Honeywell RM7800, RM7823, RM7830, RM7838, RM7840 User Manual

RM/EC 7800 Burner Controller

1 Scope and Purpose of the Document

This document provides an overview of the user responsibilities for installation and operation of the Honeywell 7800 Series Relay Modules in order to maintain the designed safety level. Items that will be addressed are proof testing, repair and replacement of the device, reliability data, lifetime, environmental and application limits, and parameter settings.

This Safety Manual is limited to Models: RM7800, RM7823, RM7830, RM7838, RM7840, RM7845, RM7850, RM7865, RM7885, RM7888, RM7890, RM7895, RM7896, RM7897, RM7898, EC7820, EC7823, EC7830, EC7840, EC7850, EC7890, EC7895 with one of the following Flame Detectors and Flame Amplifiers:

Table 1. 7800 Series Burner Controller Models and Series

MODEL	SERIES	MODEL	SERIES	MODEL	SERIES	MODEL	SERIES
RM7800	9	RM7850	5	RM7895	6	EC7820	7
RM7823	6	RM7865	4	RM7896	6	EC7823	4
RM7830	5	RM7885	5	RM7897	6	EC7830	6
RM7838	9	RM7888	5	RM7898	6	EC7840	5
RM7840*	8	RM7890	9			EC7850	6
RM7845	3					EC7890	5
						EC7895	5

*NOTE: RM7840E1016, RM7840L1018 and RM7840L1026 are Series 5

Table 2. R78xx Flame Amplifier Models and Series

MODEL	SERIES
R7847B	5
R7852B	1
R7847C	5
R7851C	2
R7861A	2
R7886A	2

SAFETY MANUAL

Edition 11.19 · 32-00231-01 · EN

Table 3. C7xxx Flame Sensor Models and Series

MODEL	SERIES
C7008A	1
C7009A	1
C7915A	1
C7012E	1
C7012F	1
C7061A	1
C7061F	1
C7076A	1
C7076D	1
C7961E	1
C7961F	1

CONTENTS

1	Scope and Purpose of the Document . . . . . . . . . . .		.	. .	.1. . . .
2	Using the Honeywell 7800 Series Relay Modules . .		. .	.	. 2. .
2.1		Safety Function . . . . . . . . . . . . . . . . . . .	.	.	. 2
2.2		Fail Safe State . . . . . . . . . . . . . . . . . . . .	.	.	. 2

2.3Safety Response Time . . . . . . . . . . . . . . . . . . . 2

2.4Diagnostic Response Time . . . . . . . . . . . . . . . . .2

2.5Maximum Achievable SIL . . . . . . . . . . . . . . . . . 2

2.6Model Selection and Specification of Honeywell 7800

Series Relay Modules . . . . . . . . . . . . . . . . . . . 2

2.7Installation . . . . . . . . . . . . . . . . . . . . . . . . 3

2.8Required configuration settings . . . . . . . . . . . . . 3

2.9Reliability data . . . . . . . . . . . . . . . . . . . . . . . 3

2.10Lifetime limits . . . . . . . . . . . . . . . . . . . . . . . 4

2.11 Proof Testing . . . . . . . . . . . . . . . . . . . . . . . 4

2.12Repair and replacement . . . . . . . . . . . . . . . . . . 4

2.13Firmware update . . . . . . . . . . . . . . . . . . . . . 4

2.14 Environmental and EMC based limits . . . . . . . . . . 4

3 Definitions and Abbreviations . . . . . . . . . . . . . . . . . . . . . .5. . . . .

3.1Definitions . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2Abbreviations . . . . . . . . . . . . . . . . . . . . . . . 5

4 Status of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

4.1 Releases . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.2 Open issues . . . . . . . . . . . . . . . . . . . . . . . . 6 4.3 Future enhancements of the document . . . . . . . . . 6

SIL3

Capable

RM/EC 7800 Burner Controller Safety Manual

2Using the Honeywell 7800 Series Relay Modules

2.1Safety Function

The 7800 Series provides automatic burner flame sequencing and flame supervision with protection against loss of flame.

2.2 Fail Safe State

The Safety Shutdown (Lockout) mode is the failsafe state for the Honeywell 7800 Series Relay Modules where all safety critical terminals (main and pilot valves, and ignition transformer) are de-energized and a manual reset is required to return to normal operation.

2.3 Safety Response Time

The Honeywell 7800 Series Relay Modules (all models except of EC7823 and RM7823) will respond to loss of flame by means of shutting off all safety outputs and transitioning to the Safety Shutdown (Lockout) state within the published Flame Failure Response Time (FFRT) for the selected Flame Amplifier and Flame Sensor.

EC7823 and RM7823 will respond to loss of flame by means of shutting off the safety outputs and transitioning to the Idle state within the published Flame Failure Response Time (FFRT) for the selected Flame Amplifier and Flame Sensor. Safety Shutdown (Lockout) state is not entered and manual reset action is not needed in this case.

2.4 Diagnostic Response Time

The Honeywell 7800 Series Relay Modules will report a detectable internal failure within 3 seconds for faults to the main 7800 Relay Module and within 15 seconds for faults to the Flame Detector / Flame Amplifier.

2.5 Maximum Achievable SIL

The 7800 Relay Modules, Flame Amplifiers and Flame Detectors covered by this safety manual are suitable for use in both high and low demand mode of operation Safety Integrity Functions (SIF) up to SIL 3 in simplex (1oo1) configurations. The achieved SIL for a particular SIF needs to be verified by PFH or PFDavg calculation for the entire SIF including the failure rates of the associated sensors and actuators that are also part of the SIF.

Use of the Honeywell 7800 Series Relay Modules in a redundant (1ooN) configurations is not supported.

The 7800 Series Burner Controller System is classified as a Type B1 element according to IEC 61508, having a hardware fault tolerance of 0.

1Type B element: “Complex” element (using micro controllers or programmable logic); for details see 7.4.4.1.3 of IEC 61508-2, ed, 2010

2.6Model Selection and Specification of Honeywell 7800 Series Relay Modules

The Honeywell 7800 Series Relay Modules and optional components for certified SIL applications shall only be selected and specified for applications consistent with the guidelines presented in the Installation Instructions document and additional technical literature released for the specific model available at web site https://customer.honeywell.com and further restricted to the certified Flame Amplifiers and Flame Detectors identified in section 1 of this Safety Manual.

32-00231-01

2