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Honeywell RM7838B Installation Instructions Manual

7800 series relay module.
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RM7838B,C
7800 SERIES Relay Module
APPLICATION
The Honeywell RM7838B,C is a microprocessor based
integrated burner control for industrial process modulating
semiautomatically fired gas, oil, coal or combination fuel
single burner applications. The RM7838B,C System consists
of a relay module, wiring subbase, keyboard display module
(KDM), amplifier, and purge card. Options include Data
ControlBus Module™, remote display mounting, and first-out
expanded annunciator.
Functions provided by the RM7838B,C include automatic
modulated High Fire and Low Fire proven Purge, burner pilot
startup with pilot valve hold, a special pilot valve hold from the
Run condition, flame supervision, system status indication,
system or self-diagnostics and troubleshooting.
The RM7838C differs from the RM7838B as follows:
1. Alarms only on Safety Shutdown.
2. Requires ST7800C Purge Timer.
3. C1004 has 15 second MFEP. C1020 has 5 second
MFEP.
This document provides installation and static checkout
instructions. Other applicable publications are:
65-0084:
Q7800A,B 22-Terminal Wiring Subbase
Product Data.
65-0089:
ST7800A,C Plug-In Purge Timer
Installation Instructions.
65-0090:
S7800A Keyboard Display Module
Product Data.
65-0101:
S7830 Expanded Annunciator Product
Data.
65-0109:
R7824, R7847, R7848, R7849, R7851,
R7852, R7861, R7886 Flame Amplifiers
for the 7800 Series Product Data.
65-0131:
221818A Extension Cable Assembly
Product Data.
65-0229:
7800 Series Relay Modules Checkout and
Troubleshooting Product Data.
65-0249:
S7810M ModBus™ Module Product Data.
SPECIFICATIONS
Electrical Ratings (See Table 4):
Voltage and Frequency: 120 Vac (+10/-15%),
50/60 Hz (±10%).
SIL
Capable
3
RM7838C1020 only
INSTALLATION INSTRUCTIONS
Power Dissipation:
RM7838B,C: 10W maximum.
Maximum Total Connected Load: 2000 VA.
Fusing Total Connected Load: 15A maximum, type SC or
equivalent, fast blow.
Environmental Ratings:
Ambient Temperature:
Operating: -40°F to +140°F (-40°C to +60°C).
Storage: -40°F to +150°F (-40°C to +66°C).
Humidity: 85% relative humidity continuous, noncondensing.
Vibration: 0.5G environment.
SIL 3 Capable:
SIL 3 Capable in a properly designed Safety Instrumented
System. See form number 65-0312 for Certificate Agree-
ment.
Approvals:
Underwriters Laboratories Inc. Listed: File No. MP268, Guide
No. MCCZ.
Canadian Standards Association Certified: LR9S329-3.
Factory Mutual Approved: Report No. 1V9A0.AF.
Swiss Re (formerly Industrial Risk Insurers): Acceptable.
Federal Communications Commission: Part 15, Class B,
Emissions.
Gastec: EN298, Report 115679/4 (RM7838C1020 only)
IMPORTANT
A Flame Detection System is required for operation
and must be ordered separately. Select the
applicable Flame Signal Amplifier and matching
Flame Detector in form 65-0109.
INSTALLATION
When Installing this Product...
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and marked
on the product to make sure the product is suitable for
the application.
3. Installer must be a trained, experienced, flame
safeguard service technician.
4. After installation is complete, check out the product
operation as provided in these instructions.
66-1094-08

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Table of Contents

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   Summary of Contents for Honeywell RM7838B

