association listed tener 7 Factory Mutual: Approved. Industhal Risk insurers: Acceptable. 7 “ , ro CSD-1 AFB: Accepiable. Fe Accessories: 1. 06097 1/4 in, NPT Mount dimensions in in. (mm). '32003041-001 06097 Cover for manual reset models. 32003040-001 ©6097 Cover for recyole models. '32003089-001 Position indication Lamp Kit. ORDERING INFORMATION When purchasing replacement and modemization products from your TRADELINE® wholesaler or distributor, refer to the. ‘TRADELINE® Catalog or price sheets for complete ordering number. IFyou have addtional questions, need further informationi, or Would like to comment on cur products or services, please write or phone: 1. Your local Home and Building Control Sales Otfce (check white pages of your phone directory), 2. Home and Building Control Customer Relations Honeywell, 4885 Nouglas Drive North Minneapolis, Minnesota 55422-4386 (800) 928-5111 In Canada—Honeywell Limited/Honeywell Limite, 35 Dynamic Drive, Scarborough, Ontario M1V 429. International Sales and Service Officas in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A. 502872 2060974,8 PRESSURE SWITCHES ‘; Table 1. Pressure Switch Mode! Selection. 2 j Tiana Resst | Wonarial Reet Sheena nena oe Taxium | Maman falod operming| MOaEe™ | Mae Pease switch eure | winiram | aaximun Ditton | corte | sana skort ocat _|"Famae’ | Sets |'Sepolr | Nomis! | oximum [yea | "ipa | aout | adit | Setpont_| « commontn }ceng7Atoos |0.4t05in.|— - [o.%6 in, [0.24 in. wo |Addiive: 29 No Aires Breaks NO. Tua, ner a eemnection [ooo DaTAO [spain Sin we em we |= = Ea Yes [Aaas | Soon |e, NPT & Es Hn omerAIOeD [awa [ative aan we [= ea Nee [aoa ange Not ‘cane7At036 [121060 |t0in.we [i2inwe |— [= 50 yes [AlriGas iaB, NPT | cmaTNOW ee [ive Bw f= (= 5 Nee aoa ange aut [eeso7arass Jaw zt |= aan loan we 5 ne aitas Ear eaarnoa [swarm |= = Joatn[aaanwe 3 no aan Farge Wort eaaraio [eos = iti we [Bancwe 0 to Yas Tan NPT | SaTAGaT fjawe6o [ra we etn a a aoa IFarge woot | OmoTADGS fasion oain.we [romwe f= |= a ee [ata aan ie ei SRT [igeT [iter (tae |= a Ree [aeas ance ant > emaranne ise [iter [rarer = aa Res [ata a NPT Mone Ips oeaornTTD [eeT [= [dare faa a3 ins Jaeae Faget ss AES pal Savana [iste ore [oe a meas aa NeT * pa owt lsamormaio laawon, [= [= lorem ozainwe a ne [aes Farge Wor Cea7Aiz28 [015m |— — [= 23 Yes [avear Flange Mount jcene7B1002 |i2to 60 |i0in.we li2inwe |— = ‘Subtactive [50 Yes /AlvGas [Breaks ¥.C. [7/4 mh. NPT eee ° eee Tio SmeTBTOTO izios fomve enw [= [= so fee aes }sxmester, | Fange Mount omeTbIéae [sioath, jaan we aanwe == so Res aaa eer E out lexorerese [sate jaan we aan we [== iso Ree ates Farge waart cearam [igor ite flame = as fees | Farge Wore omararast [ier ft (am f= Bs Ree aie rian ner ceaTaiae [ware |= |= ]oaem [baa we Ey no aves Farge Wore eeaTaor [eee [= |= ]we fea | ca nao ange Noir oaoo7BI0GE [tate80 [= [= awe atin ee eas Tan er rete Ment eso7eraes [1et67 |= ave apa a Tareas Forge Hoare ie SeaaTeeT [ree [== Jaret oa a ie areas Can nT i | ir CaTERIS [swatn, |= foam oasinwe a0 re aoa rian, NET [se ie lou I we - o # Acceptable media: Natural ges, liquid propans (LP) gas, and alr 3 65-0237-206097A,8 PRESSURE SWITCHES WIRING A.WARNING Electrical Shock Hazard. Can cause serious personal injury or death. Disconnect power supply before