Honeywell 7800 Series Installation Instructions Manual
100 vac relay modules
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- Product data (64 pages) ,
- Manual (56 pages) ,
- Installation instructions manual (40 pages)
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RM7890, RM7895 100 Vac
7800 SERIES Relay Modules
APPLICATION
The Honeywell RM7890B, RM7895A Relay Modules are mi-
croprocessor based integrated burner controls for automat-
ically fired gas, oil or combination fuel single burner On/Off
applications. The RM7890B; RM7895A System consists of
the relay module, wiring subbase, amplifier and the RM7895A
also requires a purge timer. Options include Keyboard Display
Module (KDM), Data ControlBus™ Module, remote display
mounting and Modbus communications is available using the
S7810M Modbus Module or configuring the S7800 KDM.
The RM7890; RM7895 is programmed to provide a level of
safety, functional capability and features beyond the capacity
of conventional controls.
This document covers the following models:
RM7890B1063
RM7895A1089
CONTENTS
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
OPTIONAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PRINCIPAL TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . .6
SAFETY PROVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
The RM7890, RM7895 provides on/off automatic burner se-
quencing, flame supervision, system status indication, system
or self-diagnostics and troubleshooting. The RM7895 in-
cludes an output for the blower motor to provide purging.
This document provides installation and static checkout in-
structions. Other applicable publications are:
Form
number
65-0249
65-0084
65-0090
65-0091
65-0095
65-0097
65-0109
65-0295
32-00110 4-line LCD KDM S7800A2142
32-00166 NEMA4 covers for 4-line KDM, 204729A w/o
65-0131
65-0229
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INITIATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
STANDBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STATIC CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SAFETY AND SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3
SIL
Capable
INSTALLATION INSTRUCTIONS
Table 1. Other applicable publications.
Description
S7810M Modbus Module
Q7800A,B 22-Terminal Wiring Subbase Product
Data
S7800A 2-line VFD Keyboard Display Module
Product Data.
S7810A Data ControlBus Module™ Product Data
S7820 Remote Reset Module Product Data
221729C Dust Cover Packing Sheet
R7824, R7847, R7848, R7849, R7851, R7852,
R7861, R7886 Flame Amplifiers for the 7800
SERIES Product Data
NEMA4 covers for 2-line VF KDM, 50023821-
001 w/o reset, 50023821-002 with reset
reset, 204729B with reset
221818A Extension Cable Assembly Product
Data
7800 SERIES Relay Modules Checkout and
Troubleshooting
32-00216-01
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Table of Contents
Related Manuals for Honeywell 7800 Series
Summary of Contents for Honeywell 7800 Series
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Page 1: Table Of Contents
S7810A Data ControlBus Module™ Product Data APPLICATION 65-0095 S7820 Remote Reset Module Product Data The Honeywell RM7890B, RM7895A Relay Modules are mi- 65-0097 221729C Dust Cover Packing Sheet croprocessor based integrated burner controls for automat- ically fired gas, oil or combination fuel single burner On/Off... -
Page 2: Features
• Flame failure response time . Manufacturing code . Miscellaneous • On/Off status of all digital inputs and outputs . A7800A1002 7800 SERIES Tester • Software revision and version of RM7890/ RM7895 S7820A1007 Remote Reset Module and optional Keyboard Display Module . - Page 3 RM7890, RM7895 100 Vac 50023821-001 2-Line Keyboard Display Module Cover, NEMA 4, clear 50023821-002 2-Line Keyboard Display Module Cover, NEMA 4, clear with reset button 205321B Flush Display Mounting Kit. Display Module Cover for 4-line LCD: 204729A w/o reset button, 204729C with reset button 221818A Extension Cable, display, 5 ft (1.52 m) 221818C Extension Cable, display, 10 ft (3.05 m)
- Page 4 RM7890, RM7895 100 Vac Table 3. Combinations for terminals 8, 9 and 10. Pilot Valve (Terminal 8) Main Fuel Valve (Terminal 9) Ignition (Terminal 10) No Load No Load No Load Table 4. Composition of Each Combination. 4.5A ignition 50 VA Pilot Duty plus 180 VA ignition plus 2A Pilot Duty 65 VA Pilot Duty plus...
