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Honeywell 7800 Series Installation Instructions Manual

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RM7888A
7800 SERIES Relay Module
Contents
Specifications ...............................................................................
Ordering Information ................................................................
Principal Technical Features ..................................................
Saftey Provisons .......................................................................... 10
Installation ..................................................................................... 11
Wiring ............................................................................................... 13
Assembly ......................................................................................... 15
Operation ........................................................................................ 19
Static Checkout ............................................................................ 30
Checkout ......................................................................................... 32
Troubleshooting ........................................................................... 38
INSTALLATION INSTRUCTIONS
APPLICATION
The Honeywell RM7888A Relay Module is a
microprocessor based, integrated burner control for
industrial process semiautomatically fired gas, oil, coal, or
combination fuels for single and multiple burner
industrial applications. The RM7888A requires a Relay
Module, Subbase and Amplifier for operation. Options
include Keyboard Display Module, DATA CONTROLBUS
MODULE™, Modbus™ Module, and Remote Display
Mounting.
The RM7888 intended use is in conjunction with a master
system control. The master system control determines the
purge timing and confirms air supply and air flow. The
RM7888A is programmed to provide a level of safety,
functional capability and features beyond the capability of
conventional controls. The basic functions of the RM7888
include automatic burner startup sequencing, five user
selectable operating (run) sequences, four line voltage
sequence control inputs (commonly controlled with a
Programmable Logic Controller [PLC)], flame supervision,
2
system status indication, system or self-diagnostics and
2
troubleshooting.
9
This document covers the following 7800 Series Relay
Modules:
RM7888A1019
RM7888A1027
RM7888A2019
RM7888A2027
SIL
3
Capable
32-00214-01

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  Summary of Contents for Honeywell 7800 Series

  • Page 1: Table Of Contents

    Programmable Logic Controller [PLC)], flame supervision, Specifications ................system status indication, system or self-diagnostics and Ordering Information ..............troubleshooting. Principal Technical Features ..........This document covers the following 7800 Series Relay Saftey Provisons ................10 Installation ..................11 Modules: Wiring ....................13 RM7888A1019 Assembly ..................
  • Page 2: Specifications

    RM7888A 7800 SERIES RELAY MODULE FEATURES SPECIFICATIONS • Safety features: Electrical Ratings (see Table 1): Voltage and Frequency: 120 Vac (+10/-15%), 50/60 Hz — Closed loop logic test. (±10%). — Dynamic input check. Keyboard Display Module: 13.0 Vdc peak full wave recti- —...
  • Page 3 S7830 Expanded Annunciator Product Data Required for Operation: 65-0109 R7824, R7847, R7848, R7849, R7851, R7861, Plug-in Flame Signal Amplifier (see Table 4). R7886 Flame Amplifiers for the 7800 SERIES Product Data Part numbers Accessories 65-0131 221818A Extension Cable Assembly Product Data...
  • Page 4 RM7888A 7800 SERIES RELAY MODULE Table 1. Terminal Ratings. Terminal Number Description Ratings 60 to 220 Vac, current limited. Flame Sensor Ground Earth G — Earth Ground L2(N) Line Voltage Common — Alarm 120 Vac, 1A pilot duty. Line Voltage Supply (L1) 120 Vac (+10/-15%), 50/60 Hz (±10%) Air Valve 120 Vac, 9.8A FL, 58.8A LR (inrush).
  • Page 5 RM7888A 7800 SERIES RELAY MODULE Table 3. Composition of Each Combination. 4.5A ignition 50 VA Pilot Duty plus 180 VA Ignition plus 2A Pilot Duty 65 VA Pilot Duty plus 4.5A ignition Motor Valves with: motor valves with: 660 VA inrush,...
  • Page 6 RM7888A 7800 SERIES RELAY MODULE Flame Failure Response Time (FFRT) depends on selection of amplifier. Circuitry tests all electronic components in flame detection system (amplifier and detector) 12 times a minute during burner operation and shuts down burner if detection system fails.
  • Page 7 RM7888A 7800 SERIES RELAY MODULE CELL MOUNT HEAT BLOCK 1-5/8 (41) 2-3/4 1-1/16 (27) (70) 1-1/4 1-1/4 (32) (32) BUSHING WITH 3/4-14 APERTURE MAGNIFYING LENS NPSM 3/4-14 NPSM INTERNAL COLLAR, 3/4-14 NPSM THREADS INTERNAL THREADS C7915 M1982C Fig. 4. Infrared detector.
  • Page 8 RM7888A 7800 SERIES RELAY MODULE (10) MOUNTING BRACKET 6 FOOT [1.83 METER] 1-27/64 LEAD (36) WIRES (2) (22) 9/16 (14) (13) 3-5/8 (92) M1944D Fig. 7. Ultraviolet detectors (minipeepers). 1-1/16 (27) 2-1/4 1 INCH NPT (57) 2-1/4 (57) (102) 2-5/16...
  • Page 9: Principal Technical Features

