Honeywell 7800 Series Manual

Honeywell 7800 Series Manual

Relay module
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RM7830A, RM7850A Relay Module

APPLICATION

The Honeywell RM7830A or RM7850A Relay Module is a
microprocessor based integrated burner control for automatically fired
gas, oil, or combination fuel single burner full modulation (RM7850A) or
on/off (RM7830A) power burner applications. The RM7830A or
RM7850A consists of a Relay Module. Subbase, Amplifier, and Purge
Card are required to complete the system. The Keyboard Display,
which is optional, can be mounted on the Relay Module or on the face
of a panel door. The Keyboard Display can also be mounted remotely
from the panel, provided this is approved for the application.
The 7800 SERIES is programmed to provide a level of safety,
functional capability and features beyond the capacity of conventional
controls.
Functions provided by the 7800 SERIES include automatic burner
sequencing, flame supervision, system status indication, system or
self-diagnostics and troubleshooting. Text readout for the Keyboard
Display Module is available in English, Spanish, Portugese, French,
German and Italian languages.

FEATURES

Safety features:
- Interlock check.
- Closed loop logic test.
- Dynamic AMPLI-CHECK®
- Dynamic input check.
- Dynamic safety relay test.
- Dynamic self-check logic.
- Expanded safe-start check.
- High Fire Purge Switch test (RM7850A).
- Internal hardware status monitoring.
- Low Fire Start Switch test (RM7850A).
- Tamper resistant timing and logic.
® U.S. Registered Trademark
Copyright © 1996 Honeywell Inc. • All Rights Reserved
7800 SERIES
First-out annunciation and system diagnostics provided by a
2 row by 20 column Vacuum Fluorescent Display (VFD)
located on the Keyboard Display Module. Text readout for this
unique Keyboard Display Module is available in English,
Spanish, Portugese, French, German and Italian languages.
Access for external electrical voltage checks.
Application flexibility.
Dependable, long-term operation provided by microcomputer
technology.
Five sequence information Light Emitting Diodes (LEDs)-
Power, Pilot, Flame, Main, Alarm (see Fig. 17).
Five function Run/Test Switch.
Interchangeable plug-in flame amplifiers.
Nonvolatile memory for retaining history files and
sequencing status after loss of power.
Remote mounting of the Keyboard Display Module (subject to
application approval).
Remote reset (subject to application approval).
Burner controller data available on the Keyboard Display
Module:
- Sequence status.
- Sequence time.
- Hold status.
- Lockout/alarm status.
- Flame signal strength.
- Total cycles of operation.
- Total hours of operation.
- Fault history of six most recent faults:
• Cycles of operation at time of fault.
• Fault message and code.
• Hours of operation at time of fault.
• Sequence status at time of fault.
• Sequence time at time of 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 Relay Module and
Keyboard Display Module.
• Status of configuration jumpers.
• Status of Run/Test Switch.
Application .......................................................................... 1
Features .............................................................................. 1
Specifications ...................................................................... 2
Ordering Information ........................................................... 2
Principle Technical Features ............................................... 7
Safety Provisions ................................................................ 8
Installation and Wiring ......................................................... 9
Operation ............................................................................ 20
Checkout ............................................................................. 28
Troubleshooting .................................................................. 29
X-XX UL
PRODUCT DATA
Contents
65-0222

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Summary of Contents for Honeywell 7800 Series

  • Page 1: Table Of Contents

    • Sequence time at time of fault. — Diagnostic information: The 7800 SERIES is programmed to provide a level of safety, • Device type. functional capability and features beyond the capacity of conventional •...
  • Page 2: Specifications

    Honeywell Inc., 1885 Douglas Drive North Minneapolis, Minnesota 55422-4386 (612) 951-1000 In Canada—Honeywell Limited/Honeywell Limitée, 155 Gordon Baker Road, North York, Ontario M2H 2C9. International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
  • Page 3 2000 VA maximum connected load to RM7830A Assembly. Total load current, excluding Burner/Boiler Motor and Firing Rate Outputs cannot exceed 5A, 25A inrush. Honeywell has tested this output at 9.8A at P.F. = 0.5, 58.8A inrush for 100,000 cycles (EN298 approval does not require this test).
  • Page 4 Total load current, excluding Burner/Boiler Motor and Firing Rate Outputs cannot exceed 5A, 25A inrush. Can also be 24 Vac, 3A at P.F. = 0.5. Honeywell has tested this output at 9.8A at P.F. = 0.5, 58.8A inrush for 100,000 cycles (EN298 approval does not require this test).
  • Page 5 7800 SERIES RM7830A, RM7850A RELAY MODULE Table 2. Flame Detection Systems. Plug-in Flame Signal Amplifiers Applicable Flame Detectors Flame Failure Self- Response Type Color Checking Model Time Fuel Type Models Rectification Green R7847A 1 or 2 sec Rectifying C7004, C7007, C7011.
  • Page 6 7800 SERIES RM7830A, RM7850A RELAY MODULE Table 3. Sequence Timing for Normal Operation. Purge or First Safety Pilot Main Trial Main Post Device Initiate Standby Waiting Preignition Time Stab. Time*** Stab. Purge RM7830A1003 2 sec 3 sec 3 or 5 sec...
  • Page 7: Principle Technical Features

