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 32-

00110) 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.

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.

SIL

3

Capable

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).

32-00158-03

RM7897A,C 7800 SERIES RELAY MODULES

Humidity: 85% relative humidity continuous, noncon-

densing.

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 Volt-

age) 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 simultane-

ously 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 horizon-

tally 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.

32-00158—03 2

RM7897A,C 7800 SERIES RELAY MODULES

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

Series 1000 Subbase

All relay product codes that start with a 1 (example:
RM7840G
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:
RM7840G
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.

can be purchased. It is important to note which
subbase is compatible with the relay module
when purchasing repair or replacement parts.

1014/U) can be used with existing subbase

2014/U) can be used with subbase

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 (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 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.

3 32-00158—03

RM7897A,C 7800 SERIES RELAY MODULES

PROVIDE DISCONNECT MEANS AND

1

OVERLOAD PROTECTION AS REQUIRED.

2

RM7897A-INTERMITTENT PILOT.
RM7897C-INTERRUPTED PILOT.

3

RM7897A-INTERRUPTED PILOT.
RM7897C-DELAYED MAIN VALVE.

INDICATES FEEDBACK SENSING
TO RELAY STATUS FEEDBACK
AND LINE VOLT INPUTS

FIELD WIRING

INTERNAL WIRING

OPTIONAL KEYBOARD
DISPLAY MODULE

DDL

DDL
COMMUNICATIONS

M22727A

1

RS485

2

3

REMOTE
RESET

5

RUN/TEST
SWITCH

RESET
PUSHBUTTON

STATUS LEDs

LIMITS

PREIGNITION
INTERLOCK

CONFIGURATION
JUMPERS

CONTROLLER

6K1

3K1

MICROCOMPUTER

SAFETY RELAY
CIRCUIT

6

LOCKOUT
INTERLOCK
(INCLUDING
AIRFLOW SWITCH)

20

1

RELAY
DRIVE
CIRCUIT

120 VAC,
50/60 HZ

L1
(HOT)

2K

3K
4K

5K
6K

7K

1K

POWER SUPPLY

1K1 2K1 5K1

7

L2

PLUG-IN PURGE
TIMER CARD

FLAME SIGNAL

PLUG-IN

TEST

FLAME
AMPLIFIER

4K1

2K2

7K16

RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS

CONTROL
POWER

10

8

9

21

4

3

TEST
JACK

F

G

22

IGNITION

PILOT

MAIN VALVE

BLOWER

ALARM

L2

2

3

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.

32-00158—03 4

LINE VOLTAGE ALARM

BURNER MOTOR
(BLOWER)

BURNER
CONTROLLER/LIMITS

RUNNING INTERLOCK
(INCLUDING
AIRFLOW SWITCH)

LED
DISPLAY

BURNER

OPERATING
CONTROLS
AND
INTERLOCKS

FLAME
SIGNAL

INTERMITTENT
PILOT/IGNITION

MAIN FUEL VALVE(S)

IGNITION

FLAME DETECTOR

3

INITIATE
(INITIAL
POWERUP
ONLY)

POWER

PREIGNITION INTERLOCK CLOSED

STANDBY

LIMITS AND BURNER CONTROLLER CLOSED

SAFE START CHECK

Q7800

G

L2

3

4

(L1)

5

6

7

8

9

10

F

POWER

5

00

TIMED
PREPURGE

POWER

PILOT

FLAME

MAIN

BURNER/BLOWER MOTOR

10

RUNNING INTERLOCKS CLOSED

FOR DIRECT SPARK IGNITION

12

(OIL OR GAS)

13

14

15

16

17

2

18

19

PREIGNITION

20

INTERLOCK

21

22

PFEP
10 SEC.

00

(4 SEC. IF
JR1

INTERRUPTED PILOT

10

CLIPPED

POWER

PILOT

FLAME

MAIN

IGN.

20TO5

IGNITION

10

TRANSFORMER

8

MAIN VALVE

MASTER
SWITCH

20

MFEP

POWER

PILOT

FLAME

MAIN

ALARMALARMALARM

4

8 INTERMITTENT PILOT

8

21

21

MAIN VALVE

TO

6

L1

7TO

6

FLAME PROVING

RM7897A,C 7800 SERIES RELAY MODULES

L2

10-SECOND
INTERRUPTED
PILOT

L1
(HOT)

1

L2

00

RUN

POWER

PILOT

FLAME

MAIN

ALARM

9

4

POSTPURGE

POWER

STANDBY

POWER

PII

SSC

1

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

DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.

2

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

SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING.

3

PROGRAMMED ON SETUP USING S7800A1142 DISPLAY.

4

PURGE TIME DEPENDS ON WHICH ST7800 IS INSTALLED.

5

M22728C

5 32-00158—03

RM7897A,C 7800 SERIES RELAY MODULES

LINE VOLTAGE
ALARM

BURNER MOTOR
(BLOWER)

BURNER
CONTROLLER/LIMITS

RUNNING INTERLOCK
(INCLUDING
AIRFLOW SWITCH).

10 SEC. INTERRUPTED
PILOT/IGNITION

MAIN FUEL VALVE(S)

IGNITION

FLAME DETECTOR

4

L2

10

Q7800

G

3

4

5

6

7

8

9

F

(L1)

12

13

14

15

16

17

18

19

20

21

22

FOR DIRECT SPARK IGNITION
(OIL OR GAS)

IGNITION

10

TRANSFORMER

8

9

MAIN VALVE

2

DELAYED
(2ND STAGE)
MAIN VALVE

MASTER
SWITCH

L1
(HOT)

L2

PREIGNITION
INTERLOCK

1

L2

INITIATE
(INITIAL
POWERUP
ONLY)

POWER

LED
DISPLAY

BURNER

OPERATING
CONTROLS
AND
INTERLOCKS

FLAME
SIGNAL

1

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

2

DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.

3

PROGRAMMABLE POST PURGE TIMING USING S7800A1142 KDM.

STANDBY

LIMITS AND BURNER CONTROLLER CLOSED

PREIGNITION INTERLOCK CLOSED

00 00 10

TIMED
PREPURGE

POWER

SAFE START CHECK

PFEP
10 SEC.

5

(4 SEC. IF

CLIPPED

JR1

POWER

PILOT

FLAME

MAIN

POWER

PILOT

FLAME

MAIN

BURNER/BLOWER MOTOR

10

IGNITION

INTERRUPT/PILOT

RUNNING INTERLOCK

5

TO

4

5

6

RUN

POWER

PILOT

FLAME

MAIN

ALARM

9

21

7

00

3

POSTPURGE

POWER

STANDBY

POWER

PII

SSC

M22729C

20

6

MFEP

POWER

PILOT

FLAME

MAIN

ALARMALARMALARM

4

8

MAIN VALVE

DELAYED MAIN VALVE

6

L1

TO

6

TO

20

FLAME PROVING

SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING.

PURGE TIME DEPENDS ON WHICH ST7800 IS INSTALLED.

RM7897C1018 IS 14 SECONDS FOR 4 SECOND MFEP.

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

32-00158—03 6