Honeywell RM7838B, RM7838C Installation Instructions Manual

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Page 1

SIL

Capable

RM7838B,C

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7800 SERIES Relay Module

INSTALLATION INSTRUCTIONS

APPLICATION

The Honeywell RM7838B,C is a microprocessor based integrated burner control for industrial process modulating semiautomatically fired gas, oil, coal or combination fuel single burner applications. The RM7838B,C System consists of a relay module, wiring subbase, keyboard display module (KDM), amplifier, and purge card. Options include Data ControlBus Module™, remote display mounting, and first-out expanded annunciator.

Functions provided by the RM7838B,C include automatic modulated High Fire and Low Fire proven Purge, burner pilot startup with pilot valve hold, a special pilot valve hold from the Run condition, flame supervision, system status indication, system or self-diagnostics and troubleshooting.

The RM7838C differs from the RM7838B as follows:

1. Alarms only on Safety Shutdown.

2. Requires ST7800C Purge Timer.

3. C1004 has 15 second MFEP. C1020 has 5 second

MFEP. 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,C Plug-In Purge Timer

Installation Instructions.

65-0090: S7800A Keyboard Display Module

Product Data.

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 4):

Voltage and Frequency: 120 Vac (+10/-15%),

50/60 Hz (±10%).

Power Dissipation: RM7838B,C: 10W maximum. Maximum Total Connected Load: 2000 VA. Fusing Total Connected Load: 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. 1V9A0.AF. Swiss Re (formerly Industrial Risk Insurers): Acceptable. Federal Communications Commission: Part 15, Class B,

Emissions. Gastec: EN298, Report 115679/4 (RM7838C1020 only)

IMPORTANT

A Flame Detection System is required for operation and must be ordered separately. Select the applicable Flame Signal Amplifier and matching Flame Detector in form 65-0109.

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.

RM7838C1020 only

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RM7838B,C 7800 SERIES RELAY MODULE

WARNING

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Explosion or Fire Hazard. Can cause severe personal injury, death or property damage.

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

Electrical Shock Hazard. Can cause electrical shock or equipment damage.

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

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% relative humidity continuous, noncondensing, moisture environment. Condensing moisture can cause a safety shutdown.

Vibration

Do not install the relay module where it can 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 in 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 service, installation, access or removal of the RM7838B,C, Expanded Annunciator, KDM, 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; then drill the pilot holes.

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

IMPORTANT

1. Wiring connections for the relay modules are unique; refer to Fig. 2 and 3 or the appropriate Specifications for proper subbase wiring.

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 RM7838B,C must not exceed those listed on the RM7838B,C label or the Specifications; see Table 4.

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 proper jurisdiction.

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 and C7915), UV Flame Detectors C7927, and C7961 and 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, can cause interference with 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 can 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.

See Fig. 1 for the internal block diagram of the RM7838B,C Relay Module.

Wiring Subbase

Electrical Shock Hazard. Can cause serious personal injury, death or equipment damage.

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

1. Refer to Fig. 2 or 3 for proper subbase wiring.

2. For proper remote wiring of the KDM, refer to the KDM

Specifications (65-0090), Data ControlBus Module™ (65-0091) or Extension Cable Assembly (65-0131).

3. Make sure all wiring complies with all applicable electrical codes, ordinances and regulations. Wiring, where required, must comply with NEC, Class 1 (Line Voltage) wiring.

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Page 3

4. See Table 1 for recommended wire size and type.

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RM7838B,C 7800 SERIES RELAY MODULE

DDL COMMUNICATIONS

RECIRCULATING AFS

LOCKOUT INTERLOCKS AND COMBUSTION AIR BLOWER SWITCHES

PILOT VALVE HOLD SWITCH

LOW START SWITCH

HIGH PURGE RATE SWITCH

PREIGNITION INTERLOCK

BURNER CONTROL

RUN/TEST SWITCH

RESET PUSHBUTTON

STATUS LED

KEYBOARD

DDL

MANUAL VALVE OPEN SWITCH

DISPLAY MODULE

LIMITS

START SWITCH

RS485

STOP SWITCH

1/2 OF DPST ALARM SILENCING SWITCH

L1 (HOT) L2

CONFIGURATION JUMPERS

SAFETY RELAY CIRCUIT

REMOTE RESET

120 Vac

50/60 HZ

RECIRCULATING BLOWER

MICROCOMPUTER

RELAY DRIVE CIRCUIT

INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS

FIELD WIRING INTERNAL WIRING

PROVIDE DISCONNECT MEANS AND

OVERLOAD PROTECTION AS REQUIRED.

NOT REQUIRED FOR RM7838C.

PLUG-IN PURGE TIMER CARD

FLAME SIGNAL

POWER SUPPLY

6K1

1K1 2K1 5K1

4K1

2K2

3K1

TEST

PLUG-IN FLAME AMPLIFIER

RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS

CONTROL POWER

1/2 OF DPST ALARM SILENCING SWITCH

8K1

8K2

9K2

TEST JACK

COMBUSTION AIR BLOWER

IGNITION

PILOT

MAIN VALVE

ALARM

HIGH PURGE

COMMON

MODULATE

9K1

LOW FIRE

M5195D

Fig. 1. Internal block diagram of RM7838B,C (see Fig. 2 for RM7838C1020); see Fig. 3 and 4 for detailed wiring

instructions.

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RM7838B,C 7800 SERIES RELAY MODULE

L1 HOT

CONFIGURATION JUMPERS

PLUG-IN PURGE TIMER CARD

PLUG -IN

FLAM E

A M P L IF IE R

PLUG-IN FLAME AMPLIFIER

MICROCOMPUTER

RUN/TEST SWITCH

RESET PUSHBUTTON

FLAM E SIGNAL

TEST JACK

RELAY DRIVE CIRCUIT

CONTROL POWER

POWER SUPPLY

RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS

OPTIONAL KEYBOARD DISPLAY MODULE

RS485

2K2 5K1

4K1

2K1

PV1

3K1

6K1

LFS

HFS

PII

3K2

SAFETY RELAY CIRCUIT

COMBUSTION BLOWER

IGN

DDL

HIGH FIRE

COMMON

LOW FIRE

MODULATE

REMOTE RESET

8K1

8K2

9K2

9K1

INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLTAGE INPUTS

RELAY CONTACT OPEN

INTERNAL WIRING

FIELD WIRING

RELAY COIL

RELAY CONTACT CLOSED

DDL COMMUNICATIONS

USER TERMINALS

120 VAC, 50/60 Hz POWER SUPPLY.

M13959

STATUS LEDS

SHUTTER

...

