Honeywell 7800 Series Manual

Relay module
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The Honeywell RM7888A Relay Module is a microprocessor
based, integrated burner control for industrial process semiauto-
matically 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 Personal Computer Interface, Keyboard Display Module,
DATA CONTROLBUS MODULE™, Remote Display Mounting,
First-Out Expanded Annunciator and COMBUSTION SYSTEM
MANAGER™ software. The RM7888 intended use is in conjunc-
tion 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 con-
ventional 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 supervi-
sion, system status indication, system or self-diagnostics and
troubleshooting.
Safety features:
- Closed loop logic test.
- Dynamic input check.
- Dynamic safety relay test.
- Dynamic self-check logic.
- Expanded safe-start check.
- Internal hardware status monitoring.
- Tamper resistant timing and logic.
Access for external electrical voltage checks.
Application flexibility.
Communication interface capability.
First-out annunciation and system diagnostics are provided
by 2 row by 20 column Vacuum Fluorescent Display (VFD)
located on the Keyboard Display Module.
First-out expanded annunciation with 26 light emitting di-
odes (LEDs) for limits and interlocks (optional).
Five sequence information LEDs.
Interchangeable plug-in flame amplifiers.
Local or remote annunciation of RM7888A operation and
fault information.
Dependable, long-term operation provided by microcom-
puter technology.
Nonvolatile memory for retaining history files and sequenc-
ing status after loss of power.
Remote reset capability (optional).
Burner controller data:
- Sequence status.
- Sequence time.
- Hold status.
- Lockout/alarm status.
- Flame signal strength.
- Expanded annunciator status.
- Total hours of operation.
65-0175
RM7888A Relay Module
G.R. • 8-94 • ©Honeywell Inc. 1994 • Form Number 65-0175
7800 SERIES
- Total cycles of operation.
- Fault history of six most recent faults:
• Cycles of operation at the time of the fault.
• Expanded annunciator data at the time of the fault.
• Fault message and code.
• Hours of operation at the time of the fault.
• Sequence status at the time of the fault.
• Sequence time at the time of the fault.
- Diagnostic information:
• Device type.
• Flame amplifier type.
• Flame failure response time.
• Manufacturing code.
• On/Off status of all line voltage digital inputs.
• Software revision and version of RM7888A via S7800
Keyboard Display Module.
• Status of configuration jumpers.
CONTENTS
Specifications ......................................................... 2
Ordering Information ............................................ 2
Principal Technical Features ................................ 8
Safety Provisions ................................................... 9
Installation ........................................................... 11
Wiring .................................................................. 12
Assembly .............................................................. 15
Operation ............................................................. 19
Static Checkout .................................................... 34
Checkout .............................................................. 36
Troubleshooting ................................................... 43
1
65-0175

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  Summary of Contents for Honeywell 7800 Series

  • Page 1: Table Of Contents

    Operation ............. 19 — Lockout/alarm status. Static Checkout ............ 34 — Flame signal strength. Checkout .............. 36 — Expanded annunciator status. Troubleshooting ........... 43 — Total hours of operation. G.R. • 8-94 • ©Honeywell Inc. 1994 • Form Number 65-0175 65-0175 65-0175...
  • Page 2: Specifications

    M9494 Ordering Information ® When purchasing replacement and modernization products from your 7800 SERIES distributor, refer to the TRADELINE Catalog for complete ordering number. If you have additional questions, need further information, or would like to comment on our products or services, please write or phone: 1.
  • Page 3 RM7888A SPECIFICATIONS Fig. 2—Mounting dimensions of the RM7888A Relay Module and Q7800B Subbase in in. [mm]. BURNER CONTROL SCROLL MODE [127] SAVE POWER PILOT FLAME MAIN ALARM RESET [155] 5 [127] M9493 REMOVE ONLY FOR TERMINAL TEST ACCESS. NOTE: The RM7888 is a component of a larger overall Remote Display Power Supply (13 Vdc) Plug-in—...
  • Page 4 RM7888A SPECIFICATIONS TABLE 1—TERMINAL RATINGS. Terminal Number Description Ratings Flame Sensor Ground 60 to 220 Vac, current limited. 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 Controls that incorporate safe-start checks, and sensors with controls that employ constant checking means are available from Honeywell. See your Honeywell representative for specific information. Circuitry tests all electronic components in the flame detection system (amplifier and detector) 12 times a minute during burner operation and shuts down the burner if the detection system fails.
  • Page 6 RM7888A SPECIFICATIONS Fig. 4—Rectification detectors. IGNITION ELECTRODE FLAME ROD (Q179C ONLY) CERAMIC INSULATORS 1 [25] MOUNTING FLANGE 3/4–14 NPT [183] [36] [42] TARGET [10] [130] [95] [87] [13] [79] [27] 1/2–14 NPSM [133] LEADWIRES [18] FACEPLATE M1962A THREADED [20] [20] [14] MOUNTING HOLES (2)–...
  • Page 7 RM7888A SPECIFICATIONS Fig. 6—Ultraviolet detectors (minipeepers). [105] COLLAR WITH 2 [51] 1/2-14 NPSM 4 [102] 6 FOOT [1.83 METER] 1–11-1/2 NPSM INTERNAL THREADS LEADWIRES (2) INTERNAL [89] THREADS [30] [25] [27] [38] 6 FOOT [67] COLLAR WITH 1/2-14 NPSM [1.83 METER] INSERTION DEPTH LEADWIRES (2) 3 INTERNAL THREADS...
  • Page 8: Principal Technical Features