beginning installation. More than ane disconnection can be involved. Make sure that all wiring agrees with all applicable locel codes, ordinances and regulations. An opening is proved to accommodate rigid conduit or armored cable for line voltage: operation (s2e Fig. Sand 4), Do rot overload the switch contacts (see Switch Ratings in tho Spociications socton). The switching schematics shown in Fig. 5. Fig. 4. C6097 (recycle model) with cover removed. SETTINGS AND ADJUSTMENTS Pressure Setpoint Adjustment To adjust the pressure setting, turn the setpoint adjustment 1 dial Fig. 3, 4and 5) ciockwise “~W_ to Increase the pressure setting and counterclockwise x) to decreas> fhe pressure seting, Fig. 3. 66037 (manual reset switch model) with cover removed. CAO: BRENKS ONO, MAKES GE ON PRESSURE Fig. 5. C6097 schemati 8 09-0297—2C6097A,B PRESSURE SWITCHES. OPERATION AND CHECKOUT Operation ‘The manusl reset CB097A ciaphragm actuates the enap- acing switch to break a control circut and lock out when pressure falls to the scale setting. The resycle C6097A models recycle automatically when the control circuit retums to scale setting plus aitterential. ‘The manuel reset C6097B claphragm actuates the snap- acing switch that bieaks ai control circuit and locks out when the pressur.rises to the scale setting. The-recyole C6097B models recycle automatically when the control pressure falls to the scale setting minus differential Manual Resetting ‘The C6097A rianual reset models lock out when pressure fals to the scale setting and require manual resetting after the pressure rises to scale setting plus differential to resume normal operation. ‘The C8097B manual reset models lock out when pressure rises fo the scale setting and reculre manual resetting after the pressure falls to scale setting minus the cifferental to resume normal operation. ‘Toreset, once normal operating pressures restored, push the reset button in as fer as it goes, then release, IMPORTANT Lockout models cannot be made to reoyele automatically by permanently holding in the reset lever. 5.02872 Checkout (C6097 Gas Fuel Application Set cutoff pressure. ‘Open main supply line. Depress reset lever on lockout ‘models untl switch makes control circu. Set controller and limit ewitoh to call for heat. For C6097A; Ciose the manual gas shutoff valve. ‘©6097 should open conirol circuit when pressure reaches cutoff point. For G6097B: Open the manual gas shutott valve, walt a few minutes for the pressure to rise; then lower the scale setting until the switch breaks control circuit anc locks out. For CE0S7A: Open the shutoff valve, return the pressure switch ta its original seting and press the reset button (it necessary). For C60078: raise setting to normal and press reset button (if necessary). Allow system to operate through at least one complete cycle to make sure all components are functioning propery. C6097 Air Application Set cu‘oll pressure, Tum on fan, Block fan inlet or fitar area. Switch should break control circuit when pressure drops to cutoff point. Manual reset ‘models lock out. Remove obstruction. Pross resot lever (manual reset models) and allow system to operate through at least ‘one complete cycle to be sure al components are fuinctioning properly.Honeywell } i APPLICATION ‘The V5097A-E Gas Valves are used with the V4055, v4002 ard 9055 Fluid Power Actuators to conirol gas flow to commercial and industrial burners. ‘US. Registered Trademark ‘© 2004 Honaywell International Inc, ‘Al Rights Reserved (v5097A1020, Vs097A1038, ‘vs09781028, 500781036 ONLY) V5097A-E Industrial Gas Valves “PRODUCT DATA | FEATURES + Used with natural or liquefied petroleum (LP) gases. + ¥5087 normally closed valves are rated for final shutoff service (safety shutoff). + ¥5097A,C,D,E Valves are for on-off service. + ¥5097B Valve has a characterized guide and in combination with the V4055, V4062 and V9055 Fluid. Power Actuators, provides slow-opening, H-LO-OFF, and modulating functions, respectively. + V5097C,E Valves have a double seal and are used with V4055D.E Fiuid Power Actuators to provide proof-of-closure switch and valve seal overtravel interlock. + Y5087D,£ Valves are for high pressure applications (see Table 1). + Two valve body types (small and large) applicable to seven pipe sizes: — Small body type for 3/4 In. (19 mm), 1 In. (25 mm), 4-414 in, (32 mm), 4-4/2 in, (38 mm) and 2 in. (54 mm) pipes. — Large body type for 2 in. (54 mm), 2-1/2 In. (64 mm) and 3 in, (76 mm) pipe: + Eight pipe adapter sizes 3/4 in. (19 mm) to 3 in. (76 mm) have NPT or BSP-PL threaded connections. + 5097 version provides three 1/4 in. upstream and two 1/4 in, downstream taps and plugs. CE version provides an additional downstream tap and plug. + Yalve body rating of 75 psi (5 bar); body passes Underwriters Laboratories Inc. burst tost + Yellow SHUT indicator attached to the valve stem provides indication of the valve closed position. ‘+ Unpainted die-cast aluminum body. Contents Appication Features Specifications =... Ordering Information To Size Two Identical Valves Piped in Series IU Qperation ard Checkout sn. Service information CE 65-0230-6V5007A.E INDUSTRIAL GAS VALVES. SPECIFICATIONS IMPORTANT The specifications in this publication do not include normal manufacturing tolerances; therefore, an individual unit may not exactly match the ‘specifications listed. Also, this product is tested and calibrated undor olosoly controlled conditions, and some minor differences in performance can be expected if those conditions are changed. Models: See Table 1. Table 1. Industrial Gas Valve Models: ‘Model Number] Features V5Ce7A [Tow pressure on-off (with quick-onening guide. Vs0a7e Low pressure characterized quide (provides, slowly increasing gas flow on opening). For ‘slow-opaning, high-low-cff, or mbdulating service. V5097C Low pressure double-seat. Used with \V4055D, V40820,VS0550 Actuators to provide proof-of-closure switch and a valve seal overiravel interiock. VeCo7D [High proceure on off (with quick opening guide) V5097E High pressure double-seat. Used with |V4055D, V40620,VS0550 Actuators fo |provide proof-ofclosure switch and a valve sea! overiravel interlock. Type of Gas: latural or Equefied petroleum (LP) only. Pipe Size: Small Body: 9/4 in. (19 m); 1 in, (26 mm); 1-1/4 in. (82 mm), 4-41/2in, (@8 mm);2 in, (51 mm). Large Body:2 In, (51 mm); 2-1/2 in, (64 mn); 3 in. (76 mn). e Threads: NPT or BSP-PL threads (equivalent to ISOR7 and DIN 2998). Available 3/4 in. to3 in. pipe adapters. (Order soparately.) Pressure Ratings: See Table 2 