Yamatake-Honeywell 7800 Series Product Data

Relay module
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APPLICATION

The Yamatake Honeywell EC7885/RM7885 is a microprocessor based
integrated burner control for semi-automatically fired gas, oil or
combination fuel single burner industrial applications. The 7885A
requires a Relay Module Subbase and Amplifier to complete the
system. Options include Keyboard Display Module, Personal Computer
Interface, DATA CONTROLBUS MODULE™, Remote Display Module
and COMBUSTION SYSTEM MANAGER™ Software.
The 7885A is programmed to provide a level of safety, functional capability
and features beyond the capacity of conventional controls.
The 7885A is adaptable to continuous firing, high-low or modulating
firing rate for semi-automatic burner sequencing. Functions
provided by the 7885 include flame supervision, system status
indication, system or self-diagnostics and troubleshooting.
The 7885A operates with any of the following types of ignitions:
1. Torch-ignited main burner using the S445A Start-Stop Station,
or any conventional knee- or foot-operated start-stop station.
2. Torch-ignited pilot using the S445A Start-Stop Station, or any
conventional knee- or foot-operated start-stop station.
3. Direct-ignition oil burner or electrically ignited pilot, using the
S445A Start-Stop Station, which maintains electric ignition as
long as the Start Switch is depressed (up to 15 minutes).

FEATURES

Safety features:
-
Closed loop logic test.
-
Dynamic AMPLI-CHECK®.
-
Dynamic input check.
-
Dynamic safety relay test.
® U.S. Registered Trademark
Copyright © 1997 Honeywell Inc. • All Rights Reserved
EC7885A/RM7885A Relay Module
7800 SERIES
-
Dynamic self-check logic.
-
Expanded safe-start check.
-
Internal hardware status monitoring.
-
Tamper resistant timing and logic.
Lockout if Start Switch is held 15 minutes.
Access for external electrical voltage checks.
Application flexibility.
Communication interface capability.
Dependable, long-term operation provided by microcomputer
technology.
First-out annunciation and system diagnostics are provided by
an optional 2 row by 20 column Vacuum Fluorescent Display
(VFD) located on the optional Keyboard Display Module.
Five LEDs for sequence information.
Interchangeable plug-in flame amplifiers.
Local or remote annunciation of 7885A operation and fault
information (optional).
Nonvolatile memory; 7885A retains history files and
sequencing status after loss of power.
Remote reset (optional).
Report generation (optional).
Shutter drive output.
Burner controller data (optional):
-
Flame signal strength.
-
Hold status.
-
Lockout/alarm status.
-
Sequence status.
-
Sequence time.
-
Total hours of operation.
-
Total cycles of operation.
-
Fault history providing the six most recent faults:
- Cycles of operation 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.
- Software revision and release of 7885A and optional
Keyboard Display Module.
Application ........................................................................... 1
Features .............................................................................. 1
Specifications ...................................................................... 2
Ordering Informationn ......................................................... 2
Principal Technical Features ............................................... 8
Safety Provisions ................................................................ 8
Installation ........................................................................... 9
Assembly ............................................................................. 16
Operation ............................................................................ 19
Checkout ............................................................................. 21
Troubleshooting .................................................................. 28
PRODUCT DATA
Contents
65-0203

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Summary of Contents for Yamatake-Honeywell 7800 Series

  • Page 1: Table Of Contents

    7800 SERIES EC7885A/RM7885A Relay Module PRODUCT DATA — Dynamic self-check logic. — Expanded safe-start check. — Internal hardware status monitoring. — Tamper resistant timing and logic. • Lockout if Start Switch is held 15 minutes. • Access for external electrical voltage checks.
  • Page 2: Specifications

