Honeywell 7800 Series Installation Instructions Manual

Relay modules

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Product data (64 pages)

Manual (56 pages)

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EC7830A, RM7830A,

EC7850A, RM7850A

7800 SERIES Relay Modules

APPLICATION

The Honeywell EC/RM7830A and EC/RM7850A are

microprocessor-based integrated burner controls for

automatically fired gas, oil, or combination fuel single

burner full modulation (EC/RM7850A) or on/off

(EC/RM7830A) applications. The EC/RM7830A;

EC/RM7850A system consists of a relay module, subbase,

amplifier, and purge card. Options include keyboard

display module (KDM), Data ControlBus™ Module and

remote display mounting.

Functions provided by the EC/RM7830A and

EC/RM7850A include automatic burner sequencing,

flame supervision, system status indication, system or

self-diagnostics and troubleshooting. Text readout on the

Keyboard Display Module is available in various

languages.

This document covers the following 7800 Series Relay

Modules:

EC7830A1033

EC7830A1066

EC7850A1072

EC7850A1080

EC7850A1122

RM7830A1003

RM7830A1029

RM7850A1001

RM7850A1019

EC7830A2033

EC7830A2066

EC7850A2072

EC7850A2080

EC7850A2122

RM7830A2003

RM7830A2029

RM7850A2001

RM7850A2019

SIL

Capable

0063

INSTALLATION INSTRUCTIONS

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

32-00166

204729A/C KDM NEMA4 Covers for 4-line

LCD KDM

32-00235

R7824, R7847, R7848, R7849, R7861,

R7886 Flame Amplifiers for the 7800

SERIES Product Data

65-0084

Q7800A,B 22-Terminal Wiring Subbase

Product Data

65-0090

S7800A 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 Packing Instructions

65-0131

221818A Extension Cable Assembly

Product Data

65-0228

S7810B Multi-Drop Switch Module

Product Data

65-0229

7800 SERIES Relay Modules Checkout

and Troubleshooting Product Data

65-0249

S7810M ModBus Module (For CE ,

Modbus module S7810M1029 only).

