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Honeywell 7800 Series Product Data

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GENERAL
The Honeywell RM7896 is a microprocessor based integrated
burner control for automatically fired gas, oil, or combination
fuel single burner applications. The RM7896 consists of the
Relay Module. Subbase, Amplifier and Purge Card are required
to complete the system. Options include Keyboard Display
Module, Personal Computer Interface, Data ControlBus
Module™, Remote Display Module, First-Out Expanded
Annunciator and Combustion System Manager® Software.
The RM7896 is programmed to provide a level of safety,
functional capability and features beyond the capacity of
conventional controls.
Functions provided by the RM7896 include automatic burner
sequencing, flame supervision, system status indication,
system or self-diagnostics and troubleshooting.
FEATURES
Safety features:
- Airflow switch check.
- Closed loop logic test.
- Dynamic Ampli-Check®.
- Dynamic input check.
- Dynamic safety relay test.
- Dynamic self-check logic.
- Internal hardware status monitoring.
- Tamper resistant timing and logic.
Access for external electrical voltage checks.
Airflow switch check feature (RM7896B,D).
15 second postpurge.
Application flexibility.
Communication interface capability.
Delayed main valve (RM7896C,D).
Dependable, long-term operation provided by
microcomputer technology.
First-out annunciation and system diagnostics provided
by a 2 row by 20 column Vacuum Fluorescent Display
(VFD) located on the optional Keyboard Display Module
(optional).
Copyright © 1995 Honeywell Inc. • All Rights Reserved
RM7896A,B,C,D Relay Module
Specifications ...........................................................................
Ordering Information ................................................................
Principal Technical Features ....................................................
Safety Provisions .....................................................................
Installation ................................................................................
Wiring ....................................................................................... 11
Assembly ................................................................................. 14
Operation ................................................................................. 17
Checkout .................................................................................. 21
Troubleshooting ....................................................................... 27
7800 SERIES
First-out expanded annunciation with 26 Light Emitting
Diodes (LEDs) for limits and interlocks (optional).
Five (LEDs) for sequence information.
Two function Run/Test Switch (RM7896C,D).
Interchangeable plug-in flame amplifiers.
Local or remote annunciation of RM7896 operation and
fault information.
Nonvolatile memory; RM7896 retains history files and
sequencing status after loss of power.
Remote reset (optional).
Report generation (optional).
Selectable recycle or lockout on loss of airflow.
Selectable recycle or lockout on loss of flame.
Shutter drive output.
Burner controller data (optional):
- Expanded annunciator status.
- Flame signal strength.
- Hold status.
- Lockout/alarm status.
- Sequence status.
- Sequence time.
- Total cycles of operation.
- Total hours of operation.
- Fault history providing for the 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 digital inputs and outputs.
- Selected prepurge time.
- Software revision and version of RM7896 and
optional Keyboard Display Module.
- Status of configuration jumpers.
- Status of Run/Test Switch (RM7896C,D).
PRODUCT DATA
Contents
2
2
7
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65-0193

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  Summary of Contents for Honeywell 7800 Series

  • Page 1: Table Of Contents

    Troubleshooting ............... 27 • First-out annunciation and system diagnostics provided by a 2 row by 20 column Vacuum Fluorescent Display (VFD) located on the optional Keyboard Display Module (optional). 65-0193 Copyright © 1995 Honeywell Inc. • All Rights Reserved...
  • Page 2 Can also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold. ORDERING INFORMATION When purchasing replacement and modernization products from your 7800 SERIES distributor, refer to the TRADELINE® Catalog for complete ordering number.
  • Page 3 Sensitivity) Order flame rod separately; see holder Instructions. Use only Honeywell Photocell, part no. 38316. The C7012A,C; C7027, C7035 and C7044 Flame Detectors should be used only on burners that cycle on-off at least once every twenty-four hours. Appliances with burners that remain on continuously for twenty-four hours or longer should use the C7012E,F Flame Detector with the R7847C Amplifier or the C7076A,D Flame Detector with the R7886A Amplifier as the ultraviolet flame detection system.
  • Page 4 7800 SERIES RM7896A,B,C,D RELAY MODULE Sequence timing for normal operation: Flame Establishing Period Device INITIATE STANDBY PREPURGE Pilot Main POSTPURGE AFSC RM7896A 10 sec. 4 or 10 sec. 15 sec. RM7896B 10 sec. 4 or 10 sec. 15 sec. RM7896C 10 sec.
  • Page 5 7800 SERIES RM7896A,B,C,D RELAY MODULE BURNER CONTROL (127) POWER PILOT FLAME MAIN ALARM RESET 6-3/32 (155) 5 (127) REMOVE ONLY FOR TERMINAL TEST ACCESS. M5004B Fig. 2. Mounting dimensions of RM7896 Relay Module and Q7800B Subbase in in. (mm). IGNITION...
  • Page 6 7800 SERIES RM7896A,B,C,D RELAY MODULE 4-1/8 (105) 4 (102) 6 FOOT (1.83 METER) LEADWIRES (2) COLLAR WITH 2 (51) 1/2-14 NPSM 3-1/2 (89) 1–11-1/2 NPSM INTERNAL THREADS 1-3/16 INTERNAL (30) THREADS 1-1/16 (27) 31/32 1-1/2 (25) (38) COLLAR WITH 1/2-14 NPSM...
  • Page 7 7800 SERIES RM7896A,B,C,D RELAY MODULE 11-13/16 (300) 2-5/32 1-27/32 1 INCH NPT 7-13/16 (198) 5-13/16 (147) (55) (47) 15/16 [24] DIA. 5-13/16 6-7/32) (147) (158) 2-1/2 (64) 6-19/32 (168) 1 (25) 15/16–18 UNC (2 EACH) 2 (51) M5084A C7076D Fig. 4. Ultraviolet detectors dimensions in in. (mm) continued.
  • Page 8 7800 SERIES RM7896A,B,C,D RELAY MODULE 5. Main Flame Establishing Period (MFEP) (RM7896C,D) Dynamic Flame Amplifier and Shutter Check a. Airflow lockout feature is enabled and the airflow Self-checking circuitry tests all electronic components in the switch opens. flame detection system and amplifier 10 to 12 times per minute b.
  • Page 9: Installation