COMBUSTION BLOWER AFS

START

RECIRCULATING BLOWER AFS

RECIRCULATING BLOWER

STOP

BURNER CONTROL

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Fig. 2. Internal block diagram of RM7838C1020 (see Fig. 5 for detailed wiring instructions).

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RM7838B,C 7800 SERIES RELAY MODULE

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Table 1. Recommended Wire Sizes and Part Numbers.

Application Recommended Wire Size Recommended Part Numbers

Line voltage terminals 14, 16 or 18 AWG copper conductor, 600 volt

KDM 22 AWG two-wire twisted pair with ground, or five-wire. Belden 8723 shielded cable or equivalent.

Data ControlBus Module™ 22 AWG two-wire twisted pair with ground, or five-wire. Belden 8723 shielded cable or equivalent.

Remote Reset Module 22 AWG two-wire twisted pair, insulated for low voltage. —

13 Vdc full wave rectified transformer power input.

Ground Type Recommended Practice

Earth Ground (Subbase and relay module)

Signal Ground (KDM, Data ControlBus Module™

insulation, moisture-resistant wire.

18 AWG wire insulated for voltages and temperatures for given application.

Table 2. Recommended Grounding Practices.

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 15A 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 lead wire 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.

Use the shield of the signal wire to ground the device to the signal ground terminal 3(c) of each device. Connect the shield at both ends of the daisy chain to earth ground.

TTW60C, THW75C, THHN90C.

The KDM and Data ControlBus™ Module (for remote mounting or communications) 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 (31 meters).

4. See Table 2 for recommended grounding practices.

5. Use recommended wire routing of leadwires:

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.

6. KDM: Because the KDM is powered from a low voltage, energy limited source, mount it outside of a control panel if it can be protected from mechanical damage.

NOTE: Use a separate 13 Vdc power supply any time more

than two Data ControlBus Modules™ or KDM are used or are placed more than 100 feet (31 meters) from the relay module.

7. Use maximum wire lengths: a. RM7838B,C leadwires—300 feet (91 meters) to

terminal inputs (Control, Preignition Interlock, Running/Lockout Interlock, High Purge Switch and Low Fire Switch).

b. Flame Detector leadwires—limited by the flame

signal strength.

c. Remote Reset leadwires—1000 feet (305 meters) to

a Remote Reset push button.

d. Data ControlBus™ Module—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 4000 feet (1219 meters).

8. Make sure loads do not exceed the terminal ratings. Refer to the label on the RM7838B,C or to the ratings in Table 4.

FINAL WIRING CHECK

1. Check the power supply circuit. The voltage and fre-

quency tolerance must match those of the RM7838B,C. (A separate power supply may be required for the RM7838B,C.)

2. Add the required disconnect means and overload protection.

3. Check all wiring circuits and complete the static checkout in Table 3 before installing the RM7838B,C on the subbase.

4. Install the relay module.

5. Restore power to the panel.

STATIC CHECKOUT

After checking all wiring, perform this checkout before installing the RM7838B,C on the subbase. These tests verify the Q7800 Wiring Subbase is wired correctly, and the external controllers, limits, interlocks, actuators, valves, transformers, motors and other devices are operating properly.

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RM7838B,C 7800 SERIES RELAY MODULE

WARNING

CAUTION

WARNING

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Explosion and Electrical Shock Hazards. Can cause serious injury, death or equipment damage.

Close all manual fuel shutoff valve(s) before starting these tests. Use extreme care while testing the system. Line voltage is present on most terminal connections when power is on.

Open the master switch before installing or removing a jumper on the subbase. Before continuing to the next test, be sure to remove test jumper(s) used in the previous test. Replace all limits and interlocks that are not operating properly. Do not bypass limits and interlocks.

Electrical Hazard. Can cause equipment damage.

Do not perform a dielectric test with the RM7838B,C installed. Internal surge protectors break down and conduct current, causing dielectric test failure and destruction of the internal lightning and high current protection.

General Instructions

1. Perform all applicable tests listed in the Static Checkout,

Table 3, in the order listed.

2. Make sure all manual fuel shutoff valve(s) are closed.

3. Perform only those tests designated for the specific

RM7838B,C model being tested.

4. Raise the setpoint of the operating controller to simulate a call for heat.

5. For each test, open the master switch and install the jumper wires between the subbase wiring terminals listed in the Test Jumpers column.

6. Close the master switch before observing operation.

7. Read the voltage between the subbase wiring terminals

listed in the Voltmeter column.

8. If there is no voltage or the operation is abnormal, check the circuits and external devices as described in the last column.

9. Check all wiring for correct connections, tight terminal screws, correct wire, and proper wiring techniques. Replace all damaged or incorrectly sized wires.

10. Replace faulty controllers, limits, interlocks, actuators, valves, transformers, motors and other devices, as required.

11. Make sure normal operation is obtained for each required test before continuing the checkout.

12. After completing each test, be sure to remove the test jumper(s).

Equipment Recommended

Voltmeter (1M ohm/volt minimum sensitivity) set on the 0-300 Vac scale and two jumper wires; using No. 14 wire, insulated, 12 in. (304.8 mm) long with insulated alligator clips at both ends. An ammeter to test the load current can replace one of the recommended jumpers in tests verifying the combustion blower motor, ignition, pilot and main valve operation.

Table 3. Static Checkout.

Test

No.

1 None 4-L2 Line voltage at terminal 4. 1. Master Switch.

2 None 6-L2 Close burner control.

2a None 4-20 Line voltage at terminal 20. Preignition Interlock. 2b None

2c None

Test

Jumpers Voltmeter Normal Operation

Recirculating exhaust blower fan starts, then line voltage at terminal 6.

4-16 Line voltage at terminal 16. Pilot Valve Hold. Close Pilot Val ve Hold

4-17 Line voltage at terminal 17. Manual Open Valve Switch. Close Manual Open Val ve Switch

Explosion Hazard. Can cause serious injury or death.

Make sure all manual fuel shutoff valves are closed.

If Operation is Abnormal, Check These

2. Power Connected to the Master

Switch.

3. Overload protection (fuse, circuit breaker, etc) has not opened the power line.

1. Recirculating/exhaust blower fan.

2. Limits.

3. Stop Switch.

4. Burner Control.

5. Recirculating AFS.

NOTE: C1020 does not have Pilot Valve

Hold.

