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Honeywell 7800 Series Manual
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Honeywell 7800 Series Manual

Relay module
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7800 SERIES RM7895A,B,C,D
The Honeywell RM7895 is a microprocessor based
integrated burner control for automatically fired gas, oil,
or combination fuel single burner applications. The
RM7895 consists of the Relay Module. Subbase, Amplifier
and Purge Card are required to complete the system.
Options include Keyboard Display Module, Personal
Computer Interface, DATA CONTROLBUS MOD-
ULE™, Remote Display Module, First-Out Expanded
Annunciator and COMBUSTION SYSTEM MANAGER™
Software.
The RM7895 is programmed to provide a level of
safety, functional capability and features beyond the ca-
pacity of conventional controls.
Functions provided by the RM7895 include automatic
burner sequencing, flame supervision, system status indi-
cation, system or self-diagnostics and troubleshooting.
Safety features:
- Airflow switch check.
- Closed loop logic test.
- Dynamic AMPLI-CHECK™.
- Dynamic input check.
- Dynamic safety relay test.
- Dynamic self-check logic.
- Internal hardware status monitoring.
- Tamper resistant timing and logic.
Access for external electrical voltage checks.
Airflow switch check feature (RM7895B,D).
Application flexibility.
Communication interface capability.
Delayed main valve (RM7895C,D).
Dependable, long-term operation provided by microcom-
puter technology.
Early spark termination (RM7895A1048 and RM7895C1020).
First-out annunciation and system diagnostics provided by
a 2 row by 20 column Vacuum Fluorescent Display (VFD)
located on the optional Keyboard Display Module (optional).
First-out expanded annunciation with 26 Light Emitting
Diodes (LEDs) for limits and interlocks (optional).
Five (LEDs) for sequence information.
Two function Run/Test Switch (RM7895C,D).
Interchangeable plug-in flame amplifiers.
Local or remote annunciation of RM7895 operation and
fault information.
Nonvolatile memory; RM7895 retains history files and
sequencing status after loss of power.
Remote reset (optional).
Report generation (optional).
Selectable recycle or lockout on loss of airflow.
Selectable recycle or lockout on loss of flame.
Shutter drive output.
Burner controller data (optional):
- Expanded annunciator status.
- Flame signal strength.
- Hold status.
Relay Module
- Lockout/alarm status.
- Sequence status.
- Sequence time.
- Total cycles of operation.
- Total hours of operation.
- Fault history providing for the six most recent faults:
• Cycles of operation at the time of the fault.
• Expanded annunciator data at the time of the fault.
• Fault message and code.
• Hours of operation at the time of the fault.
• Sequence status at the time of the fault.
• Sequence time at the time of the fault.
- Diagnostic information:
• Device type.
• Flame amplifier type.
• Flame failure response time.
• Manufacturing code.
• On/Off status of all digital inputs and outputs.
• Selected prepurge time.
• Software revision and version of RM7895 and op-
tional Keyboard Display Module.
• Status of configuration jumpers.
• Status of Run/Test Switch (RM7895C,D).
CONTENTS
Specifications ................................................ 2
Ordering Information .................................... 2
Principal Technical Features ........................ 8
Safety Provisions ........................................... 9
Installation .................................................. 10
Wiring .......................................................... 12
Assembly ...................................................... 15
Operation .................................................... 18
Checkout ...................................................... 22
Troubleshooting .......................................... 28
B. M. • Rev. 9-93 • ©Honeywell Inc. 1993 • Form Number 65-0086-2
1
65-0086-2

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  • Page 1: Table Of Contents

    Shutter drive output. Operation ............ 18 Burner controller data (optional): — Expanded annunciator status. Checkout ............22 — Flame signal strength. Troubleshooting .......... 28 — Hold status. B. M. • Rev. 9-93 • ©Honeywell Inc. 1993 • Form Number 65-0086—2 65-0086—2...

