Honeywell 7800 Series Manual
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Honeywell 7800 Series Manual

Relay modul
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RM7800E,G,L,M Relay Module
The Honeywell RM7800 is a microprocessor based inte-
grated burner control for automatically fired gas, oil, or
combination fuel single burner applications. The RM7800
consists of a Relay Module and Keyboard Display Module.
Subbase, Amplifier, and Purge Card are required to complete
the system. Options include Personal Computer Interface,
DATA CONTROLBUS MODULE™, Remote Display Mount-
ing, First-Out Expanded Annunciator and COMBUSTION
SYSTEM MANAGER™ Software.
The RM7800 is programmed to provide a level of safety,
functional capability and features beyond the capacity of
conventional controls.
Functions provided by the RM7800 include automatic
burner sequencing, flame supervision, system status indica-
tion, system or self-diagnostics and troubleshooting.
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.
-Internal hardware status monitoring.
-Low Fire Start Switch test.
-Tamper resistant timing and logic.
Access for external electrical voltage checks.
Application flexibility.
Communication interface capability.
Dependable, long-term operation provided by microcom-
puter technology.
First-out annunciation and system diagnostics provided
by a 2 row by 20 column Vacuum Fluorescent Display
(VFD) located on the Keyboard Display Module.
First-out expanded annunciation with 26 Light Emitting
Diodes (LEDs) for limits and interlocks (optional).
Five sequence information Light Emitting Diodes (LEDs).
Five function Run/Test Switch.
Interchangeable plug-in flame amplifiers.
Local or remote annunciation of operation and fault
information.
Nonvolatile memory for retaining history files and se-
quencing status after loss of power.
Remote reset (optional).
Report generation (optional).
Burner controller data:
-Sequence status.
-Sequence time.
-Hold status.
-Lockout/alarm status.
-Flame signal strength.
-Expanded annunciator status.
-Total cycles of operation.
-Total hours of operation.
-Fault history of six most recent faults:
• Cycles of operation at time of fault.
• Expanded annunciator data 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 RM7800 and Key-
board Display Module.
• Status of configuration jumpers.
• Status of Run/Test Switch.
CONTENTS
Specifications ............................................................ 2
Ordering Information ............................................... 2
Principle Technical Features ................................... 8
Safety Provisions ...................................................... 9
Installation .............................................................. 11
Wiring ..................................................................... 13
Assembly ................................................................. 20
Operation ................................................................ 23
Static Checkout ....................................................... 32
Checkout ................................................................. 35
Troubleshooting ...................................................... 42
S. H. • Rev. 9-92 • ©Honeywell Inc. 1992 • Form Number 65-0117-2
7800 SERIES
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Summary of Contents for Honeywell 7800 Series

  • Page 1: Table Of Contents

    Assembly ..............20 —Sequence status. Operation ..............23 —Sequence time. Static Checkout ............32 —Hold status. Checkout ..............35 —Lockout/alarm status. Troubleshooting ............42 —Flame signal strength. S. H. • Rev. 9-92 • ©Honeywell Inc. 1992 • Form Number 65-0117—2...

