INSTALLATION INSTRUCTIONS
66-2062-01
YP7899A1002 - 7800 SERIES Burner Management and Fuel Air Ratio Control Panel - Single Fuel
APPLICATIONThe 7800 SERIES Burner Management and Fuel Air Ratio Control Panel is a packaged, pre-wired panel that includes the RM7800L1087 burner control, the R7999A ControLinks fuel air ratio control and a Modbus® interface. The included S7999D color touchscreen interface allows commissioning of the ControLinks system as well as monitoring and control of it and the RM7800 control, all with user-friendly menus. On board switches, buttons and alarm lights are included for customer convenience. The ML7999A2001 universal direct coupled actuators are purchased separately as well as the burner control purge card, amplifier and flame detector.
This document provides installation instructions and operation information. Other applicable publications are:
— 65-0238, R7999 ControLinks Controller— 65-0240, Q7999A ControLinks Universal Wiring Sub-
base— 65-0288, S7800A1142 Keyboard Display Module 7800
SERIES
— 65-0239, ML7999A Universal Parallel-Positioning Actuator
— 65-0321, S7999D1048 System Display— 66-1152, RM7800L1087 Relay Module with Valve
Proving— 65-0029, 7800 Series Relay Module Checkout and
Test— 65-0084, Q7800A 7800 SERIES 22-Terminals Univer-
sal Wiring Subbase— 66-2034, R78xx Amplifiers for 7800 SERIES and
R7140 Relay Modules— 65-0089, ST7800A,C 7800 SERIES Plug-In Purge
Timer— 65-0249, S7810M Modbus Module— 60-2026, C7027, C7035, C7044, C7927 Minipeeper
UV Flame Detector— 65-0267, C7961 Dynamic Self-checking Solid State
UV Flame Detector— 60-0292, C7915 Infrared Flame Detector— 65-0277, C7962 Visible Light Flame Detector— 60-2024, C7007, C7008, C7009 Flame Rod Detector— 95-8269, C7076 Adjustable Sensitivity UV Flame
Detector— 60-2398, C7012 Ultraviolet Flame Detectors
FEATURES— Pre-wired and ready to install— Includes the RM7800L1087 burner control with wir-
ing subbase, S7810M modbus module, R7999 fuel air ratio control with wiring subbase and S7999D touchscreen display
— Commission, monitor and control ControLinks through the touchscreen interface
— Fuel selector switch— Burner on/off selector switch— Alarm lights— Reset buttons— Unit shutdown / Emergency stop button— Auto/manual switch— Manual operation potentiometer— S7999D touchscreen display is modbus ready— VPS (Valve Proving System) capability via flame
safeguard control
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
66-2062—01 2
SPECIFICATIONSElectrical Ratings120 Vac, 50/60 Hz, 10 AmpsFor individual ratings, see component literature for details.
Environmental RatingsEnclosure: NEMA 12.For individual ratings, see component literature for details.
HumidityInstall the panel where the relative humidity never reaches the
saturation point. The relay module inside the panel is designed to operate in a maximum 85 percent relative humidity continuous, non-condensing, moisture environ-ment.
VibrationDo not install the panel where it could be subjected to vibra-
tion in excess of 0.5G continuous maximum vibration.
GeneralOverall panel size: 30in. high x 24 in. wide x 8 in. deep
(excluding door and door mounted components)Panel weight: approx. 91 poundsMounting holes are 0.44 in. typical diameter, 18 in. on center.
ApprovalsComponents are individually approved by the nationally recognized agencies. Please see component literature for details. The panel has UL 508A approval. Panel is assembled and wired to the UL Standards.
INSTALLATIONWhen Installing This Product…
1. Read these instructions and the appropriate product lit-erature carefully. Failure to follow them could damage the product or cause a hazardous condition.
2. Refer to the installation manuals and wiring diagrams provided with this panel for the embedded products.
3. Check the ratings given in the instructions and on the product to make sure that the product is suitable for your application.