    Card are isolated and reported by the optional Keyboard 7. All external timers must be listed or components Display Module. See 7800 SERIES System Annunciation recognized by authorities who have jurisdiction for Diagnostics and Troubleshooting, form 65-0118.
  • Page 10 7800 SERIES RM7896A,B,C,D RELAY MODULE (HOT) 120 Vac PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN MICROCOMPUTER FLAME AMPLIFIER TEST RESET PUSHBUTTON RELAY RELAY STATUS DRIVE FEEDBACK CIRCUIT AND LINE VOLTAGE INPUTS SAFETY RELAY CIRCUIT...
  • Page 11: Wiring

    7800 SERIES RM7896A,B,C,D RELAY MODULE 5. Recommended grounding practices: Vibration a. Use the earth ground to provide a connection Do not install the RM7896 where it could be subjected to between the subbase and the control panel or the vibration in excess of 0.5G continuous maximum vibration.
  • Page 12 7800 SERIES RM7896A,B,C,D RELAY MODULE Q7800 120V ALARM BURNER MOTOR (BLOWER) (L1) BURNER CONTROLLER/LIMITS AIRFLOW INTERLOCK INTERMITTENT PILOT/IGNITION MAIN FUEL VALVE(S) IGNITION RECTIFYING FLAME ROD, RECTIFYING (HOT) PHOTOCELL, OR INFRA- RED (LEAD SULFIDE) FLAME DETECTOR MASTER SWITCH C7027A, C7035A, OR...
  • Page 13 7800 SERIES RM7896A,B,C,D RELAY MODULE Q7800 120V ALARM BURNER MOTOR (BLOWER) (L1) BURNER CONTROLLER/LIMITS AIRFLOW INTERLOCK 10 SEC. INTERRUPTED PILOT/IGNITION MAIN FUEL VALVE(S) DELAYED IGNITION MAIN VALVE RECTIFYING FLAME ROD, RECTIFYING (HOT) PHOTOCELL, OR INFRA- RED (LEAD SULFIDE) FLAME DETECTOR...
  • Page 14: Assembly

    7800 SERIES RM7896A,B,C,D RELAY MODULE ASSEMBLY Mounting RM7896 NOTE: For installation dimensions, see Figs. 1 or 2. Relay Module Mounting 1. Mount the RM7896 vertically, see Figs. 9 or 10, or mount horizontally with the knife blade terminals pointing downward. When mounted on the Q7800A, the RM7896 must be in an electrical enclosure, see Fig.
  • Page 15 7800 SERIES RM7896A,B,C,D RELAY MODULE Mounting Dust Cover 1. Align the two interlocking ears of the dust cover with the two mating slots on the RM7896, see Fig. 12. 2. Insert the two interlocking ears into the two mating slots, and with a hinge action, push on the upper corners of the Dust Cover to secure it to the RM7896.
  • Page 16 7800 SERIES RM7896A,B,C,D RELAY MODULE C7076A,D ULTRAVIOLET DETECTOR INFRARED (C7015) REMOTE SENSOR WHITE EARTH GROUND BROWN SHUTTER C7076A C7076D SHUTTER TERMINAL BLOCK ULTRAVIOLET (C7027/C7035/C7044) L1 (HOT) L2 (COMMON) BLUE 7800 SERIES WHITE SOLID STATE SELF-CHECKING SOLID STATE ULTRAVIOLET (C7012E,F) ULTRAVIOLET (C7012A,C)
  • Page 17: Operation

