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RM7800G
User Manual
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Honeywell RM7800E, RM7800G User Manual

RM7800E,G,L,M; RM7840E,G,L,M
WARNING
7800 SERIES Relay Modules
INSTALLATION INSTRUCTIONS

APPLICATION

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.
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 Agree-
ment.
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.

SPECIFICATIONS

Electrical Ratings, see Table 3:
Voltage and Frequency: 120 Vac (+10/-15%), 50 or 60 Hz
(±10%).
Power Dissipation: RM7800/RM7840: 10W maximum.
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.
SIL
3
Capable
66-1085-04
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
WARNING
WARNING
Weather
The relay module is not designed to be weather tight.
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.
When installed outdoors, protect the relay module using an approved weather-tight enclosure.

Mounting Wiring Subbase

Wiring Subbase

Location

The Keyboard Display Module and Data ControlBus Module™
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.
(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.
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.
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.
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
8. Keyboard Display Module (KDM): Because the KDM is
NOTE: A 13 Vdc power supply must be used any time more
9. Maximum wire lengths follow:
Line voltage terminals 14, 16 or 18 AWG copper conductor, 600
Keyboard Display Module (KDM) 22 AWG two-wire twisted pair with
Data ControlBus Module™ 22 AWG two-wire twisted pair with
Remote Reset Module 22 AWG two-wire twisted pair, insulated
13 Vdc full-wave rectified transformer power input.
Module™, or Remote Reset Module Instructions.
powered from a low voltage, energy limited source, it can be mounted outside of a control panel if it is protected from mechanical damage.
than one Keyboard Display Module is used.
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.
Table 1. Recommended Wire Sizes and Part Numbers.
Application Recommended Wire Size Recommended Part Number(s)
volt insulation, moisture-resistant wire.
ground, or five wire.
ground, or five wire.
for low voltage.
18 AWG wire insulated for voltages and temperatures for given application.
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.
TTW60C, THW75C, THHN90C.
Belden 8723 shielded cable or equivalent.
Belden 8723 shielded cable or equivalent.
—
TTW60C, THW75C, THHN90C.
3 66-1085—04
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
CONFIGURATION JUMPERS
MICROCOMPUTER
RESET PUSHBUTTON
RUN/TEST SWITCH
STATUS LEDs
PLUG-IN PURGE TIMER CARD
SAFETY RELAY CIRCUIT
POWER SUPPLY
KEYBOARD DISPLAY MODULE
HIGH FIRE
COMMON
MODULATE
LOW FIRE
HIGH FIRE SWITCH
PLUG-IN FLAME AMPLIFIER
RELAY DRIVE CIRCUIT
CONTROL POWER
TEST JACK
REMOTE RESET
DDL
DDL COMMUNICATIONS
INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS
FIELD WIRING INTERNAL WIRING
IGNITION
PILOT
PILOT/V2
MAIN VALVE
1K
9K
RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS
LIMITS CONTROLLER
RUNNING/ LOCKOUT INTERLOCK
PRE-IGNITION INTERLOCK
1K1 2K1 5K1
8K1
8K2
9K1
9K2
120 Vac, 50/60 Hz
FLAME SIGNAL
TEST
LOW FIRE SWITCH
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
RS485
1
2
3
L1 (HOT)
L2
4
6
20
7
4K1
7K1
2K2
10
8
21
9
18
19
8K
7K
6K
5K
4K
3K
2K
F
G
22
1
BLOWER
6K1
5
ALARM
3K1
3
L2
12
13
15
14
M12258
1
66-1085—04 4
Fig. 1. Internal block diagram of the RM7800L/RM7840L (See Fig. 2, 3, 4 or 5
for individual detailed wiring instructions).
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 pro­tected 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
Earth G
Flame Sensor Ground
Earth Ground
a
a
—
—
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
9 Main Fuel Valve
10 Ignition
120 Vac
120 Vac
120 Vac
c
.
c
.
c
.
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 Vac
c
.
22 Shutter 120 Vac, 0.5A.
.aThe 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.
b
2000 VA maximum connected load to relay module assembly.
c
See tables 4 and 5.
5 66-1085—04
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