- Page 5 RM7890, RM7895 100 Vac Table 5. Flame Detection Systems. Plug-in Flame Signal Amplifiers Applicable Flame Detectors Type Color Self-Checking Model Flame Failure Fuel Type Models Response Time Rectification Green R7847A 0.8 or 3.0 sec. Rectifying C7004, C7007, C7011. Flame Rod Complete Assemblies: Holders C7008, C7009, Q179...
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Page 6: Principal Technical Features
RM7890, RM7895 100 Vac Table 6. Sequence Timing for Normal Operation. Device Initiate Standby Purge Pilot Flame Establishing Period RM7890 10 sec. — 4 or 10 sec. — RM7895 10 sec. — — 4 or 10 sec. — Standby and Run can be an infinite time period. Purge is determined by the ST7800 Purge Timing Card selected (RM7895 only). -
Page 7: Installation
RM7890, RM7895 100 Vac Dynamic Safety Relay Test Self-Diagnostics add to the First-Out Annunciation by allow- ing the relay module to distinguish between field (external Checks the ability of the dynamic safety relay contact to open device) and internal (system related) problems. Faults asso- and close. - Page 8 RM7890, RM7895 100 Vac 5 . Limits and interlocks must be rated to simultaneously 204718A Remote Display Cover Assembly or other suitable carry and break current to the ignition transformer, pilot enclosure that meets IP40 class of protection. valve, and main fuel valve(s). Relay Module and Subbase Compatiblity 6 .
- Page 9 RM7890, RM7895 100 Vac 3 . For surface mounting, use the back of the subbase as a NOTE: You might receive and error code 101 (via KDM) check template to mark the four screw locations. Drill the pilot the screws securing the relay to the subbase to check holes.
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Page 10: Wiring
RM7890, RM7895 100 Vac Fig. 5. Internal block diagram of the RM7895 Relay Module (see Fig. 7 for detailed wiring instructions). 2 . For proper remote wiring of the KDM, refer to the Specifi- WIRING cations for the 2-line VFD KDM (65-0090), the 4-line LCD KDM (32-00110), Network Data ControlBus™... - Page 11 RM7890, RM7895 100 Vac Fig. 6. Wiring the RM7890 Relay Module. Table 7. Recommended Wire Sizes and Part Numbers. Application Recommended Wire Size Recommended Part Numbers Line voltage terminals 14, 16 or 18 AWG copper conductor, TTW60C, THW75C, THHN90C. 600 volt insulation, moisture-resistant wiring.
- Page 12 RM7890, RM7895 100 Vac Fig. 7. Wiring the RM7895E,F Relay Module. 6 . For recommended grounding practices, see Table 8. Table 8. Recommended Grounding Practices. Ground Type Recommended Practice Earth ground (subbase and relay module). 1 . Use to provide a connection between the subbase and the control panel of the equipment.
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Page 13: Assembly
RM7890, RM7895 100 Vac c . KDM: The KDM is powered from a low voltage, ener- a . Allow an additional two inches (51 mm) below the relay gy-limited source, so it can be mounted outside of the module for the flame amplifier mounting. b . - Page 14 RM7890, RM7895 100 Vac Proper flame detector installation is the basis of a safe and reliable flame safeguard installation. Refer to the instructions packed with the flame detector and the equipment manufac- turer instructions. Keep the flame signal leadwires as short as possible from the flame detector to the wiring subbase.