  • Page 2: Specifications

    Can also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold. Ordering Information When purchasing replacement and modernization products from your 7800 SERIES distributor, refer to the TRADELINE® Catalog for complete ordering number.
  • Page 3 Sensitivity) Order flame rod separately; see holder Instructions. Use only Honeywell Photocell, part no. 38316. The C7012A,C, C7027, C7035 and C7044 Flame Detectors should be used only on burners that cycle on-off at least once every twenty-four hours. Appliances with burners that remain on continuously for twenty-four hours or longer should use the C7012E,F Flame Detector with the R7847C Amplifier or the C7076A,D Flame Detector with the R7886A Amplifier as the ultraviolet flame detection system.
  • Page 4 RM7895A,B,C,D SPECIFICATIONS SEQUENCE TIMING FOR NORMAL OPERATION: Flame Establishing Period Device Initiate Standby Purge Pilot Main AFSC RM7895A 10 sec. 4 or 10 sec. RM7895B 10 sec. 4 or 10 sec. RM7895C 10 sec. 4 or10 sec. 10 sec. RM7895D 10 sec.
  • Page 5 RM7895A,B,C,D SPECIFICATIONS Fig. 2—Mounting dimensions of RM7895 Relay Module and Q7800B Subbase in inches [millimeters]. BURNER CONTROL [127] POWER PILOT FLAME MAIN ALARM RESET [155] 5 [127] REMOVE ONLY FOR TERMINAL TEST ACCESS. M5004B Fig. 3—Rectification detectors. IGNITION ELECTRODE FLAME ROD (Q179C ONLY) CERAMIC INSULATORS...
  • Page 6 RM7895A,B,C,D SPECIFICATIONS Fig. 4—Ultraviolet detectors. [105] 2 [51] 1/2-14 NPSM 4 [102] COLLAR WITH 6 FOOT [1.83 METER] 1–11-1/2 NPSM INTERNAL THREADS LEADWIRES (2) [89] INTERNAL THREADS [30] [27] [25] [38] 6 FOOT COLLAR WITH 1/2-14 NPSM [67] [1.83 METER] INTERNAL THREADS INSERTION DEPTH LEADWIRES (2) 3...
  • Page 7 RM7895A,B,C,D SPECIFICATIONS Fig. 4—Ultraviolet detectors (Continued). [300] 1 INCH NPT [198] [147] 15/16 [24] DIA. [55] [47] [158] [147] [64] [168] 1 [25] 15/16–18 UNC (2 EACH) 2 [51] C7076D M5084 Fig. 5—Infrared detector. CELL MOUNT HEAT BLOCK [41] [27] [70] [32] [32]...

  • Page 8: Principal Technical Features

    RM7895A,B,C,D PRINCIPAL TECHNICAL FEATURES Principal Technical Features The RM7895 provides all customary flame safeguard 4. PILOT FLAME ESTABLISHING PERIOD (PFEP) functions while providing significant advancements in the a. Airflow lockout feature is enabled and the air- areas of safety, annunciation and system diagnostics. flow switch opens.

  • Page 9: Safety Provisions

    RM7895A,B,C,D SAFETY PROVISIONS Safety Provisions INTERNAL HARDWARE STATUS MONITORING EXPANDED SAFE-START CHECK The RM7895 checks the purge card for correct parity to The conventional safe-start check, which prevents burner prevent purge timing shifts and circuitry failures. It also start-up if flame is indicated at start-up, is expanded to include analyzes the integrity of the configuration jumpers and a flame signal check during STANDBY, an airflow switch internal hardware.

  • Page 10: Installation

    Plug-in Purge Card are isolated and reported by the optional card timing; otherwise, a recycle to the beginning of PRE- Keyboard Display Module. See the 7800 SERIES System PURGE or lockout will occur, depending on how the Annunciation Diagnostics and Troubleshooting, form 65- airflow switch selectable jumper is configured (see Table 3 0118.
  • Page 11 RM7895A,B,C,D INSTALLATION Fig. 6—Internal block diagram of the RM7895 (see Figs. 7 and 8 for detailed wiring instructions). (HOT) 120 Vac PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST SWITCH PLUG-IN MICROCOMPUTER FLAME AMPLIFIER TEST RESET PUSHBUTTON RELAY RELAY STATUS...

