Honeywell RM7800E, RM7800G User Manual

RM7800E,G,L,M; RM7840E,G,L,M

7800 SERIES Relay Modules

INSTALLATION INSTRUCTIONS

APPLICATION

The Honeywell RM7800/RM7840 Relay Modules are microprocessor-based integrated burner controls for automatically fired gas, oil, or combination fuel single burner applications. The RM7800/RM7840 Relay Modules are used for UL/CSA On/Off, UL/CSA Modulating, and FM/IRI Modulating burner applications. The RM7800/RM7840 system consists of a Relay Module. Keyboard Display Modules (standard with RM7800), Dust Cover (standard with RM7840), Subbase, Amplifier, and Purge Card. Options include DATA CONTROLBUS MODULE™, Remote Display Mounting, FirstOut Expanded Annunciator and Communications through Modbus™.

Functions provided by the RM7800/RM7840 include automatic burner sequencing, flame supervision, system status indication, system or self-diagnostics and troubleshooting. The RM7800/RM7840 is a solid state replacement for the electromechanical R4140 Automatic Programming Control.

This document provides installation and static checkout instructions. Other applicable publications are:

65-0084:Q7800A,B 22-Terminal Wiring Subbase Product Data.

65-0089:ST7800A Plug-In Purge Timer Installation Instructions.

65-0090:S7800A Keyboard Display Module Product Data.

65-0091:S7810A Data ControlBus Module™ Product Data.

65-0095:S7820 Remote Reset Module Product Data.

65-0097:221729C Dust Cover Packing Sheet.

65-0101:S7830 Expanded Annunciator Product Data.

65-0109:R7824, R7847, R7848, R7849, R7851, R7852, R7861, R7886 Flame Amplifiers for the 7800 SERIES Product Data.

65-0131:221818A Extension Cable Assembly Product Data.

65-0229:7800 SERIES RELAY MODULES Checkout and Troubleshooting Product Data.

65-0249:S7810M ModBus™ Module Product Data.

SPECIFICATIONS

Electrical Ratings, see Table 3:

Voltage and Frequency: 120 Vac (+10/-15%), 50 or 60 Hz (±10%).

Power Dissipation: RM7800/RM7840: 10W maximum.

Maximum Total Connected Load: 2000 VA.

Fusing: 15A maximum, Type SC or equivalent Fast Blow.

Environmental Ratings:

Ambient Temperature:

Operating: -40°F to +140°F (-40°C to +60°C). Storage: -40°F to +150°F (-40°C to +66°C).

Humidity: 85% relative humidity continuous, noncondensing. Vibration: 0.5G environment.

SIL 3 Capable:

SIL 3 Capable in a properly designed Safety Instrumented System. See form number 65-0312 for Certificate Agreement.

Approvals:

Underwriters Laboratories Inc. Listed: File No. MP268,

Guide No. MCCZ.

Canadian Standards Association Certified: LR9S329-3.

Factory Mutual Approved: Report No. J.I.1V9A0.AF.

Swiss Re (formerly IRI): Acceptable.

Federal Communications Commission, Part 15,

Class B—Emissions.

INSTALLATION

When Installing this Product...

1.Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.

2.Check the ratings given in the instructions and marked on the product to make sure the product is suitable for the application.

3.Installer must be a trained, experienced, flame safeguard service technician.

4.After installation is complete, check out the product operation as provided in these instructions.

WARNING

Fire or Explosion Hazard.

Can cause property damage, severe injury, or death.

To prevent possible hazardous burner operation, verify safety requirements each time a control is installed on a burner.

SIL3
Capable	66-1085-04

RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

WARNING

Electrical Shock Hazard.

Can cause serious injury or death.

Disconnect the power supply before beginning installation. More than one power supply disconnect may be required.

IMPORTANT

1.Wiring connections for the relay modules are unique; therefore, refer to Fig. 2, 3, 4, or the correct Specifications for proper subbase wiring, and sequence charts.

2.Wiring must comply with all applicable codes, ordinances and regulations.

3.Wiring must comply with NEC Class 1 (Line Voltage) wiring.

4.Loads connected to the RM7800/RM7840 must not exceed those listed on the RM7800/RM7840 label or the Specifications, see Table 1.

5.Limits and interlocks must be rated to simultaneously carry and break current to the ignition transformer, pilot valve, and main fuel valve(s).

6.All external timers must be listed or component recognized by authorities who have jurisdiction for the specific purpose for which they are used.

7.For on-off gas-fired systems, some authorities who have jurisdiction prohibit the wiring of any limit or operating contacts in series between the flame safeguard control and the main fuel valve(s).

8.Two Flame Detectors can be connected in parallel with the exception of Infrared Flame Detectors (C7015, C7915), Ultraviolet Flame Detectors (C7927, C7961) or Visible Light Detector (C7962).

9.This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class B computing device of Part 15 of FCC rules which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area may cause

interference; in which case, the users at their own expense may be required to take whatever measures are required to correct this interference.

10.This digital apparatus does not exceed the Class B limits for radio noise for digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications.

