Honeywell RM7824A User Manual
RM7824A Relay Module
GENERAL
The Honeywell RM7824A Relay Module is a 24 Vdc
microprocessor-based integrated burner control for
automatically fired gas, oil or combination fuel single burner
applications. The RM7824A consists of the Relay Module,
Subbase and Amplifier are required to complete the system.
Options include Keyboard Display Module, Personal Computer
Interface, DATA CONTROL BUS MODULE
Module and COMBUSTION SYSTEM MANAGER
The RM7824A is programmed to provide a level of safety,
functional capability and features beyond the capacity of
conventional controls.
Functions provided by the RM7824A include automatic burner
sequencing, flame supervision, system status indication,
system or self-diagnostics and troubleshooting.
FEATURES
• Safety features:
— Closed loop logic test.
— Dynamic input check.
— Dynamic safety relay check.
— Dynamic self-check logic.
— Expanded safe-start check.
— Internal hardware status monitoring.
—Tamper resistant timing and logic.
• Access for external electrical voltage checks.
• Application flexibility.
• Communications interface capability.
• Dependable, long-term operation provided by
microcomputer technology.
™
, Remote Display
™
Software.
7800 SERIES
PRODUCT DATA
• First-out annunciation and system diagnostics are provided
by a 2-row by 20-column Vacuum Fluorescent Display
(VFD) located on the optional Keyboard Display Module.
• Five light emitting diodes (LEDs) for sequence
information.
• Flame signal strength.
• Local or remote annunciation of RM7824A operation and
fault information (optional).
• Nonvolatile memory; RM7824A retains history files and
sequencing status after loss of power.
• Plug-in flame amplifier.
• Remote reset (optional).
• Report generation (optional).
• Shutter drive output.
• Burner controller data (optional):
— Hold status.
— Lockout/alarm status.
— Sequence status.
— Sequence time.
—Total cycles of operation.
—Total hours of operation.
—Fault history providing the six most recent faults:
– Cycles of operation at the time of the fault.
–Fault message and code.
– Hours of operation at the time of the fault.
– Sequence status at the time of the fault.
– Sequence time at the time of the fault.
— Diagnostic information:
–Device type.
– Flame amplifier type.
– Flame failure response time.
– Manufacturing code.
– On/Off status of all digital inputs and outputs.
– Software revision and version of RM7824A and
optional Keyboard Display Module.
– Status of configuration jumper.
Contents
General ............................................................................... 1
Features .............................................................................. 1
Specifications ...................................................................... 2
Ordering Information ........................................................... 2
Principal Technical Features ............................................... 5
Safety Provisions ................................................................ 5
Installation ........................................................................... 6
Wiring .................................................................................. 7
Assembly............................................................................. 9
Operation ............................................................................ 10
Static Checkout ................................................................... 12
Checkout ............................................................................. 13
Troubleshooting ................................................................... 18
Copyright © 1995 Honeywell Inc. • All Rights Reserved
65-0155-1
7800 SERIES RM7824A RELAY MODULE
SPECIFICATIONS
Model:
RM7824A Relay Module for the 7800 SERIES.
Electrical Ratings (See Table 1):
Voltage: 24 Vdc (22-28 Vdc).
Power Dissipation: 10W maximum.
Maximum Total Connected Load: 500 VA.
Fusing: Total Connected Load: 20A maximum, type FRN or
equivalent.
Table 1. Terminal Ratings.
Terminal No. Description Ratings
G Flame Sensor Ground
L2(N) 24 Vdc Common (-)
3 24 Vdc Supply (+) 24 Vdc (22 to 28 Vdc).
4 Alarm 24 Vdc, 1A, 5A Inrush for 6000 cycles.
5 Unused
6 Burner Controller and Limits 24 Vdc, 20 mA.
7 Unused
8 Pilot Valve/Ignition 24 Vdc, 5A Inrush, 1A Continuous.
9 Main Fuel Valve 24 Vdc, 10A Inrush, 2A Continuous or 50 VA motorized valve.
10 Ignition 24 Vdc, 5A Inrush, 1A Continuous.
F(11) Flame Sensor
12 Unused
13 Unused
14 Unused
15 Unused
16 Unused
17 Unused
18 Unused
19 Unused
20 Unused
21 Unused
1
500 VA maximum connected load to RM7824A assembly.
22 Shutter 24 Vdc, 0.5A.
Environmental Ratings:
Ambient Temperature:
Operating: -40°F to +140°F (-40°C to +50°C).