Valve Body Rating: 75 psi (5 bat); bedy passes burst test of Underwriters Laboratories inc. ORDERING INFORMATION ‘Valve Capacities: |AS ratings at 1 in. (0.25 kPa) pressure drop; based on gas with 0.64 sp or. BoltiNut Fasteners: ‘Small Body: 38-16 x 1.375, Grade 5 bolt. Matric equivalont MB x 1.25 x 35mm, class 9.8. Large Bovy: 412-13 x 2.00, Grade 5 bolt. Matric equivalent M12 x 1.75 x 50mm, class 9.8, Pipe Adapter Ratings: See Table 3, Gas Pressure Limit Switch Mounting: Two 1/4 in. NPT or BSP-PL upstream and downstream tapping and piug. Upstream Tapping and Plug: 1/4 in. NPT or BSP-PL. Downstream Tapping and Plug: 4/4 in. NPT. Ambient Operating Temperature Rating: 40°F to + 150°F (40°C to +66°C); 40°F to +125°F (40°C to +52°C) when Used with V055. Material: Die-cast aluminum, Mounting: Directly in gas supply tine. Weight: Small Body Valve: 3.68 ib (1.67 kg). Large Body Valve: 8.0 Ib (3.64 ka). ‘Small Body Pive Adapters:.67 Ib (0.3 kg). Large Body Pipe Adaptors: 2.126 Ib (.97 kg}. Replacement Parts: 133393 Replacement Seal Assembly (Includes valve seal, ‘bonnet seal and tube of lubricant) for Small Eody Valves. 133392 Replacement Seal Assembly (Includes valve seal. bonnet seal and tube of lubricant) for Large Body Valves. For al pipo adapter sizes, seo Tablo 3. Replacement Sonnet Assembly (Table 4): Includes complete bonnet assembly, plus the required replacement seal assembly, Accessories: 433637 Tube of lubricant (supplied). DSP2586 Valve Assombly Tool (UVG). When purchasing replacement and modemization procucts from your TRADELINE® wholesaler or distributor, refer to the TRADELINE® Catalog or price sheets for complete ordering number. If you have additional questions, need further information, or would like to comment on our products or services, please write or phone: 4. Your local Honeywell Automation and Control Products Sales Orfice (check white pages of your phone directory). 2. Honoywoll Customor Care 1885 Douglas Drive North Minnwapuls, Minniesuts 55422-4000 In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9. International Sales and Service Offices in al principal citios of the world. Manufacturing in Australia, Canada, Finland, Franco, Germany, Japan, Mexico, Netherlands, Spain, Taivan, United Kingdom, U.S.A, 65-2306 2V5007A-€ INDUSTRIAL GAS VALVES 4074EYK Bag Assembly, contains 2 O-rings and tube of AOT4EYE Bag Assembly, contains 6 bolts, nuts and lock lubricent—small body’ ‘washers for Large Body Valves and adapters. 4074EYL Bea Assembly, contains 2 O-rings and tube of AOTAEYF Bag Assembly, contains 6 bolts, nuts and lock lubricant—targe body. washers for Small Body Valves and adapters. — ech ——4 |-——s 12 ——+ | —_ A 9) | | i 3 mal | | He | ~ Z\ i100 21N, 61 mn) CLEARANCE FOR ACTUATOR REMOVAL, F we pm.a [pme [omc [pmo | pme | omer | ome | DIMH | bIM.s | OCTAGON i par pw orm for Par on fee] Pome Pe] wT wT] | we wi [rsa om [oan [70 [ose [aw [ee om Poona | [5 [ar [oare [os [oa [os [Sone oo Powe | 1 [rete am [raw [70 [oat [aoe Pee] an [arne |e [S| ar [ears [ae |e] os [stare] oo Petar [1 ‘2 [rie [a [8a | 70 | cre [oon | eve [an [anne | o2 | 6 ar [eare [se [70 [oa [orowe| wo [erane [71 2 [asa] ae [sam [ae [eave [en [rae] ae [aoe [oe [ea pene [ra] a [fo [epee [re = zig [rae] a0 [a6 | v6 [este fair | i139) 2a [sae | or 70 [ene [aa] 142 [se [ewe as [aa | a a fias| ae [sae | o6 [esis [air | 11a) am [2oe | ov nea femme Pua) 312 [se [ewe [res fea 1s Fig. 1. Approximate dimensions of 3/4 in. through 3 in. V5087 Valves with valve actuator, in inches and millimeters. 