    RM7888A SPECIFICATIONS • PRINCIPAL TECHNICAL FEATURES Fig. 6—Ultraviolet detectors (Continued). [300] 15/16 [24] 1 INCH NPT [198] [147] DIAMETER [55] [47] [158] [147] [64] [168] 1 [25] 15/16–18 UNC (2 EACH) 2 [51] M5084A C7076D Sequence timing for RM7888A Relay Module operation are listed in Table 3. TABLE 3—SEQUENCE TIMING FOR OPERATION.
  • Page 9: Safety Provisions

    RM7888A PRINCIPAL TECHNICAL FEATURES • SAFETY PROVISIONS h. Ignition terminal is energized after the first ten sec- g. Limits Complete is not energized. onds of PFEP. h. Main valve is not energized. i. Flame Proven terminal is energized for the first ten sec- 5.
  • Page 10 • A shutter-check amplifier and self-checking detector board Display Module. See Table 15, Hold and Fault are energized continuously during STANDBY and Message Summary, or the 7800 SERIES System Annun- the last two seconds of STANDBY. If a flame exists, ciation Diagnostics and Troubleshooting, form 65-0118.
  • Page 11: Installation

    RM7888A INSTALLATION Installation 3. This equipment generates, uses and can radiate radio WARNING frequency energy, and if not installed and used in accordance with the instructions, may cause interfer- FIRE OR EXPLOSION HAZARD CAN ence to radio communications. It has been tested and CAUSE PROPERTY DAMAGE, SEVERE found to comply with the limits for a Class B comput- INJURY, OR DEATH.
  • Page 12: Wiring

    RM7888A WIRING Wiring 1. a. For the internal block diagram of the RM7888A, 2. Disconnect the power supply from the main discon- see Fig. 7. For proper subbase wiring, refer to Figs. 8 nect before beginning installation to prevent electrical shock and 9.
  • Page 13 RM7888A WIRING Fig. 8—RM7888A wiring diagram. SERIES 90 FIRING SERIES 90 RATE CON- Q7800 SUBBASE MOTOR TROLLER HIGH 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 PILOT...
  • Page 14 3(c) provided as 2(b), 3(c)-3(c)). The order of interconnection of all part of the 7800 SERIES device ControlBus connec- the devices is not important. Be aware that modules tion. The shield should be connected at both ends to on the closes and farthest end of the daisy chain con- ground.
  • Page 15: Assembly

    RM7888A WIRING • ASSEMBLY c. RM7888A—Each RM7888A will have an earth ground d. Remote Reset: terminal that must be grounded to the metal control 1. Do not run high voltage ignition transformer wires panel with wire as short as practical. Each ground wire in the same conduit with the Remote Reset wiring.
  • Page 16 RM7888A ASSEMBLY MOUNTING THE DATA CONTROLBUS MODULE™ AND THE EXTENSION CABLE Fig. 12—Wall or burner installation. ASSEMBLY (FIGS. 14 AND 15) 1. Align the two interlocking ears with the two mating slots on the RM7888A. 2. Insert the two interlocking ears into the two mating slots and push on the lower corners of the DATA CON- TROLBUS MODULE™...
  • Page 17 RM7888A ASSEMBLY REMOTE MOUNTING THE KEYBOARD DISPLAY MODULE (FIG. 16) Fig. 16—Remote mounting of Keyboard Display Module. 1. The Keyboard Display Module can be mounted ei- ther on the face of a panel door or other remote locations. NOTE: A DATA CONTROLBUS MODULE™ or an Ex- tension Cable Assembly is required to connect RM7888A to a remote Keyboard Display Module.
  • Page 18 REMOTE SENSOR BROWN EARTH GROUND SHUTTER C7076A OR C7076D ULTRAVIOLET (C7027/C7035/C7044) SHUTTER TERMINAL BLOCK BLUE L1 (HOT) WHITE L2 (COMMON) 7800 SERIES SOLID STATE SELF-CHECKING ULTRAVIOLET SOLID STATE (C7012E,F) ULTRAVIOLET (C7012A,C) BLUE YELLOW WHITE BLUE YELLOW WHITE BLACK BLACK BLACK...
  • Page 19: Operation