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Page 15: Operation
RM7890, RM7895 100 Vac Fig. 13. RM7890 sequence. Fig. 14. RM7895 sequence. OPERATION Sequence of Operation The relay modules have operating sequences as shown in Fig. 13 through 15. INITIATE The relay module enters the INITIATE sequence if the relay module verifies voltage fluctuations of +10%/-15% or fre- quency fluctuations of ±10% during any part of the operating sequence. -
Page 16: Standby
RM7890, RM7895 100 Vac condition is not corrected and the hold condition exists for 2 . Flame must be proven by the end of the 4- or four minutes, the relay module locks out. Causes for hold con- 10-second PFEP to allow the sequence to continue. If ditions in the INITIATE sequence are: flame is not proven by the end of PFEP, a safety shutdown occurs. -
Page 17: Static Checkout
RM7890, RM7895 100 Vac Table 10. Site-Configurable Jumper Options (RM7895). Jumper Number Description Intact Clipped Pilot Flame Establishing Period 10 seconds 4 seconds Flame Failure Action Recycle Lockout Airflow Switch (ILK) Failure Recycle Lockout Equipment Recommended STATIC CHECKOUT 1 . Voltmeter (one megohm/volt minimum sensitivity), set on WARNING the 0 to 300 Vac scale. - Page 18 RM7890, RM7895 100 Vac Table 11. RM7890 Static Checkout. Test Number Test Voltmeter Normal Operation If Operation is Abnormal, Check the Items Jumpers Listed Below WARNING Explosion Hazard. Can cause severe injury, death or property damage. Make sure that all manual fuel shutoff valves are closed. IMPORTANT Low fuel pressure limits, if used, could be open.
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Page 19: Checkout
RM7890, RM7895 100 Vac Table 12. RM7895 Static Checkout. If Operation is Abnormal, Check the Items Test Number Test Jumpers Voltmeter Normal Operation Listed Below WARNING Explosion Hazard. Can cause severe injury, death or property damage. Make sure that all manual fuel shutoff valves are closed. IMPORTANT Low pressure fuel limits, if used, could be open. - Page 20 RM7890, RM7895 100 Vac 3 . Initial lightoff check for proved pilot, all installations using WARNING a pilot. 4 . Initial lightoff check for direct spark ignition (DSI) of oil, all Explosion Hazard. burners using DSI. Can cause severe injury, death or property damage. Use extreme care while testing the system.
- Page 21 RM7890, RM7895 100 Vac Initial Lightoff Check for Proved Pilot Perform this check immediately following the preliminary in- spection on all installations that use a pilot: NOTE: Low fuel pressure limits, if used, could be open; if so, bypass with jumpers during this check . 1 .
- Page 22 RM7890, RM7895 100 Vac 8 . When the pilot ignites, measure the flame signal. If the NOTE: Upon completing these tests, open the master switch pilot flame signal is unsteady or approaching the 1.25 and remove all test jumpers from the subbase termi- nals, limits/controls or switches .
- Page 23 RM7890, RM7895 100 Vac 17 . If used, remove the bypass jumpers from the low fuel pres- NITION or the RM7895 to recycle through PREPURGE. sure limit and subbase. If the Flame Failure Action jumper is clipped: push the reset pushbutton and allow the RM7890D to recycle to 18 .
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Page 24: Troubleshooting
10 . If the detector is relocated or the amplifier is replaced, re- annunciated by a lockout of the relay module that energizes peat all required Checkout tests. the ALARM LED. Refer to the 7800 SERIES Relay Modules Checkout and Troubleshooting, form 65-0229 for additional Safety Shutdown Tests (All Installations) information. - Page 25 RM7890, RM7895 100 Vac Diagnostic Information Index Historical Information Index The relay module with the optional KDM can monitor input/ The relay module has nonvolatile memory that allows it to output terminals and can display the status of the terminal on retain historical information for the six most recent lockouts.
- Page 26 RM7890, RM7895 100 Vac SERVICE NOTE: SERVICE NOTE: A lockout condition or restart of a relay module can be accom- Remove the access slot covers on the sides of the Q7800 Wir- plished by pressing the reset pushbutton on the relay module ing Subbase to check voltages.
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Page 27: Safety And Security
RM7890, RM7895 100 Vac Table 14. Sequence and Status Hold Information. (Continued) Sequence Information PILOT IGN The LED indicates the burner status, POWER, PILOT, and FLAME, which is the period of time the relay module permits the pilot valve and ignition to be energized and the pilot flame to be established. - Page 28 RM7890, RM7895 100 Vac 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...