    7800 SERIES RM7896A,B,C,D RELAY MODULE OPERATION Sequence of Operation The INITIATE sequence also delays the burner motor starter from being energized and de-energized from an intermittent The RM7896 has the following operating sequences (see AC line input or control input.
  • Page 18 7800 SERIES RM7896A,B,C,D RELAY MODULE TIMED PFEP POST PURGE INITIATE STANDBY START PURGE 4 OR 10 SEC MFEP 15 SEC STANDBY POWER POWER POWER POWER POWER POWER POWER POWER POWER DISPLAY PILOT PILOT PILOT PILOT FLAME FLAME FLAME FLAME MAIN...
  • Page 19 7800 SERIES RM7896A,B,C,D RELAY MODULE SERVICE POST PURGE NOTE: Clipping and removing a site-configurable jumper After demand is satisfied or a limit opens, de-energizing enhances the level of safety. terminal 6, the Ignition/Pilot valve, main valve and delayed main valve, terminals 8, 9, and 21 are de-energized. The Static Checkout blower motor, terminal 4, remains powered for 15 seconds.
  • Page 20 7800 SERIES RM7896A,B,C,D RELAY MODULE 4. Raise the set point of the operating controller to 9. Check all wiring for correct connections, tight terminal simulate a call for heat. screws, correct wire, and proper wiring techniques. 5. For each test, open the master switch and install the Replace all damaged or incorrectly sized wires.
  • Page 21: Checkout

    CAUTION Flame Signal Measurement (Fig. 20 and If an RM7896 is replaced with a lower or higher functioning 7800 SERIES Relay Module, the burner Table 5) will not sequence unless wiring changes are made. Measure the flame signal at the appropriate times defined in IMPORTANT the following checkout tests.
  • Page 22 7800 SERIES RM7896A,B,C,D RELAY MODULE • Open circuits. POSITIVE (+) • Short circuits. METER LEAD • Leakage paths caused by moisture, soot or 20K OHM/ accumulated dirt. VOLT METER NEGATIVE (-) METER LEAD 3. For a flame rod, make sure: •...
  • Page 23 7800 SERIES RM7896A,B,C,D RELAY MODULE d. If the ignition spark is not strong and continuous, that the pilot is established during PILOT IGN and the open the master switch and adjust the ignition main burner flame is established during MAIN IGN electrode spark gap setting to the manufacturer within the normal lightoff time.
  • Page 24 7800 SERIES RM7896A,B,C,D RELAY MODULE by the equipment manufacturer, close the manual fuel 5. Close the master switch and start the system with a call shutoff valve(s) and open the master switch. for heat . Raise the set point of the operating controller.
  • Page 25 7800 SERIES RM7896A,B,C,D RELAY MODULE NOTE: If there is no flame for fifteen seconds with the 3. Check for correct spacing on the ignition electrode: sequence stopped at this point, the RM7896 a. 6,000V systems — 1/16 to 3/32 in. (1.6 to 2.4 mm).
  • Page 26 0.5 Vdc. 4. Failure to ignite pilot. a. Close the pilot and main fuel manual shutoff valve(s). NOTE: The Honeywell Q624A Solid State Spark Generator b. Depress the reset pushbutton. will prevent detection of ignition spark when properly c. Start the system.
  • Page 27: Troubleshooting

    RM7896, which energizes the ALARM RM7896 but will not reset a lockout condition. LED or by using the optional Keyboard Display Module. The 7800 SERIES provides a System Annunciation Diagnostics and SERVICE Troubleshooting manual, form 65-0118.
  • Page 28 7800 SERIES RM7896A,B,C,D RELAY MODULE Table 6. Sequence and status hold information. NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type. Sequence Status INITIATE The LED indicates the burner status, POWER, which is a stabilization period for the RM7896 to check for any fluctuations in AC line voltage inputs or control input on power-up or during normal operation.
  • Page 29 7800 SERIES RM7896A,B,C,D RELAY MODULE Table 6. Sequence and status hold information (Continued). NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type. Sequence Status If the RM7896 is in a HOLD status, the following condition could exist:...
  • Page 30 7800 SERIES RM7896A,B,C,D RELAY MODULE 65-0193...
  • Page 31 7800 SERIES RM7896A,B,C,D RELAY MODULE 65-0193...
  • Page 32 7800 SERIES RM7896A,B,C,D RELAY MODULE Home and Building Control Home and Building Control Helping You Control Your World Honeywell Inc. Honeywell Limited-Honeywell Limitée 740 Ellesmere Road Honeywell Plaza P.O. Box 524 Scarborough, Ontario Minneapolis, MN 55408-0524 M1P 2V9 65-0193 G.R.

This manual is also suitable for:

Rm7896aRm7896bRm7896cRm7896d