Honeywell 7800 SERIES Installation Instructions Manual
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Honeywell 7800 SERIES Installation Instructions Manual

Honeywell 7800 SERIES Installation Instructions Manual

Relay modules
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APPLICATION
The Honeywell RM7838A is a microprocessor-based
integrated burner control for semi-automatically fired gas, oil,
or combination fuel single burner applications. The RM7838A
Relay Module is intended to replace the Industrial
R4138A,B,C and D Flame Safeguard Primary Control, but
does not include an override on momentary power
interruptions. The RM7838A System consists of a relay
module, keyboard display module, subbase, amplifier and
purge card. Options include Personal Computer Interface,
Data ControlBus Module™, remote display mounting, first-out
expanded annunciator and Combustion System Manager
Software.
Functions provided by the RM7838A include semi-automatic
burner sequencing, flame supervision, system status
indication, system or self-diagnosis and troubleshooting.
This document provides installation and static checkout
instructions. Other applicable publications are:
63-2278 Q7700 Network Interface Unit Product Data.
65-0084 Q7800A,B 22-Terminal Wiring Subbase Product
Data.
65-0089 ST7800A Plug-in Purge Timer Installation
Instructions.
65-0090 S7800A Keyboard Display Module Product Data.
65-0091 S7810A Data ControlBus Module™ Product
Data.
65-0101 S7830 Expanded Annunciator Product Data.
65-0109 R7824, R7847, R7848, R7849, R7861, R7886
Flame Amplifiers for the 7800 SERIES Product Data.
65-0131 221818A Extension Cable Assembly
65-0229 7800 SERIES Relay Modules Checkout and
Troubleshooting.
SPECIFICATIONS
Electrical Ratings, see Table 3:
Voltage and Frequency: 120 Vac (+10/-15%), 50/60 Hz
(±10%).
Power Dissipation: 10W maximum.
Maximum Total Connected Load: 2000 VA.
Fusing Total Connected Load: 20A maximum, type FRN
or equivalent.
® U.S. Registered Trademark
Copyright © 1998 Honeywell Inc. • All Rights Reserved
7800 SERIES Relay Modules
Environmental Ratings:
Ambient Temperatures:
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.
Approvals:
Underwriters Laboratories Inc. Listed: File No. MP268,
Guide MCCZ.
Canadian Standards Association Certified: LR9S329-3.
Factory Mutual Approved: Report No. J.I.1V9AO.AF.
®
Industrial Risk Insurers: 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
your application.
3. Installer must be a trained, experienced, flame
safeguard technician.
4. After installation is complete, check out the product
operation as provided in these instructions.
RM7838A
INSTALLATION INSTRUCTIONS
WARNING
Fire or Explosion Hazard.
Can cause property damage, severe injury,
or death.
Verify safety requirements each time a control is
installed on a burner.
CAUTION
Electrical Shock Hazard.
Can cause electrical shock or equipment/
control damage.
Disconnect the power supply before beginning
installation.
66-1087-2

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Summary of Contents for Honeywell 7800 SERIES

  • Page 1 4. After installation is complete, check out the product 65-0109 R7824, R7847, R7848, R7849, R7861, R7886 operation as provided in these instructions. Flame Amplifiers for the 7800 SERIES Product Data. 65-0131 221818A Extension Cable Assembly WARNING 65-0229 7800 SERIES Relay Modules Checkout and Troubleshooting.

