Honeywell RM7897A, RM7897C INSTALLATION INSTRUCTIONS

RM7897A,C 7800 SERIES

Relay Modules

INSTALLATION INSTRUCTIONS

APPLICATION

The RM7897A,C are microprocessor-based integrated burner controls for automatically fired gas, oil, or combination fuel single burner applications. The RM7897A,C system consist of a relay module, subbase, amplifier, and purge card. Options include: 2-line VFD (see document 65-0090) or 4-line LCD (see document 3200110) Keyboard Display Module, Data ControlBus™ Module, remote display mounting, Expanded Annunciator or Modbus module.

Functions provided by the RM7897A,C include automatic burner sequencing, flame supervision, system status indication, system or self-diagnostics and troubleshooting.

The RM7897 adds a proof of closure input to the standard primary control function of the RM7895/RM7896 product. It adds a blinking fault code function to the POWER LED on Alarm shutdown. It also adds programmable postpurge using the S7800A1142 Keyboard Display Module (KDM).

The RM7897A1002 offers selectable pilot operation, intermittent on terminal 8 or interrupted on terminal 21.

The RM7897C1000 offers interrupted pilot and delayed main valve for 2-step firing (Low-High-Low) applications.

The RM7897C1018 has 4 second MFEP (main flame establishing period).

The RM7897C1026 provides a special recycle function for configuration of Jumper JR2:

—JR 2 intact: Recycle on loss of flame.

—JR2 clipped: If flame loss occurs during the first 15 seconds in the Run period, then lockout occurs. If flame loss occurs after 15 seconds into the Run period, then recycle.

Factory default for Post Purge time: 15 seconds.

SIL3

Capable

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

Publication
No.	Product
32-00110	S7800A2142 4-line LCD Keyboard Display
	Module Product Data
65-0084	Q7800A,B 22-Terminal Wiring Subbase
	Product Data
65-0288	S7800A1142 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 Installation
	Instructions
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.

This document covers the following 7800 Series Relay Modules:

•RM7897A1002

•RM7897A2002

•RM7897C1000

•RM7897C2000

SPECIFICATIONS

Electrical Ratings (See Table 3):

Voltage and Frequency:

RM7897A,C: 120 Vac (+10/-15%), 50/60 Hz (± 10%). Power Dissipation: 10W maximum.

Maximum Total Connected Load: 2000 VA.

Fusing Total Connected Load: 15A Fast Blow, type SC or equivalent.

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).

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RM7897A,C 7800 SERIES RELAY MODULES

Humidity: 85% relative humidity continuous, noncondensing.

Vibration: 0.5G environment.

SIL 3 Capable:

SIL 3 Capable in a properly designed Safety Instru-

mented System. See form 65-0312 for Certificate

Agreement

Approvals:

Underwriters Laboratories Inc. Listed: File No. MP268,

Guide No. MCCZ.

Factory Mutual Approved: Report No. 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 severe injury, death or property damage.

Follow applicable safety requirements when installing a control on a burner to prevent death or severe injury.

WARNING

Electrical Shock Hazard.

Can cause serious injury, death or equipment damage.

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

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 RM7897A,C must not exceed those listed on the RM7897A,C 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 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 Flame Detectors C7015, C7915, C7927, C7961 and C7952.

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 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% 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 servicing, installation, access or removal of the relay module, Expanded Annunciator, Keyboard Display Module, flame amplifier, flame amplifier signal voltage probes, Run/Test Switch, electrical signal voltage probes and electrical field connections.

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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

NOTE: There are several different subbase models that can be purchased. It is important to note which subbase is compatible with the relay module when purchasing repair or replacement parts.

Series 1000 Subbase

All relay product codes that start with a 1 (example: RM7840G1014/U) can be used with existing subbase Q7800A1005/U. These relays can also be used on the Series 2000 subbase noted below.

Series 2000 Subbase

All relay product codes that start with a 2 (example: RM7840G2014/U) can be used with subbase Q7800A2005/U.

Subbase Compatibility

Any relay module in the 1000 series is fully backward compatible with any subbase already installed in the field (Q7800A1005/U, Q7800B1003/U, Q7800A2005/U, Q7800B2003/U).