  • Page 2: Specifications

    Operating frequency chosen by RM7800 selection. 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 Circuitry tests the flame signal amplifier 12 times a minute during burner operation and shuts down the burner if the amplifier fai Flame Rod separately; see Instructions for the holder. Order Use on Honeywell Photocell, part no. 38316. 65-0117—2...
  • Page 4 RM7800E,G,L,M SPECIFICATIONS SEQUENCE TIMING FOR NORMAL OPERATION Post Firing Energy Approval Flame Establishing Period Purge Interlock Rate Saving Code Device Initiate Standby Purge Pilot Main Timing Circuits Circuit Prepurge Bodies RM7800E 10 sec. 4 or 10 sec. 10 or 15 sec. 15 sec.
  • Page 5 RM7800E,G,L,M SPECIFICATIONS ACCESSORIES: Expanded Annunciator—part no. S7830A1005. Optional: Flame Simulators: ControlBus 5-Wire Electrical Connector—part —part no. 203659 UV Flame Simulator. no. 203541. —part no. 123514A Rectification Simulator. COMBUSTION SYSYEM MANAGER™—part Keyboard Display Module—part no. S7800A1001. no. ZM7850A1001. Remote Reset Module—part no. S7820A1007 Communication Interface Base Unit—part no.
  • Page 6 RM7800E,G,L,M SPECIFICATIONS Fig. 4—Rectification detectors. IGNITION ELECTRODE FLAME ROD (Q179C ONLY) CERAMIC INSULATORS 1 [25] 3/4–14 NPT OR 1–11-1/2 NPT MOUNTING FLANGE [183] [42] [36] TARGET [10] [130] [95] [13] [79] [27] [87] 1/2–14 NPSM [18] [133] LEADWIRES FACEPLATE M1962 THREADED [20] [20]...
  • Page 7 RM7800E,G,L,M SPECIFICATIONS Fig. 6—Ultraviolet detectors. [105] COLLAR WITH 2 [51] 1/2-14 NPSM 4 [102] INTERNAL THREADS 6 FOOT [1.83 METER] 1–11-1/2 NPSM LEADWIRES (2) INTERNAL [89] THREADS [30] [25] [38] [27] 6 FOOT [67] COLLAR WITH 1/2-14 NPSM [1.83 METER] INTERNAL THREADS INSERTION DEPTH LEADWIRES (2) 3...

  • Page 8: Principle Technical Features

    RM7800E,G,L,M SPECIFICATIONS • PRINCIPAL TECHNICAL FEATURES Fig. 6— Ultraviolet detectors (Continued) [300] 1 INCH NPT [198] [147] 15/16 [24] DIA. [55] [47] [158] [147] [64] [168] 1 [25] 15/16–18 UNC (2 EACH) 2 [51] M5084 C7076D Principal Technical Features The RM7800 provides all customary flame safeguard f.

  • Page 9: Safety Provisions

    RM7800E,G,L,M PRINCPLE TECHNICAL FEATURES • SAFETY PROVISIONS f. Purge card is not installed or removed. c. Main valve terminal is energized. g. Purge card is bad. d. Internal system fault. 7. POSTPURGE Period e. Purge card is removed. a. Preignition Interlock does not close within five- f.
  • Page 10 Interlock must be energized throughout PREPURGE. If the board Display Module, see Troubleshooting section and Preignition Interlock opens during STANDBY, it causes a 7800 SERIES System Annunciation Diagnostics and hold (30 seconds). The RM7800 will lockout if the interlock Troubleshooting, form 65-0118.

  • Page 11: Installation

    RM7800E,G,L,M INSTALLATION Installation WARNING 3. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause interfer- FIRE OR EXPLOSION HAZARD ence to radio communications. It has been tested and CAN CAUSE PROPERTY DAMAGE, found to comply with the limits for a Class B computing SEVERE INJURY, OR DEATH.
  • Page 12 RM7800E,G,L,M INSTALLATION Fig. 7—Internal block diagram of the RM7800 (See Figs. 8, 9, 10, 11, 12 or 13 for detailed wiring instructions). (HOT) 120 Vac PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN FLAME MICROCOMPUTER AMPLIFIER TEST RESET...