  • Page 2: Mounting Wiring Subbase

    RM7838A 7800 SERIES RELAY MODULES IMPORTANT Mounting Wiring Subbase 1. Wiring connections for the relay module are unique; 1. Mount the subbase in any position except horizontally refer to Fig. 2 or the correct Specifications for proper with the bifurcated contacts pointing down. The standard subbase wiring and sequence charts.
  • Page 3 RM7838A 7800 SERIES RELAY MODULES BURNER (HOT) CONTROL 120 Vac 50/60 Hz PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK PLUG-IN MICROCOMPUTER FLAME AMPLIFIER TEST RESET PUSHBUTTON RELAY DRIVE RELAY CIRCUIT STATUS FEEDBACK AND LINE VOLTAGE INPUTS SAFETY RELAY...
  • Page 4 RM7838A 7800 SERIES RELAY MODULES 5. For recommended wire size and type, see Table 1. c. Remote reset leadwires: The maximum length of 6. For recommended grounding practices, see Table 2. wire is 1000 feet (305 meters) to a remote reset 7.

  • Page 5: Final Wiring Check

    RM7838A 7800 SERIES RELAY MODULES Table 3. Terminal Ratings. Terminal No. Description Ratings Flame Sensor Ground — Earth G Earth Ground — L2(N) Line Voltage Common — Alarm 120 Vac, 1A pilot duty. Line Voltage Supply (L1) 120 Vac, (+10/-15%), 50/60- Hz (±10%) Unused —...

  • Page 6: Static Checkout

    RM7838A 7800 SERIES RELAY MODULES STATIC CHECKOUT Equipment Recommended 1. Voltmeter (1M ohm/volt minimum sensitivity) set on the 0 to 300 Vac scale. After checking all wiring, perform this checkout before 2. Two jumper wires, No. 14 wire, insulated, 12 in.

  • Page 7: Mounting Other System Components (Fig. 3)

    RM7838A 7800 SERIES RELAY MODULES Table 7. Static Checkout (continued). Test If Operation is Abnormal, Test Jumpers Voltmeter Normal Operation Check the Items Listed Below May need to 19-L2 Manually drive damper motor High Fire Switch. jumper limits open and look for High Fire Firing rate motor and transformer.
  • Page 8 RM7838A 7800 SERIES RELAY MODULES Q7800 SUBBASE (HOT) MASTER BURNER SWITCH CONTROL ALTERNATE CONNECTION WHEN USING THE R4155A ALARM 120V ALARM SILENCING RELAY. THE Q7800 REMAINING CONNECTIONS ARE (L1) SUBBASE THE SAME FOR THE RM7838A. R4155A DPST ALARM SILENCING SWITCH...

  • Page 9: Principal Technical Features

    RM7838A 7800 SERIES RELAY MODULES WIRING SUBBASE RUN/TEST SWITCH H O N E Y W E LL RELAY MODULE CONFIGURATION JUMPERS PURGE TIMER SEQUENCE STATUS LED PANEL POWE R RESET PILOT BUTTON FLAME MAIN ALARM CAPTIVE KEYBOARD RESET MOUNTING DISPLAY...

  • Page 10: Sequence Of Operation

    RM7838A 7800 SERIES RELAY MODULES 5. RUN Period Purge Hold T19 (High Fire Switch) is displayed until the High Intermittent pilot valve/1st stage oil terminal is not Fire Switch is proven. energized. Main valve terminal is not energized. PURGE timing begins when the damper motor is manually No flame is present.

  • Page 11: Settings And Adjustments

    RM7838A 7800 SERIES RELAY MODULES Keyboard Display Module (KDM) SELECTABLE CONFIGURATION JUMPER The Keyboard Display Module (see Fig. 3) is provided with the RM7838A Relay Module. The first line of the Vacuum Fluorescent Display (VFD) provides: 1. Current status of the burner sequence (STANDBY, PURGE, PILOT IGN, MAIN IGN and RUN).
  • Page 12 RM7838A 7800 SERIES RELAY MODULES Home and Building Control Home and Building Control Honeywell Inc. Honeywell Limited-Honeywell Limitée 155 Gordon Baker Road Honeywell Plaza P.O. Box 524 North York, Ontario Minneapolis MN 55408-0524 M2H 3N7 Printed in U.S.A. on recycled paper containing at least 10% www.honeywell.com...

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