Storage: -60°F to +150°F (-49°C to +66°C).
Humidity: 85% relative humidity, noncondensing.
Vibration: 0.5G environment.
Dimensions:
See Fig. 1 through 4.
1
ORDERING INFORMATION
When purchasing replacement and modernization products from your 7800 SERIES distributor, refer to the TRADELINE®
Catalog or price sheets 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. Your local Honeywell Home and Building Control Sales Office (check white pages of phone directory).
2. Home and Building Control Customer Logistics
Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9. 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.
65-0155—1
2
7800 SERIES RM7824A RELAY MODULE
Weight:
RM7824A with Dust Cover: 1 pound, 12 ounces, unpacked.
IMPORTANT
Flame Detection System available for use with
RM7824A. To select your Plug-in Flame Signal
Amplifier and applicable Flame Detector, see Table 2
and Fig. 3.
Table 2. Flame Detection Systems.
Plug-in Flame Signal Amplifiers Applicable Flame Detectors
Flame Failure
Type Color Self-Checking Model
Rectification Green Dynamic
R7824C
Response Time Fuel Type Models
a
3 sec Gas, oil, coal Ultraviolet
Self-Check
Infrared Red No R7848A 3 sec Gas, oil, coal Infrared
Dynamic
R7848B 3 sec Gas, oil, coal Infrared
AMPLI-CHECK®
a
Circuitry tests all electronic components in the flame detection system (amplifier and detector) 12 times a minute during burner
operation and shuts down the burner if the detection system fails.
Table 3. Sequence Timing For Normal Operation.
Device Initiate Standby Pilot Flame Establishing Period Run
RM7824A 10 sec * 4 or 10 sec *
*STANDBY and RUN can be an infinite time period.
CAUTION
To prevent the control from sequencing on power up,
RM7824 Relay Modules with software revision 2424
or less should not be used with R7848 Infrared
Amplifiers and C7015 Infrared Flame Detectors,
unless a ten-second delay is provided.
C7024E,F
(Purple Peeper)
C7015.
(Lead Sulfide)
C7015.
(Lead Sulfide)
Approval Bodies:
Underwriters Laboratories Inc. Component Recognized:
File no. MP268, guide no. MCCZ.
Canadian Standards Association certified: LR9S329-3.
Federal Communications Commission: Part 15,
Class B-Emissions.
BURNER CONTROL
5 (127)
REMOVE ONLY FOR TERMINAL TEST ACCESS.
1
5
(127)
Mounting:
Q7800A for panel mount or Q7800B for wall or burner mount.
Required Components:
Plug-in Flame Signal Amplifier; see Fig. 2.
Q7800A or Q7800B.
1
5-1/4 (133)
M5872
Fig. 1. Mounting dimensions of RM7824A Relay Module and Q7800A Subbase in in. (mm).
3
65-0155—1
7800 SERIES RM7824A RELAY MODULE
BURNER CONTROL
5
(127)
1
5 (127)
REMOVE ONLY FOR TERMINAL TEST ACCESS.
1
Fig. 2. Mounting dimensions of RM7824A Relay Module and Q7800B Subbase in in. (mm).
Dust Cover is part number 221729A.
Accessories:
Optional:
COMBUSTION SYSTEM MANAGER™: Part
number ZM7850A1001.
Communication Interface Base Unit: Part
number Q7700A1014.
Communication Interface ControlBus Module: Part
number QS7800A1001.
ControlBus 5-Wire Electrical Connector: Part
number 203541.
DATA CONTROLBUS MODULE™: Part
number S7810A1009.
Flush Mounting Kit for S7800 Keyboard Display Module:
Part number 205321B.
Keyboard Display Module (S7800A): English, Spanish,
French, German, Italian.
NEMA 4 and NEMA 1 Weatherproofing Kit for S7800
Keyboard Display Module: Part number 204718A,B.
Remote Display Mounting Bracket: Part
number 203765.
Remote Reset Module: Part number S7820A1007.
Sixty-inch Extension Cable Assembly: Part
number 221818A.
