Honeywell 7800 Series Installation Instructions Manual
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Honeywell 7800 Series Installation Instructions Manual

Relay modules
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Table of Contents

See also: Product Data , Instruction Manual
RM7838B, RM7838C
7800 SERIES Relay Modules

APPLICATION

The Honeywell RM7838B,C is a microprocessor based
integrated burner control for industrial process
semiautomatically fired gas, oil, coal or combination fuel
single burner modulation applications and available Valve
Proving System (VPS) feature. The RM7838B,C System
consists of a relay module, wiring subbase, keyboard
display module (KDM), amplifier, and purge card. Options
include personal computer interface, Data ControlBus
Module™, remote display mounting, first-out expanded
annunciator and Modbus™ network capable.
Functions provided by the RM7838B,C include automatic
modulated High Fire and Low Fire proven Purge, then the
sequence stops, waiting for a Start Switch input, 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. Has 15-second MFEP.
3. Requires ST7800C Purge Timer.
This document covers the following 7800 Series Relay
Modules:
RM7838B1021
RM7838B2021
RM7838C1012
RM7838C2012
Contents
APPLICATION................................................................................ 1
SPECIFICATIONS......................................................................... 2
................................................................................... 2
FINAL WIRING CHECK .............................................................. 7
............................................................................ 8
V
................................................................ 11
........................................................................................ 19
......................................................................... 22
SAFETY AND SECURITY............................................................ 27
................................................ 17
....................................................... 21
SIL
3
Capable
INSTALLATION INSTRUCTIONS
This document provides installation and static checkout
instructions. Other applicable publications are:
Form Number
32-00110
S7800A2142 4-line LCD Keyboard
Display Module Product Data
32-00166
204729A/C KDM NEMA4 Covers for
4-line LCD KDM
65-0084
Q7800A,B 22-Terminal Wiring
Subbase Product Data.
65-0089
ST7800A,C Plug-In Purge Timer
Installation Instructions.
65-0288
S7800A1142 Keyboard Display
Module Product Data.
65-0091
S7810A Data ControlBus Module™
Product Data.
65-0095
S7820 Remote Reset Module Product
Data.
65-0097
221729 Dust Cover Installation
Instructions.
65-0101
S7830 Expanded Annunciator Product
Data.
32-00235
R7824, R7847, R7848, R7849, R7861,
R7862, 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.
65-0295
50023821-001/2 NEMA4 Covers for
2-line Keyboard Display Module
Description
32-00211-01

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Summary of Contents for Honeywell 7800 Series

  • Page 1: Table Of Contents

    3. Requires ST7800C Purge Timer. 65-0101 S7830 Expanded Annunciator Product Data. 32-00235 R7824, R7847, R7848, R7849, R7861, This document covers the following 7800 Series Relay R7862, R7886 Flame Amplifiers for Modules: the 7800 Series Product Data. 65-0131 221818A Extension Cable Assembly RM7838B1021 Product Data.

  • Page 2: Specifications

    RM7838B, RM7838C 7800 SERIES RELAY MODULES The RM7838B1021 and RM7838C1012 Relay Modules MV2—Wired to terminal 17. It is the main valve located offer VPS, thus they differ in the following manner from closest to the burner. the RM7838B1013 and RM7838C1004: The Proof of Closure Switch (PII—Pre-Ignition Interlock)

  • Page 3: Installation

    RM7838B, RM7838C 7800 SERIES RELAY MODULES INSTALLATION 9. This equipment generates, uses and can radiate radio frequency energy and, if not installed and When Installing this Product... used in accordance with the instructions, can cause interference with radio communications. It 1.
  • Page 4 RM7838B, RM7838C 7800 SERIES RELAY MODULES Relay Module and Subbase Any relay module in the new 2000 series will only be able to be installed on subbase Q7800A2005/U, Compatiblity Q7800B2003/U and will not be backward compatible with any Q7800A1003/U and Q7800A1005/U subbases NOTE: There are several different subbase models that already installed in the field.
  • Page 5 RM7838B, RM7838C 7800 SERIES RELAY MODULES chain configuration string require a 120 ohm (1/4 watt NOTE: Use a separate 13 Vdc power supply any time minimum) resistor termination across terminals 1 and 2 of more than two Data ControlBus Modules™ or...
  • Page 6 RM7838B, RM7838C 7800 SERIES RELAY MODULES BURNER CONTROL (HOT) 120 Vac 50/60 HZ RECIRCULATING BLOWER PLUG-IN PURGE TIMER CARD CONFIGURATION TEST JUMPERS JACK FLAME SIGNAL RUN/TEST SWITCH PLUG-IN FLAME MICROCOMPUTER AMPLIFIER TEST RESET PUSHBUTTON RELAY DRIVE RELAY CIRCUIT STATUS FEEDBACK...