NOTE: C1020 does not have MOV.

Items

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RM7838B,C 7800 SERIES RELAY MODULE

CAUTION

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Table 3. Static Checkout. (Continued)

Test

No.

3 None 21-L2 With test 2 still running, press Start Switch. 120

4 None 6-L2 Push and hold Stop Switch. No voltage present

5 4-3 None Alarm (if used) turns on. 1. Alarm.

6 4-5 7-L2 Close burner control. Recirculating/exhaust

7 4-8 None Automatic pilot valve opens. First stage valve

8 4-9 None Automatic main fuel valves open. (DSI checks

9 4-10 None Ignition spark (if ignition transformer connected

10 12-13 18-L2 Firing rate motor drives open; zero volts at

11 12-13 19-L2 Firing rate motor reaches High Purge Rate

12 13-14

13 13-14

14 13-15

Final

Test

Jumpers Voltmeter Normal Operation

Vac is present at terminal 21.

at terminal 6.

blower fan starts, then line voltage is present at terminal 6.

1. Combustion air fan starts.

2. Line voltage at terminal 7 within 10 seconds.

(DSI application only). Ignition spark (if ignition transformer connected).

optional second state fuel valve.)

to terminal 10.

terminal 18 after motor leaves Low Fire position.

position; 120 Vac at terminal 19 when High Purge Rate Switch closes.

19-L2 Firing rate motor leaves High Purge Rate (13-15 for C1020)

18-L2 Firing rate motor drives to Low Purge Rate (13-15 for C1020)

None Adjust firing rate control and watch tracking (13-14 for C1020)

Position; zero Vac at terminal 19 when High Purge Rate Switch opens.

position; 120 Vac at terminal 18 when switch closes.

action of the firing rate motor.

If Operation is Abnormal, Check These

1. Start Switch.

2. Preignition Interlock. Stop Switch.

2. Alarm Silencing Switch (B model only).

1. Combustion air fan circuit: a. Manual switch on air fan motor. b. Air fan power supply, overload protec-

tion, and starter.

2. Combustion Blower Air Flow Switch.

3. Alarm Silencing Switch (B model only).

4. Recirculating Air Flow Switch.

1. Listen for click or feel head of valve for activation.

2. Watch for spark or listen for buzz: a. Ignition electrodes are clean. b. Ignition transformer is okay.

Listen for and observe operation of the main fuel valve(s) and actuator(s).

1. Watch for spark or listen for buzz: a. Ignition electrodes are clean. b. Ignition transformer is okay.

1. Low Fire Start Switch.

2. Firing rate motor and transformer.

1. High Purge Rate Switch.

2. Firing rate motor and transformer.

1. High Purge Rate Switch.

2. Firing rate motor and transformer.

1. Low Purge Rate Switch.

2. Firing rate motor and transformer.

1. Firing rate control.

2. Firing rate motor and transformer.

Items

Electrical Hazard. Can cause equipment damage.

After completing these tests, open the Master Switch and remove all test jumpers from the subbase terminals. Also remove bypass jumpers from the low fuel pressure limits if used.

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RM7838B,C 7800 SERIES RELAY MODULE

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Table 4. Terminal Ratings.

Terminal No. Description Ratings

Earth G

L2 Line Voltage Common —

3 Alarm 120 Vac, 1A pilot duty.

4 Line Voltage Supply (L1)

5 Combustion Blower 120 Vac, 9.8 AFL, 58.8 ALR (inrush).

6 Stop Input 120 Vac, 1 mA.

7 Lockout Interlock 120 Vac, 8A running, 43A inrush.

8 Interrupted Pilot

9 Main Fuel Valve

10 Ignition

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 Pilot Valve Hold Input 120 Vac, 1 mA.

17 Manual Open Switch 120 Vac, 1 mA.

18 Low Fire Switch 120 Vac, 1 mA.

19 High Fire Switch 120 Vac, 1 mA.

20 Preignition Interlock 120 Vac, 1 mA.

21 Start Switch Input 120 Vac, 1A pilot duty.

22 Shutter 120 Vac, 0.5A.

See Table 2.

2000 VA maximum load connected to RM7838B,C Assembly.

See Tables 5 and 6.

Flame Sensor Ground

Earth Ground

—

120 Vac (+10/-15%), 50/60 Hz (+/-10%).

120 Vac.

Table 5. Combinations for Terminals 8, 9, and 10.

Pilot Fuel 8 Main 9 Ignition 10

C F No Load

B F No Load

FF A

No Load

DF A

DD A

No Load

Jumper Terminals 8 to 9 for direct spark ignition.

ABCDF

4.5A ignition 50 VA Pilot Duty plus

4.5A ignition

66-1094—08 8

Table 6. Composition of Each Combination.

180 VA Ignition plus Motor Valves with: 660 VA inrush, 360 VA open, 250 VA hold.

2A Pilot Duty 65 VA Pilot Duty plus

motor valves with: 3850 VA inrush, 700 VA open, 250 VA hold.

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RM7838B,C 7800 SERIES RELAY MODULE

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Table 7. RM7838C1020 Alternate Terminal Ratings

Terminal No. Abbreviation Description Ratings

G—

Earth G —

N — Line Voltage Common (Neutral) —

3 AL Alarm (Normally Open) 1A, 10A inrush for 5000 cycles

4 L1 Line Voltage Supply (L1)

5 FAN Combustion Blower Motor

6 — Stop Input 1mA

7 LD2 Airflow Switch Input (Lockout Interlock) 5A

8 pv1 Pilot Valve 1 (Interrupted)

9 MV Main Fuel Valve

10 IGN Ignition 2A at PF = 0.2

F(11) — Flame Sensor 60 to 220 Vac, current limited.

12 HI Firing Rate High Fire

13 COM Firing Rate Common

14 MOD Firing Rate Modulate

15 LO Firing Rate Low FIre

16 — Alarm (Normally Closed) 1A, 10A inrush for 5000 cycles; carry 5A for

17 —

18 ES1 Low Fire Switch Input 1mA

19 ES3 High Fire Switch Input 1mA

20 LOS Preignition Interlock 1mA

21 Start Switch Start Switch 1mA

22 SHTR Shutter Shutter drive for dynamic self-check flame

See Table 2.

2000 VA maximum connected load to relay module.

Honeywell has tested this output at 9.8A at PF = 0.5, 58.A inrush for 100,000 cycles

Total load current, excluding Burner/Boiler Motor and Firing Rate Outputs cannot exceed 5A, 25A inrush.