4. Installer must be a trained, experienced combustion ser-vice technician.
5. Disconnect the power supply before beginning installa-tion to prevent electrical shock and equipment damage. More than one disconnect may be involved.
6. All wiring must comply with the National Electric Code (NEC) and any applicable local electrical codes, ordi-nances and regulations.
7. After installation is complete, check out product opera-tion as provided in the appropriate product installation instructions.
WARNINGFire or Explosion Hazard. Can cause severe injury, death or property damage.To prevent possible hazardous burner operation, verify safety requirements each time a controller is installed on a burner.
WIRING
WARNINGElectrical Shock Hazard. Can cause serious injury, death or equipment damage.Disconnect the power supply before beginning wiring to prevent electrical shock, equipment and control damage. More than one disconnect may be involved.
Ground ConnectionEarth ground is required for proper operation of the panel and components. The earth ground must be capable of conducting enough current to blow the fuse or breaker in the event of an internal short. Ensure the panel is bonded to a substantial earth ground. Make sure that mechanically tightened joints along the ground path are free of nonconductive coatings and protected against corrosion on mating surfaces.
Electrical Connections1. Refer to the appropriate product data sheet for details.2. Wire size and length will vary, depending on the compo-
nent. Refer to the component literature for specific wire lengths, sizes and type recommendations.
3. Wire according to specifications, following all local ordi-nances and requirements.
4. Field knockouts are required for the wiring. When drill-ing holes, take care to protect the electronics from metal pieces and debris.
IMPORTANTRun line voltage and low voltage wiring in separate conduit to avoid signal interference.
Carefully check field wiring and terminal designa-tions in this document and the associated wiring dia-gram. They are different from those of the individual components.
Panel InspectionAfter mounting and wiring, but before powering the panel, inspect all internal panel wire connections. Each panel is fully tested at the factory, however, wires may loosen during transit. Verify that all internal wire connections are secure from the Q7999 and Q7800 subbases to the components mounted on the door and the S7999D touchscreen interface.
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
3 66-2062—01
Final Wiring Check and Static CheckoutAll wiring shall be in accordance with the National Electric Codes (NEC) and local electrical codes.
1. Check the power supply circuit. The voltage and fre-quency must match the specification listed.
2. Check wiring terminations and routing to ensure proper connections.
3. Follow any system checkout recommendations for indi-vidual components as found in the component literature.
4. Restore power to the panel.
CAUTIONTest each limit and interlock to ensure system operates correctly as defined in the 7800 Series "Checkout and Test" document (Form #65-0229).
WARNINGExplosion and Electrical Shock Hazard. Can cause serious injury, death or equipment damage.
1. Close all manual fuel shutoff valves before starting these tests.
2. Use extreme care while testing the system. Line volt-age is present on most terminal connections when power is on.
3. Replace all limits and interlocks that are not operat-ing properly. Do not bypass limit and interlocks.
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
66-2062—01 4
TROUBLESHOOTING
System DiagnosticsThe S7999D touchscreen interface indicates the current fault and keeps a fault history log. The R7999 ControLinks control, the ML7999A Universal Parallel-Positioning Actuator and the
RM7800L control also have LED fault blink codes. Refer to the appropriate product instruction sheet for further troubleshooting information and diagnostic codes.
Field Wiring
Table 1. Field Wiring and Terminal Designation.1
Terminal #To Connecting
Device Description
12 L1 Panel Power 120Vac Power Supply, 10A Max. Provide disconnect means and overload protection as required.
2 L2 Panel Neutral
GND Panel Ground
4 L1 L1 customer convenience wire point - provided for 4 actuators - 120Vac, 50/60Hz
2 L2 L2 customer convenience wire point - provided for 4 actuators
GND Panel Ground GND customer convenience wire point - provided for 4 actuators
27-53 Airflow Switch Combustion airflow (pressure) switch
5-63 LP Switch Fuel low pressure/temperature switch
6-73 HP Switch Fuel high pressure/temperature switch
7-83 Interlocks Fuel customer interlocks and limits, including LWCO, high-limit, etc.
