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Travis Jordan
 
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wrote:
We purchased a Honeywell RTH7400D unit (5+1+1). Now I'm feeling like


The old set was very simple: two wires connected. One to "R" and the
other to "4".


Old R - transformer power - connect to R on RTH7400
Old 4 - call for heat - connect to W on RTH7400

Don't ask why Honeywell shows it differently in their owner's manual.
For your application, their instructions are incorrect.

Enjoy.