Can also be 24Vac, 3A at PF = 0.5.

Flame Sensor Ground

Earth Ground

—

120 Vac (+10/-15%), 50/60 Hz (+/-10%).

4A at PF =0.5, 20A inrush

4A at PF = 0.5, 20A inrush

0.5A at PF = 0.5

250,000 cycles

sensor.

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RM7838B,C 7800 SERIES RELAY MODULE

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L1 (HOT)

MASTER SWITCH

RECIRCULATING BLOWER

Q7800 SUBBASE

HIGH FIRE

SERIES 90 FIRING RATE MOTOR

SERIES 90 CONTROLLER

BURNER

CONTROL

DPST ALARM SILENCING SWITCH

120V ALARM

RECIRCULATING AFS

120V, 50/60 HZ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

SHUTTER CHECK FLAME DETECTION SYSTEM REQUIRED WHEN USING THE PILOT VALVE HOLD FUNCTION.

SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS FOR CORRECT WIRING.

15 SECOND FOR RM7838C.

ALARM SILENCING SWITCH NOT NEEDED FOR RM7838C APPLICATIONS.

COMBUSTION BLOWER AFS

S445

STOP

START

COMBUSTION AIR FAN

INTERMITTENT/ 10 SECOND INTERRUPTED PILOT/IGNITION

MAIN FUELVALVE(S)

5 SECOND IGNITION (EARLY SPARK TERMINATION)

FLAME DETECTOR

LIMITS

(L1)

COMMON

LOW FIRE

MODULATE

PILOT VALVE HOLD

MANUAL VALVE OPEN SWITCH

LOW FIRE START SWITCH

HIGH PURGE RATE SWITCH

PREIGNITION INTERLOCK

M15101D

Fig. 3. Wiring subbase for RM7838B,C with S445 Start-Stop Station (not the RM7838C1020).

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L1 (HOT)

BURNER CONTROL

RECIRCULATING AFS

MASTER SWITCH

START

RECIRCULATING BLOWER

120V ALARM

COMBUSTION BLOWER AFS

STOP

DPST ALARM SILENCING SWITCH

COMBUSTION BLOWER

LIMITS

INTERMITTENT/ 10 SECOND INTERRUPTED PILOT/IGNITION

MAIN FUEL VALVE(S)

5 SECOND IGNITION (EARLY SPARK TERMINATION)

FLAME DETECTOR

Q7800 SUBBASE

(L1)

RM7838B,C 7800 SERIES RELAY MODULE

SERIES 90 FIRING RATE MOTOR

HIGH FIRE

COMMON

LOW FIRE

MODULATE

PILOT VALVE HOLD

MANUAL VALVE OPEN SWITCH

LOW FIRE START SWITCH

HIGH PURGE RATE SWITCH

PREIGNITION INTERLOCK

SERIES 90 CONTROLLER

HIGH FIRE

COMMON

LOW FIRE

MODULATE

M7284 4-20 mA FIRING RATE MOTOR

–

OUTPUT CONTROLLER

–

120V, 50/60 HZ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

SHUTTER CHECK FLAME DETECTION SYSTEM REQUIRED WHEN USING THE PILOT VALVE HOLD FUNCTION.

ALTERNATIVE WIRING FOR 4-20 MA SYSTEM.

SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS FOR CORRECT WIRING.

ALARM SILENCING SWITCH NOT NEEDED FOR RM7838C APPLICATIONS.

Fig. 4. Wiring subbase for RM7838B,C with separate Start and Stop Stations (not the RM7838C1020).

M15100C

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RM7838B,C 7800 SERIES RELAY MODULE

314

415

718

819

920

ALARM

COMBUSTION BLOWER

RECIRCULATING BLOWER AFS

COMBUSTION BLOWER AFS

INTERMITTENT/10 SECOND INTERRUPTED PILOT/ IGNITION

5 SECOND IGNITION

MAIN FUEL VALVE(S)

–

HIGH FIRE

COMMON

MODULATE

LOW FIRE

LOW FIRE START SWITCH

HIGH PURGE RATE SWITCH

PREIGNITION INTERLOCK

FLAME DETECTOR

120 VAC, 50/60 HZ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

SEE FLAME DETECTOR INSTRUCTIONS FOR CORRECT WIRING.

Q7800

START

STOP

RECIRCULATING BLOWER

M29090

BURNER CONTROL

maxon.su

Fig. 5. Hookup of RM7838C1020.

Mounting RM7838B,C Relay Module

1. Mount the RM7838B,C vertically on the Q7800

Subbase, or mount horizontally with the knife blade terminals pointing down. (For mounting on the Q7800A,

2. When mounting in an electrical enclosure, provide

mount the RM7838B,C in an electrical enclosure.)

adequate clearance for service, installation and removal of the RM7838B,C, KDM, flame amplifier, flame amplifier signal voltage probes, electrical signal voltage probes, and electrical connections. a. Allow an additional 2 in. (51 mm) below the

RM7838B,C for the flame amplifier mounting.

b. Allow an optional 3 in. (76 mm) minimum to both

sides of the RM7838B,C for electrical signal voltage probes.

3. Make sure no subbase wiring is projecting beyond the terminal blocks. Tuck in wiring against the back of the subbase so it does not interfere with the knife blade terminals or bifurcated contacts.

IMPORTANT

Install the RM7838B,C with a plug-in motion rather than a hinge action.

4. Mount the RM7838B,C by aligning the four L-shaped corner guides and knife blade terminals with the bifurcated contacts on the wiring subbase and securely tightening the two screws without deforming the plastic.

66-1094—08 12

Page 13

RM7838B,C 7800 SERIES RELAY MODULE

HONEYWELL

POWER

PIL

FLAME

MAIN

ALARM

RES

KEYBOARD DISPLAY MODULE

PURGE TIMER

WIRING SUBBASE

CAPTIVE MOUNTING SCREW

RUN/TEST SWITCH

CONFIGURATION JUMPERS

RELAY MODULE

SEQUENCE STATUS LED PANEL

RESET BUTTON

FLAME AMPLIFIER

SCR

OLL

MODE

- SAV

E -

BURNER CONTROL

M1230

maxon.su

Mounting Other System Components (Fig. 4)

Mount other required and optional system components by referring to Fig. 4 and the instructions provided with each component.