    7800 SERIES EC7885A/RM7885A RELAY MODULE Power Dissipation: RM7885A: 10W maximum. SPECIFICATIONS Maximum Total Connected Load: 2000 VA. Electrical Ratings, RM7885A see Table 1A: Fusing: Total Connected Load: 20A maximum, type FRN Voltage and Frequency: 100 Vac (+10/-15%), 50 or 60 Hz or equivalent.
  • Page 3 7800 SERIES EC7885A/RM7885A RELAY MODULE Electrical Ratings, EC7885A see Table 1B: Dimensions: Voltage and Frequency: 200 Vac (+10/-15%), 50 or 60 Hz Refer to Fig. 1 and 2. (+/- 10%) Power Dissipation: RM7885A: 10W maximum. Weight: Maximum Total Connected Load: 2000 VA.
  • Page 4 7800 SERIES EC7885A/RM7885A RELAY MODULE Table 2. Flame Detection Systems. Plug-in Flame Signal Amplifiers Applicable Flame Detectors Self- Flame Failure Type Color Checking Model Response Time Fuel Type Models Rectification Green R7847A .8 or 3 sec Rectifying C7004, C7007, C7011.
  • Page 5 7800 SERIES EC7885A/RM7885A RELAY MODULE Sequence Timing for Normal Operation Accessories: Optional: Device Initiate Standby Ignition ControlBus 5-Wire Electrical Connector, part no. 203541. 7885A 10 sec. COMBUSTION SYSTEM MANAGER™, part no. * STANDBY and RUN can be an infinite time period.
  • Page 6 7800 SERIES EC7885A/RM7885A RELAY MODULE BURNER CONTROL (127) POWER PILOT FLAME MAIN ALARM RESET 6-3/32 (155) 5 (127) REMOVE ONLY FOR TERMINAL TEST ACCESS. M11134 Fig. 2. Mounting dimensions of 7885A Relay Module and Q7800B Subbase in in. (mm). IGNITION...
  • Page 7 7800 SERIES EC7885A/RM7885A RELAY MODULE 4-1/8 (105) 4 (102) 6 FOOT (1.83 METER) LEADWIRES (2) 2 (51) 1/2-14 NPSM COLLAR WITH 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 8: Principal Technical Features

    7800 SERIES EC7885A/RM7885A 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) C7076D M5084B Fig. 4. Ultraviolet detectors mounting dimensions in in. (mm) (continued from previous page).
  • Page 9: Installation

    7885A to distinguish between field (external device) and internal (system related) problems. Faults associated within the flame detection subsystem or 7885A are isolated and reported by the optional Keyboard Display Module. See the 7800 SERIES System Annunciation Diagnostics and Troubleshooting, form 65-0118. 65-0203...
  • Page 10 7800 SERIES EC7885A/RM7885A RELAY MODULE Weather WARNING The 7885A is not designed to be weather tight. If installed outdoors, the 7885A must be protected by an approved This equipment generates, uses, and can radiate weather-tight enclosure. radio frequency energy, and if not installed and used...
  • Page 11 7800 SERIES EC7885A/RM7885A RELAY MODULE Q7800 DPST ALARM SILENCING SWITCH ALARM (L1) S445A START-STOP STATION STOP LIMITS INTERNAL JUMPER INTERMITTENT START PILOT MAIN FUEL VALVE(S) IGNITION FOR DIRECT SPARK IGNITION (HOT) (OIL OR GAS) MASTER SWITCH MAIN VALVE 100V, 50 OR 60 HZ. (RM7885); 200V, 50 OR 60 HZ (EC7885) POWER SUPPLY.
  • Page 12 7800 SERIES EC7885A/RM7885A RELAY MODULE Q7800 DPST ALARM (L1) SILENCING SWITCH ALARM R482B S445A START-STOP STATION STOP LIMITS INTERNAL JUMPER INTERMITTENT START PILOT FUEL CONTROLLER PRESSURE SWITCH LOW FIRE MOTOR MANUAL END SWITCH VALVE IGNITION HI-LO OR MODULATING MOTOR (HOT)
  • Page 13 7800 SERIES EC7885A/RM7885A RELAY MODULE Q7800 Q7800 DPST ALARM DPST ALARM (L1) (L1) SILENCING SILENCING SWITCH SWITCH ALARM ALARM S445A S445A START-STOP START-STOP STATION STATION STOP STOP LIMITS INTERNAL INTERNAL JUMPER JUMPER IGNITION IGNITION START START LIMITS INTERMITTENT INTERMITTENT PILOT...
  • Page 14 7800 SERIES EC7885A/RM7885A RELAY MODULE Q7800 PILOT MOTOR DPST ALARM (L1) SILENCING GANGED 3 POLE SWITCH DOUBLE THROW SWITCH ALARM R482B R482B S445A START-STOP STATION STOP LIMITS INTERNAL JUMPER START IGNITION FUEL FUEL PRESSURE PRESSURE SWITCH SWITCH LOW FIRE MOTOR...
  • Page 15 7800 SERIES EC7885A/RM7885A RELAY MODULE Q7800 (L1) ALARM S445A START-STOP STATION STOP LIMITS INTERNAL JUMPER INTERMITTENT START PILOT MAIN FUEL VALVE(S) IGNITION FOR DIRECT SPARK IGNITION (HOT) (OIL OR GAS) MASTER SWITCH MAIN VALVE 100V, 50 OR 60 HZ. (RM7885); 200V, 50 OR 60 HZ (EC7885) POWER SUPPLY.
  • Page 16: Assembly