    RM7888A OPERATION Operation SELECTABLE SITE-CONFIGURABLE JUMPERS WARNING The RM7888A has five site-configurable jumper options and three options that will result in a lockout, see Fig. 19 and The user of the RM7888A is responsible for pro- Table 4. The site-configurable jumpers should be clipped viding an effective purge that meets the approval with side cutters and the resistor removed from the Relay of the authority having jurisdiction for a particular...
  • Page 20 RM7888A OPERATION Pilot Configuration Operating Sequence. b. MV Lo Fire: will not allow the pilot to be re-estab- The Pilot Configuration Operating Sequence has two lished once RUN has been entered; the main valve distinct operating sequences that are entered from the Stand- remains energized with Lo Fire being the lowest firing by/Standby Purge states.
  • Page 21 RM7888A OPERATION TABLE 5—PILOT CONFIGURATION OPERATING SEQUENCE STATES (Continued). Pilot S7800 Keyboard Configuration Display Module State Name Displayed Text Purpose of State — When special function input terminal 20 is off, relay module will command a Low Fire motor position. @Low 10 Sec When the Low Fire input becomes energized for a continuous time period of 10 seconds, the sequence will leave the Release to...
  • Page 22 RM7888A OPERATION During Standby/Standby-Purge states, when special func- WARNING tion 1 is de-energized, special function terminals 2, 3 and 4 provide a signal that requests that the RM7888A command The user of the RM7888A is responsible for pro- a particular motor position and Air Valve status. If any one viding an effective purge that meets the approval or more of the special function inputs (terminals 17, 19, or of the authority having jurisdiction for a particular...
  • Page 23 RM7888A OPERATION At the end of the ten second period, the pilot is com- WARNING manded off and a five second minimum flame stabilization period begins. When the stabilization period is completed, The Flame Proven output is an RM7888 safety out- the RM7888A will respond to the status on special function 4.
  • Page 24 RM7888A OPERATION the motor is commanded to the Modulate position. The Mod- Fire input becomes continuously energized for three sec- ulate position is commanded to detect a process load increase onds. If special function 2 is de-energized, a lockout will by noticing that the modulating control has requested a occur.
  • Page 25 RM7888A OPERATION Fig. 20— RM7888A Relay Module Pilot Sequuence timing diagram. PV Return and MV Lo Fire PV Return Only PILOT PILOT RELIGHT PILOT- MAIN BURNER RELEASE TO PILOT DRIVE TO LOW RETURN STANDBY BURNER FUEL VALVE MODULATION RELIGHT AFTER 10 SEC FIRE POSITION TO MAIN IGNITION...
  • Page 26 RM7888A OPERATION Initiate State For the first four seconds, the Normal—Part 1 state The Initiate state will be entered when the RM7888A is attempts to establish a Pilot (Low Fire Valve) flame. At the powered. The sequence will transition to the Standby state end of the first four seconds, the Ignition output is com- after a ten second period.
  • Page 27 RM7888A OPERATION the Low Fire input is de-energized anytime after four min- started. The commanded motor position is changed from utes and a lockout will occur after a total of eight minutes has Low Fire to Modulate. A lockout will occur if a flame failure elapsed.
  • Page 28 RM7888A OPERATION Fig. 21—DSI Normal sequence timing diagram. STANDBY NORMAL- NORMAL- NORMAL- PART 1 PART 2 PART 3 INPUT & OUTPUT 4 SECONDS, 5 SECONDS, SIGNALS POSSIBLE POSSIBLE 0 TO STANDBY- INFINITE INFINITE INFINITE PURGE HOLD HOLD SECONDS POWER POWER POWER POWER POWER...
  • Page 29 RM7888A OPERATION Fig. 22—DSI High/Low Stepfire sequence timing diagram. 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 4 SECONDS SECONDS SECONDS POWER POWER...
  • Page 30 RM7888A OPERATION Fig. 23—DSI On/Off Stepfire sequence diagram. STANDBY OFF/ON OFF/ON STEPFIRE- STEPFIRE- INPUT & PART 1 PART 2 OUTPUT SIGNALS 5 TO STANDBY- INFINITE PURGE 4 SECONDS SECONDS POWER POWER POWER POWER POWER PILOT PILOT PILOT FLAME FLAME FLAME MAIN MAIN ALARM...
  • Page 31 RM7888A OPERATION Fig. 24—Keyboard Display Module and Fig. 26 (↔ ↔ ↔ ↔ ↔ )—Change-Level pushbutton sequence. function FIVE WIRE CONNECTOR FOR DI=DIAGNOSIS COMMUNICATIONS, REMOTE H1= HISTORY KEYBOARD DISPLAY AND EA=EXPANDED REMOTE RESET ANNUNCIATOR SEQUENCE CAPTIVE STATUS MOUNTING SCREW SELECTABLE MESSAGE OR KEYBOARD PRE-EMPTIVE...
  • Page 32 RM7888A OPERATION Fig. 27—Mode pushbutton function. SAVE SAVE M1934B Fig. 28—Save function. SAVE M1935A SELECTABLE MESSAGES VFD Second Line Display, Two-Level Hierarchy; see Table 8. The display values are as follows: n represents a numbered value. T represents the terminal number. TABLE 8—SELECTABLE MESSAGES.
  • Page 33 ↔ (see Table 9) Remote Command NONE/HOLD/HF/LF Expanded Annunciator Diagnostic Current Status Messages can be reviewed in Table 9. The RM7888A uses different terminal descriptions than other 7800 SERIES™ controls. Refer to Table 1 for the actual RM7888A terminal designations. 65-0175...
  • Page 34: Static Checkout