  • Page 13: Wiring

    RM7800E,G,L,M WIRING Wiring 1. a. For proper subbase wiring, refer to Figs. 8, 9, 10 or shielded cable or equivalent. The Keyboard Dis- play Module, DATA CONTROLBUS MOD- b. For proper remote wiring of the Keyboard Dis- ULE™ (for remote mounting or communications) play Module, refer to Figs.
  • Page 14 3(c) NOTE: A 13 Vdc power supply must be used any time more provided as part of the 7800 SERIES device than one Keyboard Display Module is used. ControlBus connection. Connect the shield at both ends to earth ground.
  • Page 15 RM7800E,G,L,M WIRING Fig. 8—Wiring RM7800E. SERIES 90 FIRING RATE SERIES 90 MOTOR Q7800 CONTROLLER HIGH FIRE COMMON LOW FIRE 120V ALARM MODULATE BURNER MOTOR (BLOWER) BURNER CONTROLLER/LIMITS LOCKOUT INTERLOCKS LOW FIRE (INC. AIR FLOW SWITCH) START SWITCH 10 SEC. INTERRUPTED HIGH FIRE PILOT/IGNITION PURGE SWITCH...
  • Page 16 RM7800E,G,L,M WIRING Fig. 9—Wiring RM7800G. SERIES 90 FIRING RATE SERIES 90 MOTOR Q7800 CONTROLLER HIGH FIRE COMMON LOW FIRE 120V ALARM MODULATE BURNER MOTOR (BLOWER) BURNER CONTROLLER/LIMITS RUNNING INTERLOCKS LOW FIRE (INC. AIR FLOW SWITCH) START SWITCH 10 SEC. INTERRUPTED PILOT/IGNITION JUMPER WIRE FOR 30s MFEP MAIN FUEL...
  • Page 17 RM7800E,G,L,M WIRING Fig. 10—Wiring RM7800L. SERIES 90 FIRING RATE SERIES 90 Q7800 MOTOR CONTROLLER HIGH FIRE COMMON LOW FIRE 120V ALARM MODULATE BURNER MOTOR (BLOWER) BURNER CONTROLLER/LIMITS LOCKOUT INTERLOCKS LOW FIRE (INC. AIR FLOW SWITCH) START SWITCH 10 SEC. INTERRUPTED HIGH FIRE PILOT/IGNITION PURGE SWITCH...
  • Page 18 RM7800E,G,L,M WIRING Fig. 11—Wiring RM7800M. Q7800 COMMON 120V ALARM DAMPER MODULATE MOTOR BURNER MOTOR (BLOWER) BURNER CONTROLLER/LIMITS RUNNING INTERLOCKS LOW FIRE (INC. AIR FLOW SWITCH) START SWITCH 10 SEC. INTERRUPTED PILOT/IGNITION MAIN FUEL PREIGNITION VALVE(S) INTERLOCK 5 SECOND IGNITION INTERMITTENT (EARLY SPARK PILOT TERMINATION)
  • Page 19 Fig. 12—Wiring the Keyboard Display Module with Fig. 13—Wiring multiple Keyboard Display Communication Interface ControlBus Module. Modules. S7800 KEYBOARD DISPLAY MODULE S7800 KEYBOARD DISPLAY MODULE (MOUNTED ON 7800 SERIES RELAY MODULE) (MOUNTED ON 7800 SERIES RELAY MODULE) MOMENTARY MOMENTARY PUSH BUTTON PUSH BUTTON...

  • Page 20: Assembly

    RM7800E,G,L,M ASSEMBLY Assembly MOUNTING RM7800 Fig. 15—Electrical panel installation. NOTE: For installation dimensions, see Figs. 1 or 2 . RELAY MODULE MOUNTING 1. Mount the RM7800 vertically, see Figs. 15 or 16, or mount horizontally with the knife blade terminals pointing downward.
  • Page 21 RM7800E,G,L,M ASSEMBLY Fig. 17—ST7800 Purge Card installation. Fig. 20— Extension Cable Assembly mounting. Fig. 18—Keyboard Display Module mounting. REMOTE MOUNTING OF KEYBOARD DISPLAY MODULE (VFD) 1. The Keyboard Display Module (VFD) can be mounted either on the face of a panel door or on other remote locations, see Fig.
  • Page 22 M7800E,G,L,M ASSEMBLY Fig. 21—Remote mounting of Keyboard Display INSTALLING PLUG-IN FLAME SIGNAL Module. AMPLIFIER 1. Disconnect power supply before beginning installa- tion to prevent electrical shock and equipment damage. More than one disconnect may be involved, see Fig. 22. 2. Align the amplifier circuit board edge connector with the keyed receptacle on the RM7800.