Location

Humidity

Install the relay module where the relative humidity never reaches the saturation point. The relay module is designed to operate in a maximum 85 percent relative humidity continuous, noncondensing, moisture environment. Condensing moisture may cause a safety shutdown.

Vibration

Do not install the relay module where it could be subjected to vibration in excess of 0.5G continuous maximum vibration.

Weather

The relay module is not designed to be weather tight. When installed outdoors, protect the relay module using an approved weather-tight enclosure.

Mounting Wiring Subbase

1.Mount the subbase in any position except horizontally with the bifurcated contacts pointing down. The standard vertical position is recommended. Any other position decreases the maximum ambient temperature rating.

2.Select a location on a wall, burner or electrical panel. The Q7800 can be mounted directly in the control cabinet. Be sure to allow adequate clearance for servicing, installation, access or removal of the RM7800/RM7840, Expanded Annunciator, Keyboard Display Module, flame amplifier, flame amplifier signal voltage probes, Run/Test Switch, electrical signal voltage probes and electrical field connections.

3.For surface mounting, use the back of the subbase as a template to mark the four screw locations. Drill the pilot holes.

4.Securely mount the subbase using four no. 6 screws.

Wiring Subbase

WARNING

Electrical Shock Hazard.

Can cause serious injury, death or equipment damage.

Disconnect the power supply before beginning installation to prevent electrical shock, equipment and control damage. More than one power supply disconnect may be required.

1.For proper subbase wiring, refer to Figs. 2, 3, 4 or 5.

2.For proper remote wiring of the Keyboard Display Module, through a 203541 5-wire Connector, refer to the Specifications for the Keyboard Display Module (65-0090), Data ControlBus Module™ (65-0091) or Extension Cable Assembly (65-0131).

3.Disconnect the power supply from the main disconnect before beginning installation to prevent electrical shock and equipment damage. More than one disconnect may be required.

4.All wiring must comply with all applicable electrical codes, ordinances and regulations. Wiring, where required, must comply with NEC, Class 1 (Line Voltage) wiring.

5.Recommended wire size and type: see Table 1.

6.Recommended grounding practices: see Table 2.

The Keyboard Display Module and Data ControlBus Module™ (for remote mounting or communications), through a 203541 5-wire Connector, must be wired in a daisy chain configuration, (1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). The order of interconnection of all the devices listed above is not important. Be aware that modules on the closest and farthest end of the daisy chain configuration string require a 120 ohm (1/4 watt minimum) resistor termination across terminals 1 and 2 of the electrical connectors, for connections over

100 feet.

7.Recommended wire routing of leadwires:

66-1085—04

2

RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

a.Do not run high voltage ignition transformer wires in the same conduit with the flame detector, Data Controlbus Module™, or Remote Reset Module wiring.

b.Do not route flame detector, Data Controlbus Module™, or Remote Reset Module leadwires in conduit with line voltage circuits.

c.Enclose flame detector leadwires without armor cable in metal cable or conduit.

d.Follow directions in flame detector, Data Controlbus Module™, or Remote Reset Module Instructions.

8.Keyboard Display Module (KDM): Because the KDM is powered from a low voltage, energy limited source, it can be mounted outside of a control panel if it is protected from mechanical damage.

NOTE: A 13 Vdc power supply must be used any time more than one Keyboard Display Module is used.

9.Maximum wire lengths follow:

a.RM7800/RM7840 leadwires—The maximum length of leadwire is 300 feet to terminal inputs (Control, Preignition Interlock, Running/Lockout Interlock, High Fire Switch and Low Fire Switch).

b.Flame Detector leadwires—The maximum flame sensor leadwire length is limited by the flame signal strength.

c.Remote Reset leadwires—The maximum length of wire is 1000 feet to a Remote Reset pushbutton.

d.Data Controlbus Module™—The maximum Data Controlbus Module™ cable length depends on the number of system modules connected, the noise conditions and the cable used. The maximum length of all Data Controlbus Module™ interconnecting wire is 1000 feet.

10.Make sure loads do not exceed the terminal ratings. Refer to the label on the RM7800/RM7840 or to the ratings in Tables 3, 4 and 5.

Final Wiring Check

1.Check the power supply circuit. The voltage and frequency tolerance must match those of the RM7800/RM7840. A separate power supply circuit may be required for the RM7800/RM7840. Add the required disconnect means and overload protection.

2.Check all wiring circuits and complete the Static Checkout, see Table 8, before installing the RM7800/RM7840 on the subbase.

3.Install all electrical connectors.

4.Restore power to the panel.

Table 1. Recommended Wire Sizes and Part Numbers.

Application		Recommended Wire Size	Recommended Part Number(s)
Line voltage terminals	14, 16 or 18 AWG copper conductor, 600		TTW60C, THW75C, THHN90C.
	volt insulation, moisture-resistant wire.
Keyboard Display Module (KDM)	22	AWG two-wire twisted pair with	Belden 8723 shielded cable or equivalent.
	ground, or five wire.
Data ControlBus Module™	22	AWG two-wire twisted pair with	Belden 8723 shielded cable or equivalent.
	ground, or five wire.
Remote Reset Module	22	AWG two-wire twisted pair, insulated	—
	for low voltage.
13 Vdc full-wave rectified transformer	18	AWG wire insulated for voltages and	TTW60C, THW75C, THHN90C.
power input.	temperatures for given application.