Any relay module in the new 2000 series will only be able to be installed on subbase Q7800A2005/U, and will not be backward compatible with any Q7800A1005/U legacy subbases already installed in the field.

RM7897A,C 7800 SERIES RELAY MODULES

IMPORTANT

Make sure to check the relay model number and check the subbase compatibly prior to ordering or attempting a new installation or field upgrade.

If you attempt to place a 2000 series relay on a non-compatible 1000 series subbase, you will receive an error code of 101. This indicates that you must a) change out the subbase to a Q7800A2005/U or b) chose a compatible 1000 series relay module.

WARNING

Electrical Shock Hazard.

Can cause severe injury, death or equipment damage.

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

The internal block diagram of the RM7897A,C is shown in Fig. 1.

1.For proper subbase wiring and sequence chart, refer to Fig. 2 and 3.

2.For remote wiring of the Keyboard Display Module, refer to the Specifications for the Keyboard Display Module. There are two options for the separately purchased display: 2-line VFD display (65-0090) or a 4-line LCD display (32-00110), Data ControlBus™ Module (65-0091) or Extension Cable Assembly (650131).

3.Disconnect the power supply from the main disconnect before beginning installation to prevent electrical shock and equipment damage. More than one disconnect can 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.For recommended wire size and type, see Table 1.

6.For recommended grounding practices, see Table 2.

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RM7897A,C 7800 SERIES RELAY MODULES

120 VAC,

50/60 HZ

L1

L2

(HOT)

1

1 PROVIDE DISCONNECT MEANS AND

5

L2

OVERLOAD PROTECTION AS REQUIRED.

2

RM7897A-INTERMITTENT PILOT.

PLUG-IN PURGE

RM7897C-INTERRUPTED PILOT.

CONFIGURATION

TIMER CARD

JUMPERS

3

RM7897A-INTERRUPTED PILOT.

FLAME SIGNAL

TEST

RM7897C-DELAYED MAIN VALVE.

JACK

RUN/TEST

SWITCH

F

INDICATES FEEDBACK SENSING

TEST

PLUG-IN

TO RELAY STATUS FEEDBACK

MICROCOMPUTER

FLAME

G

AND LINE VOLT INPUTS

AMPLIFIER

22

FIELD WIRING

2K

INTERNAL WIRING

RESET

3K

RELAY

PUSHBUTTON

RELAY

STATUS

DRIVE

4K

FEEDBACK

CIRCUIT

5K

AND LINE

6K

VOLTAGE

INPUTS

7K

SAFETY RELAY

1K

STATUS LEDs

CIRCUIT

CONTROL

POWER SUPPLY

POWER

1K1

2K1 5K1

6

7

10

IGNITION

LIMITS

CONTROLLER

LOCKOUT

4K1

INTERLOCK

8

PILOT

2

(INCLUDING

OPTIONAL KEYBOARD

AIRFLOW SWITCH)

2K2

DDL

DISPLAY MODULE

PREIGNITION

9

MAIN VALVE

RS485

20

INTERLOCK

7K16

1

21

3

6K1

DDL

2

REMOTE

4

BLOWER

COMMUNICATIONS

3

RESET

3K1

M22727A

3

ALARM

Fig. 1. Internal block diagram of RM7897A,C (see Fig. 2 and 3 for detailed wiring instructions).

7.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.

8.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 KDM is used.

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RM7897A,C 7800 SERIES RELAY MODULES

		Q7800
	G		12	FOR DIRECT SPARK IGNITION
				(OIL OR GAS)
	L2		13	10	IGNITION
					TRANSFORMER
						L2
LINE VOLTAGE ALARM	3		14	8	MAIN VALVE
BURNER MOTOR	4		15
(BLOWER)
	5	(L1)	16
BURNER			17
CONTROLLER/LIMITS	6
				2
RUNNING INTERLOCK
(INCLUDING	7		18
AIRFLOW SWITCH)
INTERMITTENT	8		19
PILOT/IGNITION
MAIN FUEL VALVE(S)	9		20	PREIGNITION
				INTERLOCK
						10-SECOND
IGNITION	10		21			INTERRUPTED
						PILOT
FLAME DETECTOR	F		22	MASTER
				SWITCH
					L1
					(HOT)
3					L2	1