HEAT BLOCKCELL MOUNT
1-5/8 (41)
2 LEADS IN A
48 INCH (1.2 METER)
FLEXIBLE CONDUIT
BUSHING WITH
MAGNIFYING LENS
2-3/4
(70)
1-1/4
(32)
APERTURE
COLLAR, 3/4-14 NPSM
INTERNAL THREADS
1-1/16 (27)
3/4-14
NPSM
1-1/4
(32)
3/4-14 NPSM
INTERNAL
THREADS
M1982A
6-3/32 (155)
MOUNTING FLANGE
7-7/32 (183)
3-3/4
(95)
1/2–14 NPSM
LEADWIRES
5-1/8
(130)
3-7/16
(87)
FACEPLATE
C7024E
1–11-1/2 NPT
FACEPLATE
PIPE
UNION
1-1/2
(38)
1(25)
3 (76)
2-1/16
(52)
8
(203)
DIA.
1/2–14 NPT
LEADWIRES
9 (229)
2(51)
C7024F
Fig. 4. Rectification detectors in in. (mm).
M5873
3/4–14 NPT
5-1/4 (133)
(127)
2
(51)
5/16–18 UNC–2B BY
7/16 [11] DEEP
MOUNTING HOLES (2)
M5818
5
Fig. 3. Infrared detector dimensions in in. (mm).
65-0155—1
4
7800 SERIES RM7824A RELAY MODULE
PRINCIPAL TECHNICAL FEATURES
The RM7824A provides all customary flame safeguard
functions while providing significant advancements in the
areas of safety, annunciation and system diagnostics.
Safety Shutdown (Lockout) Occurs If:
1. INITIATE PERIOD.
a. 24 Vdc power errors occurred, see Operation
section.
b. Configuration jumper has been changed (after
200 hours).
c. Four minute INITIATE period has been exceeded.
2. STANDBY PERIOD.
a. Flame signal is present after 40 seconds.
b. Ignition/intermittent pilot valve terminal is
energized.
c. Internal system fault occurred.
d. Main valve terminal is energized.
3. SAFE START CHECK.
a. Flame signal is present.
b. Ignition/intermittent pilot valve terminal is
energized.
c. Internal system fault occurred.
d. Main valve terminal is energized.
4. PILOT FLAME ESTABLISHING PERIOD (PFEP).
a. Ignition/intermittent pilot valve terminal is not
energized.
b. Internal system fault occurred.
c. Main valve terminal is energized.
d. No flame present at end of PFEP.
5. RUN PERIOD.
a. Ignition terminal is energized.
b. Internal system fault occurred.
c. Main valve terminal is not energized.
d. No flame present.
e. Pilot valve terminal is not energized.
SAFETY PROVISIONS
Dynamic Input Check
All system input circuits are examined to assure that the
RM7824A is capable of recognizing the true status of external
controls, limits and interlocks. If any input fails this test, a
safety shutdown occurs and the fault will be annunciated.
Dynamic Safety Relay Test
Checks the ability of the dynamic safety relay contact to open
and close. Verifies that the safety critical loads, terminals 8, 9
and 10, can be de-energized, as required, by the Dynamic
Self-check logic.
Dynamic Self-Check Safety Circuit
The microcomputer tests itself and related hardware, and at
the same time, the safety relay system tests the
microcomputer operation. If a microcomputer or safety relay
failure occurs and does not allow proper execution of the selfcheck routine, safety shutdown occurs and all safety critical
loads will be de-energized.
Expanded Safe-Start Check
The conventional safe-start check, which prevents burner
start-up if flame is indicated at start-up, is expanded to
include a flame signal check during STANDBY and a safety
critical load check.
Off Cycle (Standby) Flame Signal Check
The flame detection subsystem (flame detector and amplifier)
is monitored during STANDBY. If a flame simulating condition
or an actual flame exists for 40 seconds in STANDBY, a safety
shutdown occurs and startup is prevented. If the flame signal
exists at any time after the 40 seconds during STANDBY, a
safety shutdown occurs and is annunciated. The self-checking
detector is energized for the first 40 seconds during
STANDBY and the last two seconds before exiting STANDBY.
If a flame exists after the first 40 seconds during STANDBY,
the self-checking detector is energized during the last ten
seconds of the 40 second flame detection period. If a flame
exists, a safety shutdown occurs.
Internal Hardware Status Monitoring
The RM7824A analyzes the integrity of the configuration
jumper and internal hardware. The POWER LED will blink
every four seconds, signifying an internal hardware check.