3	66-1085—04

RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
						L1
						(HOT)	L2
4						1
						120 Vac,					L2
			CONFIGURATION			50/60 Hz		PLUG-IN PURGE
								TIMER CARD
			JUMPERS
								FLAME SIGNAL			TEST
											JACK
RUN/TEST											F
SWITCH										PLUG-IN
											G
				MICROCOMPUTER						FLAME
RESET								TEST		AMPLIFIER	22
PUSHBUTTON
						2K
						3K
				RELAY		4K
						5K
				DRIVE						RELAY
						6K
				CIRCUIT
										STATUS
						7K
										FEEDBACK
						8K				AND LINE
										VOLTAGE
						9K
										INPUTS
			SAFETY RELAY		1K
			CIRCUIT
STATUS LEDs
						POWER SUPPLY				CONTROL
										POWER
			20
PRE-IGNITION
INTERLOCK			RUNNING/
			LOCKOUT
LIMITS	CONTROLLER		INTERLOCK			1K1		2K1	5K1
			6			7				10	IGNITION
			LOW FIRE SWITCH					4K1		8
											PILOT
			18					7K1
										21
			HIGH FIRE SWITCH								PILOT/V2
								2K2
			19							9	MAIN VALVE
		6K1								5	BLOWER
		3K1								3	ALARM
						HIGH FIRE		12
	KEYBOARD
DDL				8K1
	DISPLAY MODULE					COMMON		13		INDICATES FEEDBACK SENSING
		RS485								OF RELAY CONTACT STATUS
				8K2		MODULATE
										AND LINE VOLT INPUTS
								15
	1
DDL		2		9K2		9K1
										FIELD WIRING
			REMOTE
COMMUNICATIONS		3				LOW FIRE		14
										INTERNAL WIRING
			RESET
1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.											M12258

Fig. 1. Internal block diagram of the RM7800L/RM7840L (See Fig. 2, 3, 4 or 5 for individual detailed wiring instructions).

66-1085—04

4

	RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
Table 2. Recommended Grounding Practices.
Ground Type		Recommended Practice
Earth ground (subbase and relay module).		1. Use to provide a connection between the subbase and
		the control panel of the equipment. Earth ground must be
		capable of conducting enough current to blow the 20A fuse
		(or breaker) in the event of an internal short circuit.
		2. Use wide straps or brackets to provide minimum length,
		maximum surface area ground conductors. If a leadwire
		must be used, use 14 AWG copper wire.
		3. Make sure that mechanically tightened joints along the
		ground path are free of nonconductive coatings and pro-
		tected against corrosion on mating surfaces.
Signal ground (KDM, Data ControlBus Module™		Use the shield of the signal wire to ground the device to the
		signal ground terminals [3(c)] of each device. Connect the
		shield at both ends of the chain to earth ground.

Table 3. Terminal Ratings.

Terminal No.	Description		Ratings
G	Flame Sensor Grounda	—
Earth G	Earth Grounda	—
L2(N)	Line Voltage Common	—
3	Alarm	120	Vac, 1A pilot duty.
4	Line Voltage Supply (L1)	120	Vac (+10%/-15%), 50 or 60 Hz (±10%)b
5	Burner Motor	120	Vac, 9.8 AFL, 58.8 ALR (inrush).
6	Burner Controller and Limits	120	Vac, 1 mA.
7	Lockout/Running Interlock	120 Vac, 8A run, 43A inrush.
8	Pilot Valve/Ignition	120	Vacc.
9	Main Fuel Valve	120	Vacc.
10	Ignition	120	Vacc.
F(11)	Flame Sensor	60 to 220 Vac, current limited.
12	Firing Rate High Fire	120	Vac, 75 VA pilot duty.
13	Firing Rate Common	120	Vac, 75 VA pilot duty.
14	Firing Rate Low Fire	120	Vac, 75 VA pilot duty.
15	Firing Rate Modulate	120	Vac, 75 VA pilot duty.
16	Unused	—
17	Unused	—
18	Low Fire Switch Input	120	Vac, 1 mA.
19	High Fire Switch Input	120	Vac, 1 mA.
20	Preignition Interlock Input	120	Vac, 1 mA.
21	Interrupted/Intermittent Pilot Valve/First Stage Oil Valve	120	Vacc.
22	Shutter	120	Vac, 0.5A.

.a The relay module must have an earth ground providing a connection between the subbase and the control panel or the equipment. The earth ground wire must be capable of conducting the current to blow the 15A fuse (or breaker) in event of an internal short circuit. The relay module requires a low impedance ground connection to the equipment frame, which, in turn, requires a low impedance connection to earth ground.

b2000 VA maximum connected load to relay module assembly.

cSee tables 4 and 5.

5	66-1085—04