  • Page 23: Operation

    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) BLUE BLUE YELLOW YELLOW WHITE WHITE BLACK BLACK BLACK BLACK...
  • Page 24 RM7800E,G,L,M OPERATION STANDBY throughout the Ignition Trial state. The RM7800 is ready 2. Flame must be proven by the end of the four or ten STANDBY to start an operating se- second PFEP to allow the sequence to continue. If Total Cycles quence when the operat- flame is not proven by the end of PFEP, a safety...
  • Page 25 RM7800E,G,L,M OPERATION Fig. 24—RM7800E,L sequence. RM7800E,L PREPURGE PREPURGE DRIVE TO TIMED DRIVE TO PFEP HIGH FIRE PURGE LOW FIRE POSTPURGE DISPLAY INITIATE STANDBY 4 OR 10 SEC MFEP STANDBY POWER POWER POWER POWER POWER POWER POWER POWER POWER POWER PILOT PILOT PILOT PILOT...
  • Page 26 RM7800E,G,L,M OPERATION Fig. 26—RM7800M sequence. RM7800M TIMED PFEP PURGE DISPLAY INITIATE STANDBY PREPURGE 4 OR 10 SEC MFEP POSTPURGE STANDBY POWER POWER POWER POWER POWER POWER POWER POWER POWER PILOT PILOT PILOT PILOT DISPLAY FLAME FLAME FLAME FLAME MAIN MAIN MAIN MAIN ALARM...
  • Page 27 RM7800E,G,L,M OPERATION TABLE 3—SEQUENCE STATUS DISPLAY INFORMATION (See Fig. 27). NOTE: Normal sequences are in BOLD TYPE, while abnormal sequences are not in bold type. Burner Sequence LEDs Energized INITIATE minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM ◊selectable—message INITIATE HOLD: AC POWER, PILOT, FLAME, MAIN AND ALARM (AC Freq/Noise) INITIATE HOLD: AC...
  • Page 28 Burner Sequence LEDs Energized Additional sequence status information when an Expanded Annunciator is connected to the Relay Module, also see 7800 SERIES System Annunciation Diagnostics and Troubleshooting, form 65-0118, Table 7. BURNER OFF: T6 POWER, PILOT, FLAME, MAIN AND ALARM...
  • Page 29 RM7800E,G,L,M OPERATION Fig. 30—MODE pushbutton function. Fig. 31—SAVE function. SAVE SAVE M1935A 4. SAVE function, see Fig. 31. The SAVE function enables users to identify the select- able message they want to view upon power restoration. The second line selectable message will be restored to the most recently saved selection when power returns.
  • Page 30 ◊Expanded Annun.↔ (see Table 5) ◊Remote Command NONE/HOLD/HF/LF EXPANDED ANNUNCIATOR MESSAGES, shown, see Table 5 and 7800 SERIES System Annunciation See Table 5 Diagnostics and Troubleshooting, form 65-0118, Tables 6 The Expanded Annunciator (EA) may or may not be and 7 for fault codes. When accessing Expanded Annuncia- connected because it is an optional device.
  • Page 31 ◊Software Revision (SW Rev.) ↓EA nnnn< Expanded Annunciator Diagnostic Current Status Messages can be reviewed in 7800 SERIES System Annunciation Diagnostics and Troubleshooting, form 65-0118, Table 7. RUN/TEST SWITCH FUNCTIONS PFEP for the RM7800E,L if terminals 8 and 9 or 9 and 21 The Run/Test Switch is located on the top side of the are jumpered.

  • Page 32: Static Checkout

    RM7800E,G,L,M OPERATION • STATIC CHECKOUT TABLE 6—SITE CONFIGURABLE JUMPER OPTIONS. Jumper Number Description Intact Clipped RM7800 Type Pilot Flame Establishing Period (PFEP) 10 Seconds 4 Seconds (All) Pilot Valve /Main Flame 10 Seconds Intermittent 15 or 30 Seconds Interrupted (RM7800G) Establishing Period (MFEP) Start-up Interlock Check Disabled...
  • Page 33 RM7800E,G,L,M STATIC CHECKOUT 5. For each test, open the master switch and install the 10. Replace faulty controllers, limits, interlocks, actua- jumper wire(s) between the subbase wiring terminals listed in tors, valves, transformers, motors and other devices as the Test Jumpers column. required.
  • Page 34 RM7800E,G,L,M STATIC CHECKOUT TABLE 7—STATIC CHECKOUT (Continued) Test RM7800 Test Volt- If Operation Is Abnormal, Models Jumpers meter Normal Operation Check The Items Listed Below WARNING Make sure all manual fuel shutoff valves are closed. — Automatic main fuel valve(s) opens. 1.