  • Page 12: Wiring

    RM7895A,B,C,D INSTALLATION • WIRING MOUNTING WIRING SUBBASE sure to allow adequate clearance for servicing, instal-lation, access and removal of the RM7895, Dust Cover, flame NOTE: For installation dimensions, see Figs. 1 or 2. amplifier, flame amplifier signal voltage probes, Run/Test Switch, electrical signal voltage probes and electrical field 1.
  • Page 13 RM7895A,B,C,D WIRING Fig. 7—Wiring the RM7895A,B. Q7800 120V ALARM BURNER MOTOR (BLOWER) BURNER CONTROLLER/LIMITS AIRFLOW INTERLOCK INTERMITTENT PILOT/IGNITION MAIN FUEL VALVE(S) IGNITION RECTIFYING FLAME ROD, RECTIFYING (HOT) PHOTOCELL, OR INFRA- RED (LEAD SULFIDE) MASTER FLAME DETECTOR SWITCH C7027A, C7035A, OR FOR DIRECT SPARK IGNITION (OIL WHITE BLUE...
  • Page 14 RM7895A,B,C,D WIRING Fig. 8—Wiring the RM7895C,D. Q7800 120V ALARM BURNER MOTOR (BLOWER) BURNER CONTROLLER/LIMITS AIRFLOW INTERLOCK 10 SEC. INTERRUPTED PILOT/IGNITION MAIN FUEL VALVE(S) DELAYED IGNITION MAIN VALVE RECTIFYING FLAME ROD, RECTIFYING (HOT) PHOTOCELL, OR INFRA- RED (LEAD SULFIDE) MASTER FLAME DETECTOR SWITCH C7027A, C7035A, OR BLUE...

  • Page 15: Assembly

    RM7895A,B,C,D ASSEMBLY Assembly MOUNTING RM7895 Fig. 10—Wall or burner installation. NOTE: For installation dimensions, see Figs. 1 or 2. RELAY MODULE MOUNTING 1. Mount the RM7895 vertically, see Figs. 9 or 10, or mount horizontally with the knife blade terminals pointing downward.
  • Page 16 RM7895A,B,C,D ASSEMBLY 5. Reinstall the Dust Cover, Keyboard Display Module, DATA CONTROLBUS MODULE™ or Extension Cable Fig. 13—Flame signal amplifier mounting. Assembly onto the RM7895 and restore power to the device. Run the burner system through at least one complete cycle to verify the system is operating as desired.
  • Page 17 SENSOR WHITE EARTH GROUND BROWN SHUTTER C7076A C7076D SHUTTER TERMINAL BLOCK ULTRAVIOLET (C7027/C7035/C7044) L1 (HOT) L2 (COMMON) BLUE 7800 SERIES WHITE SOLID STATE SELF-CHECKING SOLID STATE ULTRAVIOLET (C7012E,F) ULTRAVIOLET (C7012A,C) BLUE BLUE YELLOW YELLOW WHITE WHITE BLACK BLACK BLACK BLACK...

  • Page 18: Operation

    RM7895A,B,C,D OPERATION Operation Sequence of Operation NORMAL START-UP The RM7895 has the following operating sequences, PREPURGE see Figs. 15, 16 and 18. The RM7895 provides a selectable PREPURGE timing from two seconds to 30 minutes with power applied and INITIATE the RM7895 operating control indicating a call for heat.
  • Page 19 RM7895A,B,C,D OPERATION Fig. 16—RM7895C,D sequence. TIMED PFEP PURGE 4 OR 10 SEC INITIATE STANDBY START MFEP STANDBY POWER POWER POWER POWER POWER POWER POWER POWER DISPLAY PILOT PILOT PILOT PILOT FLAME FLAME FLAME FLAME MAIN MAIN MAIN MAIN ALARM ALARM ALARM ALARM BURNER...
  • Page 20 RM7895A,B,C,D OPERATION See Table 6 for further details of Hold conditions. NOTE: When the RM7895C,D is switched to the TEST mode, it stops and holds at the next Run/Test Switch RUN/TEST SWITCH FUNCTIONS point in the operating sequence. MAKE SURE THAT The Run/Test Switch is located on the top side of the THE RUN/TEST SWITCH IS IN THE RUN POSITION RM7895C,D, see Fig.
  • Page 21 RM7895A,B,C,D OPERATION GENERAL INSTRUCTIONS 8. If there is no voltage or the operation is abnormal, 1. Perform all applicable tests listed in Static Checkout, check the circuits and external devices as described in the Table 5, in the order listed. last column.