  • Page 1 Run condition, flame supervision, system status indication, System. See form number 65-0312 for Certificate Agree- system or self-diagnostics and troubleshooting. ment. The RM7838C differs from the RM7838B as follows: Approvals: Underwriters Laboratories Inc. Listed: File No. MP268, Guide 1. Alarms only on Safety Shutdown.
  • Page 2 Department of Communications. 1. Mount the subbase in any position except horizontally with the bifurcated contacts pointing down. The See Fig. 1 for the internal block diagram of the RM7838B,C standard vertical position is recommended; any other Relay Module. position decreases the maximum ambient temperature rating.
  • Page 3 RATE SWITCH PROVIDE DISCONNECT MEANS AND START SWITCH OVERLOAD PROTECTION AS REQUIRED. PREIGNITION INTERLOCK NOT REQUIRED FOR RM7838C. M5195D Fig. 1. Internal block diagram of RM7838B,C (see Fig. 2 for RM7838C1020); see Fig. 3 and 4 for detailed wiring instructions. 66-1094—08...
  • Page 4 RM7838B,C 7800 SERIES RELAY MODULE BURNER HOT N CONTROL PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST F L A M E S IG N A L JACK RECIRCULATING RUN/TEST BLOWER SWITCH P L U G -IN PLUG-IN MICROCOMPUTER F L A M E...
  • Page 5 100 feet (31 8. Make sure loads do not exceed the terminal ratings. meters). Refer to the label on the RM7838B,C or to the ratings in Table 4. 4. See Table 2 for recommended grounding practices.
  • Page 6 10. Replace faulty controllers, limits, interlocks, actuators, Can cause equipment damage. valves, transformers, motors and other devices, as Do not perform a dielectric test with the RM7838B,C required. installed. Internal surge protectors break down and 11. Make sure normal operation is obtained for each conduct current, causing dielectric test failure and required test before continuing the checkout.
  • Page 7 RM7838B,C 7800 SERIES RELAY MODULE Table 3. Static Checkout. (Continued) Test Test If Operation is Abnormal, Check These Jumpers Voltmeter Normal Operation Items None 21-L2 With test 2 still running, press Start Switch. 120 1. Start Switch. Vac is present at terminal 21.
  • Page 8 Start Switch Input 120 Vac, 1A pilot duty. Shutter 120 Vac, 0.5A. See Table 2. 2000 VA maximum load connected to RM7838B,C Assembly. See Tables 5 and 6. Table 5. Combinations for Terminals 8, 9, and 10. Pilot Fuel 8 Main 9...
  • Page 9 See Table 2. 2000 VA maximum connected load to relay module. Honeywell has tested this output at 9.8A at PF = 0.5, 58.A inrush for 100,000 cycles Total load current, excluding Burner/Boiler Motor and Firing Rate Outputs cannot exceed 5A, 25A inrush.
  • Page 10 SHUTTER CHECK FLAME DETECTION SYSTEM REQUIRED WHEN USING THE PILOT VALVE HOLD FUNCTION. SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS FOR CORRECT WIRING. 15 SECOND FOR RM7838C. ALARM SILENCING SWITCH NOT NEEDED FOR RM7838C APPLICATIONS. M15101D Fig. 3. Wiring subbase for RM7838B,C with S445 Start-Stop Station (not the RM7838C1020). 66-1094—08...
  • Page 11 SHUTTER CHECK FLAME DETECTION SYSTEM REQUIRED WHEN USING THE PILOT VALVE HOLD FUNCTION. ALTERNATIVE WIRING FOR 4-20 MA SYSTEM. M15100C SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS FOR CORRECT WIRING. ALARM SILENCING SWITCH NOT NEEDED FOR RM7838C APPLICATIONS. Fig. 4. Wiring subbase for RM7838B,C with separate Start and Stop Stations (not the RM7838C1020). 66-1094—08...
  • Page 12 RM7838B,C, KDM, flame amplifier, flame amplifier signal voltage probes, electrical signal voltage 4. Mount the RM7838B,C by aligning the four L-shaped probes, and electrical connections. corner guides and knife blade terminals with the a. Allow an additional 2 in. (51 mm) below the bifurcated contacts on the wiring subbase and securely RM7838B,C for the flame amplifier mounting.
  • Page 13 AMPLIFIER SC RO LL MO DE - SA VE - M 1 2 3 0 Fig. 6. RM7838B,C Relay Module exploded view. Mounting Other System Components Safety Shutdown (Lockout) Occurs (Fig. 4) Mount other required and optional system components by 1.
  • Page 14 The RM7838B,C has the operating sequences listed below. commanded to drive to high fire position. The RM7838B,C LED provide positive visual indication of the d. Low Fire Start Switch fails to close within four min- program sequence: POWER, PILOT, FLAME, MAIN and utes, fifteen seconds after the firing rate motor is ALARM.
  • Page 15 (terminals 13 and 15 are closed) (terminal 13 and 14 for C1020). 1. Pilot Flame Establishing Period (PFEP): 2. The RM7838B,C is now in RUN and remains in RUN a. When the PFEP begins: until the controller input, terminal 6, opens (burner...
  • Page 16 MOTOR ALARM IS OFF FOR RM7838C. WHEN CONFIGURATION JUMPER J3 IS CLIPPED, THE RM7838B/C AUTOMATICALLY CONTINUES INTO THE MFEP (NO WAITING TIME BETWEEN THE PFEP AND MFEP). T17 MUST CLOSE WITHIN 10 SECONDS. ALARM (TERMINAL 3) IS DE-ENERGIZED AS SOON AS FLAME IS DETECTED (RM7838B ONLY).
  • Page 17 RM7838B,C 7800 SERIES RELAY MODULE DISPLAY PFEP INITIATE PURGE START MFEP POWER POWER POWER POWER POWER POWER POWER PILOT PILOT PILOT PILOT FLAME FLAME FLAME FLAME MAIN MAIN MAIN MAIN ALARM ALARM ALARM ALARM 10 SEC 5 SEC STANDBY PURGE...
  • Page 18 RM7838B,C 7800 SERIES RELAY MODULE Fig. 9. RM7838B,C Relay Module operation (using pilot valve hold) (not C1020). 66-1094—08...
  • Page 19 The Run/Test Switch is located on the top side of the two-letter code (DI—Diagnostic Information, H1—Fault RM7838B,C, see Fig. 7. The Run/Test Switch allows the History Information, and EA—Expanded Annunciator). When burner sequence to be altered as follows: the arrow and two-letter code are displayed, it indicates the 1.
  • Page 20 Unclipped: RM7838B,C waits indefinitely for a 120V Man- ual Open Valve input. When input is received, 10 second SELECTABLE CONFIGURATION JUMPERS MFEP begins. The RM7838B,C also turns on terminal 9. RUN/TEST SWITCH Clipped: After the required PFEP, the RM7838B,C immediately goes to MFEP by outputting 120 Vac to the Main Valve terminal 9.

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