8-93 High Limit High limit device
10 Blower Motor Combustion blower motor line voltage output from burner control
144 Shutter Drive Shutter drive output connection from burner control
164 F Flame detector F lead connection from burner control
GND4 Panel Ground Flame detector G lead connection from burner control
25-28 Burner Control On/off burner operating control
XF-25 Ignition Spark ignition transformer
4-193 POC Switch 1 Main fuel valve 1 proof of closure switch (pre-ignition interlock switch)
19-203 POC Switch 2 Main fuel valve 2 proof of closure switch (pre-ignition interlock switch)
17-2 Pilot Vavle(s) Pilot fuel valve(s) connection to burner control output - 10 second interrupted pilot
18-26 Main Valve(s) Main fuel valve(s) connection to burner control output
2027,8 DR1 Air Actuator DR1 command input
2037,8 DR2 Air Actuator DR2 command input
2047,8 CW Air Actuator potentiometer CW output
2057,8 S Air Actuator potentiometer S output
2067,8 CCW Air Actuator potentiometer CCW output
GND7,8 Ground Air Actuator ground
2077,8 DR1 Fuel 1 Actuator DR1 command input
2087,8 DR2 Fuel 1 Actuator DR2 command input
2097,8 CW Fuel 1 Actuator potentiometer CW output
2107,8 S Fuel 1 Actuator potentiometer S output
2117,8 CCW Fuel 1 Actuator potentiometer CCW output
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
5 66-2062—01
1Carefully check field wiring and terminal designations in this document and the associated wiring diagram. They are different from those of the individual components.
2The circuit protection incorporated into this control panel is designed to serve as supplemental protection only. It is the responsi-bility of the end user to provide appropriate protection on the service to this control panel. Refer to the National Electric Code and UL standard 1077 for more information on this subject.
3Jumper all unused limits and interlocks.4Refer to the appropriate flame detector product sheet for wiring size and length information. Run flame detector F and G leads in
their own conduit, independent of other power carrying leadwires. Flame detector power and shutter wires (if applicable) must be run in their own conduit as well, avoiding other electrical noise carrying wiring. The scanner wires should remain separated a minimum of 2 inches from other line voltage wires in the control panel to the flame safeguard device.
5Refer to the appropriate ignition transformer product sheet for wiring size and length information. Separate the high voltage igni-tion cable from other wires to avoid interference. Ignition cable to the spark electrode must be run in separate conduit (if applica-ble).
6If VPS (Valve Proving System) usage is required with the RM7800 burner control, contact factory for advice regarding wiring.7Low voltage wire to the firing rate actuators must be run in separate conduit. Line voltage wiring to actuators provided by cus-
tomer. Run line voltage wires in separate conduit. Refer to the ML7999A product sheet for details.8Connect the shield ground of the ML7999A actuator(s) to the earth ground strip provided in the Q7999 universal subbase, on the
low voltage side. Connect the shield at the controller end only. Refer to the ML7999A product sheet for details.9COM 2 on the S7999D is wired to the S7810M Modbus module on the RM7800L burner control. Customer may wire Modbus-
enabled UDC2500/3200/3500 controls in a daisy-chain fashion to the customer terminals provided for display on the S7999D. Refer to the S7999D and UDC control product manuals for further information on wiring and S7999D display set-up.
10Installation, operation and maintenance shall conform with National Fire Protection Association standards, national and local codes and authorities having jurisdiction.
11For detailed device wiring information, refer to the RM7800, Q7999, R7999, Q7999A, ML7999A and S7999D1048 product sheets.
12Spare/unused terminals are provided for customer field use.