  • Page 7: Final Wiring Check

    RM7838B, RM7838C 7800 SERIES RELAY MODULES SERIES 90 FIRING RATE SERIES 90 M7284 4-20 mA Q7800 SUBBASE MOTOR CONTROLLER FIRING RATE OUTPUT MOTOR CONTROLLER HIGH FIRE HIGH FIRE COMMON COMMON LOW FIRE LOW FIRE LINE VOLTAGE ALARM MODULATE MODULATE (L1)

  • Page 8: Static Checkout

    RM7838B, RM7838C 7800 SERIES RELAY MODULES STATIC CHECKOUT 3. Ammeter can be used to verify loads (e.g. valves, ignition transformers) connected to the wiring sub- base. After checking all wiring, perform this checkout before installing the RM7838B,C on the subbase. These tests...
  • Page 9 RM7838B, RM7838C 7800 SERIES RELAY MODULES Table 3. Static Checkout. (Continued) Test Test Jumpers Voltmeter Normal Operation If Operation is Abnormal, Check These Items None 6-L2 Push and hold Stop Switch. Stop Switch. No voltage present at terminal 6. 1. Alarm.
  • Page 10 RM7838B, RM7838C 7800 SERIES RELAY MODULES Table 4. Terminal Ratings. Terminal No. Description Ratings — Flame Sensor Ground Earth G — Earth Ground Line Voltage Common — Alarm 120 Vac, 1A pilot duty. Line Voltage Supply (L1) 120 Vac (+10/-15%), 50/60 Hz (+/-10%).

  • Page 11: Valve Proving System

    RM7838B, RM7838C 7800 SERIES RELAY MODULES Keyboard Display Module VALVE PROVING SYSTEM The KDM (see Fig. 5) is provided with the RM7838B,C The Valve Proving System feature provides a systematic Relay Module. The first line of the Vacuum Fluorescent way of testing the valve seat integrity to assure the valves...
  • Page 12 (Because the gas pressure has decreased due to a leaky downstream valve.) (High pressure test.) Table 7. Honeywell Pressure Switch Selection for Valve Proving System. Maximum Maximum Operating...
  • Page 13 RM7838B, RM7838C 7800 SERIES RELAY MODULES Edit: Edit: M22663B M22665B Fig. 7. Password screen. Fig. 10. Save Changes screen. 3. Use the up/down arrows to enter the first number—7. 9. Use the down arrow to save changes. After pressing 4. Use the far right key to shift over one space.
  • Page 14 RM7838B, RM7838C 7800 SERIES RELAY MODULES 11. Press down arrow to select. 16. Press ENTER. 12. “Getting Data” will be momentarily displayed, fol- lowed by the screen shown in Fig. 14. Install Postpurge Edit: M22671B Fig. 17. Confirmation Correct screen.
  • Page 15 RM7838B, RM7838C 7800 SERIES RELAY MODULES 23. Go to the relay module and press and hold the RESET button for five seconds to program the Valve Proving setup into the relay module. The Release Reset screen will appear on the KDM.
  • Page 16 RM7838B, RM7838C 7800 SERIES RELAY MODULES Mounting RM7838B,C Relay 3. Make sure no subbase wiring is projecting beyond the terminal blocks. Tuck in wiring against the back Module of the subbase so it does not interfere with the knife blade terminals or bifurcated contacts.