LED

DISPLAY

BURNER

OPERATING CONTROLS AND INTERLOCKS

FLAME

SIGNAL

INITIATE (INITIAL POWERUP ONLY)

POWER

	5	PFEP
		10 SEC.
00TIMED 00 (4 SEC. IF 10			20		00	4
STANDBY	PREPURGE	JR1 CLIPPED	MFEP	RUN	POSTPURGE		STANDBY
POWER	POWER	POWER	POWER	POWER		POWER	POWER
	PILOT	PILOT	PILOT	PILOT
	FLAME	FLAME	FLAME	FLAME
	MAIN	MAIN	MAIN	MAIN
	ALARM	ALARM	ALARM	ALARM

BURNER/BLOWER MOTOR		4
10	IGN.
	INTERMITTENT PILOT	8
	INTERRUPTED PILOT 21
	MAIN VALVE		9
LIMITS AND BURNER CONTROLLER CLOSED L1 TO		6
RUNNING INTERLOCKS CLOSED 6 TO		7
PREIGNITION INTERLOCK CLOSED	5 TO 20		PII
SAFE START CHECK	FLAME PROVING		SSC

	1 120 VAC, 50/60 HZ POWER SUPPLY. PROVIDE DISCONNECT MEANS	3	SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING.
	AND OVERLOAD PROTECTION AS REQUIRED.
	2 DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.	4	PROGRAMMED ON SETUP USING S7800A1142 DISPLAY.
		5	PURGE TIME DEPENDS ON WHICH ST7800 IS INSTALLED.
			M22728C

Fig. 2. Wiring subbase and sequence chart for RM7897A.

5	32-00158—03

RM7897A,C 7800 SERIES RELAY MODULES
		Q7800
	G		12	FOR DIRECT SPARK IGNITION
				(OIL OR GAS)
	L2		13	10	IGNITION
					TRANSFORMER
LINE VOLTAGE				8		L2
ALARM	3		14
BURNER MOTOR	4		15	9	MAIN VALVE
(BLOWER)
	5	(L1)	16
BURNER	6		17
CONTROLLER/LIMITS
				2
RUNNING INTERLOCK	7		18
(INCLUDING
AIRFLOW SWITCH).
10 SEC. INTERRUPTED	8		19
PILOT/IGNITION
MAIN FUEL VALVE(S)	9		20		PREIGNITION
					INTERLOCK
				DELAYED
IGNITION	10		21	(2ND STAGE)
				MAIN VALVE
FLAME DETECTOR	F		22
				MASTER
4				SWITCH
					L1
					(HOT)
					L2	1

LED

DISPLAY

BURNER

OPERATING CONTROLS AND INTERLOCKS

FLAME

SIGNAL

INITIATE			PFEP
(INITIAL			10 SEC.					00
POWERUP		00 TIMED 5 00(4 SEC. IF 10			6	20			3
ONLY)	STANDBY	PREPURGE	JR1 CLIPPED	MFEP			RUN	POSTPURGE		STANDBY
POWER	POWER	POWER	POWER	POWER			POWER		POWER	POWER
		PILOT	PILOT	PILOT			PILOT
		FLAME	FLAME	FLAME			FLAME
		MAIN	MAIN	MAIN			MAIN
		ALARM	ALARM	ALARM			ALARM
		BURNER/BLOWER MOTOR					4
		10	IGNITION
			INTERRUPT/PILOT		8
				MAIN VALVE			9
			DELAYED MAIN VALVE 21
	LIMITS AND BURNER CONTROLLER CLOSED				L1 TO		6
		RUNNING INTERLOCK			6	TO	7
PREIGNITION INTERLOCK CLOSED			5 TO 20							PII
	SAFE START CHECK			FLAME PROVING						SSC

1	120 VAC, 50/60 HZ POWER SUPPLY. PROVIDE DISCONNECT MEANS	4	SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING.
	AND OVERLOAD PROTECTION AS REQUIRED.
		5	PURGE TIME DEPENDS ON WHICH ST7800 IS INSTALLED.
2	DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.
		6	RM7897C1018 IS 14 SECONDS FOR 4 SECOND MFEP.
3	PROGRAMMABLE POST PURGE TIMING USING S7800A1142 KDM.		M22729C

Fig. 3. Wiring subbase and sequence chart for RM7897C.

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