3 65-0230-65097A-E INDUSTRIAL GAS VALVES rr apilliag D Ld ouise 2109 Vea FUR ACTURIUN HHUA, vae[_oma [ome | omc | omo | OME | DMF | DIM. [ EA TS ECO EO A 7 Tae fas eme fetter [ater ery ster feet eee toes 3 Tae [reas fase} feats ae Lao Late fe | oar ae [oe [ eo a sar refs [eae se[a[anm per [ oer [aes [oe [ooo fe os 7 zfs [ase fear a fears ore | a [ae [ose Tor epee [ore bar fee er fe Bim [rea [ase [oe [peso art] = [ae fae Pat] eos ene Heap oie La fae Fa Fig. . Approximate dimensions of two small and large V5087 Valves with valve actuators and pipe adapters in inches and millimeters. Table 2, V5097 Models. a ‘Standard Pressure Actuators High Pressure Actuators 'V40S5A,0, vaoesz, Va05, Va0358,6 Pipesize| _MOPD* | mor> | mcop® | wopD® | mop? | mGOP* | Model (iu. NPT) | pei_| mbar|_pai_[mbar| pst [bar| pst | bar | wei | bar [pst | bar] (SendadPressurevaves asto2 8 fad [te tooo we 1 fs} Te fs 7 ORT AE [2103 13 [380 | igh Pressure Valves [satoz fe [aa [ao _]orou [re_[s (5 [re eas hisndathiead Bes 1s [eon fae pfs [fat fia [as 8 ® Maximum operating pressure differential. Once open, the valve and actuator operate correclly against this pressure at 85% of rated voltage. ® Maximum opening pressure. Actuator opens valve against this pressure at 85% of rated voltage, © Maximum close-off pressure. Maximum allowable pressure drop across fuky closed valve prevents seal leakage (independent of 75 psi valve body rating). 65.0230-6 4(C<> XO OD Approvals: Underwriters Laborateries Inc. Listed: File MH1639, Guide No. Yi02: Vé055A,8 D,EIV5097AB,CD.E. V4062V5097A,8,C,E. \V90SSIVS097A.B,C.E. Industrial Risk Insurers (Formerly FIA) Acceptable: \VéDS5A,B D,EIV5097A.B,C,D.E. Va0SSVSI97AB,CE Factory Mutual Approved: All, International Approval Services (IAS) Design Certified: Report No. 24-1G: \VAOSSAVSOSTA.B. \Vd0558/V'50970, \v4085DV'5097¢. \V40B5E/VEOO7E. \v40621V50978,C. \Vs055/V5097B 6. NOTE: IAS does not certily models equipped with BSP threads, . International Approval Services (IAS) Certified (60 He Aquator Models Only): Report No. 1029-SS\-4098: VAD55A,B,0.E/V5097.8,CD, E. v4062V50978. \Vo085/V50978. CE Approved: CE-0063AR1359 (V5097A1020, V5097A1038, ‘609701026, V50875 1930 Orly). Australian Gas Association Approved (Pending). Table 4. Replacement Bonnet Assamblios, Y80S7A-£ INDUSTRIAL GAS VALVES Table 3. Valve Plus Two Pipe Adapters Ratings. Adapter CEA Ratod Capacity Part Number | Size (in.)_ | (efH) | (cu mia) (32000708001 [SENET 668 188 [32000109-002 NPT 960 [272 ja2000108.003__|[tvaNPT [1406 [50.8 [s2000109-004 42NPT|t717 [48.5 '3200109-005 2NPT 1990 (56.9 (Smal Body) 32001605007 |2NPT 362014025 (Large Body) '32001605-002 24/2NPT [4250 1203 [32001605003 [SNPT 5200/1481 32000109-006 34 BSP [665 188 | j32000108-007 ‘| BSP 960 272 on1eD08 «BSP [406 aes CS [s2000109-009 (BSP [A7ty (ane '32001605-004 «(2 BSP 3620 1025 (Large Boy) | 22001605005 [2aiBsP 4260 e058 [32001605-006 3 BSP 5230 [148.1 Valve Modal Pipe Adapter Size (in. NPT) | Replacement Bonnet Assembly (part no) |V6087A7004 (On-Off) [B, 1, 