    RM7888A 7800 SERIES RELAY MODULE Table 5. Sequence Timing for Operation. Pilot Flame Main Flame RM7888A Establishing Period Establishing Sequence Initiate Standby Purge (PFEP) Period (MFEP) Pilot Relight Pilot: PV 10 seconds 10 seconds 10 seconds 5 sec to Return...
  • Page 10: Saftey Provisons

    RM7888A 7800 SERIES RELAY MODULE a. Limits Complete is not energized. Expanded Safe-Start Check b. Special Function 2 is not energized The conventional safe-start check, which prevents burner c. Flame failure. start-up if flame is indicated at start-up, is expanded to d.
  • Page 11: Installation

    RM7888A 7800 SERIES RELAY MODULE amplifier and output circuits. The system distinguishes When Installing This Product... modes of failure and detects and annunciates difficult-to- 1. Read these instructions carefully. Failure to follow find intermittent failures. them could damage the product or cause a hazard- ous condition.
  • Page 12 RM7888A 7800 SERIES RELAY MODULE IMPORTANT: Series 2000 Relay Modules 1. For on-off gas-fired systems, some authorities All relay product codes that start with a 2 (example: who have jurisdiction prohibit the wiring of any RM7840G2014/U) must be used with subbase limit or operating contacts in series between the Q7800A2003/U and Q7800A2005/U.
  • Page 13: Wiring

    RM7888A 7800 SERIES RELAY MODULE 4. Mount the subbase securely using four No. 6 screws. WIRING NOTE: You might receive an error code 101 (via KDM) if one of the following conditions exist: a. For the internal block diagram of the RM7888A, a.
  • Page 14 RM7888A 7800 SERIES RELAY MODULE SERIES 90 FIRING SERIES 90 RATE Q7800 SUBBASE HIGH CONTROLLER MOTOR FIRE (HOT) MASTER SWITCH COMMON FIRE 120V ALARM LIMITS MODULATE (L1) SPECIAL FUNCTION 1 AIR VALVE SPECIAL FUNCTION 2 LOW FIRE SWITCH SPECIAL FUNCTION 3...
  • Page 15: Assembly

    RM7888A 7800 SERIES RELAY MODULE d. Remote Reset—Use 22 AWG or greater twisted 7. Maximum wire lengths: pair wire, insulated for low voltage. a. For the flame detector leadwires, the maximum 5. Recommended grounding practices: flame sensor leadwire length is limited by the a.
  • Page 16 RM7888A 7800 SERIES RELAY MODULE 3. Make sure the Keyboard Display Module is firmly in place. Fig. 14. Keyboard Display Module mounting. Mounting the Data Controlbus Module™, Modbus Module or the Fig. 12. Electrical panel installation. Extension Cable Assembly (Figs. 15 and 16) 1.
  • Page 17 RM7888A 7800 SERIES RELAY MODULE Installing the Plug-in Flame Signal Amplifier 1. Disconnect the power supply before beginning the installation to prevent electrical shock and equip- ment damage. More than one disconnect may be involved. 2. Align the amplifier circuit board edge connector with the keyed receptacle on the RM7888A.
  • Page 18 RM7888A 7800 SERIES RELAY MODULE Installing the Flame Detector (Fig. NOTE: Table 4 lists the flame detection systems avail- able for use with the RM7888A. Make sure the correct combination of amplifier and flame detec- tor(s) is used. Proper flame detector installation is the basis of a safe and reliable flame safeguard installation.
  • Page 19: Operation