PRINCIPAL TECHNICAL FEATURES

The RM7838B,C provides all customary flame safeguard functions as well as significant advancements in safety, annunciation and system diagnostics.

Fig. 6. RM7838B,C Relay Module exploded view.

Safety Shutdown (Lockout) Occurs If:

1. INITIATE Period

a. Purge card is not installed or removed. b. Purge card is bad. c. Configuration jumpers were changed after

200 hours of operation. d. AC line power errors, see Operation. e. Four minute INITIATE period is exceeded.

2. STANDBY Period a. Flame signal is present after 240 seconds after Run

Complete. b. Preignition Interlock is open after 30 seconds. c. Ignition/pilot valve terminal is energized. d. Main valve terminal is energized. e. Internal system fault. f. Purge card is not installed or removed. g. Purge card is bad. h. Flame detected during the last two seconds.

13 66-1094—08

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RM7838B,C 7800 SERIES RELAY MODULE

maxon.su

3. PURGE Period a. Preignition Interlock opens anytime during purge. b. Flame signal detected during purge . c. High Purge Rate Switch fails to close within four

minutes, fifteen seconds after the firing rate motor is commanded to drive to high fire position.

d. Low Fire Start Switch fails to close within four min-

utes, fifteen seconds after the firing rate motor is commanded to drive to low fire position.

e. Lockout Interlock does not close within five sec-

onds. f. Lockout Interlock opens during purge . g. Ignition/pilot valve/intermittent pilot valve terminal is

energized. h. Main valve terminal is energized. i. Internal system fault. j. Purge card is not installed or removed. k. Purge card is bad.

4. Purge Hold: T21 a. Preignition Interlock opens. b. Flame is detected. c. Lockout Interlock opens during Hold. d. Ignition/pilot valve/main valve is energized. e. Internal system fault. f. Purge card is removed. g. Purge card is bad.

5. PILOT FLAME ESTABLISHING Period (PFEP) a. Low Fire Switch opens. b. Lockout Interlock opens . c. Ignition/pilot valve/intermittent pilot valve terminal is

not energized. d. No flame is present at end of PFEP. e. Internal system fault. f. Purge card is not installed or removed. g. Purge card is bad.

6. MAIN FLAME ESTABLISHING Period (MFEP) a. Low Fire Switch opens. b. Lockout Interlock opens . c. Ignition/pilot valve/intermittent pilot valve terminal is

not energized. d. Main valve terminal is not energized. e. No flame is present at end of MFEP. f. Internal system fault. g. Purge card is not installed or removed. h. Purge card is bad.

7. RUN Period a. Flame is present. b. Lockout Interlock opens. c. Main valve terminal is de-energized. d. Internal system fault. e. Purge card is not installed or removed. f. Purge card is bad.

8. Pilot Valve Hold a. Low Fire Switch opens. b. Lockout Interlock opens. c. Ignition/pilot valve terminal is not energized. d. No flame is present at end of PFEP. e. Internal system fault. f. Purge card is not installed or removed. g. Purge card is bad. h. Non Shutter Check Amplifier/Detector used.

OPERATION

Sequence of Operation

The RM7838B,C has the operating sequences listed below. The RM7838B,C LED provide positive visual indication of the program sequence: POWER, PILOT, FLAME, MAIN and ALARM. Fig. 5 and 6 show the operating sequences not using pilot valve hold and using pilot valve hold, respectively.

Initiate

The RM7838B,C enters the INITIATE sequence when the Relay Module is initially powered. The RM7838B,C can also enter the INITIATE sequence if the Relay Module verifies voltage fluctuations of +10/-15 percent or frequency fluctuations of ±10 percent during any part of the operating sequence. The INITIATE sequence lasts for ten seconds unless the voltage or frequency tolerances are not met. When the tolerances are not met, a hold condition is initiated and displayed on the KDM for at least five seconds. When the tolerances are met, the INITIATE sequence restarts. If the condition is not corrected and the hold condition exists for four minutes, the RM7838B,C locks out. Causes for hold conditions in the INITIATE sequence:

a. ac line dropout detection. b. ac line noise that prevents a sufficient reading of the

line voltage inputs.

c. Low line voltage brownouts. The Alarm, terminal 3, is energized during INITIATE (RM7838B only).

Standby

The RM7838B,C remains in STANDBY until the Burner Control Switch is closed. Two seconds before leaving STANDBY, the shutter circuit is energized and verifies that no flame is present. The Alarm, terminal 3, is energized until flame is sensed (RM7838B only).

Purge

The RM7838B,C provides PURGE timing selectable from two seconds to thirty minutes. The RM7838C requires the ST7800C Purge Timer for correct operation. The ST7800C Purge Timer will not fit into an RM7838B.

1. Closing the burner control switch starts the recirculating/ exhaust blower. PURGE sequence begins when power is applied to the RM7838B,C through the recirculating/ exhaust blower airflow switch, Stop Station, and the limit string to terminal 6. The Run/Test switch and all microcomputer-monitored circuits must also be in the correct operating state.

2. The RM7838B,C Relay Module commands the firing rate motor to the high purge rate position by closing a circuit between terminals 12 and 13. PURGE timing begins when the High Fire Switch closes, providing input to terminal 19. Four minutes, 15 seconds are provided for the High Fire Switch to close. A jumpered High Fire Switch adds 30 seconds to the PURGE timing.

3. When the PURGE timing is complete, the RM7838B,C commands the firing rate motor to the low fire position by closing a circuit between terminals 13 and 14 (terminals 13 and 15 for the C1020). Four minutes, 15 seconds are provided for the motor to reach the low fire position.

66-1094—08 14

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RM7838B,C 7800 SERIES RELAY MODULE

maxon.su

4. When the Low Fire Proving Switch is proven (input on terminal 18), the RM7838B,C commands the Combustion Blower to turn on through terminal 5. A jumpered Low Fire Switch adds 30 seconds to the PURGE timing.

5. The RM7838C will wait indefinitely for the Combustion Airflow Switch , terminal 7, to close. Once closed, five seconds are provided for it to stabilize. Safety shutdown occurs if the Combustion Blower Airflow Switch opens after this five-second period, during ignition trials or RUN.

6. The RM7838B,C waits indefinitely for the Start Input to terminal 21.

7. The Preignition Interlock must remain closed throughout PURGE timing or a safety shutdown occurs.

8. The Alarm is powered during PURGE timing (RM7838B only).

Ignition Trials

Ignition trials begin when the momentary Start input is received at terminal 21 of the RM7838B,C. The RM7838B,C locks out if the Start Switch is not released.