    7800 SERIES RM7830A, RM7850A RELAY MODULE SAFETY 1 Period. PRINCIPAL TECHNICAL FEATURES Lockout Input opens during SAFETY 1. Airflow Switch opens during SAFETY 1. The RM7830A or RM7850A Relay Module provide all Low Fire Switch opens (RM7850A). customary flame safeguard functions while providing No flame is present at the end of SAFETY 1.
  • Page 8: Safety Provisions

    7800 SERIES RM7830A, RM7850A RELAY MODULE SAFETY PROVISIONS High Fire Purge and Low Fire Start Switch Tests (RM7850A) Internal Hardware Status Monitoring High Fire Purge Switch Test examines the Purge Position Interlock Switch at the moment the firing rate motor is The RM7830A or RM7850A Relay Module check the purge commanded to the high fire position.
  • Page 9: Installation And Wiring

    7800 SERIES RM7830A, RM7850A RELAY MODULE First-Out Annunciation and Preignition Interlock The Preignition Interlock input (ES2) is typically connected to Self-Diagnostics proof-of-closure switches for fuel valve(s). The Preignition Sequence Status Lights (LEDs) provide positive visual Interlock must be energized throughout PURGE and indication of the program sequence: POWER, PILOT, PREIGNITION.
  • Page 10 7800 SERIES RM7830A, RM7850A RELAY MODULE Keyboard Display Module, DATA CONTROLBUS Mounting Wiring Subbase MODULE™ or Remote Reset Module—The shield, if used, should be connected to the signal NOTE: For installation dimensions, see Fig. 1. ground terminal 3(c) provided as part of the 7800 SERIES device connection.
  • Page 11 7800 SERIES RM7830A, RM7850A RELAY MODULE HOT N 120 Vac CONFIGURATION PLUG-IN PURGE TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN MICROCOMPUTER FLAME AMPLIFIER RESET SHUTTER PUSHBUTTON RELAY DRIVE CIRCUIT RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS SAFETY RELAY...
  • Page 12 7800 SERIES RM7830A, RM7850A RELAY MODULE HOT N 120 Vac CONFIGURATION PLUG-IN PURGE TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN MICROCOMPUTER FLAME AMPLIFIER RESET SHUTTER PUSHBUTTON RELAY DRIVE CIRCUIT RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS SAFETY RELAY...
  • Page 13 7800 SERIES RM7830A, RM7850A RELAY MODULE Q7800 (L1) RECTIFYING FLAME ROD, LEGEND RECTIFYING ALARM PHOTOCELL (NORMALLY OPEN) OR INFRARED PREIGNITION (LEAD SULFIDE) INTERLOCK INPUT FLAME BURNER/BLOWER DETECTOR MOTOR IGNITION LINE VOLTAGE SUPPLY C7027A, C7035A, OR LOCKOUT INPUT BLUE WHITE C7044A...
  • Page 14 7800 SERIES RM7830A, RM7850A RELAY MODULE SERIES 90 SERIES 90 FIRING RATE CONTROLLER Q7800 MOTOR HIGH FIRE COMMON MODULATE LOW FIRE (L1) RECTIFYING LEGEND FLAME ROD, ALARM RECTIFYING (NORMALLY OPEN) PHOTOCELL LOW FIRE SWITCH OR INFRARED INPUT (LEAD SULFIDE) PREIGNITION...
  • Page 15 7800 SERIES RM7830A, RM7850A RELAY MODULE S7800 KEYBOARD DISPLAY MODULE Mounting Relay Module (MOUNTED ON 7800 SERIES RELAY MODULE) MOMENTARY NOTE: For installation dimensions, see Fig. 1 . PUSHBUTTON SWITCH Relay Module Mounting Mount the Relay Module vertically, see Fig. 7, or mount...
  • Page 16 7800 SERIES RM7830A, RM7850A RELAY MODULE Mounting Data Controlbus Module™ and Extension Cable Assembly Align the two interlocking ears with the two mating slots on the Relay Module, See Figs. 10 and 11. Insert the two interlocking ears into the two mating slots and push on the lower corners of the DATA CONTROLBUS MODULE™...
  • Page 17 7800 SERIES RM7830A, RM7850A RELAY MODULE Remote Mounting of Keyboard Display Module If permitted by application approval (see Approvals), the Keyboard Display Module can be mounted either on the face of a panel door or on other remote locations, see Fig.
  • Page 18 7800 SERIES RM7830A, RM7850A RELAY MODULE Selectable Site-Configurable Jumpers During RUN, the Run/Test Switch, when placed in the TEST position, drives the firing rate motor to the Low The RM7830A or RM7850A has three site-configurable jumper Fire position. options, see Figure 15 and Table 4. The site-configurable jumpers should be clipped with side cutters and the resistors removed from the Relay Module.
  • Page 19 7800 SERIES RM7830A, RM7850A RELAY MODULE SOLID STATE SELF-CHECKING SOLID STATE SELF-CHECKING ULTRAVIOLET (C7012E,F) ULTRAVIOLET (C7061A) BLUE BLUE YELLOW YELLOW WHITE WHITE WHITE WHITE BLACK BLACK INFRARED (C7015) C7076A,D ULTRAVIOLET DETECTOR WHITE REMOTE SENSOR BROWN EARTH GROUND ULTRAVIOLET (C7027/C7035/C7044) SHUTTER...
  • Page 20: Operation