    RM7888A 7800 SERIES RELAY MODULE OPERATION Selectable Site-Configurable Jumpers The RM7888A has five site-configurable jumper options WARNING and three options that will result in a lockout, see Fig. 20 The user of the RM7888A is responsible for and Table 6. The site-configurable jumpers should be...
  • Page 20 RM7888A 7800 SERIES RELAY MODULE Table 7. Pilot Configuration Operation Sequence States. S7800 Keyboard Pilot Configuration Display Module State Name Displayed Text Purpose of State Initiate (See below) The Initiate state allows the relay module to complete initialization after a power-up or whenever a problem that would prevent normal operation (such as an ac line problem), the Initiate state is entered.
  • Page 21 RM7888A 7800 SERIES RELAY MODULE Pilot Configuration Sequence of When special function 1 is energized, a request for burner operation is in effect, the Air Valve will be commanded off Operation and the LowFire motor position commanded. In this case, special functions 2, 3, and 4 are ignored.
  • Page 22 RM7888A 7800 SERIES RELAY MODULE Pilot Configuration Ignition Trials the Low Fire switch has at least three seconds to stabilize. This reduces the possibility of a contact bounce causing a (PV Return and MV Lo Fire lockout. The RM7888A will lockout if the Limits Complete input becomes de-energized.
  • Page 23 RM7888A 7800 SERIES RELAY MODULE A lockout will occur if the Low Fire input or the Limits At the end of the ten-second period, the Wait for Low Off Complete becomes de-energized, or a flame failure state is entered. The ignition, main valve and Air Valve are occurs, or Flame Proven output is de-energized.
  • Page 24 RM7888A 7800 SERIES RELAY MODULE Normal sequence is used when the application requires the burner flame to be modulated during the Run state. Table 9. DSI Configuration Operation Sequence States. Displayed DSI State Name Text Purpose Normal—Part 1 (Main Flame MAIN IGN Establish a Low Fire flame.
  • Page 25 RM7888A 7800 SERIES RELAY MODULE PV Return and MV Lo Fire PV Return Only PILOT RELEASE TO PILOT RELIGHT DRIVE TO LOW RETURN PILOT- MAIN BURNER BURNER PILOT STANDBY AFTER 10 SEC IGNITION TRAIN FUEL VALVE MODULATION RELIGHT FIRE POSITION...
  • Page 26 RM7888A 7800 SERIES RELAY MODULE ignored during this timed period. At the end of the timed WARNING period, the sequence will go back to the end of the Normal—Part 1 state if special function 2 is de-energized. The user of the RM7888A is responsible for...
  • Page 27 RM7888A 7800 SERIES RELAY MODULE High State becomes de-energized. Special functions 2, 3 and 4 are ignored. At the end of the time period, if the flame has not Upon entry to High State, the Main and Air Valves are been established, a lockout will occur.
  • Page 28 RM7888A 7800 SERIES RELAY MODULE STANDBY NORMAL- NORMAL- NORMAL- PART 1* PART 2 PART 3 INPUT & OUTPUT 5 SECONDS, SIGNALS POSSIBLE POSSIBLE 0 TO STANDBY- INFINITE INFINITE INFINITE PURGE HOLD HOLD SECONDS POWER POWER POWER POWER POWER PILOT PILOT...
  • Page 29 RM7888A 7800 SERIES RELAY MODULE STANDBY HIGH/LOW HIGH/LOW HIGH RETURN TO STEPFIRE- STEPFIRE- HIGH/LOW INPUT & PART 1* PART 2 STEPFIRE- OUTPUT PART 2 SIGNALS 2 TO 2 TO STANDBY- INFINITE INFINITE PURGE SECONDS SECONDS POWER POWER POWER POWER POWER...
  • Page 30: Static Checkout

    RM7888A 7800 SERIES RELAY MODULE STANDBY OFF/ON OFF/ON STEPFIRE- STEPFIRE- INPUT & PART 1* PART 2 OUTPUT SIGNALS 5 TO STANDBY- INFINITE PURGE SECONDS POWER POWER POWER POWER POWER PILOT PILOT PILOT FLAME FLAME FLAME MAIN MAIN ALARM IGNITION- T10...
  • Page 31 RM7888A 7800 SERIES RELAY MODULE Equipment Recomended 3. For each test, open the master switch and install the jumper wire(s) between the subbase wiring termi- • Voltmeter 1Mohm/volt minimum sensitivity set on the nals listed in the Test Jumpers column.
  • Page 32: Checkout

    CAUTION the specified time. If an RM7888A is replaced with a lower functioning 7800 SERIES Relay Module, the burner will not sequence unless wiring changes are made. IMPORTANT 1. If the system fails to perform properly, refer to the...
  • Page 33 RM7888A 7800 SERIES RELAY MODULE Equipment Recommended 3. Correct combination of amplifier and flame detec- tor(s) is used. See Table 4 in the Specifications sec- Volt-ohmmeter (1 Megohm/volt minimum sensitivity) tion. with: 4. Plug-in amplifier is securely in place. 5. Burner is completely installed and ready to fire; con- •...
  • Page 34 RM7888A 7800 SERIES RELAY MODULE This minimum or stronger signal should be obtained easily if the detector is correctly installed and positioned to prop- erly sense the flame. This voltage must be obtained before completing checkout. The flame signal amplifier circuitry is tested one-half second every five seconds during burner operation and shuts down the burner if the amplifier fails (all installations).
  • Page 35 RM7888A 7800 SERIES RELAY MODULE Reinstall the RM7888A on the subbase and close 23. Make sure all readings are in the required ranges the master switch, then return to step 3. before proceeding. 8. When the pilot ignites, measure the flame signal. If 24.
  • Page 36 RM7888A 7800 SERIES RELAY MODULE 17. Shut down the system by opening the burner switch 7. Repeat step 6 to verify the pilot gas pressure reading or by de-energizing terminal 6 (Special Function 1). at the exact point the FLAME LED light goes out.
  • Page 37 Infrared radiation from a hot NOTE: The Honeywell Q624A Solid State Spark Genera- refractory is steady, but radiation from a flame has a tor will prevent detection of ignition spark when flickering characteristic.
  • Page 38: Troubleshooting

    ALARM LED, by using the e. Safety shutdown will occur. optional Keyboard Display Module or 7800 SERIES System Annunciation Diagnostics and Troubleshooting, form 65-0118. The RM7888A provides diagnostic information to aid the service mechanic to obtain information when troubleshooting the system, see Table 7 or Table 9.
  • Page 39 RM7888A 7800 SERIES RELAY MODULE The optional Keyboard Display Module displays sequence CAUTION status messages indicating: STANDBY, PREPURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE. The selectable Reinstall access slot covers on the Q7800A,B messages also provide visual indication, current status subbase after performing voltage checks.
  • Page 40 RM7888A 7800 SERIES RELAY MODULE 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. Honeywell Process Solutions...

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