    RM7888A OPERATION • STATIC CHECKOUT EXPANDED ANNUNCIATOR MESSAGES be shown. If the EA is connected, display messages will be (TABLE 9) shown (see Table 4, 14 or 15) for fault codes. When The Expanded Annunciator (EA) may or may not be accessing Expanded Annunciator Messages, follow the connected because it is an optional device.
  • Page 35 RM7888A STATIC CHECKOUT GENERAL INSTRUCTIONS 6. If there is no voltage or the operation is abnormal, 1. Perform all applicable tests listed in Static Checkout, check the circuits and external devices as described in the Table 10, in the order listed. last column.
  • Page 36: Checkout

    RM7888A STATIC CHECKOUT • CHECKOUT TABLE 10—STATIC CHECKOUT (Continued). Test Test Normal If Operation Is Abnormal, Check The Jumpers Voltmeter Operation Items Listed Below 15-13 — 1. If modulation is used, raise 1. Series 90 Controller. setpoint of series 90 controller— 2.
  • Page 37 Make certain that: If an RM7888A is replaced with a lower function- 1. Wiring connections are correct and all terminal screws ing 7800 SERIES Relay Module, the burner will are tight. not sequence unless wiring changes are made. 2. Flame detector(s) is clean, installed and positioned properly.
  • Page 38 RM7888A CHECKOUT TABLE 11—FLAME SIGNAL. Flame Signal Minimum Acceptable Maximum Expected Detector Amplifier Steady dc Voltage dc Voltage Flame Rod Photocell R7847A,B 1.25 Vdc 5.0 Vdc at Keyboard Display Module C7012A,C or 5.0 Vdc at a 20 kohm/volt meter C7012E,F R7847C C7015A R7848A,B...
  • Page 39 RM7888A CHECKOUT 6 If the pilot flame is not established in ten seconds, 16. If the main burner flame is not established after two safety shutdown occurs. Let the sequence complete its attempts: cycle. Consult the equipment operating manual for further a.
  • Page 40 RM7888A CHECKOUT 4. Verify that the combustion chamber has been prop- NOTE: Upon completing these tests, open the master switch erly purged. and remove all test jumpers from the subbase terminals, 5. Close the master switch and start the system by limits/controls or switches.
  • Page 41 RM7888A CHECKOUT 9. Energize the appropriate special function input (ter- 4. Make sure the leadwires from the flame rod and minal 17, 19, or 20) and let the sequence proceed. At ten ignition electrode are not too close together. seconds into the Ignition Trial period, make sure the auto- 5.
  • Page 42 Simulate a flame to cause the flame signal voltage level to be at least 1.25 Vdc for 40 seconds after entry NOTE: The Honeywell Q624A Solid State Spark Genera- to STANDBY. tor will prevent detection of ignition spark when prop- b.
  • Page 43: Troubleshooting

    RM7888A lock- nal, OFF is displayed. out, which energizes the ALARM LED, by using the optional Keyboard Display Module or 7800 SERIES System Annun- Historical Information Index ciation Diagnostics and Troubleshooting, form 65-0118.
  • Page 44 1/8 DIA. (2) M5082 Home and Building Control Home and Building Control Helping You Control Your World Honeywell Inc. Honeywell Limited—Honeywell Limitée 1985 Douglas Drive North 740 Ellesmere Road Golden Valley, MN 55422 Scarborough, Ontario M1P 2V9 QUALITY IS KEY 65-0175 Printed in U.S.A.

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