GND7,8 Ground Fuel 1 Actuator ground
2147,8 DR1 FGR/4th Channel Actuator DR1 command input
2157,8 DR2 FGR/4th Channel Actuator DR2 command input
2167,8 CW FGR/4th Channel Actuator potentiometer CW output
2177,8 S FGR/4th Channel Actuator potentiometer S output
2187,8 CCW FGR/4th Channel Actuator potentiometer CCW output
GND7,8 Ground FGR/4th Channel Actuator ground
220 XmA+ Auxiliary 4-20mA+ input from Stack/Water temperature sensor (used for low fire hold)
212 XmA- Auxiliary 4-20mA- input from Stack/Water temperature sensor (used for low fire hold)
221 CmA+ 4-20mA+ input from Firing Rate control
222 CmA- 4-20mA- input from Firing Rate control
2289 COM 2 A S7999D COM 2 modbus A / Data + terminal
2299 COM 2 B S7999D COM 2 modbus B / Data - terminal
2259 COM 2 GND S7999D COM 2 Modbus C / Ground terminal
Table 1. Field Wiring and Terminal Designation.1 (Continued)
Terminal #To Connecting
Device Description
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
66-2062—01 6
Fig. 1.
24 (610)
30(762)
INDICATES EXTERNAL WIRING
(MAIN TERMINAL BLOCK).
INDICATES TERMINALS IN MAXON VALVES
INDICATES COMPONENT TERMINALS
INDICATES TERMINALS AND WIRING IN MAXON CONTROL PANEL.
INFORMATION ON THIS SUBJECT.
1. THE CIRCUIT PROTECTION INCORPORATED INTO THIS CONTROL PANEL IS DESIGNEDTO SERVE AS SUPPLEMENTAL PROTECTION ONLY. IT IS THE RESPONSIBILITY OF THEEND USER TO PROVIDE APPROPRIATE PROTECTION ON THE SERVICE TO THIS CONTROLPANEL. REFER TO THE NATIONAL ELECTRIC CODE AND UL STANDARD 1077 FOR MORE
EQUAL. WIRE MUST NOT BE IN THE SAME CONDUIT WITH POWER WIRING.5. FIELD WIRE TO THE DETECTOR SHOULD BE #14 AWG. TYPE TW 600V INSULATED WIRE OR
7. WIRE TO THE FIRING RATE ACTUATOR MUST BE RUN IN SEPARATE CONDUIT.
2. JUMPER ALL UNUSED LIMITS AND INTERLOCKS.
4. FIELD WIRING SHOWN FOR BLOCK AND BLEED VALVE ARRANGEMENT.
6. IGNITION CABLE TO THE SPARK ELECTRODE MUST BE RUN IN SEPARATE CONDUIT.
AUTHORITIES HAVING JURISDICTION.FIRE PROTECTION ASSOCIATION STANDARDS, NATIONAL AND LOCAL CODES, AND
8. INSTALLATION, OPERATION AND MAINTENANCE SHALL CONFORM WITH NATIONAL
(IF APPLICABLE)
NOTES:
3. THE USE OF A HIGH TEMPERATURE LIMIT IS STRONGLY RECOMMENDED ON ALLAPPLICATIONS. THIS DEVICE IS TO BE SUPPLIED BY THE CUSTOMER, IN THE FIELD.IF AFTER CAREFUL REVIEW OF YOUR APPLICATION (BY QUALIFIED PERSONNEL) IT ISDETERMINED THIS DEVICE IS NOT REQUIRED, THEN IT MAY BE OMITTED.
WIRE CODE
120 VAC (NEUTRAL)
TYPE J THERMOCOUPLETYPE K THERMOCOUPLE
VDC
GROUND
220VAC (HOT)220 VAC (NEUTRAL)
120 VAC (HOT)
FUNCTION
16 (MTW)WHITE
20 (POLYVINYL)20 (POLYVINYL)YELLOW/RED
WHITE/RED
GREEN
BLUE
14 (MTW)
16 (MTW)
COLORBLACKWHITE
RED
16 (MTW)16 (MTW)16 (MTW)
AWG
24 VAC BROWN 16 (MTW)
EXTERNAL POWER SOURCE 16 (MTW)YELLOW
4-20mA SIGNAL BLUE 16 (MTW)
DRY CONTACTS 16 (MTW)YELLOW
FSG RESETS/DISPLAY/CONTROL BUS BELDON 22 (AWG) TWISTED PAIR
M34546
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
7 66-2062—01
Fig. 2 - Part 1.