  • Page 35: Checkout

    If an RM7800 is replaced with a lower functioning 6. Combustion chamber and flues are clear of fuel and 7800 SERIES Relay Module, the burner will not fuel vapor. sequence unless wiring changes are made. 7. Power is connected to the system disconnect switch, (master switch).
  • Page 36 RM7800E,G,L,M CHECKOUT TABLE 8—FLAME SIGNAL. Minimum Acceptable Maximum Flame Flame Signal Steady dc Expected Detector Amplifier Voltage dc Voltage Flame Rod R7847A,B 1.25 Vdc 5.0 Vdc at Photocell Keyboard Display C7012A,C Module C7012E,F R7847C C7015A R7848A,B C7027A R7849A,B C7035A 5.0 Vdc at C7044A 20 kohm/volt meter C7076A,D...
  • Page 37 RM7800E,G,L,M CHECKOUT 1. Open the master switch. 9. When the MAIN IGN period is displayed on the VFD, 2. Make sure that the manual main fuel shutoff valve(s) make sure the automatic main fuel valve is open; then is closed. Open the manual pilot shutoff valve. If the pilot smoothly open the manual main fuel shutoff valve(s) and takeoff is downstream from the manual main fuel shutoff watch for main burner flame ignition.
  • Page 38 RM7800E,G,L,M CHECKOUT INITIAL LIGHTOFF CHECK FOR DIRECT 18. If a second stage is used, make sure the automatic SPARK IGNITION second stage fuel valve(s) has opened. Check the lightoff as This check applies to gas and oil burners not using a pilot. follows (otherwise proceed to step 19): It should immediately follow the preliminary inspection.
  • Page 39 RM7800E,G,L,M CHECKOUT 6. When the PILOT IGN begins, set the Run/Test Switch NOTE: This step requires two people, one to open the manual to TEST position to stop the sequence. The FLAME LED valve(s) and one to watch for ignition. will come on when the pilot ignites.
  • Page 40 Infrared radiation from a hot refrac- tory is steady, but radiation from a flame has a flickering NOTE: The Honeywell Q624A Solid State Spark Generator characteristic. The infrared detection system responds only will prevent detection of ignition spark when properly to flickering infrared radiation;...
  • Page 41 RM7800E,G,L,M CHECKOUT Check the pilot alone, the main burner flame alone, and both e. *Pilot Flame Fail* fault will be displayed on the together (unless monitoring only the pilot flame when using VFD. Fault code 28 will be displayed four or ten an intermittent pilot, or only the main burner flame when seconds (depending on the jumper configuration using DSI).

  • Page 42: Troubleshooting

    OFF The RM7800 provides 118 diagnostic messages for trouble- is displayed, see Table 4. shooting the system (see 7800 SERIES System Annuncia- tion Diagnostics and Troubleshooting, form 65-0118). Historical Information Index...
  • Page 43 RM7800E,G,L,M TROUBLESHOOTING TABLE 9—HOLD AND FAULT MESSAGE SUMMARY. Fault Number Annunciation Message Fault 1 *No Purge Card* Fault 2 *AC Frequen/Noise* Fault 3 *AC Line Dropout* Fault 4 *AC Frequency* Fault 5 *Low Line Voltage* Fault 6 *Purge Card Error* Fault 7 *Flame Amplifier* Fault 8...
  • Page 44 Fig. 35—Flush mounting of a Keyboard Display Module template. 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, Minnesota 55422 Scarborough, Ontario M1P 2V9 QUALITY IS...

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