65-0295

50023821-001/2 KDM NEMA4 Covers for

classic 2-line VFD KDM

Description

32-00198-01

Table of Contents

Summary of Contents for Honeywell 7800 Series

Page 1 Text readout on the Data Keyboard Display Module is available in various languages. 65-0091 S7810A Data ControlBus™ Module Product Data This document covers the following 7800 Series Relay 65-0095 S7820 Remote Reset Module Product Modules: Data 65-0097 221729C Dust Cover Packing Instructions...
Page 2: Specifications
EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES SPECIFICATIONS INSTALLATION Electrical Ratings (See Tables 3A, 3B, 3C and 3D): When Installing this Product… Voltage and Frequency: RM7830A and RM7850A: 1. Read these instructions carefully. Failure to follow 120 Vac (+10/-15%), 50/60 Hz (±10%).
Page 3: Mounting Wiring Subbase
EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES 8. Two flame detectors can be connected in parallel Mounting Wiring Subbase with the exception of C7915 Infrared Flame Detec- 1. Mount the subbase in any position except tors, C7927 or C7961 Ultraviolet Flame Detectors horizontally with the bifurcated contacts pointing and C7962 Visible Light Detector.
Page 4: Wiring Subbase
EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES Any relay module in the new 2000 series will only be able 3. Disconnect the power supply from the main discon- to be installed on subbase Q7800A2005/U, nect before beginning installation to prevent electri- Q7800B2003/U and will not be backward compatible with cal shock and equipment damage.
Page 5 EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES HOT N PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST JACK FLAME SIGNAL RUN/TEST SWITCH PLUG-IN MICROCOMPUTER FLAME RESET AMPLIFIER PUSHBUTTON SHUTTER RELAY DRIVE CIRCUIT RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS SAFETY RELAY...
Page 6 EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES HOT N PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN MICROCOMPUTER FLAME AMPLIFIER RESET SHUTTER PUSHBUTTON RELAY DRIVE CIRCUIT RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS SAFETY RELAY...
Page 7 EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES Q7800 LEGEND ALARM (NORMALLY OPEN) PREIGNITION INTERLOCK INPUT BURNER/BLOWER MOTOR IGNITION LINE VOLTAGE SUPPLY (L1) LOCKOUT INPUT AIRFLOW SWITCH INPUT MAIN FUEL VALVE PILOT VALVE 1 (INTERRUPTED) PILOT VALVE 2 (INTERMITTENT) LIMITS AND BURNER...
Page 8 EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES SERIES 90 LEGEND SERIES 90 FIRING RATE ALARM CONTROLLER Q7800 MOTOR (NORMALLY OPEN) HIGH FIRE LOW FIRE SWITCH INPUT COMMON PREIGNITION INTERLOCK INPUT MODULATE HIGH FIRE SWITCH INPUT LOW FIRE BURNER/BLOWER (L1)
Page 9: Final Wiring Check
EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES Table 1. Recommended Wire Sizes and Part Numbers. Application Recommended Wire Size Recommended Part Numbers Line Voltage Terminals TTW60C, THW75C, THHN90C. 14, 16, or 18 AWG (0.75, 1.5 or 2.5 mm ) copper conductor, 600 volt insulation, moisture-resistant wire.
Page 10: Static Checkout
See Table 2. Honeywell has tested this output at 9.8A at PF = 0.5, 58.8A inrush for 100,000 cycles (EN298 approval does not require this test). 2000 VA maximum connected load to relay module.
Page 11 See Table 2. 2000 VA maximum connected load to relay module. Honeywell has tested this output at 9.8A at PF = 0.5, 58.8A inrush for 100,000 cycles (EN298 approval does not require this test). Total load current, excluding Burner/Boiler Motor and Firing Rate Outputs cannot exceed 5A, 25A inrush.
Page 12: Equipment Recommended
EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES 3. Replace all limits and interlocks that are not operat- WARNING ing properly. Do not bypass limits and interlocks. Fire or Explosion Hazard. Equipment Recommended Can cause severe injury, death, or property damage.
Page 13 EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES Table 5. EC/RM7830A Static Checkout. (Continued) Test Test If Operation is Abnormal, Check the Items Jumpers Voltmeter Normal Operation Listed Below — 1. Ignition spark (if ignition trans- 1. Watch for spark or listen for buzz.
Page 14: Principal Technical Features
EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES Table 6. EC/RM7850A Static Checkout. (Continued) Test Test Jumper Voltmeter Normal Operation If Operation is Abnormal, Check These Items 4-21 — Same test as no. 4 for connections to Same as test no. 4. If using direct spark ignition, terminal 8.
Page 15: Sequence Of Operation
EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES c. High Fire Switch fails to close within five minutes g. Pilot valve is energized during MAIN TRIAL after the firing rate motor is commanded to drive stabilization. to high fire position at start of purge h.
Page 16 EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES Normal Start-Up Purge The relay module provides PURGE timing selectable from 1. The firing rate motor releases to modulation. two seconds to thirty minutes with power applied and the 2. The relay module is now in RUN and remains in RUN operating control indicating a call for heat.
Page 17: Settings And Adjustments
EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES SETTINGS AND reads the settings of these configuration jumpers at startup. After 200 hours of main valve operation, the relay ADJUSTMENTS module locks the jumper settings into internal memory. If these jumpers are changed after the 200 hours occur, the relay module locks out.
Page 18: Safety And Security
EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES SAFETY AND SECURITY RUN/TEST SWITCH SELECTABLE CONFIGURATION JUMPERS 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 19 EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES 32-00198—01...
Page 20 EC7830A, RM7830A, EC7850A, RM7850A 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 7800 Series Installation Instructions Manual

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