CUSTOMERINTERLOCKS
FIELD DEVICE
PS103A
LOW GASPRESSURE
FIELD DEVICE
PS103
COMBUSTIONAIR PRESSURE
FIELD DEVICE
PS103B
HIGH GASPRESSURE
FIELD DEVICE
27 5 6 7
FIELD DEVICE
LIMITHIGH TEMP
HTL
FU10110A
PB101
EMERGENCYSTOP
21
43
9
9 2W
LT105
PROVENINTERLOCKS
16
14
GND
CR114
FSGALARM
209
13 14
NONC
15
R
LT112
X1 X2 ALARMFSG
24
23
from 205
24
from 204
23
from 210
27
ULTRAVIOLETDETECTOR
BLU
WHTST112
FIELD DEVICE
20
6
4
12
15
18
19
22
F
G
7 L2
5
8
9
3
10
PREIGNITIONINTERLOCK
BRN CTRLLIMITS
L1LINE VOLTAGE SUPPLY
HIGH FIRE
MODULATE
LOW FIRE SWITCH INPUT
HIGH FIRESWITCH INPUT
FLAMESENSOR
SHUTTER
FLAME SENSORGROUND
LOCKOUT/RUNNING INTERLOCKS
LINE VOLTAGECOMMON
BURNERMOTOR
PILOT VALVE/
IGNITION
MAIN FUELVALVE
ALARM
IGNITION
14
LOW FIRE
13
COMMON
17
DEMAND VALVE PROVING
16
VALVE PROVINGSWITCH
21
15 SEC INTERR.
PILOT VLV, MV2
FSG107RM7800L-1087
HONEYWELL
4 19 20
XF H1 H2TRANSFORMER
SPARK IGNITION
XF115
X2X1FIELD DEVICE
PLUGSPARK
SP115
FIELD DEVICE
2
to 120
17
to 124
18
to 119
4
to 119
2
USE 16 AWG MTW WIRE120/1/60
200
201PB113
FLAMESAFEGUARD
43
RESETfrom 228
225from 229
228from 228
229
SOL127
MAIN FUELVALVE
(PROOF OF CLOSURE)FIELD DEVICE
SOL130
BLOCKING FUELVALVE
(PROOF OF CLOSURE)FIELD DEVICE
to 206
11
to 208
12
to 207
13
CLR
.B
LK.
RE
D.
MODBUS
1 2 3 4 5 6 7 8HONEYWELL
S7810M-1003-
KBD114
1 2
10
8
M34544
NOTE 2
NOTE 6
NOTE 3
NOTE 1
NOTE 5
27
2
15
L1 L2
4
27
9 2 2
15
1124734-ECC
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
4
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
66-2062—01 8
Fig. 2 - Part 2.
VENT PILOTVALVE
SOL120FIELD DEVICE
MAIN PILOTVALVE
SOL121FIELD DEVICE
BLOCKING PILOTVALVE
SOL122FIELD DEVICE
B
LT119
X1 X2 ENERGIZEDPILOT VALVES
17
17
2
from 115
17
from 1182
to 200
18 2
2
218
18
from 116
18
18G
LT132
X1 X2BURNER ON
MAIN FUELVALVE
SOL127FIELD DEVICE
118
GND
GND
MAIN FUELVENT VALVE
SOL124FIELD DEVICE
GND
GND
BLOCKING FUELVALVE
SOL130FIELD DEVICE
118
GND
GND
M34657
NOTE 4
NOTE 4
2
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
from 1184
to 200
4
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
9 66-2062—01
Fig. 3 - Part 1.