1. Pilot Flame Establishing Period (PFEP): a. When the PFEP begins:

(1) The pilot valve and ignition transformer,

terminals 8 and 10, are energized.

(2) Five seconds into PFEP, Ignition terminal 10 is

de-energized.

(3) Flame must be proven by the end of the ten

second PFEP (four seconds if Configuration Jumper JR1 is clipped); to allow the sequence to continue. If a flame is not proven by the end of PFEP, a safety shutdown occurs.

(4) During PFEP, the Low Fire Switch must remain

closed. If it opens, a safety shutdown occurs.

(5) The Preignition Interlock input is ignored

throughout the Ignition Trial state.

(6) The alarm output stops when flame is proven.

(RM7838B only)

(7) The RM7838B,C (except C1020):

(a)holds indefinitely, waiting for Manual Open

Valve command (terminal 17).

(b)holds indefinitely with a Pilot Valve Hold

command present on terminal 16.

(c)automatically sequences to Main Flame

Establishing Period (MFEP) if the configuration jumper JR3 was clipped and the Pilot Valve Hold Command is not present. Manual Open Valve input, terminal 17, must be closed at the end of MFEP.

b. With flame proven, the alarm, terminal 3, is

de-energized (RM7838B only).

2. Main Flame Establishing Period (MFEP) (except C1020 as it does not have a manual open valve switch input): a. With the configuration jumper JR3 intact, the

RM7838B,C waits for Manual Open Valve Switch input to terminal 17 through a Manual Open Valve

Switch. With the configuration jumper JR3 clipped and the Pilot Valve Hold command on terminal 16 open, the RM7838B,C initiates immediate MFEP. (1) Main valve terminal 9 is energized by the

RM7838B,C and the relay module is in the RUN period.

(2) If configuration jumper JR2 is clipped, ten sec-

onds after terminal 9 is energized (15 seconds for the C1004, 5 seconds for the C1020), the pilot valve terminal 8 is de-energized. If flame is lost during this MFEP, safety shutdown occurs and the ALARM sounds.

(3) If configuration jumper JR3 is clipped, a Manual

Open Valve Switch input must be present at terminal 17 at the end of the MFEP or safety shutdown occurs and the Alarm sounds.

b. The C1020 proceeds immediately to a 5 sec MFEP.

Run

1. The RM7838B,C releases the firing rate motor to

modulation (terminals 13 and 15 are closed) (terminal 13 and 14 for C1020).

2. The RM7838B,C is now in RUN and remains in RUN until the controller input, terminal 6, opens (burner control opens, Stop Switch is pushed, running interlocks open, a limit opens, Run/Test is switched to Test), indicating that the demand is satisfied or a limit opened, or the Pilot Valve Hold (terminal 16) is energized.

Pilot Valve Hold (except C1020)

Pilot Valve Hold (switched line voltage input to terminal 16) allows the burner to be cycled back to Pilot from the Run position without the need to do a complete burner startup. This allows for batch loading in process applications.

A shutter-type flame detection system is required to use the Pilot Valve Hold function.

Pilot Valve Hold can also be used to hold the burner at the end of PFEP if configuration jumper JR3 was clipped.

A switch closure to the RM7838B,C terminal 16 while in the Run position initiates the Pilot Valve Hold:

1. RM7838B,C commands the firing rate motor to Low Fire position.

2. Once Low Fire is proven (input to terminal 18 through Low Fire Switch), the pilot valve terminal is energized.

3. Forty-five seconds later, the main valve terminal is de-energized and the ignition terminal is energized for ten seconds, then shut off.

4. Pilot valve, terminal 8, remains energized throughout Pilot Valve Hold.

5. RM7838B,C remains in Hold as long as a Pilot Valve Hold input is present on terminal 16.

6. Opening the Pilot Valve Hold input to terminal 16 puts the RM7838B,C ready to initiate MFEP.

The RM7838B,C goes into safety shutdown and sounds the Alarm if flame is lost at any time during this sequence.

NOTE: A Shutter Check Detection System must be in place

to use the Pilot Valve Hold function. Fault 46 occurs along with safety shutdown.

15 66-1094—08

Page 16

RM7838B,C 7800 SERIES RELAY MODULE

maxon.su

Keyboard Display Module

The KDM (see Fig. 7) is provided with the RM7838B,C Relay Module. The first line of the Vacuum Fluorescent Display (VFD) provides:

LED DISPLAY

POWER

PILOT

FLAME

MAIN

ALARM ALARM

POWER

INITIATE

STANDBY

(INDEFINITE)

POWER

ALARM

DRIVE

HIGH

FIRE

HF SWITCH CLOSED (TERM 19)

PURGE

PURGE TIME IS SELECTABLE

THROUGH VARIOUS

ST7800 PURGE TIMER CARDS

RM7838B/C ENERGIZED (TERMINAL 4 AND L2)

TERMINAL 3 ENERGIZED (ALARM)

DRIVE

SECONDS LOW FIRE

TERMINAL 6 ENERGIZED (LIMITS/STOP SWITCH)

a. Current status of the burner sequence (STANDBY,

PURGE, PILOT IGN, MAIN IGN and RUN).

b. Timing information (PURGE, PILOT IGN and MAIN

IGN) in minutes and seconds. c. Hold information (PURGE HOLD). d. Lockout information (Lockout, Fault Code, Message

and Sequence).

START MFEP RUN

POWER

ALARM

HOLD (INDE-

MAX

FINITE)

LF SWITCH CLOSED (TERMINAL 18)

PFEPINITIATE PURGE

POWER

PILOT

FLAME MAIN

PFEP

J1 INTACT (10 SEC) J1 CLIPPED (4 SEC)

HOLD (INDEFINITE)

J3 INTACT

2010000000 00

POWER

10 SEC 10 SEC

MFEP NORMAL

PILOT

FLAME MAIN

POWER

PILOT

FLAME MAIN

BURNER

RUN

TERMINAL 5 ENERGIZED (COMBUSTION AIR FAN)

TERMINAL 7 ENERGIZED (COMBUSTION AIRFLOW SWITCH)

BURNER

OPERATING CONTROLS AND INTERLOCKS

FLAME SIGNAL

FIRING

TERMINAL 13 TO 14 TERMINAL 13 TO 14

RATE MOTOR

ALARM IS OFF FOR RM7838C.