    7800 SERIES RM7830A, RM7850A RELAY MODULE Normal Start-Up RUN/TEST SWITCH SELECTABLE CONFIGURATION PURGE 00:30 JUMPERS Purge Total Hours The RM7830A or RM7850A M1996 provides a PURGE timing selectable from two seconds to 30 minutes with power applied and the Relay Module operating control indicating a c all for heat: a.
  • Page 21 7800 SERIES RM7830A, RM7850A RELAY MODULE 65-0222...
  • Page 22 7800 SERIES RM7830A, RM7850A RELAY MODULE 65-0222...
  • Page 23 7800 SERIES RM7830A, RM7850A RELAY MODULE During MAIN TRIAL, the Low Fire Switch Input see Fig. 17. The extreme right side of the first line will either must be closed (RM7850A). If it opens, a safety be blank or it will show a small arrow pointing to the second shutdown occurs.
  • Page 24 7800 SERIES RM7830A, RM7850A RELAY MODULE Table 5. Sequence Status Display Information (See Fig. 17). NOTE: Normal sequences are in BOLD TYPE, while abnormal sequences are not in bold type. LEDs Energized Burner Sequence INITIATE minutes: seconds selectable __ message...
  • Page 25 7800 SERIES RM7830A, RM7850A RELAY MODULE two per second. When the last item of the selectable Keyboard Functions message is viewed, the display wraps around and displays The keyboard contains four pushbuttons and each has the first selectable message again.
  • Page 26 7800 SERIES RM7830A, RM7850A RELAY MODULE Mode pushbutton, see Fig. 20. Save function, see Fig. 21. The MODE pushbutton instantaneously switches the display The SAVE function enables users to identify the selectable from a second-line-selectable message to second-line- message they want to view upon power restoration. The preempted message.
  • Page 27 7800 SERIES RM7830A, RM7850A RELAY MODULE Table 6. Selectable Messages. Selectable Message (Second Line) Display Value (Second Line) First Line Message Flame Signal n.nV Total Cycles nnnnn Total Hours nnnnn Fault History ↓H1 Fault Cycle nnnnn ↓H1 Fault Hours nnnnn ↓H1...
  • Page 28: Checkout

    7800 SERIES RM7830A, RM7850A RELAY MODULE CHECKOUT Use 1M ohm/volt meter with a 0 to 10 Vdc capability. Set the 1M ohm/volt meter to the 0 to 10 Vdc range. Insert the positive (red) probe into the + jack of the Equipment Recommended flame amplifier.
  • Page 29: Troubleshooting

    7800 SERIES RM7830A, RM7850A RELAY MODULE TROUBLESHOOTING Diagnostic Information Index The Relay Module monitors input/output terminals and can display the status of the terminal at the Keyboard Display RM7800 Series System Diagnostics Module (example: Pilot Valve T8 ON). See Table 6 for a Troubleshooting control system equipment failures is made complete terminal description and number.
  • Page 30 7800 SERIES RM7830A, RM7850A RELAY MODULE Table 8. Hold and Fault Message Summary. Fault Number Annunciation Message Description Fault 1 *No Purge Card* Purge card problem. Fault 2 *AC Frequen/Noise* Lockout due to inability to take minimum number of samples.
  • Page 31 7800 SERIES RM7830A, RM7850A RELAY MODULE Table 8. Hold and Fault Message Summary (Continued). Fault Number Annunciation Message Description Fault 53 *Lockout Switch* Lockout Input has opened. Fault 67 *AC Phase* L1 and N connections are miswired. Fault 105-107 *Internal Fault* Internal Fault.
  • Page 32 7800 SERIES RM7830A, RM7850A 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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Rm7830aRm7850a

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