  • Page 22: Checkout

    If an RM7895 is replaced with a lower or higher 5. Burner is completely installed and ready to fire; con- functioning 7800 SERIES Relay Module, the sult equipment manufacturer instructions. Fuel lines are burner will not sequence unless wiring changes purged of air.
  • Page 23 RM7895A,B,C,D CHECKOUT FLAME SIGNAL MEASUREMENT (Fig. 20 and Table 5) TABLE 5—FLAME SIGNAL. Minimum Flame Acceptable Maximum Detector Flame Signal Amplifier Steady DC Voltage Expected DC Voltage Flame Rod R7847A,B 1.25 Vdc 5.0 Vdc at the Keyboard Photocell Display Module C7012A,C C7012E,F R7847C...
  • Page 24 RM7895A,B,C,D CHECKOUT INITIAL LIGHTOFF CHECK FOR PROVED PILOT l. Reinstall the RM7895 on the subbase and close Perform this check on all installations that use a pilot. the master switch, then return to step 4. It should immediately follow the preliminary inspection. 7.
  • Page 25 RM7840E,G,L,M CHECKOUT 21. Return the system to normal operation. sure the burner flame goes out and make sure all automatic 22. Make sure all readings are in the required ranges be- fuel valve(s) close. fore proceeding. 17. If used, remove the bypass jumpers from the low fuel pressure limit and subbase.
  • Page 26 RM7895A,B,C,D CHECKOUT NOTE: INTERMITTENT PILOT MODELS should con- 9. Repeat step 8 to verify the pilot gas pressure reading tinue with step 6. INTERRUPTED PILOT MODELS at the exact point the FLAME LED light goes out. should proceed to step 7. 10.
  • Page 27 The refrac- NOTE: The Honeywell Q624A Solid State Spark Genera- tory steady signal can be made to fluctuate if it is tor will prevent detection of ignition spark when prop-...

  • Page 28: Troubleshooting

    30 seconds during PREPURGE. b. Safety shutdown will occur. Troubleshooting RM7895 SYSTEM DIAGNOSTICS Display Module. The 7800 SERIES provides a System An- Troubleshooting control system equipment failures is nunciation Diagnostics and Troubleshooting manual, form easier with the RM7895 self-diagnostics and first-out annun- 65-0118.
  • Page 29 RM7895A,B,C,D TROUBLESHOOTING Total Hours, Fault History, Diagnostic Information and when the fault occurred, and the fault message and burner Expanded Annunciator Terminal Status (if used). With status when the fault occurred. The Historical Informa- this information most problems can be diagnosed without tion can be viewed by the optional S7800A1001 Keyboard extensive trial and error testing.
  • Page 30 RM795A,B,C,D TROUBLESHOOTING TABLE 6—SEQUENCE AND STATUS HOLD MESSAGES (Continued) NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type. Sequence Status STANDBY The LED indicates the burner status, POWER. The burner can be placed in STANDBY by opening the burner switch or if the operating controller indicates its set point has been satisfied.
  • Page 31 RM7895A,B,C,D TROUBLESHOOTING TABLE 6—SEQUENCE AND STATUS HOLD MESSAGES (Continued) Sequence Status The LEDs indicate the burner status, POWER, FLAME and MAIN, which is the period of time after the Ignition Trials and before the operating controller set point is reached. During this time, the burner is firing under the control of the operating control- ler (RM7895C,D).
  • Page 32 Home and Building Control Home and Building Control Helping You Control Your World Honeywell Inc. Honeywell Limited—Honeywell Limitée 1985 Douglas Drive North 740 Ellesmere Road Golden Valley, Minnesota 55422 Scarborough, Ontario M1P 2V9 QUALITY IS Printed in U.S.A.

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Rm7895bRm7895cRm7895d7800 series rm7895a

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