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
GND
22
DR1
DR2
CW
S
VALVECONTROL VALVECONTROLINKS
CCW
L1
L2
GND
CV203
FIELD DEVICE
DR1
DR2
CW
S
VALVECONTROL VALVECONTROLINKS
CCW
L1
L2
GND
CV206
FIELD DEVICE
DR1
DR2
CW
S
VALVECONTROL VALVECONTROLINKS
CCW
L1
L2
GND
CV212
FIELD DEVICE
SS201CONTROL
AUTO MANUALOX
43
214
to 103
27
to 117
23
to 116
24
from 109
11
from 111
13
from 110
12
SS209BURNER
OFF ONOX43
4 25 CR114
9 1
FSGALARM
222
221
212
220
219
213PB212
CONTROLINKSRESET
43
R
LT202
ALARMCONTROLINKS
4
2
4
2
4
2
GND
GND
GND
2
from 229
225
from 228
226
from 228
227
from 1354
from 1352
to 203,206,212,219
4
to 219
2
from 218
4
from 218
4
from 218
4
BLK. .
CLR. .
RE
D
CLR
BLK
VR213
1
3
5K OHMS
MANUALOPERATOR
2
212
1
16
L1
A-2
15
4AUTO/MAN
5FUEL SLCT1
6FUEL SLCT2
10DRIVE TO
11
12
13
17CW
18S
19CCW
20
21
22
23
24
35
36
37
38
39
40
A-1
7ALARM
8HIGH FIRE
9LOW FIRE
PROVEN
PROVEN
HIGH FIRE
MODULATEVALVE
DRIVE TOLOW FIRE
LIMIT/CTRL IN
AIR
F1-2
CW
S
CCW
F1-1
FUEL 1
REMOTERESET (RR)
MANUAL CNTRL(MNC)
TEMP SENS(XmA+)
TEMP SENS(XmA-)
CNTRL INPUT(CmA+)
CNTRL INPUT(CmA-)
BA CRS485 DDL
2GND
3L2
14LIMIT/CTRL OUT
26F2-2
25
27CW
28S
29CCW
30
31
32
33
34
F2-1
FUEL 2
FG-2
CW
S
CCW
FG-1
FGR
CTRL200R7999A1005HONEYWELL
CONTROLINKS
202
203
204
205
206
207
208
209
210
211
214
215
216
217
218
GND
GND
GND
28ON/OFF
CUSTOMER
RED.
RED
RED. .
WHT
WHT. .
WHT. .
BLK. .
BLK. .
BLK
BRN
BRN. .
BRN. .
GRN
GRN. .
GRN. .
M34545
2
26
4
24
23
22
12
13
11
NOTE 7
NOTE 7
NOTE 7
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
66-2062—01 10
Fig. 3 - Part 2.
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
4 2
GND
FU221.5A
227
226
225
228
229
225
to 218
227
to 218
226
to 217
225
to 112
228to 112
229to 113
225
from 2184
from 2182
BLK
..
WH
T.
.
RE
D.
.
BR
N.
.
GR
N.
.
BLK. .
CLR. .
RED. .
RED. .
CLR. .
BLK. .
1 2 3 4 5 6 7 8
CO
M
+24
VA
C
CO
M1
C
CO
M1
B
CO
M1
A
CO
M2
A
CO
M2
B
CO
M2
C
HONEYWELLS7999D1048
HMI224
SYSTEM DISPLAY
223
INPUT 120 VAC
OUTPUT 24VAC
SYSTEM DISPLAY
XF220
(-)(+)
(G)
(N)(L)
POWER SUPPLY
M34658
2
223 224 225
4 2
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
11 66-2062—01
Fig 4.
M34547
21 (533)
27(686)
YP7899A1002 - 7800 SERIES BURNER MANAGEMENT AND FUEL AIR RATIO CONTROL PANEL - SINGLE FUEL
Automation and Control SolutionsHoneywell International Inc.
1985 Douglas Drive North
Golden Valley, MN 55422
customer.honeywell.com
® U.S. Registered Trademark© 2013 Honeywell International Inc.66-2062—01 M.S. 03-13 Printed in United States