Closed Loop Logic Test
The test verifies the integrity of all safety critical loads,
terminals 8, 9 and 10. If the loads are not energized properly;
i.e., the main valve terminal is powered during STANDBY, the
RM7824A will lockout on safety shutdown. The RM7824A
must react to input changes but avoid the occurrence of
nuisance
24 Vdc voltage inputs to verify proper operation in the
presence of
voltage spikes or short periods of voltage dropout.
shutdown events. Signal conditioning is applied to
normal
electrical line noise such as transient high
Dynamic Flame Amplifier and Shutter Check
Self-checking circuitry tests all electronic components in the
flame detection system and amplifier twelve times per minute
and shuts down the RM7824A if the detection system fails.
Safety and logic timings are inaccessible and cannot be
altered or defeated.
Verified Spark Termination
The ignition terminal is monitored to assure early spark
termination (ten seconds ignition and pilot and ten seconds
pilot and main only)
First-Out Annunciation and Self-Diagnostics
Sequence Status Lights (LEDs)
indication of the program sequence: POWER, PILOT, FLAME,
MAIN and ALARM. The green POWER LED blinks every four
seconds, signifying that the RM7824A hardware is running
correctly.
Optional multi-function Keyboard Display Module
elapsed time during PILOT IGNITION. As an additional
troubleshooting aid, it provides sequence timing, diagnostic
information and historical information during normal operation
or when a safety shutdown or hold occurs.
5
.
provide positive visual
shows
65-0155—1
7800 SERIES RM7824A RELAY MODULE
First-out Annunciation
or identifies the cause of a failure to start or continue the
burner control sequence with an English text and numbered
code via the optional Keyboard Display Module. It monitors all
field input circuits, including the flame signal amplifier. The
system distinguishes 39 modes of failure and detects and
annunciates difficult-to-find intermittent failures.
Self-diagnostics
the RM7824A to distinguish between field (external device)
and internal (system related) problems. Faults associated
within the flame detection subsystem or RM7824A are
isolated and reported by the optional Keyboard Display
Module. See the 7800 SERIES System Annunciation
Diagnostics and Troubleshooting, form 65-0118.
reports the cause of a safety shutdown
add to the First-out Annunciation by allowing
INSTALLATION
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY, OR
DEATH.
To prevent possible hazardous burner operation,
perform verification of safety requirements
a control is installed on a burner.
each time
7. All external timers must be listed or component
recognized by authorities who have jurisdiction for the
specific purpose for which they are used.
IMPORTANT
1. 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).
2. Two C7024E,F Detectors can be connected in
parallel.
3. 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.
4. This digital apparatus does not exceed the Class
B limits for radio noise of digital apparatus set out
in the Radio Interference Regulations of the
Canadian Department of Communications.
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
your 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.
CAUTION
To prevent electrical shock and equipment damage,
disconnect the power supply before beginning
installation. More than one power supply disconnect
may be involved.
1. To prevent electrical shock and equipment damage,
disconnect the power supply before beginning
installation. More than one power supply disconnect
may be involved.
2. Wiring connections for the RM7824A are unique;
therefore, refer to Fig. 6 or the correct specifications for
proper subbase wiring.
3. Wiring must comply with all applicable codes,
ordinances and regulations.
4. Wiring, where required, must comply with NEC Class 1
wiring.
5. Loads connected to the RM7824A must not exceed
those listed on the RM7824A label or the specifications
(see Table 1).
6. Limits and interlocks must be rated to carry and break
current simultaneously to the ignition transformer, pilot
valve, and main fuel valve(s).
Humidity
Install the RM7824A where the relative humidity never
reaches the saturation point. The RM7824A is designed to
operate in a maximum 85 percent relative humidity,
continuous, noncondensing moisture environment.
Condensing moisture can cause a shutdown.
Vibration
Do not install the RM7824A where it could be subjected to
vibration in excess of 0.5G continuous maximum vibration.
Weather
The RM7824A is not designed to be weather tight. If installed
outdoors, the RM7824A must be protected by an approved
weather-tight enclosure.
Mounting Wiring Subbase
NOTE: For installation dimensions, see Fig. 1 or 2.
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 in an electrical
panel. The Q7800 can be mounted directly in the
control cabinet. Be sure to allow adequate clearance for
servicing, installation, access and removal of the
RM7824A, dust cover, flame amplifier, flame amplifier
signal voltage probes, 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. Mount the subbase securely using four No. 6 screws.
65-0155—1
6
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