  • Page 17: Principal Technical Features

    RM7838B, RM7838C 7800 SERIES RELAY MODULES PRINCIPAL TECHNICAL a. Low Fire Switch opens. b. Lockout Interlock opens. FEATURES c. Ignition/pilot valve terminal is not energized. d. Main valve terminal is not energized. e. No flame is present at end of MFEP.
  • Page 18 RM7838B, RM7838C 7800 SERIES RELAY MODULES WIRING SUBBASE RUN/TEST SWITCH H O N E Y W E LL RELAY MODULE CONFIGURATION JUMPERS PURGE TIMER SEQUENCE STATUS LED PANEL POWE R RESET PILOT BUTTON FLAM E MAIN ALARM CAPTIVE KEYBOARD RESE T...

  • Page 19: Operation

    RM7838B, RM7838C 7800 SERIES RELAY MODULES OPERATION Sequence of Operation The RM7838B,C has the operating sequences listed below. The RM7838B,C LED provide positive visual indication of the program sequence: POWER, PILOT, FLAME, MAIN and ALARM. Fig. 26 shows the operating sequence.
  • Page 20 RM7838B, RM7838C 7800 SERIES RELAY MODULES Initiate terminal 6 is powered, either through lockout interlock switches or just a jumper. Leave JR3 The RM7838B,C enters the INITIATE sequence when the intact (as received) for these applications. Relay Module is initially powered. The RM7838B,C can •...

  • Page 21: Settings And Adjustments

    RM7838B, RM7838C 7800 SERIES RELAY MODULES a. Configuration jumper JR2 intact: This activates a 15 second flameout timer that (1) Main valve terminals 9 and 17 are energized. permits pilot flame adjustment without nuisance (2) After a 10 second (15 second for RM7838C) safety shutdowns.

  • Page 22: Troubleshooting

    RM7838B, RM7838C 7800 SERIES RELAY MODULES — Some applications exist that do not use combus- TROUBLESHOOTING tion blowers, so power is available on terminal 7 at the same time as terminal 6, either through lockout Troubleshooting can be accomplished by using the S7800 interlock switches or just a jumper.
  • Page 23 RM7838B, RM7838C 7800 SERIES RELAY MODULES Table 9. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code System Failure Recommended Troubleshooting Code 2-3 Flame signal value is 1. Make sure the flame detector and flame amplifier are compatible. *Flame Signal too high to be valid.
  • Page 24 RM7838B, RM7838C 7800 SERIES RELAY MODULES Table 9. Blinking Fault Codes and Recommended Troubleshooting. (Continued) Blink Code System Failure Recommended Troubleshooting Code 4-3 Flame not sensed, or 1. Check wiring; correct any errors. *Flame sensed when it should 2. Make sure the flame amplifier and flame detector are compatible.
  • Page 25 RM7838B, RM7838C 7800 SERIES RELAY MODULES APPENDIX A Valve Proving Test The Valve Proving System feature offers a systematic The following steps are to determine the test time for the way of testing the valve seat integrity to assure the valves...
  • Page 26 X = 0.0218 + 0.0267 + (3.356 x 1.75 ÷ 144) = 0.0893. Round up to 14 seconds; enter 14 seconds into the VPS Setup. Calculation of Valve Proving Test Time: Table 12. V1 Upstream Volumes for Honeywell Valves. Pipe Size NPT (inches) V4295...

  • Page 27: Safety And Security

    RM7838B, RM7838C 7800 SERIES RELAY MODULES Table 14. Schedule 40 Pipe Internal Cross-Sectional Cross-Sectional Area (Sq. Area. Pipe Size NPT (Inches) In.) “A” Cross-Sectional Area (Sq. 3.356 Pipe Size NPT (Inches) In.) “A” 2-1/2 4.788 0.191 7.393 0.304 12.730 0.533 0.864...
  • Page 28 RM7838B, RM7838C 7800 SERIES RELAY MODULES For More Information The Honeywell Thermal Solutions family of products includes Honeywell Combustion Safety, Eclipse, Exothermics, Hauck, Kromschröder and Maxon. To learn more about our products, visit ThermalSolutions.honeywell.com or contact your Honeywell Sales Engineer.

This manual is also suitable for:

Rm7838b1021Rm7838b2021Rm7838c1012Rm7838c2012Rm7838bRm7838c

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