WHEN CONFIGURATION JUMPER J3 IS CLIPPED, THE RM7838B/C AUTOMATICALLY CONTINUES INTO THE MFEP (NO WAITING TIME BETWEEN THE PFEP AND MFEP).

T17 MUST CLOSE WITHIN 10 SECONDS.

ALARM (TERMINAL 3) IS DE-ENERGIZED AS SOON AS FLAME IS DETECTED (RM7838B ONLY).

NORMAL SHUTDOWN OCCURS WHEN TERMINAL 6 IS DE-ENERGIZED.

15 SECONDS FOR RM7838C.

PREIGNITION INTERLOCKS CLOSED (TERM 20 ENERGIZED)

SAFE START CHECK

TERMINAL 13 TO 12

TERMINAL 21 ENERGIZED

TERM 10

(IGNITION)

TERMINAL 8 ENERGIZED (J2 INTACT)

TERMINAL 8 ENERGIZED (J2 CUT)

FLAME PROVING

(INTERRUPTED

TERMINAL 17

TERMINAL 9

PILOT)

TERMINAL

13 TO 15

M9745E

(INTERMITTENT PILOT)

(STARTS

MFEP)

(MAIN

VALVE)

Fig. 7. RM7838B,C Relay Module operation (not using pilot valve hold); see Fig. 8 for the C1020.

66-1094—08 16

Page 17

LED

maxon.su

DISPLAY

INITIATE PURGE

POWER

PILOT

FLAME

MAIN

ALARM ALARM

POWER

INITIATE

STANDBY

(INDEFINITE)

DRIVE

HIGH

FIRE

POWER

ALARM

PURGE TIME IS SELECTABLE

ST7800 PURGE TIMER CARDS

PURGE

THROUGH VARIOUS

RM7838C ENERGIZED (TERMINAL 4 AND L2)

RM7838B,C 7800 SERIES RELAY MODULE

START MFEP RUN

POWER

ALARM

HOLD

DRIVE

LOW FIRE

MAX

(INDE-

FINITE)

J1 INTACT (10 SEC) J1 CLIPPED (4 SEC)

SECONDS

TERMINAL 6 ENERGIZED (STOP SWITCH)

PFEP

POWER

PILOT

FLAME

MAIN

2010000000 00

POWER

PILOT

FLAME MAIN

5 SEC 10 SEC

MFEP NORMAL

POWER

PILOT

FLAME MAIN

BURNER

RUN

HF SWITCH CLOSED (TERM 19)

BURNER

OPERATING CONTROLS AND INTERLOCKS

FLAME SIGNAL

FIRING

TERMINAL 13 TO 15 TERMINAL 13 TO 15

RATE MOTOR

1 NORMAL SHUTDOWN OCCURS WHEN TERMINAL 6 IS DE-ENERGIZED.

PREIGNITION INTERLOCKS CLOSED (TERM 20 ENERGIZED)

SAFE START CHECK

TERMINAL 13 TO 12

LF SWITCH CLOSED (TERMINAL 18)

TERMINAL 5 ENERGIZED (COMBUSTION AIR FAN)

TERMINAL 7 ENERGIZED (COMBUSTION AIRFLOW SWITCH)

Fig. 8. RM7838C1020 Relay Module operation.

TERMINAL 21 ENERGIZED

TERM 10

TERMINAL 8 ENERGIZED (J2 INTACT)

TERMINAL 8 ENERGIZED (J2 CUT)

(IGNITION)

TERMINAL 9

FLAME PROVING

(INTERMITTENT PILOT)

(INTERRUPTED

PILOT)

(MAIN

VALVE)

TERMINAL

13 TO 14

M29083

17 66-1094—08

Page 18

RM7838B,C 7800 SERIES RELAY MODULE

INITIATE

POWER

PILOT

FLAME

MAIN

ALARM ALARM

STANDBY

(INDEFINITE)

POWER

ALARM

POWER

DRIVE

HIGH

FIRE

DRIVE

LOW

FIRE

DRIVE

LOW

FIRE

MAIN

VALVE

PFEP HOLD

SECONDS

MAX

10 SEC 10 SEC10 SEC 10 SEC45 SEC

HOLD

(INDE-

FINITE)

HOLD

(INDEFINITE)

PURGE

PREPURGE TIME IS

SELECTABLE THROUGH

VARIOUS ST7800

PURGE TIMER CARDS

PFEP

J1 INTACT (10 SEC)

J1 CLIPPED (4 SEC)

MFEP MFEP

NORMAL

BURNER

RUN

NORMAL

BURNER

RUN

RM7838B/C ENERGIZED (TERMINAL 4 AND L2)

TERMINAL 3 ENERGIZED (ALARM)

TERMINAL 6 ENERGIZED (START/STOP SWITCH)

LOW FIRE SWITCH CLOSED (TERMINAL 18)

HIGH FIRE SWITCH

CLOSED (TERM 19)

PREIGNITION INTERLOCKS CLOSED (TERM 20 ENERGIZED)

SAFE START CHECK

TERMINAL 13 TO 12

TERMINAL

13 TO 15

TERMINAL

13 TO 15

TERMINAL 13 TO 14 TERMINAL 13 TO 14 TERMINAL 13 TO 14

TERMINAL 18

TERM 10

TERM 21 ENERGIZED

TERMINAL 5 ENERGIZED (COMBUSTION AIR FAN)

TERMINAL 7 ENERGIZED (COMBUSTION AIRFLOW SWITCH)

TERMINAL 8 ENERGIZED (J2 INTACT)

TERMINAL 17 ENERGIZED

TERMINAL 16 ENERGIZED

FLAME PROVING

TERMINAL 9

TERMINAL 8 ENERGIZED (J2 CUT) TERMINAL 8

MAIN

PILOT

FLAME

POWER

MAIN

PILOT

FLAME

POWER

MAIN

PILOT

FLAME

POWER

MAIN

PILOT

FLAME

POWER

MAIN

PILOT

FLAME

POWER

MAIN

PILOT

FLAME

POWER

MAIN

PILOT

FLAME

POWER

MAIN

PILOT

FLAME

POWER

MAIN

PILOT

FLAME

POWER

M9744F

PILOT VALVE HOLD

ALARM IS OFF FOR RM7838C.

WHEN CONFIGURATION JUMPER J3 IS CLIPPED, THE RM7838B AUTOMATICALLY

CONTINUES INTO THE MFEP (NO WAITING TIME BETWEEN THE PFEP AND MFEP).