    7800 SERIES EC7885A/RM7885A RELAY MODULE Ground the earth ground terminal for each 7885A 2. Select the location in the electrical enclosure. Be sure that must be grounded to the metal control panel to allow adequate clearance for servicing, installation with wire as short as practical. Each ground wire...
  • Page 17 7800 SERIES EC7885A/RM7885A RELAY MODULE Mounting Dust Cover 1. Align the two interlocking ears of the Dust Cover with the two mating slots on the 7885A, see Fig. 14. 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 7885A.
  • Page 18 7800 SERIES EC7885A/RM7885A 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 19: Operation

    7800 SERIES EC7885A/RM7885A RELAY MODULE OPERATION Normal Start-Up When the Start Switch is pressed, the Ignition Transformer is Sequence of Operation energized and power is applied to terminal 10 of the 7885A. If The operating sequence for the 7885A follows, see Figs. 17, all microcomputer monitored circuits are in the correct state, 18, and Table 3.
  • Page 20 7800 SERIES EC7885A/RM7885A RELAY MODULE CAPTIVE MOUNTING SCREW DUST COVER SEQUENCE RELAY STATUS MODULE LEDs FLAME AMPLIFIER RESET PUSHBUTTON M11177 Fig. 18. Sequence status LEDs. Table 3. LED sequence status display information. Burner Sequence LEDs Energized INITIATE POWER , PILOT, FLAME, MAIN and ALARM...
  • Page 21: Checkout

    • Response to other ultraviolet sources—all installations If an 7885A is replaced with a lower or higher using Ultraviolet Flame Detectors. functioning 7800 SERIES Relay Module, the burner • Flame signal with hot combustion chamber—all will not sequence unless wiring changes are made.
  • Page 22 7800 SERIES EC7885A/RM7885A RELAY MODULE See Fig. 18 for location of component parts and see Fig. 7 or POSITIVE (+) Q7800 Specification for terminal locations. METER LEAD Preliminary Inspection MEGOHM/VOLT NEGATIVE (-) METER METER LEAD Perform the following inspections to avoid common problems.
  • Page 23 7800 SERIES EC7885A/RM7885A RELAY MODULE 3. For a flame rod, make sure: Close the master switch, press the Start Switch, • Ground area is large enough. and observe the spark. • Flame rod is properly located in the flame. After a continuous spark is obtained, release the •...
  • Page 24 7800 SERIES EC7885A/RM7885A RELAY MODULE 17. Run the burner through another sequence, observing 11. If necessary, repeat steps 8, 9 and 10 to establish the the flame signal for: first stage burner flame. Pilot flame alone (unless using direct spark 12.
  • Page 25 7800 SERIES EC7885A/RM7885A RELAY MODULE 9. If the main flame is not established within five seconds or If hot refractory saturation occurs, the condition must be the normal lightoff period specified by the burner manu- corrected. Add an orifice plate in front of the cell to restrict the facturer, close the manual main fuel shutoff valve(s) and viewing area.
  • Page 26 7800 SERIES EC7885A/RM7885A RELAY MODULE Pilot Turndown Test Ignition Interference Test (All Flame Rods) Test to be sure that a false signal from a spark ignition system (All Installations Using A Pilot) is not superimposed on the flame signal. Perform this check on all installations that use a pilot. The...
  • Page 27 7800 SERIES EC7885A/RM7885A RELAY MODULE To check rectifying photocells for hot refractory hold-in, 3. If the flame signal is higher than 0.5 Vdc and the operate the burner until the refractory reaches its maximum FLAME LED does come on, consult the equipment temperature.
  • Page 28: Troubleshooting

    7800 SERIES EC7885A/RM7885A RELAY MODULE 2. Failure to ignite pilot. Flame Signal, Total Cycles, Total Hours, Fault History, Close the pilot and main fuel manual shutoff Diagnostic Information and Expanded Annunciator Terminal valve(s). Status (if used). With this information, most problems can be Press the Start Switch.
  • Page 29 7800 SERIES EC7885A/RM7885A 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 Explanation INITIATE The LED indicates the burner status, POWER, which is a stabilization period for the 7885A to check for any fluctuations in AC line voltage inputs or control input on power-up or during normal operation.
  • Page 30 7800 SERIES EC7885A/RM7885A RELAY MODULE 65-0203...
  • Page 31 7800 SERIES EC7885A/RM7885A RELAY MODULE 65-0203...
  • Page 32 7800 SERIES EC7885A/RM7885A RELAY MODULE Home and Building Control Home and Building Control Honeywell Asia Pacific Inc. Honeywell Inc. Honeywell Limited-Honeywell Limitée Room 3213-3225 Honeywell Plaza 155 Gordon Baker Road Sun Hung Kai Centre P.O. Box 524 North York, Ontario No.

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