1-104, 1-112,2 (small) [TS3aS8RA | [VeOS7AT012 2, 2-112, 3 (large) _ 1334170 'V60878 1002 (Cheracterized guide) _|3/4, 1, 1M, 1-1/2, 2 (email 133398BA_ | \v5097B1010 2,247, 3 (large) aS417BA \ve097C1000 [3/4 4, 4-104, 1-172, 2 (small) 733398CA Vs0s7C 1018 2, 2-112, 3 (large) 1334170. [V5097D 1008 3/4, 1, 1-414, 1-112, 2 (smail) 136308AA_ lvs0a7b 1016 2, 2-1/2, 3 (larga) F1SE307AA ~ |Vs097E 1005 (3/4, 1, 1-114, 1472, 2 (emall) 736308BA [W5097E1013 2, 2-472, 3 llarge) [1363078 } Gas Valve Sizing 4. For gases with specific gravities other than 0.64, correct, Honeywell gas valve capacties are shown in cubic fest per hour (fh) or cuble meters per hour (m*h} for gas with a. specific gravity of 0.64 (1 cfh = 0.0283 mh), 1. Chock the burner nameplate for (a) the type of gas used, and (b) the gas flow capacity (listed In Btuh or in th), 2. Call the gas utiity for information on (a) sp gr and (b) Btu/cu ft for type of gas used. 3. the capacity is isted in Btuh, convert to cih using the following formala: Capacity in cfh = Btuh {from buiner nar Biwlof (front ga ullily) the cfh from the nameplate or from the formula in step 3 for the specific gravity of gas usad, following the information tn Fig. 3 5. Use the cfh capacity (for 0.64 or the corrected cfh from step 4) for determining the gas valve size in Fig, 4. Determine the maximum pressure drop across the valvo and draw a horizontal line at this pressure in Fig. 4. 7. Draw a vortical line in Fig. 4 at the capacity (cfh) raviously determined. Use the corrected capacily for ‘a gas with a specific gravity otner than 0.64 8. Use the valve size at the intersection of the horizontal and vertical lines. Ifthe intersection is between valve sizes. use the next largar valve eiva in Fig.A 6502306V6007A-E INDUSTRIAL GAS VALVES TO SIZE TWO IDENTICAL VALVES PIPED IN SERIES 1. Find the cffh for the type of gas used. 2. Consider both vaives as one unit. Determine the total maximum pressure drop across the unit. 3. Find the pressure drop across the first valve by assuming It to be 46 percent of the total pressure drop. 4. Find tho valve size from Fig. 4 5. The second valve will be the same size as the first valve. How to use the Specific Gravity Conversion Factors (Fig. 3) Listed valve capaci ratings are based on 0.64 spoatic gravity (so gr) gas. When the required cin capacty is known for gas of other specific gravity, t can be converted to the 0.64 ‘equivalent by using the correct multiplying factor obtained from Fig. 3. ™ 200 28 sPecIrICGRAWTY us 050 125 me O7) ODA Forexample, a valve capacity of 2670 ofh based on 0.72 spat gas is required. What valve capacity, based on 0.64 sp gr gas, will be required? (On the vertical scale of Fig. 3, find 0.72 specific gravity (left side of igure). Draw a line horizontally from that point to the right to intersect the curve, then move straignt down the chart to the bottom scale and read the conversion factor (1.06, in this example), Mutiply the 2670 off by the convarsion factor (1.06) to obtain a valve capacity of 2830 cfh. ‘Applying this number to Fig. 4, assuming a 1 in. we pressure ‘drop, use a 2 in. (large body) V5097 Valve for that flow (step 8 of Gas Valve Sizing). “a ia 1S eT 1 ‘CONVERSION FACTORS wre Fig. 3. Specific gravity conversion factors. 85-0230-8 6