ALARM (TERMINAL 3) IS DE-ENERGIZED AS SOON AS FLAME IS DETECTED

(RM7838B ONLY).

NORMAL SHUTDOWN OCCURS WHEN TERMINAL 6 IS DE-ENERGIZED.

THE RM7838B/C STARTS THE PILOT VALVE HOLD SEQUENCE WHEN TERMINAL 16 IS ENERGIZED.

THE RM7838B/C REMAINS IN PILOT VALVE HOLD INDEFINITELY OR UNTIL TERMINAL 16 IS DE-ENERGIZED.

15 SECONDS FOR RM7838C.

PFEPINITIATE PURGE MFEP RUN MFEP RUN

PILOT

VALVE

HOLD

(CLOSED)

PILOT

VALVE

HOLD

(CLOSED)

PILOT

VALVE

HOLD

(CLOSED)

PILOT

VALVE

HOLD

(CLOSED)

MOV SWITCH

CLOSED

LED

DISPLAY

2010000000 00 00 45 55

J3 INTACT

BURNER

OPERATING

CONTROLS

AND

INTERLOCKS

FLAME

SIGNAL

FIRING

RATE

M OTOR

maxon.su

66-1094—08 18

Fig. 9. RM7838B,C Relay Module operation (using pilot valve hold) (not C1020).

Page 19

RM7838B,C 7800 SERIES RELAY MODULE

maxon.su

The extreme right side of the first line is either blank or shows a small arrow pointing to the second line followed by a two-letter code (DI—Diagnostic Information, H1—Fault History Information, and EA—Expanded Annunciator). When the arrow and two-letter code are displayed, it indicates the second line is showing a selectable message submenu. The second line displays selectable or preemptive messages.

A selectable message supplies information for flame strength, system status indication, system or self-diagnostics and troubleshooting. Refer to checkout and troubleshooting instructions; see applicable publications listed on page 1.

A preemptive message has parentheses around the message and supplies a detailed message to support the sequence status information. A preemptive message can also be a lockout message. A preemptive message replaces a selectable message to support the sequence status information. It also replaces a selectable message after 60 seconds if it or a lockout message is available.

NOTE: NOTE:RM7838B,C LED provide positive visual

indication of the program sequence: POWER, PILOT, FLAME, MAIN and ALARM. See Fig. 7.

FIVE WIRE CONNECTOR FOR COMMUNICATIONS, REMOTE KEYBOARD DISPLAY AND REMOTE RESET

RUN/TEST SWITCH

SEQUENCE STATUS

SELECTABLE MESSAGE OR PRE-EMPTIVE MESSAGE

SEQUENCE STATUS LEDs

RESET PUSHBUTTON

FLAME SIMULATOR INPUT

DI = DIAGNOSTICS H1 = HISTORY EA = EXPANDED ANNUNCIATOR

CAPTIVE MOUNTING SCREW

PLUG-IN PURGE CARD

KEYBOARD DISPLAY MODULE

RELAY MODULE

FLAME AMPLIFIER

FLAME CURRENT TEST JACKS

M7359

Run/Test Switch

The Run/Test Switch is located on the top side of the RM7838B,C, see Fig. 7. The Run/Test Switch allows the burner sequence to be altered as follows:

1. In Prepurge Drive to High Fire position, the Run/Test Switch, when placed in the TEST position, holds in PURGE with the firing rate motor in the High Fire position.

2. In the measured PURGE sequence, the Run/Test Switch, when placed in the TEST position, causes the PURGE timing to stop. The firing rate motor is in the High Fire position.

3. In Purge Drive to Low Fire position, the Run/Test Switch, when placed in the TEST position, holds the burner sequence in PURGE with the firing rate motor in the Low Fire position.

4. In PFEP, the Run/Test Switch, when placed in the TEST position, stops the timer during the first eight seconds when a ten-second PFEP is selected or during the first three seconds when a four-second PFEP is selected, allows pilot-turn-down test and other burner adjustments to be made. This activates a 15 second flameout timer that permits pilot flame adjustment without nuisance safety shutdowns. The Run/Test Switch is ignored during PFEP for the RM7838B,C if terminals 8 and 9 are jumpered.

5. During Run, the Run/Test Switch, when placed in the TEST position, drives the firing rate motor to the Low Fire position.

NOTE: When the RM7838B,C is switched to the TEST

mode, it stops and holds at the next Run/Test Switch point in the operating sequence. Make sure that the Run/Test Switch is in the RUN position before leaving the installation.

Fig. 10. Relay Module and associated system

components.

19 66-1094—08

Page 20

RM7838B,C 7800 SERIES RELAY MODULE

maxon.su

SETTINGS AND ADJUSTMENTS

Selectable Site-Configurable Jumpers

The RM7838B,C has a three site-configurable jumper option, see Fig. 8 and Table 7. If necessary, clip the site-configurable jumper with side cutters and remove the resistors from the Relay Module.

SELECTABLE CONFIGURATION JUMPERS

RUN/TEST SWITCH

M7428

Fig. 11. Selectable site-configurable jumpers.

Table 8. Site Configurable Jumper Options.

Jumper Number Description Intact Clipped

JR1 Pilot Flame

Establishing Period (PFEP)

JR2 Pilot Valve Intermittent Interrupted

a,b,c

JR3

Unclipped: RM7838B,C waits indefinitely for a 120V Manual Open Valve input. When input is received, 10 second MFEP begins. The RM7838B,C also turns on terminal 9.

Clipped: After the required PFEP, the RM7838B,C immediately goes to MFEP by outputting 120 Vac to the Main Valve terminal 9. At the end of the 10 second MFEP, if there is not an input on the Manual Open Valve terminal 17, the RM7838B,C goes to safety shutdown. If automatic main valves are used, a jumper is required between terminals 4 and 17.

RM7838C1020 does not have JR3.

NOTE: SERVICE NOTE: Clipping and removing a

IMPORTANT

Deferred or immediate Main Flame

site-configurable jumper enhances the level of safety.

Clipping and removing a site-configurable jumper after 200 hours of operation results in a nonresettable Fault 110 and a lockout.

10 seconds 4 seconds

Deferred Immediate

Automation and Control Solutions

Honeywell International Inc.

1985 Douglas Drive North

Golden Valley, MN 55422

Honeywell Limited-Honeywell Limitée

35 Dynamic Drive

Toronto, Ontario M1V 4Z9

customer.honeywell.com