Honeywell 7800 Series Installation Instructions Manual
Relay modules
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RM7838A
7800 SERIES Relay Modules
APPLICATION
The Honeywell RM7838A is a microprocessor-based
integrated on/off 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 Data
ControlBus Module™, remote display mounting, first-out
expanded annunciator and Modbus™ communications
capable.
This document covers the following modules:
RM7838A1014
RM7838A2014
Functions provided by the RM7838A include semi-
automatic on/off 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:
Form Number
32-00110
S7800A2142 4-line LCD Keyboard
Display Module Product Data
32-00160
Tester for 2000 Series Flame Relays
A7800A2010, (accommodates
grounding pin)
32-00166
204729A/C KDM NEMA4 Covers for
4-line LCD KDM
32-00235
R7824, R7847, R7848, R7849, R7851,
R7861, R7886 Flame Amplifiers for
the 7800 SERIES Product Data (for CE,
Modbus module S7810M1029 only)
65-0084
Q7800A,B 22-Terminal Wiring
Subbase Product Data.
65-0089
ST7800A,C Plug-In Purge Timer
Installation Instructions.
65-0090
S7800A 2-line VFD Keyboard Display
Module Product Data.
Description
SIL
3
Capable
INSTALLATION INSTRUCTIONS
Form Number
65-0091
S7810A Data ControlBus Module™
Product Data.
65-0101
S7830 Expanded Annunciator Product
Data.
65-0131
221818A Extension Cable Assembly
Product Data.
65-0229
7800 Series Relay Modules Checkout
and Troubleshooting Product Data.
65-0295
50023821-001/2 NEMA4 Covers for
2-line Keyboard Display Module
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: 15A maximum, type SC
fast blow or equivalent.
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, noncon-
densing.
Vibration: 0.5G environment.
SIL 3 Capable:
SIL 3 Capable in a properly designed Safety Instrumented
System. See form number 65-0312-04 for Certificate
Agreement.
Approvals:
cULus Underwriters Laboratories Inc. Listed: File No.
MP268. ANSI/UL 60730-2-5 / CSA C22.2 No. 60730-
2-5 - Automatic Electrical Controls for Household and
Similar Use, Part 2-5: Particular Requirements for
Automatic Electrical Burner Control Systems
FM Factory Mutual Approved: Report No. 1V9A0.AF.
Swiss Re (formerly Industrial Risk Insurers): Acceptable.
FCC Federal Communications Commission: Part 15, Class
B, Emissions.
Description
32-00213-01
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Table of Contents
Related Manuals for Honeywell 7800 Series
Summary of Contents for Honeywell 7800 Series
- Page 1 32-00235 R7824, R7847, R7848, R7849, R7851, Approvals: R7861, R7886 Flame Amplifiers for the 7800 SERIES Product Data (for CE, cULus Underwriters Laboratories Inc. Listed: File No. Modbus module S7810M1029 only) MP268. ANSI/UL 60730-2-5 / CSA C22.2 No. 60730- 2-5 - Automatic Electrical Controls for Household and...
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Page 2: Installation
7800 SERIES RELAY MODULES SIL 3 capable Exida: IEC/EN 61508:2010 Parts 1-7, SIL 3 WARNING capable. CSD Control Safety Devices: Acceptable CSD-1 Fire or Explosion Hazard.Can cause property EAC: TC N RU д-US.Aи3O.B.04013 damage, severe injury, or death. Verify safety requirements each time a control is installed on a burner. -
Page 3: Mounting Wiring Subbase
7800 SERIES RELAY MODULES Vibration Subbase Compatibility Any Relay Module in the 1000 Series with a Software Do not install the relay module where it could be subjected Revision level number starting with a "5" or greater will be to vibration in excess of 0.5G continuous maximum compatible with all subbase models both installed and vibration. - Page 4 7800 SERIES RELAY MODULES d. Do not route flame detector, Data ControlBus Follow directions in flame detector, Data Control- Module™ or remote reset module leadwires in Bus Module™ or remote reset module instruc- conduit with line voltage circuits. tions. e. Enclose flame detector leadwires without armor cable in metal cable or conduit.
- Page 5 7800 SERIES RELAY MODULES NOTE: A 13 Vdc power supply must be used any time more than one keyboard display module is used. Table 2. Recommended Grounding Practices. A maximum of two keyboard display modules or Data ControlBus Modules™ are allowed in any...
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Page 6: Final Wiring Check
7800 SERIES RELAY MODULES Table 3. Terminal Ratings Table 4. Combinations for Terminals 8, 9 and 10. Terminal No. Description Ratings Pilot Fuel 8 Main 9 Ignition 10 Flame Sensor No Load Ground No Load Earth G Earth Ground L2(N) -
Page 7: Equipment Recommended
7800 SERIES RELAY MODULES General Instructions WARNING 1. Perform all applicable tests listed in Static Checkout, Explosion Hazard.Can cause explosion, electrical Table 7, in the order listed. shock or equipment damage. 2. Make sure all manual fuel shutoff valves are closed. - Page 8 7800 SERIES RELAY MODULES Table 6. Static Checkout Test Test Voltmete If Operation is Abnormal, Jumpers Normal Operation Check the Items Listed Below Automatic main fuel 1. Listen for and observe operation of the main fuel valve(s) valve(s) opens. and actuator(s).
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Page 9: Mounting Other System Components (Fig. 3)
7800 SERIES RELAY MODULES Mounting Other System Components (Fig. 3) Refer to the applicable specifications for mounting other system components. Q7800 SUBBASE (HOT) MASTER BURNER SWITCH CONTROL ALTERNATE CONNECTION WHEN USING THE R4155A ALARM 120V ALARM SILENCING RELAY. THE Q7800... -
Page 10: Principal Technical Features
7800 SERIES RELAY MODULES SUBBASE (Q7800A1005 plastic panel mount version) 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 FLAM E MAIN ALARM CAPTIVE... -
Page 11: Operation
7800 SERIES RELAY MODULES a. Intermittent pilot valve/1st stage oil terminal is Normal Start-Up Purge not energized. Closing the burner control switch energizes the b. Main valve terminal is not energized. combustion fan and provides power to terminal 7 through c. -
Page 12: Settings And Adjustments
7800 SERIES RELAY MODULES 4. The alarm, terminal 3, is de-energized during RUN and energized when shutdown occurs. SELECTABLE CONFIGURATION JUMPER Keyboard Display Module (KDM) 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. -
Page 13: Safety And Security
7800 SERIES RELAY MODULES SAFETY AND SECURITY Physical device protection Device shall be accessible to authorized personnel only – Installation on publicly accessible places is not recommended as this could lead to unwanted and potentially unsafe changes to device (wiring, configuration, etc). - Page 14 7800 SERIES RELAY MODULES 32-00213—01...
- Page 15 7800 SERIES RELAY MODULES 32-00213—01...
- Page 16 7800 SERIES RELAY MODULES For More Information The Honeywell Thermal Solutions family of products includes Honeywell Combustion Safety, Eclipse, Exothermics, Hauck, Kromschröder and Maxon. To learn more about our products, visit ThermalSolutions.honeywell.com or contact your Honeywell Sales Engineer. Honeywell Process Solutions...